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Beretta POWER MAX Series Installation And User Manual
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Beretta POWER MAX Series Installation And User Manual

Beretta POWER MAX Series Installation And User Manual

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Installation and User Manual
POWER MAX
Condensation | Heating module
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Installation and User Manual

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Summary of Contents for Beretta POWER MAX Series

  • Page 1 Installation and User Manual POWER MAX Condensation | Heating module Installation and User Manual...
  • Page 2 POWER MAX 150 20128436 Please accept our thanks and our congratulations on your choice of product. ACCESSORIES Beretta For a complete list of accessories and details of their com- patibility, refer to the Catalogue. CONFORMITY thermal modules POWER MAX comply with:...

  • Page 3: Table Of Contents

    CONTENTS GENERAL INFORMATION ....4 COMMISSIONING AND MAINTENANCE . . . 41 General Safety Information ....4 Preparing for initial startup.

  • Page 4: General Information

    Regularly check that the condensate drain is free GENERAL INFORMATION from obstruction. We recommend cleaning inside the exchanger once 1.1 General Safety Information a year, extracting jet and burner and removing any installation debris by suction. This operation should be done by personnel from the Technical Assistance After removing the packaging, check the condition Centre only.

  • Page 5: Description Of The Appliance

    1.3 Description of the appliance 1.4 Safety devices it is a condensing, pre-mixed thermal module All appliance functions are electronically controlled by a POWER MAX consisting in a modulating thermal element. dual processor technology board approved for safety func- It is available in various models, ranging from 57kW to tions.

  • Page 6: Identification

    1.5 Identification The products are identified by: Technical data plate It indicates the technical and performance data. Central heating section Rated heat input Rated useful heat output Electric degree of protection Maximum operating pressure, CH circuit Temperature Efficiency η NOx class IT-GB-GR-IE-PT-SI: G20=20mbar G30/G31=28-30/37mbar II2H3+ SK: G20=20mbar (ES=18mbar) G30=28-30mbar G31=37mbar...

  • Page 7: System Layout

    1.6 System layout POWER MAX 65 P - 80 P Flue gas analysis outlet Flue gas exhaust connection Gas valve Combustion chamber Electrical panel Smoke-exhaust flue non-return valve Drain cock Minimum Pressure Switch set at 0,7 bar Pump Main switch Central heating return Gas supply Central heating flow...
  • Page 8 POWER MAX 100 - 110 - 130 - 150 Flue gas analysis outlet Flue gas exhaust connection Combustion chamber Electrical panel Smoke-exhaust flue non-return valve Drain cock Minimum Pressure Switch set at 0,7 bar Main switch Central heating return Gas supply Central heating flow Condensate drain connection Flow-meter...

  • Page 9: Technical Specifications

    1.7 Technical specifications POWER MAX Description U.M. 65 P 80 P Condensing boiler heating system Appliance type B23; B53; B53P; C13*; C33*; C53*; C63* IT-GB-GR-IE-PT-SI: G20=20mbar G30/G31=28-30/37m- bar; II2H3+ SK: G20=20mbar G30=28-30mbar G31=37mbar; II2H3+ ES: G20=18mbar G30=28-30mbar G31=37mbar; II2H3+ BE: G20/25=20/25mbar; I2E(S) BE: G30/G31=28-30 /37mbar G31=28-30/37mbar;...
  • Page 10 POWER MAX Description U.M. 65 P 80 P at P Noise level (sound power) dB(A) (re- Emissions (**) ferred 34,2 36,4 38,1 38,7 39,3 46,1 to HCV) 9 - 9 (*****) Emissions at max./min. heat input, G20 79/6,5 90/6,5 81/7,5 91,5/7,5 89/4,6 91,5/5,6...

  • Page 11: Pumps

    Thermal modules POWER MAX 100, POWER MAX 110, 1.8 Pumps POWER MAX 130 and POWER MAX 150 are not equipped The thermal modules POWER MAX 65 P and POWER MAX with a circulator, which must be inside or outside the appli- 80 P are fitted with a circulator.

  • Page 12: Water Circuit

    1.9 Water circuit 1.10 Positioning the temperature sensors 6 7 8 Probes placed on the related sockets of the thermal module (POWER MAX 65 P ÷ POWER MAX 150): Exhaust flue probe Safety thermostat CH flow temperature sensor Return probe Heat exchanger Circulator (only for models POWER MAX 65 P - POWER MAX 80 P)

  • Page 13: Control Panel

    1.11 Control panel CONTROL PANEL AND SYMBOLS RESET PROG MENU Rear light display MENU/Reset key: access to the main menu and restore functioning further to a failure lock-out Navigation keys Main switch (located on the lower part of the appliance) SECONDARY INFORMATION/DISPLAY VISUALISATION 8.8:8.8 8.8:8.8...

  • Page 14: Installation

    The instruction manual is an integral part of the ap- pliance; therefore, it should be read and stored care- fully. Keep the documentation envelope in a safe place. Any replacement documents must be ordered from Beretta who reserve the right to charge for the cost of the replacement.

  • Page 15: Installation Premises

    The minimum surface of ventilation openings is 3,000 cm 2.3 Installation premises for gas fuel heating systems. The thermal module POWER MAX can be installed in rooms that are permanently ventilated and equipped with suitably sized ventilation openings in line with Technical Standards 2.4 Installation in older systems and and Regulations applicable to the installation site.

  • Page 16: Moving And Removing The Packing

    2.5 Moving and removing the packing Do not remove the cardboard packaging until your reach the installation location. Before handling the appliance and removing the packaging, wear PPE and use tools suitable for the appliance's size and weight. This step must be carried out by several individuals equipped with suitable means with respect to the ap- pliance's size.
  • Page 17 After installing the thermal module: Locate the envelope containing the product documentation - remove the locking screw. and stick the Energy Efficiency Label (if any) contained in - pull the front panel outwards and then to the top to the envelope onto the panel. decouple it from points A.

  • Page 18: Water Connections

    2.7 Water connections The dimensions and position of thermal module's hydraulic connections are shown in the table below. Front view Bottom view POWER MAX DESCRIPTION 65 P 80 P 143,5 143,5 143,5 143,5 143,5 143,5 63,5 63,5 63,5 63,5 63,5 63,5 283,5 283,5...

  • Page 19: Typical Water System Schematics

    2.8 Typical water system schematics Layout 1: circuit with thermal module directly linked to heating system (check that the pump's discharge head is sufficient to ensure adequate circulation) 10 9 Layout 2: circuit with thermal module directly linked to heating system and DHW tank. (check that the pump's discharge head is sufficient to ensure adequate circulation) 9 10 10 9...
  • Page 20 Layout 3: circuit with thermal module connected to a heating system via a separator 10 9 Layout 4: circuit with thermal module linked to DHW tank and heating system via a separator 10 9 9 10 Isolating valve Water softener filter Outdoor sensor Non-return valve Pressure reducer...
  • Page 21 Layout 5: circuit with thermal module linked to heating system and DHW. tank via a separator 9 10 10 9 Isolating valve Pressure reducer Outdoor sensor Non-return valve Storage cylinder High temperature Anti-scald mixer valve Diverter valve system flow Expansion tank Pump (fitted as standard for High temperature Safety valve...

  • Page 22: Gas Connections

    2.9 Gas connections 2.10 Discharge of combustion products The gas connection must be made respecting the instal- lation regulations in force, and sized to ensure the correct The appliance is supplied as standard in B-type configu- gas delivery to the burner. ration (B23-B23P-B53P), i.e.
  • Page 23 Condensation appliances described in this hand- book must be installed with flue gas pipes compliant with applicable legislation and expressly manufac- tured for this specific use. Check that pipes and joints are not damaged. Joint seals must be executed with materials that with- stand the condensate's acidity and the temperatures of the appliance's flue gases.
  • Page 24 The table with available residual discharge heads is shown C TYPE INSTALLATION below. Double pipes Ø 80-125 mm Pressure drop Discharge head Maximum Description Model length 45° 90° Ø 80-125 mm POWER MAX 65 P bend bend POWER MAX 65 P 15 m POWER MAX 80 P POWER MAX 80 P...

  • Page 25: Preparation For The Condensate Drain

    Fill the siphon with water before activating on the ther- 2.10.1 Preparation for the condensate drain mal module in order not to release any combustion The evacuation of the condensate produced by the appli- products into the environment when the thermal mod- ance POWER MAX during its normal operationmust be car- ule is first switched on.

  • Page 26: System Filling And Emptying

    All data in the table refer to water contained in the 2.12 System filling and emptying system after 8 weeks' operation. The thermal module POWER MAX must be provided with a Do not use excessively softened water. Excessive charging system to be connected to the appliance's return water softening (total hardness <...

  • Page 27: Emptying

    - Unscrew the vent valve's release cap 2.12.2 Emptying - Open the shut-off cocks in order to slowly fill the sys- Before starting to empty the appliance and the storage cyl- inder: - Use the pressure gauge to check that the pressure is - Switch the system's master switch to the OFF position rising and the water is exiting through the vent valves and the thermal module's master switch to ( 0 ).

  • Page 28: Wiring Diagram

    2.13 Wiring diagram J6-3 J6-10 J6-12 J6-5 J7-2 J7-4 J12-4 J12-1 J7-6 J7-7 J7-8 J12-5 J12-2 J21-1 / J6-1 J21-5 / J6-2 J21-4 / J6-8 J21-6 J21-3 10 11 12 13 14 15 16 17 18 0-10V Modbus BUS 1 BUS 2 0V (GND) 0-10V...
  • Page 29 J2-1 J2-4 J1-4 J1-5 J1-1 J4-2 J4-3 J4-6 J4-5 J4-4 J4-1 J5-2 J5-1 J3-1 J3-7 J3-2 J3-3 J3-8 J3-5 J3-10 J3-4 J2-3 J3-9 J3-6 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 PC (*) (ACS) PC (PS) AE (230V ~ 50Hz)

  • Page 30: Electrical Connections

    To switch it off (during the heating stage) use a room/ 2.14 Electrical connections heat demand thermostat. The On-Off key can only be The thermal module POWER MAX is manufactured fully actioned whist the appliance is in stand-by or emer- wired and only needs to be connected to the mains, the gency mode.
  • Page 31 Loosen the fixing screws (2) and remove the protection (3) For connection, see the following figure: ~ 230 V 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Circuit breaker Relay / Switch (230V AC) Refer to the device type for the supply tension.
  • Page 32 Electrical wiring referred to layout 2 at page "19". Electrical wiring referred to layout 4 at page "20". 10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17 101 102 103 104 105 106 101 102 103 104 105 106 0-10V Modbus...

  • Page 33: Menu Navigation

    2.15 Menu navigation 2.15.1 USER navigation MENU Whilst turning on or when any key is pushed for more than 4 minutes, the display is placed on the "basic display" and it provides some general information on the thermal module. °C RESET PROG MENU...
  • Page 34 USER menu Param- Par. Factory eter Description Range setting name CH set- Defines the desired delivery temperature in heating mode (Par. Par. 2023… 2003 °C point 2001) = 0. Par. 2024 2048 tank set- Establishes the DHW storage tank set-point. 40…71 °C point...

  • Page 35: Navigation Menu Installer

    2.15.2 Navigation Menu INSTALLER / MANUFACTURER It is necessary to enter the password to access the IN- - Press "PROG +" and "PROG -" to increase or de- STALLER / MANUFACTURER parameters crease the value of the first blinking digit - Press "MENU/RESET"...
  • Page 36 MENU INSTALLER / MANUFACTURER Par. Parameter Description Range Default setting name Defines the thermal module's various heating operation 2001 CH mode 0…5 modes. Defines the desired delivery temperature in heating Par. 2023… 2003 CH set-point °C mode (Par. 2001) = 0. Par.
  • Page 37 MENU INSTALLER / MANUFACTURER Par. Parameter Description Range Default setting name Defines the priority type: 0 = Time: time priority between the two circuits defined by Par. 2043; 1 = Off: priority for CH; 2042 DHW Priority 0…3 2 = On 2 = On: priority for DHW;...
  • Page 38 MENU INSTALLER / MANUFACTURER Par. Parameter Description Range Default setting name 0 = Disabled 1 = General Pump 2 = CH Pump 3 = DHW Pump 4 = System Pump 5 = Cascade Pump 6 = Alarm Relay 7 = Filling Valve 0,1,2,3,4,5,6, Prog.
  • Page 39 MENU INSTALLER / MANUFACTURER Par. Parameter Description Range Default setting name Bitron, Huba: DN8, DN10, 2129 Flow sensor Defines the type of flow sensor used. Huba DN25 DN15, DN15, DN20, DN25 Flow Scaling 2130 Flow rate scaling factor 0…25.5 rpm/l Factor 2131 Min.
  • Page 40 MENU INSTALLER / MANUFACTURER Par. Parameter Description Range Default setting name Defines the proportional parameter for modulation during 2016 CH PID P 0…1275 heating operation. 2017 CH PID I Defines the modulation integral term during heating operation. 0…1275 Defines the modulation derivative term during heating opera- 2018 CH PID D 0…1275...

  • Page 41: Commissioning And Maintenance

    Example of display on stand-by (outdoor probe is not COMMISSIONING AND connected) MAINTENANCE °C 3.1 Preparing for initial startup The thermal module POWER MAX must be commis- sioned by Technical Assistance Centre , after which step the appliance may operate automatically. Perform the following checks before starting up the boiler: Example of display on stand-by (outdoor probe is con- - Check that the fuel shut-off cock and heating system...

  • Page 42: Setting The Heating Parameters

    3.2.3 Setting the heating parameters Par. Description The parameter 2001establishes the thermal module's vari- Establishes the minimum outdoor temperature to ous heating operation modes. 2020 which the maximum set-point can be associated for climatic regulation Mode 0 Establishes the minimum set-point at the maxi- (Operation with room thermostat/heat demand and fixed 2021 mum outdoor temperature for climatic regulation...
  • Page 43 Mode 2 Mode 3 (Working on climatic mode with attenuation controlled by a (Continuous fixed set-point operation with attenuation con- room/heat demand thermostat, variable set point accord- trolled by room/heat demand thermostat) ing to the outdoor temperature) In this mode the fixed set-point is adjusted in the same way In this case the thermal module operates with a set-point as described for Mode 0.

  • Page 44: Setting The Domestic Hot Water Parameters

    Mode 4 3.2.4 Setting the domestic hot water (Set-point adjustment based on a 0-10V analogical input) parameters The maximum and minimum set-point values are defined The parameter 2035 defines the various operation modes respectively by Par. 2111 and 2110. of the thermal module for DHW production Par.
  • Page 45 Mode 2 Anti-Legionella function (DHW production with storage tank controlled by a ther- This function is only on when the circuit for DHW production mostat) is on mode 1. In this case the thermal module is activated when the con- tact in boiler's thermostat is closed and is deactivated The anti-legionella function is activated automatically on when the latter is opened.

  • Page 46: Checks During And After Initial Start-Up

    3.3 Checks during and after initial SUPPLY GAS PRESSURE CHECK start-up - Turn the main system switch "off" - Remove the locking screws and the panel's front side When the appliance it started, it must be checked by stop- - Loosen by about two turns the pressure inlet screw ping and then restarting the thermal module in the following (1) upstream of the gas valve and connect the pres- way:...

  • Page 47: Error List

    3.4 Error List When a display has a technical fault, a numeric error code appears that will enable the maintenance operator to identify the possible cause. There are 3 categories of errors: 1 Permanent: errors that require a manual reset 2 Temporary: errors that are automatically reset once the cause that generated them is removed or stopped 3 Notices: simple warnings that do not block the appliance's operation 3.4.1 Permanent Errors...

  • Page 48: Temporary Errors

    Nr. Error Description Checks Solutions STACK_ER- Internal software error Control board replacement INSTRUC- TION_ER- Internal software error Control board replacement ION_ CHECK_ Internal software error Control board replacement FAILED FLAME_ Flame still present 10 OUT_TOO_ seconds after closing Replace the gas valve LATE the gas valve FLAME_BE-...

  • Page 49: Warnings

    Nr. Error Description Checks Solutions If the wiring is damaged, replace it Check the integrity of Verify that the temperature sensor the wire connections 122 DHW_OPEN DHW sensor open has the correct resistance values. If Check the DHW tem- values are incorrect sensor must be perature sensor replaced.

  • Page 50: Transformation From One Gas Type To Another

    3.5 Transformation from one gas Versions POWER MAX 65 P to POWER MAX 80 P - disconnect the electrical connections of the fan and type to another the gas valve - unscrew the swivel nut (2) on the gas pipe The thermal module POWER MAX is supplied for operation - unscrew the fan screws to separate the fan from the with G20 (natural gas).
  • Page 51 - if it is difficult to insert the diaphragm, unscrew the Versions POWER MAX 100 - POWER MAX 150 - disconnect the electrical connections of the fan and swivel nut (3) to completely free the gas pipe. the gas valve - unscrew the swivel nut (1) to remove the gas pipe from the fan - loosen or unscrew the swivel nut on the gas valve to...

  • Page 52: Adjustments

    3.6 Adjustments CO2 ADJUSTMENT AT MINIMUM POWER - Select "Lo" using "PROG +" and "PROG -" and press The thermal module POWER MAX is supplied for operation "MENU/RESET" to confirm. with G20 (methane gas), as indicated by the type plate, - the appliance will operate at minimum power.

  • Page 53: Temporary Or Short-Term Shut-Down

    3.7 Temporary or short-term shut- 3.9 Display board replacement down System configurations must be performed only by the In the event of temporary or short-term shut-down (e.g. due Technical Assistance Centre or by personnel author- to holidays), proceed as follows: ized by - Disconnect the power supply by positioning the ther- When the front control panel is replaced, at the next restart...

  • Page 54: Control Board Replacement

    3.10 Control board replacement 3.11 Maintenance It is mandatory to perform maintenance and cleaning of the System configurations must be performed only by the device at least once a year. Technical Assistance Centre or by personnel author- ized by The non-performance of the annual maintenance will When the front control panel is replaced, at the next restart invalidate the warranty.

  • Page 55: Cleaning And Removing Internal Components

    3.12 Cleaning and removing internal Access to the control panel and the internal parts of the thermal module components - Remove the locking screws and the panel's front side - Pull and slide the electrical panel's box towards the Before any cleaning operation, disconnect the electric outside (1) power supply by switching the main system switch to "off”.
  • Page 56 Disassembling of the fan and burners models POWER Disassembling of the fan and burners models POWER MAX 65 P - POWER MAX 80 P MAX 100 - POWER MAX 110 - POWER MAX 130 - POW- ER MAX 150 - Remove the locking screws and the panel's front side - Remove cables (1) and (2) for the fan (3) - Remove the locking screws and the panel's front side - Remove the air tube from the fan if the thermal mod-...
  • Page 57 disassembling of the flange for cleaning up the heatex- Disassembling the flange for cleaning the exchanger changer models POWER MAX 65 P - POWER MAX 80 P models POWER MAX 100 - POWER MAX 110 - POWER - Remove the locking screws and the panel's front side MAX 130 - POWER MAX 150 - Remove cables (1) and (2) for the fan (3) - Remove the locking screws and the panel's front side...

  • Page 58: Condensate Drain Siphon Cleaning

    - Loosen the clamp (2), detach the condensate drain- 3.12.1 Condensate drain siphon cleaning age corrugated tube (3), remove the siphon and re- For models POWER MAX 65 P, POWER MAX 80 P, POWER move it using the two screw plugs (4) MAX 100, POWER MAX 110, POWER MAX 130, POWER - Remove the float and clean all internal components.

  • Page 59: Troubleshooting

    3.13 Troubleshooting FAULT CAUSE SOLUTION - Check the seal of the gaskets and Gas supply circuit the closure of the pressure tapping There is a smell of gas 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 60: System Manager

    SYSTEM MANAGER - Switch the system's master switch to the ON position SYSTEM MANAGER and the thermal module's master switch to ( I ). 4.1 Putting into service The appliance must be maintained and adjusted at least once a year by Technical Assistance Centre or by professionally qualified staff in compliance with all applicable National and Local provisions.

  • Page 61: Temporary Or Short-Term Shut-Down

    SYSTEM MANAGER 4.2 Temporary or short-term shut- 4.4 Cleaning down Use a cloth damped in soapy water to clean the boiler’s external casing. In the event of temporary or short-term shut-down (e.g. due To remove stubborn marks, use a cloth damped in a 50% to holidays), proceed as follows: mix of water and denatured alcohol or a suitable cleaning product.

  • Page 62: Useful Information

    SYSTEM MANAGER 4.6 Useful information Seller:................... Installer:................Mr.: ..................Mr.: ..................Address: ................Address: ................Tel.: ..................Tel.: ..................Technical Assistance Centre: ..........Mr.: ..................Address: ................Tel.: ..................Date Work done Fuel oil supplier: ..............Mr.: ..................Address: ................Tel.: ..................

  • Page 63: Recycling And Disposal

    SYSTEM MANAGER RECYCLING AND DISPOSAL The appliance is manufactured using various materials, such as metal, plastics, and electric and electronic components. At the end of the life cycle, safely remove the components and dispose of them in a responsible manner, in compliance with the installation country's applicable environmental legislation.
  • Page 64 Via Risorgimento, 23 A 23900 - Lecco (LC) www.berettaboilers.com The manufacturer strives to continuously improve all products. Appearance, dimensions, technical specifications, standard equipment and accessories are therefore liable to modification without notice.

This manual is also suitable for:

Power max 65 pPower max 80 pPower max 100Power max 110Power max 130Power max 150 ... Show all