Beretta Power Plus Box 150 Installation Manual
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Beretta Power Plus Box 150 Installation Manual

Beretta Power Plus Box 150 Installation Manual

Thermal modules; condensing
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Installation Manual

Power Plus Box
THERMAL MODULES | CONDENSING
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Installation Manual

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Summary of Contents for Beretta Power Plus Box 150

  • Page 1: Installation Manual

    Installation Manual Power Plus Box THERMAL MODULES | CONDENSING Installation Manual...
  • Page 2 MODEL CODE fort in the home for many years to come. POWER PLUS BOX 150 20071998 This manual provides information that is essential to the in- POWER PLUS BOX 200 20071999 stallation of the appliance.
  • Page 3 CONTENTS GENERAL INFORMATION COMMISSIONING AND MAINTENANCE General Safety Information ....4 Initial startup ......34 Precautions .

  • Page 4: General Information

    GENERAL INFORMATION 1 2 Precautions The operation of any appliance that uses fuel, electrical power and water demands that a number of fundamental 1 1 General Safety Information safety precautions be respected: Do not allow children or infirm persons to operate the After removing the packaging, check the condition system unsupervised.

  • Page 5: Safety Devices

    Depending on the model, the heat input (ref. PCI) of every Power Plus Box modular system reaches 110, 135 or 180 kW, and can be Base module consisting of 4 heat generators for heating modulated between 10% and 100%. and DHW production systems. Efficiency reaches 107.7% (100% ref.
  • Page 6 The modular system must not be operated, even tem- porarily, if the safety devices are not functioning or have been tampered with. The safety devices must be replaced by Technical Assistance Centre, only using original components from the manufacturer. Refer to the spare parts cata- logue provided with the modular system.
  • Page 7 1 6 System layout Control panel Single heating element Control panel Bus cable passage cable gland for the cascade connection Flue gas manifold Gas manifold System delivery manifold Condensate drain manifold System return manifold Single heating element flue gas analysis outlet Single heating element flue gas exhaust union Automatic bleed valve Safety thermostat...
  • Page 8 COMPENSATORE POWER PLUS BOX 200 IDRAULICO 80°C 60°C 50°C 30°C COMPENSATORE POWER PLUS BOX 150 POWER PLUS BOX 200 IDRAULICO Delivery manifold sensor Low system temperature sensor Boiler sensor Outdoor sensor Zone 1 circulator (high temperature) Zone 2 circulator (low temperature)

  • Page 9: Technical Specifications

    1 8 Technical specifications Power Plus Box MODEL Fuel G20 - G30 - G31 Device category II2H3+ Device type B23, B53 Furnace heat output ref. PCS (min - max) 16,0 - 150 16,0 - 200 Furnace heat output ref. PCI (min - max) 14,4 - 134,9 14,4 - 179,8 Useful heat output (80°/60°C)
  • Page 10 Power Plus Box Detail Maximum rated heat input Minimum rated heat input 16,7 16,7 Domestic hot water maximum rated thermal input (80-60) Domestic hot water minimum rated thermal input (80-60) PARAMETER Seasonal heating energy efficiency class Water heating energy efficiency class Rated input Prated 132,6...
  • Page 11 1 9 Water circuit Safety valve Automatic bleed valve Air inlet Burner Exhaust flue duct Heat exchanger Condensate outlet Drain cock Central heating flow Differential water and minimum pressure switch Central heating return Circulator (or 2-way valve) Gas supply Gas valve Flue gas exhaust union with check valve and flue gas analysis outlet Manual diverting valve...
  • Page 12 WATER SIDE PRESSURE DROP FOR EVERY HEATING ELEMENT Every heating element of the Power Plus Box modular system is equipped with a circulator, whose performance curve is provided below, in reference to speed 3. 1200 1 heating element 1100 1000 Circulator characteristic curve P available for...
  • Page 13 1 10 Location of sensors Delivery manifold sensor Low system temperature sensor Boiler sensor Outdoor sensor Zone 1 circulator (high temperature) SAFETY Zone 2 circulator (low temperature) HEATING THERMOSTAT Boiler circulator DELIVERY SENSOR (triggering at 90°C) Mixer valve HEATING RETURN SENSOR 80°C FLUE GAS...

  • Page 14: Wiring Diagrams

    1 11 Wiring diagrams MODULAR SYSTEM HEATING ELEMENT Modular system main switch Heating element circulator (or 2-way valve) Contact for external safeties Flow probe Boiler circulator Return probe Zone 1 circulator (high temperature) Exhaust flue probe Zone 2 circulator (low temperature) Safety thermostat Mixer valve Gas valve...
  • Page 15 The circulators must be connected with the interposition of suitable contactors with manual emergency actuation.
  • Page 16 1 12 Control panels 4 5 6 4 5 6 4 5 6 14 15 Electric power supply signal Display Master user interface Value increase button Slave user interface Value decrease button Slave card operating status signal: Save button - FLASHES in absence of heat demand Parameter selection button - FLASHES QUICKLY during the ignition cycle Operating mode selection button...
  • Page 17 - The exhaust function: the high and low temperature Functional notes The Power Plus Box modular system control panel manag- circuit pumps remain in operation for 5 minutes after the last burner is turned off. The waiting time before - The DHW priority function which, in the case of a the heating element circulator is stopped once the DHW demand, the master card can also serve the burner is shut off is 6 minutes.
  • Page 18 1 13 1 Display mode The red (error) LED turns on in the case of faults that involve the permanent block of a heating element (normal operation can be reset by pressing the Master or Slave reset button). The green (on) LED indicates the presence of the electric power supply. The 3 digits with seven segments display the system statuses: SYSTEM STATUS DISPLAY...
  • Page 19 1 13 3 Changing the user parameters Pressing displays the following values in succession: - manifold delivery temperature T1 - DHW temperature T3 - low temperature circuit delivery temperature T6. To change the relative setpoints: - press the "Set/esc" button: the relative value will appear, the two digits on the right will flash - if the value should not be changed, press ”Set/esc”...
  • Page 20 The following values for each single unit can be visualized with POS. DIMENSIONS DISPLAY Flow temperature (e.g. 70° C) Return temperature (e.g. 50° C) Exhaust flue temperature (e.g. 60° C) Ionization current (index from 0 to 99). E.g. fig. Ionization current index 44. Fan PWM signal (%).

  • Page 21: Error Mode

    1 13 6 Test mode In test mode it is possible to generate a high temperature heating demand at maximum power and at minimum power. All system fans must be activated. If the installer turns off the switch for some Slaves, the others, connected to the Master, must continue to operate.

  • Page 22: Installation

    INSTALLATION 2 2 Opening Remove the straps (1) and the cardboard packaging (2). 2 1 Unpacking the product 1 Strap 2 Cardboard packaging The Power Plus Box condensing system is supplied on a 3 Pallet pallet, strapped and protected by cardboard packaging. 4 Modular condensing system Its condition and compliance with what was ordered must 5 Document envelope containing:...

  • Page 23: Overall Dimensions And Weights

    2 3 Overall dimensions and weights 1250 Power Plus Box DESCRIPTION System delivery manifold 5" DN 125 - PN 6 Ø - DN System return manifold 5" DN 125 - PN 6 Ø - DN Gas manifold 3" DN 80 - PN 6 Ø...

  • Page 24: Handling

    2 4 Handling The packaging material must be disposed of care- fully and must not be abandoned, as it is a source of A transpallet or forklift must be used for handling. potential danger. 2 5 Installation premises The Power Plus Box systems (models EXT ) are designed for outdoor installation.

  • Page 25: Water Connections

    - Make sure that the electrical supply system has been installed by a qualified electrician in compliance with applicable standards - Make sure that the flow rate, head and direction of flow of the pumps are suitable and correct - Make sure that the fuel feed line and any storage tank are made and installed in compliance with applicable standards - Make sure that expansion vessels are big enough to...

  • Page 26: Flue Gas Evacuation For Installations In A

    Flue gas evacuation Description output (kW) length (m) line diameter (mm) ≤ 150 Power Plus Box ≤ 200 Power Plus Box ( Power Plus Box 150) x 2 ≤ 300 ..≤ 350 ..≤ 400 ..≤ 450 ..

  • Page 27: Central Heating Plant

    2 9 Condensate evacuation Any condensate neutralisation devices can be con- nected after the siphon. For the calculation of the condensation systems produce a conden- Power Plus Box duration of the neutralisation load, the amount of sate flow depending on the operating conditions. The max- neutraliser consumption must be evaluated after one imum hourly flow of condensation produced is indicated for year of operation.

  • Page 28: Electrical Connections

    Maintenance Neutralisation device maintenance must be performed at regular intervals and as required (minimum once per year). The requirement for maintenance depends on the system characteristics. For this purpose, the filling level of the dol- omitic granules must be checked. The minimum filling level is equal to 15 cm, starting from the upper edge of the box.
  • Page 29 ROTATE ROTATE identify the cable glands (5) located on the rear part of the modular system and use them to pass the pump, sensor and electric power supply cables inside the modular sys- - Identify the terminal board (6), located inside the electric panel, and direct the pump and sensor ca- bles (7) towards it through the holes made in the panel casing.
  • Page 30 TERMINAL BOARD INSIDE THE CONTROL PANEL Pump PB (*) High temperature DHW circulator zone 1 sensor Pump PZ1 (*) System circulator Boiler sensor High temperature Pump 3 PZ2 (*) System circulator Low temperature Low temperature zone 2 sensor Circ. 2 Valv.

  • Page 31: Outdoor Sensor Installation

    2 12 Outdoor sensor installation The correct positioning of the outdoor sensor is of funda- mental importance for proper climate control operation. The sensor must be installed outside the building to be heated, at approx. 2/3 the height of the NORTH or NORTH WEST façade and far from flues, doors, windows and sun- ny areas.

  • Page 32: System Filling And Emptying

    2 13 System filling and emptying - Open the filling tap (4), provided on the system, until the pressure indicated on the pressure gauge is 1.5 The Power Plus Box filling system is not equipped with a filling tap, which must be installed on the system return. - Close the filling tap (4).

  • Page 33: Preparing For Initial Startup

    EMPTYING THE HEATING ELEMENT - the hydraulic circuit pressure, when cold, is approx. - Close the diverting valve (1) and the return tap (2) for and the circuit has been deaerated 1.5 bar the heating element - connect a plastic pipe to the heating element's drain tap (5) and open it Before opening the drain tap (5) protect the underly- ing electric devices from the existing water...

  • Page 34: Initial Startup

    COMMISSIONING AND MAINTENANCE 3 1 Initial startup - Turn the main system switch "on" - press the button: the manifold delivery tempera- ture will be displayed, preceded by the symbol “1” - press “Set/esc” : the relative setpoint is displayed and the two digits to the right will flash.
  • Page 35 In the case of low temperature systems, select a temperature between 20°C and 45°C. By setting the "low temperature" type system, the maximum deliv- ery temperature setting will be limited to 50°C (Par. 23=T_CH_Low_limit). Changing the delivery temperature involves chang- ing the climatic curve (see the “Heat control setting”).
  • Page 36 Check that the modular system stops completely when turning the main system switch to "off". Electrically power the modular system by turning the main system switch and the main device switch to "on". - generate the heat demand using the room thermo- stat.
  • Page 37 3 3 Adjusting the functional - generate the heat demand using the room thermo- stat. The system will operate at maximum power, in- parameters dicating “H” on the display followed by the delivery temperature (flue cleaning function) The heating functions can be set for the high temperature, - combustion can be checked by unscrewing the cap low temperature and DHW circuits based on the system (4) and inserting the analyser sensor in the foreseen...
  • Page 38 3 4 Setting the heating parameters The following heating parameters can be set: Setpoint_T_CH_High High temperature circuit setpoint (parameter 1) If the "fixed point" operating mode is set (par. 14=CH_type_high=0), it is the target temperature. If the "climatic control" operating mode is set (par. 14=1) , it is the maximum target temperature with minimum outdoor temperature (T_out_min=par.
  • Page 39 3 6 Heat control setting CH_Priority Heating priority (parameter 16) Attenuation_High If set to 0, the system will work without heating priority with HIGH TEMPERATURE circuit attenuation function the high temperature and low temperature circuits served (parameter 21) in parallel. There are 2 cases: If set to 1, the demand from the low temperature circuit is - Fixed point operation Par.
  • Page 40 If the outdoor temperature = Tout_min=Par. 37, preset to If the outdoor temperature = Tout_min=Par. 37, preset to 0°C, then setpoint =setpoint_T_Ch_high. 0°C, then setpoint =setpoint_T_Ch_low. If the outdoor temperature = Tout_max=Par. 38, preset If the outdoor temperature = Tout_max=Par. 38, preset to 18°C, then setpoint T_ch_high_ foot=Par.
  • Page 41 MODE: MINIMUM QUANTITY OF BURNERS IGNITED Low load (PAR. 33=0) The low load function prevents burner ignition and shut off System power modulation is controlled by a PID regulator, in the case of a low heat demand. The conditions for low which controls the manifold temperature and the setpoint load operation activation is controlled in every Slave card is that of the active circuit (high or low temperature circuit...
  • Page 42 The burner shuts off when: - Delivery temp. > Setpoint_ch_high (Par.1) + Ch_ high_hist_off (Par.20) - (Delivery temp. > Setpoint_ch_low (Par.3) + Ch_low_ hist_off (Par.27)) MIX VALVE MANAGEMENT The mix valve is controlled by the parameters: - Mix_valve_step_open_time: Par.28 preset to 5s - Mix_valve_step_close_time: Par.29 preset to 7s - Mix_valve_interval_time: Par.30 preset to 5s - Mix_valve_p_hyst: Par.31 preset to 2°C...
  • Page 43 Safety functions of the Slave cards Checking ∆T uses the parameter ∆T_max (preset to 35°C) If the delivery temperature > 90°C for 5s, the slave card is and limits the burner power as follows: - if ∆T_max -5°C > ∆T > ∆T_max –10°C = burner mod- blocked (no.
  • Page 44 Example of a cascading configuration with 1 system Power Plus Box 200 and 1 Power Plus Box 150 In this case, there are two blocks: the first consisting of four generators and the third of three. Therefore, two blocks must be configured, respectively with addresses 1 and 2.
  • Page 45 3 8 Error List A and E type errors possibly encountered with Power Plus Box are given in the tables below. In this sense it should be specified that an E-type error (volatile error) is a fault which automatically disappears as soon as the fault is resolved;...
  • Page 46 No. on the PC Cause Troubleshooting Internal error Replace the Slave card. Internal software error Press the rest button. Internal error Replace the Slave card. The limit thermostat contact is Connector disconnected or defective. open with the burner off Limit thermostat defective. Delivery sensor error due to Check that the flow rate in each unit’s water circuit is exceeding the limit temp.
  • Page 47 3 9 List of parameters The list of parameters for Power Plus Box is given here below. The user may only alter the first three parameters, whilst Technical Assistance Centre must be called in for the others. User parameters Factory Lower Upper Parameter name...
  • Page 48 Factory Lower Upper Parameter name Description setting limit limit CH1 max. Temp. 80°C 10°C 80°C Max. settable value for high system CH1 min. Temp. 50°C 10°C Par.1 Min temp. value high system (at max. external T.). Burner re-ignites after said differential. CH1 ON diff.
  • Page 49 3 10 Transformation from one gas 6.75 type to another The Power Plus Box system is supplied for operating with G20 (natural gas). It can however be transformed to oper- ate with G30-G31 (LPG) using the provided kit. The transformations may only be carried out by Tech- nical Assistance Centre or by personnel authorised , also on already installed modular systems.

  • Page 50: Temporary Shutdown

    CO2 ADJUSTMENT AT MAXIMUM POWER With the electric power supply remaining active, as sig- - Press the “Set/esc” and buttons at the same time nalled by the flashing green LED and the supply of the gas, for 5 seconds the modular system is protected. - use to select the maximum fan speed - generate the heat demand using the room thermo-...
  • Page 51 3 14 Maintenance Access to the control panel and the internal modular system parts Period maintenance is "mandatory', required by Presiden- - open the two front doors in the casing tial Degree 26 August 1993 no. 412, and is also essential - loosen the screw (1) and turn the main control panel for device safety, efficiency and duration It makes it possi- ble to reduce consumption, polluting emissions and keep...
  • Page 52 Pump Pump Pump 3 Circ. 2 Valv.Mix Alarm Analogic Input Circ.2 Once the maintenance operations are complete, refit the Once the maintenance operations are complete, refit the components working in the opposite direction of what was components working in the opposite direction of what was described.
  • Page 53 Disassembling and cleaning the burner and exchanger Disassembling the doors - open the two front doors in the casing In particular operations must be carried out inside the mod- - disconnect the wiring (16) of the fan (17) ular system, the two front doors can be disassembled. - unscrew the two screws (19) that fix the fan (17) to the Proceed as follows: air conveyor (20)

  • Page 54: Troubleshooting

    3 16 Troubleshooting FAULT CAUSE SOLUTION - Check the seal of the gaskets and There is a smell of gas Gas supply circuit. the closure of the pressure tapping points - Check the gasket seals Flue gas circuit - Make sure there are no obstructions Odour of unburnt gas - Check the combustion quality Burner gas pressure...
  • Page 55 FAULT CAUSE SOLUTION - Check/unseize the pump - Replace the circulator. The circulator does not start Pump malfunctioning - Check the electrical connection of the circulator System safety valve - Check calibration or efficiency - Check the circuit pressure Frequent tripping of the system System circuit pressure safety valve - Check pressure reducer functioning...
  • Page 56 WATER IN CENTRAL HEATING General note on water used to top up systems: - If softened water is used to top up a system, 8 weeks SYSTEMS of functioning after topping up, verify that the water in the system respects the above limits, in particular for INTRODUCTION electrical conductivity - This check is not necessary if demineralised water is...
  • Page 57 3.2 Stray current corrosion Corrosion from stray currents can occur due to the differ- ing electrical potentials between water in the boiler and the metallic mass of the boiler or piping. This process leaves unmistakeable traces i.e. small regular conical holes. All metallic parts should be grounded by an efficient earth cable for this reason.
  • Page 58 The safety valve with the CE marking according to directive 97/23/ EC will be installed directly on each module by the manufacturer on the delivery manifold and therefore does not require any additional safety valve downstream of the last module. Beretta...
  • Page 60 Commercial Offices: Via Risorgimento, 23 A 23900 - Lecco www.berettaboilers.com Beretta reserves the right to modify the characteristics and specifications given in this publication at any time and without prior notice as part of its policy of continuous product improvement.

This manual is also suitable for:

Power plus box 300

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