Beretta POWER MAX 50 P DEP, POWER MAX 50 P, POWER MAX 100, POWER MAX 130, POWER MAX 110 Installation And Operation Manual

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Page 1

Installation and Operation Manual

Condensation | Heating module

POWER MAX

Installation and Operation Manual

Page 2

RANGE

MODEL CODE

POWER MAX 50 P DEP 20128429 POWER MAX 50 P 20128430 POWER MAX 65 P 20128431 POWER MAX 80 P 20128432 POWER MAX 100 20128433 POWER MAX 110 20128434 POWER MAX 130 20128435 POWER MAX 150 20128436

ACCESSORIES

For a complete list of accessories and details of their compatibility, refer to the Catalogue.

ENGLISH

Dear heating engineer, congratulations on having chosen a thermal module B, a quality product that is designed to give dependable, efcient and safe service and to provide comfort in the home for many years to come. This manual provides information that is essential to the installation of the appliance. Used in conjunction with your own knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly.

Please accept our thanks and our congratulations on your choice of product. Beretta

CONFORMITY

thermal modules

POWER MAX

comply with:

- Gas Appliances Directive 2009/142/EC (until 20 April

2018) and Regulation (EU) 2016/426 (from 21 April

2018)

- Directive 92/42/EEC on efciency requirements and Annex E and Pres. Republic Decree n. 412, 26 August 1993 (****)

- Electromagnetic Compatibility Directive 2014/30/EU

- Low Voltage Directive 2014/35/EU

- Ecodesign Directive 2009/125/CE for energy-related products

- Energy Labelling Directive 2010/30/EU

- Delegated Regulation (EU) N. 811/2013

- Delegated Regulation (EU) N. 813/2013

- Standard for gas-red heating boilers - General requirements and tests - EN 15502-1

- Specic standard for type C appliances and type B2, B3 and B5 appliances of nominal heat input not exceeding 1000 kW - EN 15502-2/1

- SSIGA Gas Appliance Directive G1

- AICAA Fire prevention requirements

- CFST LPG Directive Part 2

- VARIOUS cantonal and communal provisions on air quality and energy saving.

Page 3

This manual, Code 20133145 - Rev. 3 (06/18) comprises 60 pages.

CONTENTS

The following symbols are used in this manual:

CAUTION! =

Identies actions that require caution

and adequate preparation.

STOP! =

Identies actions that you MUST NOT do.

This manual, Code

- Rev. comprises pages.

1 GENERAL INFORMATION . . . . . . . . . . . . . . .4

1.1 General Safety Information . . . . . . . . . . . . . . . . . 4

1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Description of the appliance . . . . . . . . . . . . . . . . 5

1.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5 Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.6 System layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.7 Technical specications . . . . . . . . . . . . . . . . . . 10

1.8 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.9 Water circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.10 Positioning the temperature sensors . . . . . . . . . 12

1.11 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .14

2.1 Unpacking the product . . . . . . . . . . . . . . . . . . . 14

2.1.1 Positioning of labels. . . . . . . . . . . . . . . . . . . . . . 14

2.2 Overall dimensions and weights . . . . . . . . . . . . 14

2.3 Installation premises . . . . . . . . . . . . . . . . . . . . . 15

2.3.1 Recommended minimum distances . . . . . . . . . 15

2.4 Installation in older systems and systems

requiring modernisation. . . . . . . . . . . . . . . . . . . 15

2.5 Moving and removing the packing . . . . . . . . . . 16

2.6 Thermal module assembly. . . . . . . . . . . . . . . . . 16

2.7 Water connections . . . . . . . . . . . . . . . . . . . . . . . 18

2.8 Typical water system schematics . . . . . . . . . . . 19

2.9 Gas connections . . . . . . . . . . . . . . . . . . . . . . . . 22

2.10 Discharge of combustion products . . . . . . . . . . 22

2.10.1 Preparation for the condensate drain . . . . . . . . 24

2.11 Neutralising the condensate . . . . . . . . . . . . . . . 24

2.11.1 Water quality requirements . . . . . . . . . . . . . . . . 24

2.12 System lling and emptying. . . . . . . . . . . . . . . . 25

2.12.1 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.12.2 Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.13 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.14 Electrical connections . . . . . . . . . . . . . . . . . . . . 29

2.14.1 USER navigation MENU. . . . . . . . . . . . . . . . . . . 32

2.15 Navigation Menu INSTALLER /

MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . 34

3 COMMISSIONING AND MAINTENANCE . . . 39

3.1 Preparing for initial startup. . . . . . . . . . . . . . . . . 39

3.2 Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.2.1 Switching the appliance on and off . . . . . . . . . . 39

3.2.2 Password access. . . . . . . . . . . . . . . . . . . . . . . . 39

3.2.3 Setting the heating parameters . . . . . . . . . . . . . 40

3.2.4 Setting the domestic hot water parameters. . . . 42

3.3 Checks during and after initial start-up . . . . . . . 43

3.4 Error List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4.1 Permanent Errors . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4.2 Temporary Errors . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.5 Transformation from one gas type to another . . 45

3.6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.7 Temporary or short-term shut-down . . . . . . . . . 48

3.8 Preparing for extended periods of disuse . . . . . 48

3.9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.10 Cleaning and removing internal components . . 49

3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 53

4 SYSTEM MANAGER . . . . . . . . . . . . . . . . . . .54

4.1 Putting into service . . . . . . . . . . . . . . . . . . . . . . 54

4.2 Temporary or short-term shut-down . . . . . . . . . 55

4.3 Preparing for extended periods of disuse . . . . . 55

4.4 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.6 Useful information . . . . . . . . . . . . . . . . . . . . . . . 56

5 RECYCLING AND DISPOSAL. . . . . . . . . . . . 57

Page 4

1 GENERAL INFORMATION

1.1 General Safety Information

After removing the packaging, check the condition and completeness of the supply. If there are any problems, contact the company

B that sold the

equipment.

This product must be installed by a legally qualied

heating engineer. On completion of the installation, the installer must issue the owner with a declaration

of conformity conrming that the installation has been

completed to the highest standards in compliance with the instructions provided by B in this instruction manual, and that it conforms to all applicable laws and standards.

This product must only be used for the purpose

for which it is designed and made, as specied by

B. B declines all responsibility, contractual or

other, for damage to property or injury to persons or animals caused by improper installation, adjustment, maintenance or use.

In the event of a water leak, disconnect the thermal module from the main power supply, shut off the water supply and promptly notify the Technical Assistance Centre B or professionally qualied personnel.

Periodically check that operating pressure in the water circuit is over 1 bar but below the maximum limit

specied for the boiler. If this is not the case, contact

Technical Assistance Centre B or a professional-

ly qualied heating engineer.

The following operations shall be necessary if the thermal module is not used for a long period of time:

- Switch the boiler OFF at the control panel

- Turn the main system switch "off"

- Close the fuel cock and heating circuit water cock

- Drain the central heating circuit if there is any risk of freezing.

Maintenance must be performed on the thermal module at least once a year.

This manual is an integral part of the appliance and must therefore be kept with care and must ALWAYS accompany the thermal module, even when it is passed on to another owner or user or transferred to another installation. If it is lost or damaged, please contact your local Technical Assistance Centre B for a new copy.

This manual must be read carefully so as to ensure the correct and safe installation, operation and maintenance of the appliance. The Owner must be adequately informed and trained on how to operate the appliance. Make sure that he/she is familiar with all the information required for safe system operation.

The thermal module, before being connected to the hydraulic system, the gas network, and the electrical system, may be exposed to temperatures ranging from 4°C to 40°C. After it can activate the Frost Protection function, it can be exposed to temperatures ranging from -20°C to 40° C

Regularly check that the condensate drain is free from obstruction.

We recommend cleaning inside the exchanger once a year, extracting jet and burner and removing any installation debris by suction. This operation will be done by personnel from the Technical Assistance Centre only.

1.2 Precautions

The operation of any appliance that uses fuel, electrical power and water demands that a number of fundamental safety precautions be respected:

Do not allow children or inrm persons to operate the

system unsupervised.

It is forbidden to use electrical devices or equipment, such as switches, appliances, etc. if there is a smell of gas or un-burnt products. If so:

- Ventilate the room, opening doors and windows

- Close the fuel shut-off cock

- Report the fault immediately to the B's Technical Assistance Centre or a professionally qualied heating engineer.

Do not touch the boiler while barefoot or wet.

Any technical or cleaning activity is forbidden before disconnecting the appliance from the main power supply by switching the system's master switch and the appliance's main switch to the "OFF" position.

Do not tamper with or adjust the safety or control devices without prior authorisation and instructions from the manufacturer.

Do not plug or block the condensate drain outlet.

Never pull, disconnect, or twist the electrical cables coming from the appliance even if it is disconnected from the mains electricity supply.

Do not obstruct or restrict the vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion.

Do not expose the appliance to weather elements (without using the dedicated accessory). It has been designed for indoor use.

Do not switch off the appliance if the outdoor temperature may drop to below ZERO (frost hazard).

Do not leave ammable containers and substances

in the room where the device is installed.

Do not dispose of packaging material into the environment, or leave it within the reach of children, since it can become a potential hazard. Dispose of packaging material in compliance with applicable legislation.

Do not activate the thermal module without water.

Individuals without specic qualications and skills

are not allowed not remove the thermal module's casing.

Page 5

1.3 Description of the appliance

POWER MAX

it is a condensing, pre-mixed thermal module consisting in a modulating thermal element. It is available in various models, ranging from 35kW to 131kW. Optimal combustion management supports high yields (over 109%, calculated over NVC, in condensation regime) and low polluting emissions (Class 6 pursuant to EN

15502). The thermal module is designed for open chamber operation, but can be converted to sealed chamber operation by

tting a dedicated accessory. The appliance in standard conguration is envisaged for

indoor installation to guarantee an IPX4D protection level.

Appliances may be cascaded

POWER MAX

to reach

a maximum power of 1.12 MW.

The appliance's key technical features are

- pre-mix burner with constant air-gas ratio;

- helicoidal heat exchanger with double coil with smooth stainless steel pipe, to guarantee good corrosion resistance and the option of operating with high ∆ts (up to 40°C), reducing system set-up times;

- power from 35 to 131 kW;

- maximum ue gas output temperature 100°C;

- microprocessor management and control with self-diagnostics, shown by means of a display, and logging of main errors;

- Anti-Frost function;

- pre-setting for room/heat demand thermostat for low and high temperature ranges;

- option to manage a CH circuit and a DHW circuit with storage tank;

- high-efciency and high residual discharge head circulator (for models up to 70kW; a circulator is available as an accessory upon request for other models);

- climate control function (available only when using the outdoor temperature sensor accessory).

1.4 Safety devices

All appliance functions are electronically controlled by a dual processor technology board approved for safety functions. Any malfunction results in the appliance being shut down and the automatic closure of the gas valve.

The following is installed on the water circuit:

Safety thermostat

Flow sensor

capable of monitoring the main circuit's

ow on an ongoing basis and of stopping the appliance in the event of insufcient ow.

Temperature probes

on delivery and return lines that

measure the temperature difference (∆t) between input and output uid and enable activation of the

control.

Minimum pressure switch

The following is installed on the combustion circuit:

Gas solenoid

in class B+C , with pneumatic gas ow

compensation depending on the suction line's air

ow rate.

Ignition/detection electrode

Flue gases temperature probe

The triggering of safety devices indicates the malfunction of a potentially hazardous thermal module. Therefore, contact Technical Assistance Centre immediately. After a brief pause, it is possible to try and restart the appliance (see Paragraph "Initial startup").

Safety devices must be replaced by Technical Assistance Centre, using only original parts. Refer to the spare parts catalogue supplied with the appliance. After making the repair, check that the appliance is working properly.

The appliance must not be put in service, even temporarily, when tampered safety devices are not in operation or have been tampered with.

Page 6

1.5 Identication

The products are identied by:

1 Technical data plate

It indicates the technical and performance data.

2 Gas label

Is located on the appliance's side and states the type of fuel used and the country of destination.

Paese di destinazione:

Tipo di apparecchio Caldaia categoria::

B23

II2H3+

Pressioni di alimentazione gas:

Regolazione effettuata dal costruttore:

G20 - 20 mbar - 2H METANO

ATTENZIONE

Leggere attentamente il libretto istruzioni prima di installare e mettere in servizio l'apparecchio.

(Laterale DX)

Temperatura ambiente:

min. -10°C max. 50°C

Questo apparecchio puó essere installato e funzionare all'aperto o solo in locali permanentemente ventilati secondo norma UNI7129.

068411_E0

G20 20 mbar G30 28-30 mbar G31 37 mbar

European Directive

92/42/EEC:

Gas type:

Category:

Caldaia a condensazione - Chaudierè a condensation - Brennwertkessel - Condenserende verwamingsketel

G20 G25

Qn(max)=

Cod.

N°

Pn(max)=

Qn(min)=

Pn(min)=

P.min.G20= 20 mbar

G20 - 20 mbar

NOx:

bar

°C

T067692GE

CALDAIA REGOLATA PER:

CHAUDIERE REGLEE POUR:

KESSEL GEREGELT FUR:

VERWARMINGSKETEL INGESTELD OP:

KEDEL REGULERET TIL:

CENTRALA REGLATA PENTRU:

A KAZAN AZ ALABBI ADAKTORA LETT BEALLITVA:

PAESE DI DESTINAZIONE:

PAYS DE DESTINATION:

LAND VON BESTEMMING:

BESTIMMUNGSLAND:

LAND,HVOR KEDLEN SKAN INSTALLERES:

TARA DE DESTINATIE:

RENDELTETESI ORSZAG:

PMS=

Beretta Caldaie Via Risorgimento, 13 23900 Lecco (LC)

Central heating section

Rated heat input

Rated useful heat output

Electric degree of protection

PMS

Maximum operating pressure, CH circuit

Temperature

Efciency

NOx

NOx class

If these plates or any other means of clearly identifying the product are defaced, removed or lost, proper installation

and servicing may be rendered difcult.

Page 7

1.6 System layout

POWER MAX

50 P DEP - 50 P

13 14 15

2 3

23 22

Flue gas analysis outlet

Flue gas exhaust connection

Gas valve

Fan

Flue gases pressure switch

Combustion chamber

Electrical panel

Minimum Pressure Switch set at 0,7 bar

Exhaust ue probe

Condensate drain siphon

Drain cock

Main switch

Central heating return

Gas supply

Central heating ow

Condensate drain connection

Flow-meter

Pump

Return probe

Control panel

Safety Thermostat with manual reset by PCB

Flow probe

Automatic bleed valve

Ignition/detection electrode

Casing

Smoke-exhaust ue non-return valve

Page 8

POWER MAX

65 P - 80 P

1 2

10 16

1211 13 14

Flue gas analysis outlet

Flue gas exhaust connection

Gas valve

Fan

Combustion chamber

Electrical panel

Smoke-exhaust ue non-return valve

Drain cock

Minimum Pressure Switch set at 0,7 bar

Pump

Main switch

Central heating return

Gas supply

Central heating ow

Condensate drain connection

Flow-meter

Exhaust ue probe

Return probe

Control panel

Ignition/detection electrode

Safety Thermostat with manual reset by PCB

Flow probe

Automatic bleed valve

Casing

Page 9

POWER MAX

100 - 110 - 130 - 150

109 11 12

Flue gas analysis outlet

Flue gas exhaust connection

Fan

Combustion chamber

Electrical panel

Smoke-exhaust ue non-return valve

Drain cock

Minimum Pressure Switch set at 0,7 bar

Main switch

Central heating return

Gas supply

Central heating ow

Condensate drain connection

Flow-meter

Gas valve

Exhaust ue probe

Return probe

Control panel

Ignition/detection electrode

Safety Thermostat with manual reset by PCB

Flow probe

Automatic bleed valve

Casing

Page 10

1.7 Technical specications

Description

POWER MAX

U.M.

50 P DEP

50 P 65 P 80 P 100 110 130 150

Appliance type

Condensing boiler heating system

B23, B53; B53P Fuel G20-G25-G30-G31 Device category II2H3P Combustion chamber vertical Maximum rated heat input at furnace referred to HVC

(LCV)

38,7

(34,9)50(45)63(57)76(68)

100 (90)

108 (97)

124

(112)

146

(131)

Minimum rated heat input at furnace referred to HVC (LCV)

(9)10(9)15(14)15(14)

21,6

(19,4)

21,6

(19,4)

24,9

(22,4)

29,2

(26,2)

Useful (rated) heat output 34,4 44,2 56 68 88 95 110 129 kW Maximum rated heat output (80-60°C) P4 G20 34,4 44,2 55,7 67,0 88,3 95,3

109,8 129,0

Maximum rated heat output (50-30°C) - G20 38,0 48,8 61,9 73,9 97,4

105,1 121,1 142,1

Maximum nominal heat output (6040°C)

- G20 36,6 47,0 59,6 71,4 93,8

101,1 116,2 137,3

30% heat output with return at 30°C P1 G20 11,5 14,7 18,7 22,3 29,4 31,7 36,6 43,0 kW Minimum rated heat output (80-60°C) - G20 8,9 8,9 13,5 13,5 19,2 19,2 22,1 26 kW

Efciency class in central heating mode A A A A - - - - Seasonal energy efciency in central

heating mode

ηs

94 94 94 94 94 94 94 94 %

Efciency at rated heat input and High

temperature GCV (NCV) regime

η4

useful Pn

(60-80°C)

88,5

(98,4)

88,4

(98,3)

88,4

(98,3)

88,2

(97,9)

88,3

(98,0)

88,2

(97,9)

88,6

(98,3)

88,2

(97,9)

Efciency at 30% of the nominal thermal ow and on low PCS temperature

regime

η1

useful

30% of

98,4

(109,5)

98,2

(109,2)

98,2

(109,2)98(108,8)

98,1

(108,9)98(108,8)98(108,8)

98,1

(108,9)

Chimney losses with burner on at max. Pn (80-60°C) 2,3 2,3 2,3 2,3 2,5 2,6 2,5 2,6 % Chimney losses with burner on at max. 30% Pn (50-

30°C)

0,5 0,5 0,5 0,5 0,6 0,6 0,5 0,6 %

Heat loss in standby mode Pstby

45 57 72 87 115 124 143 168 W

0,1 % Annual energy consumption QHE 71 91 117 141 - - - - GJ Noise level (sound power)

LWA

at P max 51 52 53 54 55 56 57 57 dB(A)

Emissions (*)

NOx

(referred

to HCV)

42,0 43,9 34,2 36,4 38,1 38,7 39,3 46,1

mg/

kWh

Emissions at max./min. heat input, G20

2 9 - 9 %

63/2,3 73/2,3 79/6,5 90/6,5 81/7,5

91,5/7,5

89/4,6

91,5/5,6

ppm Maximum rated heat input (LCV) G25 35 50 53 65 85 93 107 127 kW Minimum rated heat input (LCV) G25 9 9 13 13 18,1 18,5 21,4 24,5 kW

Emissions at max./min. heat input, G25

2 9 - 9 %

72/3,2 80/3,2

92/7

93,5/7

84/8 94/8 92/6 95/7 ppm

Emissions at max./min. power G30

2 10,4-9,9 10,4-10,4 %

132/6 137/6

138/10 142/10 148/11 159/11 172/13 180/15

ppm

Emissions at max./min. power G31

2 10,4-9,9 10,4-10,4 %

136/8 141/8

142/11 147/11 153/12 163/12 177/14 185/16

ppm Flue gas temperature at max. power and min. power

80-60°C

66,5/61 67,5/61

71/61 72/61 76/62 78/62 75/61 77/61

°C

Flue gas temperature at max. power and min. power 50-30°C

44/32 45/32 45/33 46/33 47/35 49/35 45/33 48/35

°C

Flue gas mass ow rate (**)

0,015

0,02

0,025

0,03 0,04

0,046

0,05 0,06 Kg/s

(*)

Weights calculated according to EN 15502.

(**)

Values referred to atmospheric pressure at sea level.

Page 11

Description

POWER MAX

U.M.

50 P DEP

50 P 65 P 80 P 100 110 130 150

Water-side resistance (∆T 20°C)

- - - - 160 210 350 510 mbar

Available useful discharge head (∆T 20°C)

420 250 490 390 - - - - mbar Maximum working pressure 6 bar Minimum supply pressure 0,7 bar Maximum permitted temperature 100 °C Lockout thermostat activation temperature 95 °C Adjustment temperature (min / max) 30 / 80 (***) °C Thermal module water content 5 5 15 15 17 17 23 25 l Maximum condensation at 100% rated heat output

(50-30°C)

5,4 7,0 8,9 10,1 13,6 15,0 17,5 19,8 l/h

Power supply 230-50 V-Hz Index of protection IPX4D IP Consumption at full load Elmax 75 105 63 77 150 203 205 302 W Consumption at part load Elmin 31 34 30 30 36 31 44 45 W Electrical consumption in standby

mode

Psb 9 9 13 13 6 6 6 8 W

(***)

Up to 85°C if combined with the plate heat exchanger accessory.

1.8 Pumps

The thermal modulesPOWER MAX 50 P DEP, POWER MAX

50 P, POWER MAX 65 P and POWER MAX 80 P are tted

with a circulator.

Residual head (mbar)

100

200

300

400

500

600

700

800

900

0 1,5 2 2,5 3 3,510,5 4

POWER MAX 65 P POWER MAX 80 P

POWER MAX 50 P DEP

POWER MAX 50 P

Flow-rate (m3/h)

At the rst start-up, and at least once a year, the rotation of the circulator shaft should be checked as, especially after long periods of not being operated, deposits and/or residuals could impede its free rotation.

Before loosening or removing the circulator cap, protect the electric devices located underneath from any water that exits.

It is prohibited to operate the circulators without water.

Thermal modules POWER MAX 100, POWER MAX 110, POWER MAX 130 and POWER MAX 150 are not equipped with a circulator, which must be inside or outside the appliance (see accessories). For its sizing, consider the thermal module's water-side pressure drops, which are shown in the chart below.

Water-side pressure drop

Pressure drop (mbar)

100

200

300

400

500

600

700

800

900

1000

0 3 4 5 6 7 8 921

POWER MAX 110 POWER MAX 100

POWER MAX 130

POWER MAX 150

Flow-rate (m3/h)

Page 12

1.9 Water circuit

MIRI

1 6 7 8

Heat exchanger

Circulator (only for models POWER MAX 50 P DEP - POWER MAX 80 P)

Drain cock

Minimum pressure switch

NTC return probe

NTC delivery probe

Safety thermostat temperature sensor

Automatic bleed valve

Flow-meter

Central heating ow

Central heating return

Values of NTC probes' resistors with changing temperatures.

Temperature

°C

Tolerance test

±10%

Resistor

Temperature

°C

Tolerance test

±10%

Resistor

-40 191908 45 4904

-35 146593 50 4151

-30 112877 55 3529

-25 87588 60 3012

-20 68471 65 2582

-15 53910 70 2221

-10 42739 75 1918

-5 34109 80 1663 0 27396 85 1446 5 22140 90 1262

10 17999 95 1105 15 14716 100 970 20 12099 105 855 25 10000 110 755 30 8308 115 669 35 6936 120 594 40 5819 125 529

1.10 Positioning the temperature sensors

Probes placed on the related sockets of the thermal module (POWER MAX 50 P DEP - POWER MAX 50 P):

Exhaust ue probe

Safety thermostat temperature sensor

CH ow temperature sensor

Return probe

Front view Side view

Probes placed on the related sockets of the thermal module (POWER MAX 65 P ÷ POWER MAX 150):

Exhaust ue probe

Safety thermostat temperature sensor

CH ow temperature sensor

Return probe

3 2

Front view Side view

Page 13

1.11 Control panel

CONTROL PANEL AND SYMBOLS

PROG

RESET

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

OUTSIDE

°C °F

BAR PSI

1 2 3 4 5 6

Icon displayed when heating mode is enabled. Blinking when there is a heat demand

Icon displayed when DHW mode is enabled. Blinking when there is an DHW Demand

Icon displayed when entering the "Installer" or "Manufacturer" menu

Icon displayed when the appliance burner is on

Icon displayed when a Permanent or Temporary error occurs

Icon displayed when the climatic mode is on (Par. 2001= 1 o 2)

Celsius/Fahrenheit temperature

Large numeric display: current value

Small numeric display: system pressure display or parameter number

Icon displayed when the outdoor probe is connected

Page 14

2 INSTALLATION

2.1 Unpacking the product

The thermal module

POWER MAX

is shipped palletised, packaged and with cardboard protections. The following material is supplied in a plastic envelope inside the package (1):

- Instruction manual

- Warranty information leaet B

- LPG conversion kit

- Wall-mounting bracket with plugs (no.4 plugs s=10 mm suitable for concrete, brick, compact stone and concrete hollow brick walls)

- Hydraulic test certicate

- Energy Efciency Label (for models <70kW)

2.1.1 Positioning of labels

CALDAIA MURALE A GAS WALL HUNG GAS BOILER CHAUDIERE MURALE A GAZ GAS - WANDHEIZKESSEL

Packing label

The instruction manual is an integral part of the appliance; therefore, it should be read and stored carefully.

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.

2.2 Overall dimensions and weights

Description

POWER MAX

50 P DEP

50 P 65 P 80 P

L 600 600 600 600 mm P 435 435 435 435 mm H 1000 1000 1000 1000 mm Net weight 65 65 70 64 kg

Description

POWER MAX

100 110 130 150

L 600 600 600 600 mm P 435 435 435 435 mm H 1000 1000 1165 1165 mm Net weight 78 78 90 95 kg

Page 15

2.3 Installation premises

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 and Regulations applicable to the installation site.

When installing the boiler, allow sufcient space

around it to access all safety and control devices and to permit easy maintenance.

Check that the electric protection level of the appliance is suitable for features of the room where it is installed.

Make sure that comburent air is not contaminated by

substances containing chlorine or uorine (elements

found in sprays, paints, detergents etc.).

Do not obstruct or restrict the air vents in the room where the boiler is installed. A free air supply is essential for correct combustion.

It is forbidden to leave ammable containers and

substances in the room where the thermal module is installed.

2.3.1 Recommended minimum distances

Clearances for the assembly and the maintenance of the

appliance are shown in the gure.

≥ 1 m

≥ 0,85 m

≥ 0,4 m

≥ 0,5 m

The minimum surface of ventilation openings is 3,000 cm2 for gas fuel heating systems.

2.4 Installation in older systems and systems requiring modernisation

When installing these boilers in older systems or systems requiring modernisation, always perform the following checks:

- Make sure that the ue is able to withstand the temperature of the combustion gases and that it has been designed and made in compliance with applicable standards. The ue must also be as straight as possible, sealed, insulated and not blocked or choked. See Paragraph "Discharge of combustion products" for any additional information.

- Make sure that the electrical supply system has been

installed by a qualied electrician in compliance with

applicable standards

- 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 contain the additional volume generated by thermal expansion

- Make sure that the ow rate, head and direction of

ow of the pumps are suitable and correct

- The system has been washed, cleaned of mud and grime and water seals have been checked

- A treatment system is tted when the supply/rell water has values other than those indicated in Paragraph "Water quality requirements"

The manufacturer declines all responsibility for dam-

age caused by incorrectly constructed ue systems.

Page 16

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 appliance's size. Make sure that the load is not unbalanced during handling.

Proceed as follows to remove the packing:

- Remove the strapping that secures the cardboard packaging to the pallet

- Remove the cardboard

- Remove edge protectors (1)

- Remove the Styrofoam protection (2)

- Remove the protective bag (3)

2.6 Thermal module assembly

Thermal modules

POWER MAX

are supplied complete with

a wall-mounting bracket.

Check that the wall on which the appliance is to be tted is sufciently solid and supports safe screw xing points.

The appliance's height must be selected so as to facilitate dismantling it and maintaining it.

Model Height (H) mm

POWER MAX 50 P DEP 1850<H<2000 POWER MAX 50 P 1850<H<2000 POWER MAX 65 P 1850<H<2000 POWER MAX 80 P 1850<H<2000 POWER MAX 100 1850<H<2000 POWER MAX 110 1850<H<2000 POWER MAX 130 2000<H<2150 POWER MAX 150 2000<H<2150

For installation:

- Position the bracket (1) onto the wall (2), at the point where you wish to install the appliance

- Ensure that the bracket is horizontal and mark the

points where the holes for xing plugs must be drilled

- Drill the holes and insert expansion plugs (3)

- Fix the bracket to the wall using the screws (4)

- Secure the appliance onto the bracket

Page 17

After installing the thermal module:

- remove the locking screw

- pull the front panel outwards and then to the top to decouple it from points A.

Locate the envelope containing the product documentation

and stick the Energy Efciency Label (if any) contained in

the envelope onto the panel.

25 kW

30 mm

25 mm

Close the panelling in reverse order to the one described above.

Before proceeding with the hydraulic connections the protection plugs must be removed from the delivery, return and condensate drain piping.

Page 18

2.7 Water connections

The dimensions and position of thermal module's hydraulic connections are shown in the table below.

Front view Bottom view

RI MI

RI G MI

DESCRIPTION

POWER MAX

50 P DEP

50 P 65 P 80 P 100 110 130 150

A 387 387 387 387 387 387 387 387 mm B 143,5 143,5 143,5 143,5 143,5 143,5 143,5 143,5 mm C 63,5 63,5 63,5 63,5 63,5 63,5 63,5 63,5 mm D 283,5 283,5 283,5 283,5 283,5 283,5 283,5 283,5 mm E 98,5 98,5 98,5 98,5 98,5 98,5 98,5 98,5 mm F 92,5 92,5 92,5 92,5 92,5 92,5 92,5 92,5 mm H (optional 3-way valve

attachment)

202,5 202,5 - - - - - - mm

MI (system ow)

G 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2

RI (system return)

G 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2 MG 1" 1/2

SC (condensate drain) 25 25 25 25 25 25 25 25 Ø mm G (gas inlet) G 1" M G 1" M G 1" M G 1" M G 1" M G 1" M G 1" M G 1" M Ø

Before connecting the thermal module the protection plugs must be removed from the delivery, return and condensate drain pipes.

Before connecting the thermal module, it is necessary to clean the system. This step is absolutely required when the appliance replaces another one on pre-existing systems.

In order to carry out this cleaning activity, if the old generator is still installed on the system, it is advisable to:

- add a de-scaling additive.

- Operate the system with the generator on for around 7 days.

- Discharge dirty system water and ush the system one or more times with clean water.

If the system is very dirty, repeat the last procedure one more time. If the old generator is not present or available, use a pump to circulate the water + additive through the system for

about 10 days and perform a nal washing as described in

the previous paragraph. Once the cleaning has been completed, it is recommend-

ed to add a suitable protective uid to the system's water

before installing the thermal module. In order to clean the heat exchanger's built-in water system, please contact Technical Assistance Centre

Do not use incompatible liquid detergents, including acids (for instance, chloridric acid and similar) in any concentration.

Do not subject the heat exchanger to cyclical pressure changes because fatigue stress is very dangerous for the integrity of system components.

Page 19

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 sufcient to ensure adequate circulation)

10 9

EAF

Layout 2: circuit with thermal module directly linked to heating system and DHW tank. (check that the pump's

discharge head is sufcient to ensure adequate circulation)

UAC

EAF

10 9

EAF

Isolating valve

Non-return valve

DHW circulation pump

Expansion tank

Safety valve

Drain

Pressure gauge

Pressure switch

Water softener lter

Pressure reducer

Storage cylinder

Automatic bleed valve

Diverter valve

Pump (tted as standard for models POWER MAX 50 P DEP and POWER MAX 80 P)

High-temperature system circulator

Storage cylinder circulator

Outdoor sensor

High temperature

system ow

High temperature

system return

EAF

Domestic cold wa-

ter inlet

UAC

Domestic hot water

outlet

Domestic hot water and central heating circuits must be completed with expansion vessels of adequate capacity and suitable, correctly-sized safety valves. The discharge of safety valves and appliances must be connected to a suitable collection and disposal system (see Catalogue for compatible accessories).

The choice of system components and the method of their installation are left up to the heating engineer installing the system. Installers must use their expertise to ensure proper installation and functioning in conformity to all applicable legislation.

Special supply/rell water must be conditioned using suitable treatment systems.

It is prohibited to operate the thermal module without water.

Page 20

Layout 3: circuit with thermal module connected to a heating system via a separator

10 9

EAF

Layout 4: circuit with thermal module linked to DHW tank and heating system via a separator

UAC

EAF

10 9

EAF

Isolating valve

Non-return valve

DHW circulation pump

Expansion tank

Safety valve

Drain

Pressure gauge

Pressure switch

Water softener lter

Pressure reducer

Storage cylinder

Automatic bleed valve

Diverter valve

Pump (tted as standard for models POWER MAX 50 P DEP and POWER MAX 80 P)

High-temperature system circulator

Storage cylinder circulator

Outdoor sensor

High temperature

system ow

High temperature

system return

EAF

Domestic cold wa-

ter inlet

UAC

Domestic hot water

outlet

Special supply/rell water must be conditioned using suitable treatment systems.

It is prohibited to operate the thermal module without water.

Page 21

Layout 5: circuit with thermal module linked to heating system and DHW. tank via a separator

UAC

EAF

10 9

EAF

Isolating valve

Non-return valve

DHW circulation pump

Expansion tank

Safety valve

Drain

Pressure gauge

Pressure switch

Water softener lter

Pressure reducer

Storage cylinder

Automatic bleed valve

Diverter valve

Pump (tted as standard for models POWER MAX 50 P DEP and POWER MAX 80 P)

High-temperature system circulator

Storage cylinder circulator

Outdoor sensor

High temperature

system ow

High temperature

system return

EAF

Domestic cold wa-

ter inlet

UAC

Domestic hot water

outlet

Special supply/rell water must be conditioned using suitable treatment systems.

It is prohibited to operate the thermal module without water.

Page 22

2.9 Gas connections

The gas connection must be made respecting the installation regulations in force, and sized to ensure the correct gas delivery to the burner. Before making the connection, check that:

The gas type is suitable for the appliance

If the appliance needs to be adapted for use with another gas fuel, contact your local Technical As-

sistance Centre to have the necessary modications

made. These operations may not be performed by the installer under any circumstances.

The piping is thoroughly clean

The gas meter's ow rate is capable of ensuring the

simultaneous use of all the appliances connected to it. The appliance's connection to the gas supply line must be carried out in accordance with the current regulations.

Intake pressure with the appliance in the off position has the following reference values:

- powered by methane gas: optimal pressure 20

mbar

- powered by L.P.G.: optimal pressure 35 mbar

Check that the pressure never falls below 15 mbar

Do not use any fuels other than those provided under any circumstances.

While it is normal for the intake pressure to decrease while the appliance is in operation, it is advisable to verify that

no excessive pressure uctuations take place. In order to

limit the extent of these types of variations, the diameter of the gas supply line to be used must be assessed based on the length and the pressure drops of the line itself, from the meter to the thermal module.

If uctuations in the gas distribution pressure are encountered, it is recommended to install an appropriate pressure stabiliser upstream of the appliance's gas intake. For G30 and G31 gas supply, all the necessary precautions must be taken in order to prevent the gas from freezing in the case of extremely low outdoor temperatures.

If the gas distribution network contains solid particles, in-

stall a lter on the fuel supply line. When selecting it, consider that pressure drops due to the lter should be as low

as possible.

On completion of the installation, check that all joints are sealed.

GAS 1" M

2.10 Discharge of combustion products

The appliance is supplied as standard in B-type conguration (B23-B23P-B53P), i.e. pre-tted to suction air direct-

ly into the installation room and may be converted into a

C-type appliance with the use of specic accessories. In this conguration, the appliance will suction the air directly

from outdoors, with the possibility of coaxial or dual piping.

For ue gas extraction and the intake of combustion air, it is essential to use only specic pipes for condensing boilers

and ensure that they are correctly connected, as shown

in the instructions supplied with the ue gas accessories.

Do not connect this appliance's ue gas extraction pipes with those of other appliances, unless

this is specically authorised by the manufacturer.

Non-compliance with this precaution may cause a build-up of carbon monoxide in the room where the appliance is installed. This could jeopardise people's health and safety.

For further information on ue gas extraction pipes for

thermal modules connected in a cascaded system, see Catalogue and the instructions provided for the relevant accessories.

Ensure that combustion air (suction line air) is not contaminated by:

- waxes/chlorinated detergents

- chemical products based on swimming pool chlorine

- calcium chloride

- sodium chloride use to soften tap water

- refrigerant leaks

- paint or varnish removers

- chloridric acid/muriatic acid

- cements and glues

- anti-static softeners used in dryers

- chloride used for domestic or industrial applications as detergent, whitener or solvent

- adhesives used to glue construction and other similar products.

To prevent contamination of the thermal module, do not install suction line air intakes and gas ue extraction pipes near:

- dry-cleaners/laundry rooms and factories

- swimming pools

- metal processing plants

- beauty parlours

- fridge repair shops

- photo-processing facilities

- body-shops

- plastics manufacturing plants

- furniture workshops and manufacturing plants.

Page 23

UF AA

326

230

The AA outlet is supplied capped in B23 conguration.

DESCRIPTION

POWER MAX

50 P DEP

50 P 65 P 80 P

FO (ue gas outlet) DN80 DN80 DN80 DN80 Ø AS (air suction) DN80 DN80 DN80 DN80 Ø

DESCRIPTION

POWER MAX

100 110 130 150

FO (ue gas outlet)

DN110 DN110 DN110 DN110

AS (air suction)

DN110 DN110 DN110 DN110

For B-type installation, combustion air is taken from the environment and goes through the openings (shutters) on the rear panel of the device that must be located in a suitable and ventilated technical room.

Read the requirements, instructions and prohibitions detailed below carefully, since non-compliance with them may be result in a safety hazard or the appliance's malfunction.

Condensation appliances described in this hand-

book must be installed with ue gas pipes compliant

with applicable legislation and expressly manufac-

tured for this specic use.

Check that pipes and joints are not damaged.

Joint seals must be executed with materials that withstand the condensate's acidity and the temperatures

of the appliance's ue gases.

When installing ue pipes, always bear in mind the direction of the ue gases and of possible condensate ows.

Inadequate or incorrectly sized ue gas pipes may

increase combustion noise, create condensate extraction issues and negatively impact on combustion parameters.

Check that pipes are suitably far (min. 500 mm) from

ammable or heat-sensitive construction elements.

Make sure that condensation is not built up along the duct. For this purpose, provide a sloping duct of at least 3 degrees towards the appliance in case there is an a horizontal section. If the horizontal or vertical section is longer than 4 meters, a condensate siphon drainage must be provided at the base of the pipe. The useful height of the siphon must be at least equal to the value "H" (see gure below). The siphon discharge must then be connected to the sewerage system (see paragraph "Preparation for the condensate drain" on page 24).

It is prohibited to block or section the ue gas extraction pipe or the combustion air suction pipe, if any.

It is prohibited to use pipes that not designed for this application, because the condensate's action would damage them quickly.

Maximum equivalent lengths are provided below.

Maximum equivalent length

of ue gas exhaust pipe

Pressure drop

45° bend 90° bend

30 m 1 m 3 m

The table with available residual discharge heads is shown below.

Description

Discharge head

Max Min

POWER MAX 50 P DEP 300 45 POWER MAX 50 P 480 45 POWER MAX 65 P 510 35 POWER MAX 80 P 630 35 POWER MAX 100 560 32 POWER MAX 110 610 32 POWER MAX 130 500 30 POWER MAX 150 353 28

The residual discharge head values are shown in Pascal.

≥3°

H 350 mm

To change direction, use a T section with an inspection cap to permit easy access for cleaning inside the pipe. After cleaning, always make sure that inspection caps are replaced tightly and that their seals are undamaged and

efcient.

Page 24

2.10.1 Preparation for the condensate drain

The exhaust of the condensation produced by the appliance

POWER MAX

during its normal operation, must be carried out with an accessory (siphoned condensate collector) that needs to be installed below the thermal module itself

as specied in its assembly instructions. The condensate

coming out of the drainer must be collected for dripping into a taped vessel connected to the sewer system, if necessary by interposing a neutralizer (for more information see paragraph "Neutralising the condensate"), according to the following procedure:

- Fit a drip tray near the condensate discharge outlet, adding a condensate neutraliser if necessary

- Connect the drip collection receptacle to the local drain or sewer system using a siphon.

The drip tray can be created by tting a cup or simply a

polypropylene bend, suitable for collecting the condensate that comes out of the appliance and any liquid leaking from the safety valve. The maximum distance between the condensate drainage of the appliance and the socket (or socket pipe) must not be less than 10 mm. The connection to the local drain or sewer system must be executed using a siphon in order to prevent unpleasant odours from being released back into the room from the sewer. We advise using plastic (PP) piping for building the condensate drainage.

Never use copper pipes under any circumstances, as the condensate itself will cause them to rapidly deteriorate.

Drip tray

Condensate

basing

(accessory)

i >3% residential discharge

Execute the condensate drain outlet so as to prevent combustion gases leaking into the environment or the drain or sewage system by sizing the siphon (height H) as described in Paragraph "Discharge of combustion products".

Always maintain a slope angle “s” of over 3° and ensure that the diameter of any condensate drain pipe

is greater than that of the connection tted at the

drain outlet

Connect the condensate drain hose to a domestic water drain in accordance with national and local legislation and standards.

Fill the siphon with water before activating on the thermal module in order not to release any combustion products into the environment when the thermal

module is rst switched on.

The condensate drain must be suitably siphoned. Fill the siphon with drain in order to prevent the release

of combustion products when the appliance is rst

switched on.

It is recommended that condensate from the thermal

module and from the ue should be channelled to the

same drain pipe.

The connection pipes used must be as short and as straight as possible. Any curves or sharp bends can lead to hoses becoming clogged and, therefore, can prevent proper condensate discharge

Size the condensate drain outlet so as to ensure the proper drainage of waste liquids without leaks

The condensate drain must be connected to the drain and sewage network in such a ways so that the condensate may not freeze under any circumstances

2.11 Neutralising the condensate

The UNI 11528 Standard provides for mandatory neutralisation of condensate for systems with total power of over 200 kW. For systems with total power from 35 to 200 kW, neutralisation may or may not be mandatory depending on the number of ats (for residential applications) or the number of occupants (for non-residential applications) served by the aforementioned system.

2.11.1 Water quality requirements

It is ABSOLUTELY NECESSARY to treat the water system in order for the heat generator to work properly and to guarantee its service life, as well as that of all its components. This not only applies to jobs carried out on existing installations but also on new installations. Sludge, lime-scale and pollutants contained in the water can cause permanent damage to the heat generator, also within a short time and notwithstanding the quality standards of the materials used. Contact the Technical Assistance Centre for any further information on type and use of additives.

The heat transfer uid (water) for the central heating circuit

must conform to the quality parameters given in the following table:

Page 25

Parameters Value Unit

General characteristic

Colourless, without

sediment

PH value Min. 6.5; Max. 8 PH

Dissolved oxygen < 0,05 mg/l

Total iron (Fe) < 0,3 mg/l

Total copper (Cu) < 0,1 mg/l

Na2SO3 < 10 mg/l

N2H4 < 3 mg/l

PO4 < 15 mg/l

CaCO3 Min. 50 ; Max.150 ppm

Trisodium phosphate None ppm

Chlorine < 100 ppm

Electrical conductivity <200

micro-

siemens/

Pressure Min. 0.6; Max. 6 bar

Glycol

Max. 40% (only pro-

pylene glycol)

All data in the table refer to water contained in the system after 8 weeks' operation.

Do not use excessively softened water. Excessive water softening (total hardness < 5° f) results in corrosion due to contact with metal elements (pipes or thermal module components)

Immediately repair any leaks or drips that could result in air entering the system

Excessive pressure uctuations can cause stress

and fatigue to the heat exchanger. Keep the operating pressure constant.

Water used to ll a system for the rst time and water used to top it up must always be ltered (using synthetic or metal mesh lters with a ltration rating of no

less than 50 microns) to prevent sludge from forming and triggering deposit corrosion.

If oxygen enters a circuit continuously or even inter-

mittently (e.g. in under-oor heating systems whose

pipes are not protected by impermeable synthetic sheaths, in circuits with open expansion vessels, or in circuits that require frequent top-ups) always separate the boiler’s water circuit from the central heating circuit.

It is prohibited to top up the heating system constantly or frequently, since this can damage the thermal module's heat exchanger. The use of automatic topping up systems should be avoided for this reason.

To sum up, in order to eliminate contact between air and water (and to prevent the latter from becoming oxidized), it is necessary:

- that the expansion system be a closed vessel, correctly sized and with the correct pre-loading pressure (to be regularly checked);

- that the system be always at a pressure higher than the atmospheric one at any point (including the pump suction side) and under any operating conditions (all seals and hydraulic couplings in a system are designed to withstand pressure towards the outside, but not underpressure);

- the installation be not made with gas-permeable materials (e.g. plastic pipes without oxygen barrier for

underoor heating systems)

Damages suffered by the thermal module, caused by encrustations and corrosion, are not covered by warranty. In addition, the non compliance of the water requirements listed in this chapter will void the appliance warranty itself.

2.12 System lling and emptying

The thermal module

POWER MAX

must be provided with a charging system to be connected to the appliance's return line.

Before lling or emptying the system, switch the system's

master switch to the OFF position and the thermal module's master switch to (

2.12.1 Filling

- Make sure that drain cocks (1) are closed before you start loading the system

POWER MAX 50 P DEP - POWER MAX 50 P

Page 26

POWER MAX 65 P ÷ POWER MAX 150

- Unscrew the vent valve's release cap

- Open the shut-off cocks in order to slowly ll the system

- Use the pressure gauge to check that the pressure is rising and the water is exiting through the vent valves

- Close the shut-off cocks after the pressure reaches

1.5 bar

- Start the system pumps and the thermal module's pump as shown in Paragraph "Commissioning and maintenance"

- During this stage, check that the air is correctly eliminated

- Restore the pressure if necessary

- Switch the pumps off and on again

- Repeat the last three steps until the pressure is stabilised

The system must be lled up slowly the rst time; once it is lled and the air expelled it should never

need to be topped up again.

Systems should also be operated at maximum work-

ing temperature the rst time they are started up, in

order to facilitate de-aeration. (Gas is not released from the water at low temperatures).

An automatic spurge can be performed during the

rst ignition. The parameter that set the cycle is Par.

2139. See parameter table for more information.

2.12.2 Emptying

Before starting to empty the appliance and the storage cylinder:

- Switch the system's master switch to the OFF position and the thermal module's master switch to (0).

- Close the water supply shut-off cocks;

- In order to empty the appliance, t a rubber hose (2) (inner diameter int. Ø = 12 mm) to the thermal module's discharge valve (1).

POWER MAX 50 P DEP - POWER MAX 50 P

POWER MAX 65 P ÷ POWER MAX 150

Page 27

2.13 Wiring diagram

BUS 2

BOTTOM VIEW

BUS 1 PWMSESB SS24V

MO1

0-10V TA

SCH

PWM

0V (GND)

J9-1

J9-3

J9-2

J9-4

J6-2

J6-1

J6-8

J6-4

J6-11

J6-6

J6-13

J6-7

J6-14

J7-5

J7-10

J8 J11 J12 J7 J10 J9

J8-1

J8-2

J12-5

J12-2

J7-8

J7-7

J7-6

J12-1

J12-4

J7-4

J7-2

J6-5

J6-12

J6-10

J6-3

b h

b bl

b h bl b h b h b h b h b h

1 2 3 4 9 10 11 12 13 14 15 16 17 185 6 7 8

J7-2 h

J7-3 b

PROG

RESET

J25-1 g

J25-2 b

J25-3 y J25-4 w

J25

Key

Ignition/detection electrode

Exhaust ue probe

Flow probe

Return probe

Safety thermostat

Flue gases pressure switch (**)

Minimum pressure switch

Flow-meter

SCH

Display and control card

MO1

Low-voltage terminal board

0-10V

0-10V input

Room/heat demand thermostat

24 V

24V exit

Boiler sensor (accessory)

System probe (accessory)

Outdoor sensor (accessory)

PWM

PWM connection (*)

Cable colour

brown

blue

red

white

black

yellow/green

yellow

green

(*)

Factory connections for models POWER MAX 50 P DEP ÷ POWER MAX 80 P

(**)

Only for models POWER MAX 50 P DEP ÷ POWER MAX 50 P

Page 28

PC (*)

VG1

VE1

MO2

AE (230V ~ 50Hz)PI PC (PS)(ACS) ALPB

PWM

0V (GND)

L N

L LN

L N

J2J1J3

J4J5

J17

J2-1

J2-4

J1-4

J1-5

J1-1

J4-2 J4-3 J4-6 J4-5

J5-2 J5-1

J3-1 J3-7 J3-2 J3-3 J3-8 J3-5 J3-10 J3-4 J2-3 J3-9

J4-4 J4-1

g g

b h

w y b

b g

J3-6

101 102 103 104 105 106 107 108 109 110 111 11 2 113 114 11 5

L NL N

Key

Main switch

VG1

Gas valve

VE1

Variable speed fan

MO2

High-voltage terminal board

Storage cylinder circu-

lator/ 3-way valve/2-way valve (**)

Central heating system pump

(ACS)

DHW circulator (**)

Thermal module circulator (*)

System circulator (**)

Alarm output

Power supply

Cable colour

brown

blue

red

white

black

yellow/

green

yellow

green

(*)

For models POWER MAX 50 P DEP ÷ POWER MAX 80 P circulator tted as standard; for other models, the

circulator is provided as an accessory with connections to be executed by the installer.

(**)

Valid conguration for thermal modules without heat pump c having their own two-way valve, connected

in cascade and equipped with primary system circulator. For more information, see cascade installation manual.

Page 29

2.14 Electrical connections

The thermal module

POWER MAX

is manufactured fully wired and only needs to be connected to the mains, the room/heat demand thermostat and any other system components.

The following is mandatory:

- The use of an omnipolar magnetothermic switch, line disconnecting switch in compliance with CEI-EN standards (contact opening of at least 3 mm)

- Respect the connection L (line) - N (neutral). Keep the earth conductor 2 cm longer than the power supply conductors

- Use cables with a section greater than or equal to 1.5 mm2, complete with cable terminal caps

- Refer to the wiring diagrams in this manual for all electric operations.

The use of adaptors, multiple sockets and extensions to power the appliance is not allowed

to connect external electric components, it is necessary to use auxiliary relays and/or contactors to be

tted in a dedicated external electrical panel

Any work on the electrical system must be carried

out only by qualied personnel in compliance with all

legal provision and safety regulations in particular

Secure the cables into the dedicated cable ties in order to always guarantee their correct positioning within the appliance.

Electrical supply cables and control cables (room/ heat demand thermostat, external temperature probes, etc.) must be strictly separate the one from

the other and tting inside independent ribbed PVC

sheaths up to the electrical panel.

The connection to the electrical power supply must be performed using type 1 sheathed cables (3 x 1,5) N1VVK or equivalent, while simple N07VK type or equivalent conductors can be used for the thermoregulation and low voltage circuits.

If the electrical power provided by the electrical company is of "

PHASE-PHASE

" connection type, preventively contact the nearest Technical Assistance Centre.

Never shut the appliance off during normal operation (with the burner on) by shutting off the electrical power supply using the On-Off key or an external switch. This could cause the primary heat exchanger to overheat.

To switch it off (during the heating stage) use a room/ heat demand thermostat. The On-Off key can only be actioned whist the appliance is in stand-by or emergency mode.

Before connecting any external electrical components to the appliance (regulators, electric valves, climate control probes, etc.), check to make sure that their electrical characteristics are compatible with the available inputs and outputs (voltage, absorption, acceleration current).

Temperature probes must be NTC like. For resistance value, refer to table pag 12

Always check the proper operation of the "grounding conductor" for the electrical system to which the appliance will be connected.

B shall bear no responsibility for any personal

injuries or property damage caused by non-compliance with wiring diagrams or the electrical system's incorrect/lacking connection to the grounding system, or by non-compliance with applicable CEI Standards.

It is strictly forbidden to use pipes of any kind to ground the appliance.

It is prohibited to lay power supply and room/heat demand thermostat cables near hot surfaces (delivery pipes). If they may come into contact with parts that have a temperature of over 50°C, use a suitable type of cable.

It is prohibited to touch electric appliances with damp/wet body parts or when your feet are wet.

It is prohibited to leave the appliance exposed to weather elements (rain, sun, wind, etc.) unless it is equipped with the relevant weatherproof kit.

It is prohibited to pull, detach, or twist any electric cables coming from the thermal module even when the latter is disconnected from the mains power supply.

Proceed as follows to access the control panel terminals:

- Remove the locking screws and the panel's front side

- Pull and slide the electrical panel's box towards the outside (1)

Page 30

Loosen the xing screws (2) and remove the protection (3)

- Identify the low-tension terminal board (MO1) and the high-tension terminal board (MO2)

MO1

MO2

MO1

Control signals terminal board

MO2

Output terminal board

Cable guide

For the connection of the devices connected to the jig (pumps, circulators and diverting / mixing valves) use interposed relays unless the maximum absorption of all components connected to the board (including the module circulator) is less than or equal to 1.5 A. Relays sizing lays on the installer depending on the type of connected device.

For connection, see the following gure:

~ 230 V

( )

MO2

103104 105 106 107 108 109 110 111 11 2 11 3 11 4 11 5

Circuit breaker

Relay / Switch (230V AC)

(*)

Refer to the device type for the supply tension.

- Execute electrical wiring in compliance with the diagrams shown below

Power supply

230V ~ 50Hz

L N

104 105 106 107 108 109 11 0 111 112 113 114 115

L NL N

MO2

Live

Neutral

Earth/ground

Electrical wiring referred to layout 1 at page "19".

MO1

BUS 1 SESB SS24 V0-10V TA

1 2 3 4 9 10 11 12 13

5 6 7 8

TATA

Room/heat demand thermostat

NOTE

The room thermostat connection must be dry (no

voltage).

Page 31

Electrical wiring referred to layout 2 at page "19".

MO1

BUS 2BUS 1 PWMSESB SS24 V0-10V TA

3 4 9 10

11 12 13 14 15 16 17

5 6 7 8

TA SB PB

MO2

PIPB

L N

L LN

101 102 103 104 105

106

Room/heat demand thermostat

Connect to the storage cylinder probe (Mod.

San. 1) or to the storage cylinder thermostat (Mod. San. 2)

Connect to the deviating valve (13). Contacts 101102 control the deviation on heating, contacts 102103 control the deviation on domestic hot water

NOTE

The room thermostat connection must be dry (no voltage).

Electrical wiring referred to layout 3 at page "20".

MO1

BUS 2BUS 1 PWMSESB SS24 V0-10V TA

3 4

9 10 11 12 13 14 15 16 17

5 6 7 8

TA PI

MO2

PI PC (PS)(ACS)PB

L N

L LN

L N

101 102 103 104 105 106 107 108 109

Room/heat demand thermostat

Connect to the high temperature system pump

NOTE

The room thermostat connection must be dry (no voltage).

Electrical wiring referred to layout 4 at page "20".

MO1

BUS 2BUS 1 PWMSESB SS24 V0-10V TA

3 4 9 10

11 12 13 14 15 16 17

5 6 7 8

TA SB PB PI

MO2

PI (ACS)PB

L N

L LN

101 102 103 104 105

106

Room/heat demand thermostat

Connect to the storage cylinder probe (Mod.

San. 1) or to the storage cylinder thermostat (Mod. San. 2)

Connect to the water pump

Connect to the high temperature system pump

NOTE

The room thermostat connection must be dry (no voltage).

Electrical wiring referred to layout 5 at page "21".

MO1

BUS 2BUS 1 PWMSESB SS24 V0-10V TA

3 4 9 10

11 12 13 14 15 16 17

5 6 7 8

TA SB PB PI

MO2

PI (ACS)PB

L N

L LN

101 102 103 104 105

106

Room/heat demand thermostat

Connect to the storage cylinder probe (Mod.

San. 1) or to the storage cylinder thermostat (Mod. San. 2)

Connect to the deviating valve (13). Contacts

101-102 control the deviation on heating, contacts 102-103 control the deviation on domestic hot water

Connect to the high temperature system pump

NOTE

The room thermostat connection must be dry (no voltage).

Some electric connections of the power jig have a double function. With special reference to the principle schemes 2 and 5 where no tank pump is foreseen, the two-way valve of each module must be connected to the abovementioned connections 101-102-103.

Page 32

2.14.1 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.

PROG

RESET

°C

In this mode, keys have the following functions:

Nr. Button Function

1 "+" Raise the heat set point (when available) 2 "-" Decrease the heat set point ( when available) 3 "PROG +" Raise the DHW set point (when available) 4 "PROG -" Decrease the DHW set point (when available)

5 "MENU/RESET"

Enters into "MENU" mode If pressed for more than 2 seconds, it resets a non volatile failure

MENU selection

Enters into "MENU" mode when "MENU/RESET" key is pushed. The gures of the small display indicate "0000" which is the rst accessible menu.

PROG

RESET

In this mode, keys have the following functions:

Nr. Button Function

1 "+" Exits from the menu and cancels a parameter change 2 "-" Exits from the menu and cancels a parameter change 3 "PROG +" Selects the following menu or increases a certain parameter value 4 "PROG -" Selects the previous menu or decreases a certain parameter value 5 "MENU/RESET" Enters into the selected menu/parameter or conrms the parameter change

Page 33

USER menu

Par.

No.

Description Range

Fac-

tory

setting

0000

0003

Sets the desired ow temperature with heating mode. Active

for the heating mode Par. 2001 = 0 o 3

Par. 2023…Par.

2024

70 °C

0048

Establishes the DHW storage tank set-point Par. 2035 in mode 2.

40…71 50 °C

0200

Activates the test mode: off = test mode off fan = the fan is running at the max speed with the burner off lo = module is brought to min (when on) ign = module is brought to the ignition speed (when on) Hi = the module is brought to the max (when on) reg = the module is brought to the max power but it is set according to the temperature (when on)

off/fan/lo/ign/hi/

reg

Off

0901 It denes the temperature units C/F C 0902 It denes the pressure units bar/psi bar

1000

1001 CH ow temperature Only display °C 1002 Domestic hot water temperature Only display °C 1004 Outdoor temperature Only display °C 1006 Flue gas temperature Only display °C 1007 Flue gas temperature Only display °C 1008 Ionisation current Only display μA 1009 Status of the primary pump (on/off) Only display 1010 Status of the heating system pump (on/off) Only display 1011 Status of the DHW pump (on/off) Only display 1012 Calculated heating set point (on climatic mode) Only display °C 1013 Status of the room thermostat/heat demand (opened/closed) Only display 1015 Secondary probe temperature (if on) Only display °C 1031 Error code Only display 1040 Actual fan speed Only display RPM 1041 Ignition fan speed Only display RPM 1042 Fan speed at the minimum Only display RPM 1043 Fan speed at the maximum Only display RPM 1051 Code of the last permanent error Only display 1052 Code of the last temporary error Only display 1054 Number of successful ignitions Only display 1055 Number of failed ignitions Only display 1056 Total heating hours Only display Hr x 10 1057 Total Sanitary hours Only display Hr x 10 1058 Total working days Only display Days

1059

Time delay from the last Permanent error

The measuring unit is dened by the number preceding the

value. 1: = minutes 2: = hours 3: = days 4: = weeks

Only display

1060

Time delay from the last Temporary error

The measuring unit is dened by the number preceding the

value. 1: = minutes 2: = hours 3: = days 4: = weeks

Only display

1062 Water ow of the present module Only display

from/

min 1063 Signal voltage 0-10 on inlet Only display Volt 1098 Scheme type Only display 1099 Software version identication code Only display

Code

---> Enter menu password INSTALLER / MANUFACTURER

Page 34

2.15 Navigation Menu INSTALLER / MANUFACTURER

It is necessary to enter the password to access the INSTALLER / MANUFACTURER parameters

- Press "MENU/RESET" and select "Code" by using the "PROG +" and "PROG -".

- Press "MENU/RESET" to conrm

- "0---" is displayed on the big numeric display and the

rst digit is blinking

- Press "PROG +" and "PROG -" to increase or de-

crease the value of the rst blinking digit

- When the desired value is reached on the single gure, press "MENU/RESET" to conrm the inserted val-

ue thus the second digit starts blinking

- Repeat the same procedure for all four gures and enter the password

After entering the INSTALLER or MANUFACTURER password, the related menu and parameters will be displayed.

The system provides for three types of access: USER: password 0000 INSTALLER: password 0300 MANUFACTURER

After it is entered, the password is active during display and/or parametrisation. If the display is inactive for a few minutes, it needs to be re-entered.

PROG

RESET

In this mode, keys have the following functions:

Nr. Button Function

Page 35

INSTALLER

/ MANUFAC-

TURER

Par.

No.

Description

Range

De-

fault

setting

2000

2001

It denes the several functioning modes of the heat thermal

module.

0…5

2005

Denes the time in seconds of post-circulation of the thermal

module when working in stand-alone mode; when working in

cascade mode, it denes the post-circulation of the module

after switching off for thermoregulation.

0…900

60 Sec.

2007

Sets the value in degrees beyond the set-point at which the burner switches off for thermoregulation.

0…20

5 °C

2009

Sets the stand-by time before the appliance is switched on again after it switches off due to thermoregulation, independently from the delivery temperature dropping below the value indicated in Par. 2010. Parameter valid only in standalone mode.

10…900

120 Sec.

2010

Sets the value in degrees below which the burner switches on again notwithstanding from the time spent at Par. 2009.

0…20

16 °C

2014

Sets the heating's % max. power.

50…100

100 %

2015

Sets the heating's % min. power.

1…30

1 %

2019

Denes the max. set-point at the minimum outdoor temperature for climatic regulation.

30…90

80 °C

2020

Denes the minimum outdoor temperature to which the maximum set-point can be associated for climatic regulation.

-25…25

0 °C

2021

Denes the minimum set-point at the maximum outdoor

temperature for climatic regulation.

30…90

40 °C

2022

Denes the maximum minimum outdoor temperature to

which the minimum set-point can be associated for climatic regulation.

0…30

20 °C

2023

Limits the minimum value that can be assigned to the setpoint in heating mode (does not apply to heating mode 4).

4…82

30 °C

2024

Limits the maximum value that can be assigned to the setpoint in heating mode (does not apply to heating mode 4).

27…90

80 °C

2025

Denes the temperature of exclusion of climatic regulation.

Active for heating mode Par. 2001 = 1 or 2

0…35

22 °C

2026

Establishes the set-point temperature increase delta T, if the

heat demand in heating mode is not satised after the time interval specied in Par. 2027 (applies only to stand-alone

mode).

0…30

0 °C

2027

Denes the time interval after which the set-point is increased as dened in Par. 2026 (applies only to stand-alone

mode).

1…120

20 Min.

2028

Use the heating mode Par. 2001= 2 or 3. Denes how many degrees the ow set point is lowered.

0…30

10 °C

2035

Establishes the domestic hot water circuit's operation mode.

0 Disabled 1 Tank + sensor 2 Tank +

thermostat

2036

Denes the hysteresis to initiate the domestic hot water

demand.

0…20

5 °C

2037

Denes the hysteresis to stop the domestic hot water demand.

0…20

5 °C

2038

Denes the primary circuit's set-point increase in degrees

compared to the temperature set for the domestic hot water tank.

0…30

15 °C

2042

Denes the priority type:

On: priority for DHW; Off: priority for CH;

Time: time priority between the two circuits dened by Par.

2043; Parallel: parallel priority managed on the basis of the primary circuit's temperature compared to the heating circuit's setpoint.

On Off Time Parallel

2043

Establishes the time in minutes during which priority is alternatively allocated to the DHW and CH circuits when Par. 2043 is set to "time" mode.

1…255

30 Min.

2044

Denes the time in seconds of post-circulation of the thermal

module when working in stand-alone mode; when working in

cascade mode, it denes the post-circulation of the module

after switching off for thermoregulation.

0…900

60 Sec.

Page 36

2000

2092

Denes the number of fan rpm at max. power (it depends on the model and is dened at Par. 9098).

0…12750

De-

ned

Par.

9098

RPM

2093

Denes the number of fan rpm at minimum power (it depends on the model and is dened at Par. 9098).

0…12750

De-

ned

Par.

9098

RPM

2094

Denes the fan speeds on the module start up (depending on the model dened on Par. 9098).

0…12750

De-

ned

Par.

9098

RPM

2109

Denes the offset of the calculated set point on climatic

mode (Par. 2001= 1). Makes a climatic curve compensation.

Off, -10…10

2110

Sets the minimum delivery temperature value in heating mode (Par. 2001) = 4.

20…50

30 °C

2111

Sets the maximum delivery temperature value in heating mode (Par. 2001) = 4.

50…90

80 °C

2112

Sets the value in degrees below the set-point at which the burner switches on again for thermoregulation.

0…20

5 °C

2113

Denes the domestic hot water circuit's % max. power.

50…100

100 %

2114

Denes the domestic hot water circuit's % minimum power.

1…30

1 %

2115

Denes the Accumulation sanitary Setpoint in mode 1

40…71

50 °C

2116

The value of this parameter is dened by Par. 9097.

0 Disabled 1 Water

pressure sensor 2

CH ow switch 3 Flue

pressure switch

De-

ned

Par.

9097

2117

The value of this parameter is dened by Par. 9097.

0 Disabled 1 DHW

ow sensor 2 DHW

ow switch 3 CH ow

sensor

De-

ned

Par.

9097

2118

The value of this parameter is dened by Par. 9097.

0 Disabled 1 Drain switch 2 Gas pres-

sure switch

De-

ned

Par.

9097

2120

The value of this parameter is dened by Par. 9097.

0 Disabled 1 T_Re-

turn sensor 2 Extern

switch

De-

ned

Par.

9097

2121

The value of this parameter is dened by Par. 9097.

0 Disabled 1 T_Flue

sensor 2 Flue switch

3 APS switch

De-

ned

Par.

9097

2122

The value of this parameter is dened by Par. 9097.

0 Disabled 1

T_Flue_2 sensor 2

T_Flue_2 + Bl. Flue

3 T_System sensor 4

Blocked Flue switch 5

Cascade Sensor

De-

ned

Par.

9097

2123

The value of this parameter is dened by Par. 9097.

0 Disabled 1 T_DCW sensor 2 Water pres-

sure switch

De-

ned

Par.

9097

2124

The value of this parameter is dened by Par. 9097.

0 Disabled 1 Enabled

De-

ned

Par.

9097

2125

The value of this parameter is dened by Par. 9097.

0 Disabled 1 General

Pump 2 CH Pump 3

DHW Pump 4 System

Pump 5 Cascade

Pump 6 Alarm Relay 7 Filling Valve 8 LPG Tank 9 External Ignit-

er 10 Air Damper 14

Alarm Burner CC 15 Status Burner CC 17

Antilegionella pump

De-

ned

Par.

9097

Page 37

2000

2126

The value of this parameter is dened by Par. 9097.

0 Disabled 1 General

Pump 2 CH Pump 3

DHW Pump 4 System

Pump 5 Cascade

Pump 6 Alarm Relay

7 Filling Valve 8 LPG

Tank 9 External Ignit-

er 10 Air Damper 14 Alarm Burner CC 15

Status Burner CC 17

Antilegionella pump

De-

ned

Par.

9097

2127

The value of this parameter is dened by Par. 9097.

0 Disabled 1 General Pump 10 Air Damper

11 HIS 12 Modulating

Pump

De-

ned

Par.

9097

2128

The value of this parameter is dened by Par. 9097.

0 Disabled 1 General

Pump 2 CH Pump 3

DHW Pump 4 System

Pump 5 Cascade

Pump 6 Alarm Relay

7 Filling Valve 8 LPG

Tank

De-

ned

Par.

9097

2129

Denes the type of ow sensor used.

Bitron, Huba: DN8,

DN10, DN15, DN15,

DN20, DN25

Huba DN25

2133

Denes the delta T set for the operation of the modulating

circulator.

5…40

15 °C

2134

Denes the time in seconds from the moment the burner is

switched on to start the modulation of the circulator and

obtain the delta T specied in Par. 2133.

0…255

120 Sec.

2135

Denes the PWM circulator model installed.

Wilo Yonos , Salm-

son, Grunndfos

Grund-

fos

2136

Denes if the module pump is on modulating mode or if it is made run at a xed speed (on a percentage at the max

speed).

On/Off Modulating

Fixed 20… 100%

Modu-

lating

2137

Denes the percentage of speed that sets the minimum

speed that the circulator can reach during modulation.

0…100

30 %

2138

Value can vary depending on appliance conguration based

on Par. 9097 and 9098. This value is calculated by the

board, which, based on an internal logic, denes as a single

number the settings of Par. 9097 and 9098.

0…255

De-

pends

boiler

model

2139

Activates air purge in the system. To activate the air purge, switch on the thermal module and change the parameter from "No" to "Yes". Wait a minute. Turn off and on again. At this point at start-up, the thermal module will perform the automatic purge procedure (duration about 20 minutes). With the parameter set to "Yes", the procedure is performed each time the thermal module is switched off and back on via its own main switch. The value must be "No" if no purge procedure is required when the thermal module is started.

Yes, No

2140

Denes the ow level under which value the thermal module

is turned off. The value may vary according to the model.

0.0…100

De-

pends

boiler

model

l/min

2201

Enable Heating

Enable/Disable

Ena-

ble

2202

Enable Heating

Enable/Disable

Ena-

ble

2203

Sets the Service reminders

Off/On/Reset

Off -

2204

Days for Service

30/35/40…./1275

1000 days

Page 38

2000

2006

Sets the activation temperature when the maximum ue gas temperature is exceeded. When the ue gas temperature is

higher than a set value, the module switches off and an error

message is generated. When the ue gas temperature is in

the interval between (Par. 2006) -5°C and Par. 2006, the module reduces its power in a linear way until it reaches minimum power when the temperature measured is equal to Par. 2006.

10…120

100 °C

2012

Sets the value of the temperature difference (Delta T) between the module's delivery and return temperature. For a Delta T value ranging between Par. 2012 and (Par. 2012) +8°C, the module reduces its power in a linear fashion until it reaches the minimum power. The minimum power is maintained until reaching (Par. 2012) +8°C+5°C, after which the module switches off for a period of time equal to the value attributed to Par. 2013; at the end of this time interval, the module switches on again.

10…60

40 °C

2013

Denes the restart time after reaching the Delta T limit between delivery and return.

10…250

30 Sec.

2016

Denes the proportional parameter for modulation during

heating operation.

0…1275

100

2017

Denes the modulation integral term during heating operation.

0…1275

250

2018

Denes the modulation derivative term during heating operation.

0…1275

2039

Denes the primary circuit's restart hysteresis in modes 1

and 2 of domestic hot water (valid both for cascade and stand-alone applications).

0…20

5 °C

2040

Denes the primary circuit's shut-off hysteresis in modes 1

and 2 of domestic hot water (valid both for cascade and stand-alone applications).

0…20

5 °C

2041

Denes the value referred to the Delta T of the tank for maintenance purposes. E.g.: if it is set on 3, when the tank has a set point lowered of 3 degrees, the module turns on at the minimum to allow maintenance till the set point plus hysteresis. If this parameter is equal to 2036, this function is inactivated and the thermal module starts at the maximum sanitary power.

0…10

5 °C

2045

Denes the proportional term for modulation during operation of the DHW storage tank.

0…1255

100

2046

Denes the integral term for modulation during operation of

the DHW storage tank.

0…1255

500

2047

Denes the derivative term for modulation during operation

of the DHW storage tank.

0…1255

9000

9098

Allows to set the values of Par. 2092, 2093 and 2094 through some pre-set values of speeds which identify the module model.

1..12

9097

Allow to set the values of Par. from 2116 to 2128 through

some pre-set values which dene the conguration of the

inlets and outlets of the module.

1..2

Code

--->

Enter Password

Page 39

3 COMMISSIONING AND

MAINTENANCE

3.1 Preparing for initial startup

The thermal module

POWER MAX

B must be commissioned by Technical Assistance Centre B, after which step the appliance may operate automatically.

Perform the following checks before starting up the boiler:

- Check that the fuel shut-off cock and heating system shut-off cock are open

- Check that the central heating circuit pressure gauge shows a pressure over

1 bar

with the system cold.

Check also that the circuit is properly de-aerated

- Check that the expansion vessel is correctly precharged

- the electric connections have been made correctly

- Check that the ue and air vents are made to applica- ble laws and standards

3.2 Initial startup

- Switch the system's master switch to the ON position and the thermal module's master switch to (I).

3.2.1 Switching the appliance on and off

Once the device is on, the initialization process starts for about one minute during which no operations are allowed.

Once the process is completed, parameters can be set for heating and DHW production.

To switch off the appliance, use the "ON/OFF" switch.

Never power off the appliance before switching the master switch to the "0" position.

Never switch off the appliance with the master switch if a request is active. Always make sure that the appliance is in stand-by before switching the main switch.

Example of display on stand-by (outdoor probe is not connected)

°C

Example of display on stand-by (outdoor probe is connected). Probe available as a accessory.

OUTSIDE

°C

3.2.2 Password access

It is necessary to enter the password to access the INSTALLER / MANUFACTURER parameters

- For right procedure, refer to Par. "Navigation Menu INSTALLER / MANUFACTURER".

Page 40

3.2.3 Setting the heating parameters

The parameter 2001establishes the thermal module's various heating operation modes.

Mode 0

(Operation with room thermostat/heat demand and xed

heating setpoint)

In this mode, the thermal module operates with a xed set-

point (controlled by the parameter0003) based on whether the room/heat demand thermostat's contact is closed or not. The set point value can be set directly without entering the parameter list as indicated on Par. "USER navigation MENU".

the set point can be set within a minimum and maximum value as indicated respectively on Par. 2023 and 2024 as

shown in the gure.

The outdoor temperature sensor (accessory) is not required and if connected the outdoor temperature that is measured

does not inuence the setpoint that has been set.

The parameters regulating such temperature are:

Par.

No.

Description

0003

Sets the desired ow temperature with heating

mode. Active for the heating mode Par. 2001 = 0 o 3

2023

Limits the minimum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2024

Limits the maximum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

T ﬂow

(°C)

T outdoor (°C)

Tset min (°C)

Tset max (°C)

Setpoint

Par. 2024

Par. 2023

Par. 0003

Mode 1

(Climatic functioning with room/heat demand thermostat, variable set point according to the outdoor temperature)

In this case the thermal module operates with a variable set-point depending on outdoor temperature based on a

climatic curve dened by the following parameters:

Par.

No.

Description

2109

Denes the value of the set point calculated on

climatic mode (Par. 2001 = 1).

2019

Establishes the max. set-point at the minimum outdoor temperature for climatic regulation

Par.

No.

Description

2020

Establishes the minimum outdoor temperature to which the maximum set-point can be associated for climatic regulation

2021

Establishes the minimum set-point at the maximum outdoor temperature for climatic regulation

2022

Establishes the maximum minimum outdoor temperature to which the minimum set-point can be associated for climatic regulation

2023

Limits the minimum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2024

Limits the maximum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2025

Denes the temperature at which climatic regulation is switched off

Display on climatic mode

The demand is activated when the room/heat demand thermostat's contact is closed provided that outdoor temperature does not exceed the value set by the parameter 2025. if the outdoor temperature is higher than the one set on parameter 2025 , the burner is stopped even if there is a heat demand.

If the outdoor temperature sensor (accessory) is not detected (not installed or damaged) the system provides a warning: no. 202

The presence of the warning does not stop the thermal

module allowing a heat request to be carried out at the maximum setpoint set on the climatic regulation.

Tset min (°C)

Tset max (°C)

Par. 2109

Par. 2024

Par. 2023

Par. 2020 Par. 2022 Par. 2025

Par. 2019

Par. 2021

T ﬂow

(°C)

T outdoor (°C)

Page 41

Mode 2

(Working on climatic mode with attenuation controlled by a room/heat demand thermostat, variable set point according to the outdoor temperature)

In this case the thermal module operates with a set-point

dened by the climatic curve (which can be set in the same

way as described in Mode 1) depending on outdoor temperature. Heat demand is actioned independently from whether the room/heat demand thermostat's contact is closed and stops only when the outdoor temperature is

greater than the one dened by the parameter 2025.

In this mode the parameter 2028 denes by how many

degrees the set-point is decreased (attenuation) when the room/ heat demand thermostat's contact is opened.

Par.

No.

Description

2109

Denes the value of the set point calculated on

climatic mode (Par. 2001 = 1).

2019

Establishes the max. set-point at the minimum outdoor temperature for climatic regulation

2020

Establishes the minimum outdoor temperature to which the maximum set-point can be associated for climatic regulation

2021

Establishes the minimum set-point at the maximum outdoor temperature for climatic regulation

2022

Establishes the maximum minimum outdoor temperature to which the minimum set-point can be associated for climatic regulation

2023

Limits the minimum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2024

Limits the maximum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2025

Denes the temperature at which climatic regulation is switched off

2028

Use the heating mode Par. 2001= 2 or 3. Denes how many degrees the ow set point is lowered.

T ﬂow

(°C)

T outdoor (°C)

Tset min (°C)

Tset max (°C)

Par. 2109

Par. 2024

Par. 2023

Par. 2020 Par. 2022 Par. 2025

Par. 2019

Par. 2109

Par. 2028

Par. 2021

Mode 3

(Continuous xed set-point operation with attenuation controlled by room/heat demand thermostat)

In this mode the xed set-point is adjusted in the same way

as described for Mode 0. The difference consists in the fact that the demand is always active and the set-point is decreased (attenuation) by the value dened by the parameter 2028 when the room/heat demand thermostat's contact is opened.

Par.

No.

Description

0003

Sets the desired ow temperature with heating

mode. Active for the heating mode Par. 2001 = 0 o 3

2023

Limits the minimum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2024

Limits the maximum value that can be assigned to the set-point in heating mode (does not apply to heating mode 4).

2028

Use the heating mode Par. 2001= 2 or 3. Denes how many degrees the ow set point is lowered.

T ﬂow

(°C)

T outdoor (°C)

Tset min (°C)

Tset max (°C)

Setpoint @TA=ON

Par. 2024

Par. 2023

Par. 2028

Par. 0003

Night setback @TA=OFF

The outdoor temperature sensor (accessory) is not required and if connected the outdoor temperature

that is measured does not inuence the setpoint that

has been set.

Mode 4

(Set-point adjustment based on a 0-10V analogical input)

The maximum and minimum set-point values are dened

respectively by Par. 2111 and 2110.

Par.

No.

Description

2110

Sets the minimum delivery temperature value in heating mode (Par. 2001) = 4.

2111

Sets the maximum delivery temperature value in heating mode (Par. 2001) = 4.

The operation set-point is adjusted on the basis of the following curve:

1.51.0 2.0 100

OFF ON

ON/OFF

Hysterese

Temperature

(°C)

Voltage (V)

Par. 2111

Par. 2110

The maximum and minimum set-point values are dened

respectively by Par. 2111 and 2110. When the input voltage value exceeds 1.5V, the demand is triggered (at the minimum set-point). For voltage values ranging from 2 to 10, the set-point varies in a linear fashion from the minimum through to the maximum value. If the voltage is decreased from 10 to 2, the set-point decreases in a linear fashion and maintains thee minimum value between 2 and 1V. For values lower than 1 V the demand stops.

Page 42

3.2.4 Setting the domestic hot water parameters

The parameter 2035 denes the various operation modes

of the thermal module for DHW production

Mode 0

(No production of domestic hot water) In this mode the thermal module will work only for the heating circuit (see paragraph "Setting the heating parameters")

Mode 1

(DHW production with storage tank and storage cylinder probe) In this mode, the thermal module is activated when the temperature recorded by the storage cylinder probe falls below the DHW setpoint by an amount equal to the hysteresis value and is deactivated when the temperature rises above the DHW setpoint by the value of the hysteresis.

The parameters that control DHW production are the following:

Par.

No.

Description

2036

Denes the hysteresis to initiate the domestic hot

water demand.

2037

Denes the hysteresis to stop the domestic hot

water demand.

2038

Denes the primary circuit's set-point increase in

degrees compared to the temperature set for the domestic hot water tank.

2039

Denes the primary circuit's restart hysteresis in

modes 1 and 2 of DHW (valid both for cascade and stand-alone applications).

2040

Denes the primary circuit's shut-off hysteresis in

modes 1 and 2 of DHW (valid both for cascade and stand-alone applications).

0048 Establishes the DHW storage tank set-point.

The set point value can be set directly without entering the parameter list as indicated on Par. "USER navigation MENU".

Mode 2

(DHW production with storage tank controlled by a thermostat) In this case the thermal module is activated when the contact in boiler's thermostat is closed and is deactivated when the latter is opened.

The parameters that control DHW production are the following:

Par.

No.

Description

2038*

Denes the primary circuit's set-point increase in

degrees compared to the temperature set for the domestic hot water tank.

2039

Denes the primary circuit's restart hysteresis in

modes 1 and 2 of DHW (valid both for cascade and stand-alone applications).

2040

Denes the primary circuit's shut-off hysteresis in

modes 1 and 2 of DHW (valid both for cascade and stand-alone applications).

Par.

No.

Description

2041

Denes the value referred to the Delta T of the

tank for maintenance purposes. E.g.: if it is set on 3, when the tank has a set point lowered of 3 degrees, the module turns on at the minimum to allow maintenance till the set point plus hysteresis. If this parameter is equal to 2036, this function is inactivated and the thermal module starts at the maximum sanitary power.

0048 Establishes the DHW storage tank set-point.

(*)

Parameter 2038 is active on such mode even if the

tank probe is not installed and it inuences the ow

temperature of the module.

It can be used to limit the difference between the ow and

set temperature on the tank thermostat so that the system

efciency is maximized.

The set point value can be set directly without entering the parameter list as indicated on Par. "USER navigation MENU".

Priority setting

The parameter 2042 sets the priorities between the DHW and CH circuit.

Four modes are envisaged:

1 On

: priority allocated to the DHW circuit

2 Off

: priority given to the heating circuit

3 Time

: timed priority between the two circuits. In the event of a simultaneous demand, initially the domestic hot water circuit is made to operate for a number of minutes equal to the value assigned to the parameter

2043. At the end of this time period, the CH circuit is operated (also for the same amount of time) and so on until demand for one or the other circuit stops

4 Parallel

: both circuits operating simultaneously, with the proviso that the water delivery temperature of the primary circuit must be lower than the setpoint requested by the heating circuit. When the primary circuit's temperatures exceeds the CH setpoint, the heating pump is switched off and the priority is reverted to the DHW circuit.

Anti-Legionella function

This function is only on when the circuit for DHW production is on mode 1.

The anti-legionella function is activated automatically on the module start up and it is repeated every 7 days (this

parameter can be modied).

If the appliance is electrically discharged, the cycle described below will be repeated at the next start. During the cycle of anti-legionella the thermal module generates a demand for the sanitary gathering set with a preset set point of 60 ° C (not modiable). Once the temperature of 60 ° C is reached, the temperature is maintained for 30 minutes during which the system checks that the temperature of the probe does not drop below 57°C. At the end of this time, the anti-legionella function is terminated and the normal operation of the thermal module is reset.

Anti-legionella mode has the priority over other requests regardless of the several parameters setting.

Page 43

3.3 Checks during and after initial start-up

When the appliance it started, it must be checked by stopping and then restarting the thermal module in the following way:

- Set the operating mode of the thermal module in heating to 0 (Par. 2001) e and close the RT input to generate a heat request

- If required, increase the set-point value (CH → Heating Set-point)

°C

- Make sure that all the pumps in the system are free and rotate in the right direction

- Check the full stop of the thermal module and the heat demand by opening the “RT” contact (OFF).

- Check that the thermal module has come to a full stop by setting the system's master switch to "Off".

If all conditions are met, power the thermal module by setting the system's and the appliance's master switches to "On" and test combustion products (see Paragraph "Adjustments").

SUPPLY GAS PRESSURE CHECK

- Turn the main system switch "off"

- Remove the locking screws and the panel's front side

- Loosen by about two turns the pressure inlet screw (1) upstream of the gas valve and connect the pressure gauge

- Power the thermal module by setting the system's and the appliance's master switches to "On".

Set Par. 0200 on "Hi" by using "PROG +" and "PROG -" and

press "MENU/RESET" to conrm.

0 2 0 0

DESCRIPTION G20 G30 G31

Wobbe index 45,7 80,6 70,7 MJ/m

Nominal supply pressure 20

28-

37 mbar

After the checks:

- select "OFF" using "PROG +" and "PROG -" and press

"MENU/RESET" to conrm.

- Disconnect the pressure gauge and tighten again the pressure test point screw (1) upstream from the gas valve.

0 2 0 0

- Full the operations, place back the front panel and lock the locking screws.

Page 44

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 appli-

ance's operation

3.4.1 Permanent Errors

Nr. Error Description

E2PROM_READ_ ERROR

Internal software error

1 IGNIT_ERROR

Three unsuccessful ignition attempts in a row

GV_RELAY_ERROR

Failure detected in the GV relay

SAFETY_RELAY_ ERROR

Failure detected in safety relay

BLOCKING_ TOO_LONG

Control had a blocking error for more than 20 hours

FAN_ERROR_ NOT_RUNNING

Fan is not running for more than 60 seconds

FAN_ERROR_ TOO_SLOW

Fan runs too slow for more than 60 seconds

FAN_ERROR_ TOO_FAST

Fan runs too fast for more than 60 seconds

8 RAM_ERROR Internal software error

WRONG_EEPROM_SIGNATURE

Contents of Eeprom is not up to date

10 E2PROM_ERROR

Wrong safety parameters in Eeprom

11 STATE_ERROR Internal software error

12 ROM_ERROR Internal software error

MAX_TEMP_ERROR

The external overheat protection is enabled or the T_Supply sensor measures a temperature of over 100°C (212°F)

FLUE_GAS_ERROR

Flue temperature exceeded

the maximum ue temperature

17 STACK_ERROR Internal software error

INSTRUCTION_ ERROR

Internal software error

ION_CHECK_ FAILED

Internal software error

FLAME_OUT_ TOO_LATE

Flame still present 10 seconds after closing the gas valve

FLAME_BEFORE_IGNIT

Flame is detected before ignition

CORRUPTED_ ERROR_NR

Error code RAM byte was corrupted to an unknown error code

29 PSM_ERROR Internal software error

REGISTER_ERROR

Internal software error

3.4.2 Temporary Errors

Nr.

Error Description

100

WD_ERROR_RAM Internal software error

101

WD_ERROR_ROM Internal software error

102

WD_ERROR_ STACK

Internal software error

103

WD_ERROR_REGISTER

Internal software error

106

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

107

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

108

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

109

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

110

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

111

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

112

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

113

REFHI_TOO_HIGH / REFHI_TOO_LOW

Internal software error

114

FALSE_FLAME

Flame is detected in a state in

which no ame is allowed to

be seen.

115

LOW_WATER_ PRESSURE_ERROR

Low water pressure error

118

WD_COMM_ERROR

Watchdog communication error

119

RETURN_OPEN Return sensor open

120

SUPPLY_OPEN Supply sensor open

122

DHW_OPEN DHW sensor open

123

FLUE_OPEN Flue sensor open

126

RETURN_SHORTED

Return sensor shorted

127

SUPPLY_SHORTED

Supply sensor shorted

129

DHW_SHORTED DHW sensor shorted

130

FLUE_SHORTED Flue sensor shorted

133

RESET_BUTTON_ ERROR

Too many resets in a short time period

163

T_SELECTION1_ OPEN

Heat exchanger's ow rate too

low

3.4.3 Warnings

Nr.

Error Description

200

CC_LOSS_COMMUNICATION

Cascade system: the burner of the managing module has lost the signal of one of the depending thermal module burner

201

CC_LOSS_COMMUNICATION

Cascade system: the managing module has lost the signal of one of the depending thermal module

202

OUTDOOR_ WRONG

Outdoor sensor is open of shorted

203

T_SYSTEM_ WRONG

T_System sensor is open of shorted

204

T_CASCADE_ WRONG

T_Cascade sensor is open of shorted

Page 45

3.5 Transformation from one gas type to another

The thermal module

POWER MAX

is supplied for operation with G20 (natural gas). However, it can be converted to operation with G30-G31 (LPG) using the dedicated accessory supplied as standard.

Conversion can only be executed by Technical Assistance Centre or staff authorised by B.

In order to execute the conversion, only follow the instructions in this manual and the provisions of safety standards.

If the information contained in these instructions is not properly performed or performed by personnel not properly trained, there is a potential risk of fuel leakage and/or carbon monoxide production resulting in personal injury and/or injury.

Conversion is not complete until all the control steps described in these instructions have been carried out.

After conversion, calibrate the CO2 as shown in the “Adjustment” Paragraph.

Before making the transformation:

- Exclude the heat demand production or the DHW production by lowering the related set points and the set point of the room thermostat.

- make sure that the master switch and the thermal module's switch are in the "Off" position

- check that the fuel interception system valve is closed.

To install the accessory:

- remove the locking screw

- pull the front panel outwards and then to the top to decouple it from points A.

Versions POWER MAX 50 P DEP - POWER MAX 80 P

- unscrew the three screws (1) and the swivel nut (2) of the gas pipe in order to remove the valve from the fan

- insert the related diaphragm (3) onto the gasket (4) without removing the gasket itself

Model int. Ø (mm)

POWER MAX 50 P DEP 6.5

POWER MAX 50 P 6.5 POWER MAX 65 P 6.25 POWER MAX 80 P 6.25

- check the integrity of the gasket (5); replace it if necessary

- ret the swivel nut (2)

- ret the three screws (1)

5 2

Versions POWER MAX 100 - POWER MAX 150

- unscrew the swivel nut (1) to remove the gas pipe from the fan

- insert the related diaphragm (2) inside the brass curve

Model int. Ø (mm)

POWER MAX 100 9 mm POWER MAX 110 9 mm POWER MAX 130 9,25 mm POWER MAX 150 8.75 mm

- ret the swivel nut (1)

For all models

- Full the operations, place back the front panel and lock the locking screws.

- Open the gas detection valve.

- Switch the electricity supply ON at the system's main switch and at the control panel.

- Make sure that there is no heat or DHW demand.

Page 46

Enter the parameters and set the parameter 9098 as shown in the table below:

Model Parameter 9098

POWER MAX 50 P DEP 22

POWER MAX 50 P 20 POWER MAX 65 P 12 POWER MAX 80 P 10

POWER MAX 100 8 POWER MAX 110 6 POWER MAX 130 4 POWER MAX 150 2

Remove the adhesive (valid for G20 supply) and use the one for G30-G31.

Modulo termico regolato per:

G30 - G31 28-30/37 mbar

Paese di destinazione:

Tipo di apparecchio Caldaia categoria::

B23

II2H3+

Pressioni di alimentazione gas:

Regolazione effettuata dal costruttore:

G20 - 20 mbar - 2H METANO

ATTENZIONE

Leggere attentamente il libretto istruzioni prima di installare e mettere in servizio l'apparecchio.

(Laterale DX)

Temperatura ambiente:

min. -10°C max. 50°C

Questo apparecchio puó essere installato e funzionare all'aperto o solo in locali permanentemente ventilati secondo norma UNI7129.

068411_E0

G20 20 mbar G30 28-30 mbar G31 37 mbar

After installing the accessory, check all gaskets tightness. Carry out all calibration activities described in Paragraph " Adjustments". Restore the desired set points.

Page 47

3.6 Adjustments

The thermal module

POWER MAX

is supplied for operation with G20 (methane gas), as indicated by the type plate, and has already been factory-calibrated by the manufacturer. However, if it is necessary to repeat the adjustments, for example after non-scheduled maintenance, replacing the gas valve or after transformation from G20 gas to G30-G31 gas, or vice versa, proceed as described below.

Adjustments to maximum and minimum power must be performed in the indicated sequence and only by Technical Assistance Centre.

Before making the regulation:

- remove the locking screw

- pull the front panel outwards and then to the top to decouple it from points A.

CO2 ADJUSTMENT AT MAXIMUM POWER

- Enter the menu "0000", select Par. 0200 and

press"MENU/RESET" to conrm.

- Select "Hi" by using "PROG +" and "PROG -" and

press "MENU/RESET" to conrm.

- the appliance will operate at maximum power.

- unscrew the cap (1) and insert the combustion analyser sensor

- set the CO2 with a screwdriver on the regulation screw (2) placed on the gas valve, thus reaching the value reported on the table.

Gas type CO2% maximum power

G20 - G25 8.8-9.2 G30 - G31 10.2-10.6

CO2 ADJUSTMENT AT MINIMUM POWER

- Select "Lo" using "PROG +" and "PROG -" and press

"MENU/RESET" to conrm.

- the appliance will operate at minimum power.

- Adjust the CO2 using a screwdriver on the adjustment screw (3) on the fan unit, so as to obtain a value listed in the table.

Gas type CO2% minimum power

G20 - G25 8.8-9.2 G30 - G31 10.2-10.6

Versions POWER MAX 50 P DEP - POWER MAX 80 P

Versions POWER MAX 100 - POWER MAX 150

CHECKING THE CALIBRATION

Select "Hi", wait for the stable regime to be reached and make sure that CO values 2 are the same as the requested ones. After the checks:

- select "OFF" using "PROG +" and "PROG -" and press

"MENU/RESET" to conrm.

- remove the analyser sensor and carefully retighten the cap (1)

- place back the front panel and lock the locking screw.

Page 48

3.7 Temporary or short-term shutdown

In the event of temporary or short-term shut-down (e.g. due to holidays), proceed as follows:

- Disconnect the power supply by positioning the thermal module switch and the system's main switch to "off".

- If there is a danger of frost, keep the system on. To reduce fuel consumption, set the heating set point to the minimum allowed value.

3.8 Preparing for extended periods of disuse

The following operations shall be necessary if the POWER MAX modular system is not used for a long period of time:

- Turn the main switch of the thermal modules and the main system switch to “off”

- Close the fuel and water valves for the heating and domestic hot water system.

Empty the thermal and sanitary system if there is a danger of frost.

3.9 Maintenance

It is mandatory to perform maintenance and cleaning of the device at least once a year.

The non-performance of the annual maintenance will invalidate the warranty.

This operation, carried out by Technical Assistance Cen-

tre or by professionally qualied personnel, is necessary to monitor and ensure that the ue pipes inside and outside

of the device, the fan, the safety valves, the condensate removal devices, the water drainage tubes and all the measurement and control devices are in perfect working order.

Table of the compulsory maintenance activities (to be performed every 2000 working hours or at least once a year)

Make the combustion test Check the conditions of the inlet pipes (if present) and

the ue pipes by making sure that no leakage is present

Check the ignition electrode Clean the combustion chamber and check the condi-

tions of the gaskets you have dismantled during such operation

Clean the condensate discharge pipe Check the parameters settings Check if there is any gas leakage Check if there is any leakage on the hydraulic connec-

tions Check the integrity of the cabling system and its related

connections Make sure the ignition takes place regularly

Make sure that there is the ame after ignition

Check the safety devices down the equipment Check the system pressure

Before carrying out any maintenance or cleaning, disconnect the power from the device by turning off the bipolar main switch and closing the main gas valve. In addition, for all maintenance (to be carried out at least once a year, as noted above) always replace all

the ue and gas seals, in particular the burner seals.

Before performing any operation:

- disconnect the electric power supply by turning the main system switch to "off"

- close the gas shut-off valve.

Page 49

3.10 Cleaning and removing internal components

Before any cleaning operation, disconnect the electric power supply by switching the main system switch to "off”.

OUTSIDE

Clean the casing, the control panel, the painted parts and plastic parts with cloths moistened with soap and water. In the case of stubborn stains, moisten the cloth with a 50%

water and alcohol mixture or specic products.

Do not use fuels, sponges impregnated with abrasive solutions or powder detergents.

INSIDE

Before starting internal cleaning operations:

- close the gas shut-off valves

- close the system taps.

From time to time, check that the condensate drain is not blocked.

Access to the control panel and the internal parts of the thermal module

- Remove the locking screws and the panel's front side

- Pull and slide the electrical panel's box towards the outside (1)

Loosen the xing screws (2) and remove the protection (3)

At this point, it will be possible to access terminal boards.

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

If the electronic control box is replaced, see the electrical wiring diagram in order to reset the connections.

Page 50

Removing the fan and the burner models POWER MAX 50 P DEP - POWER MAX 50 P

- Remove the locking screws and the panel's front side

- Remove cables (1) and (2) for the fan (3)

- Remove the air pipe from the fan if the thermal mod-

ule is type C (C type conguration non standard but obtained with specic accessory)

- Unscrew the swivel nut (4) and disconnect the gas pipe

- Use a socket wrench to unscrew the four nuts (5) x-

ing the fan (3) to the ange (6)

- Take the fan (3) and the gasket (7) out

- Unscrew the four nuts (8) xing the ange (6) to the top closing (9)

- Remove the gasket (10) and the burner (11).

- Replace the gaskets (7-10) with the new ones.

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

Check that the gas connection is leak proof.

Disassembling of the fan and burners models POWER MAX 65 P - POWER MAX 80 P

- Remove the locking screws and the panel's front side

- Remove cables (1) and (2) for the fan (3)

- Remove the air pipe from the fan if the thermal mod-

ule is type C (C type conguration non standard but obtained with specic accessory)

- Unscrew the swivel nut (4) and disconnect the gas pipe

- Unscrew the four screws with a pipe wrench (5) xing

the fan (3) to the ange (6)

- Take the fan (3) and the gasket (7) out

- Unscrew the 4 screws (8) that x the ange (6) to the

lower ange (9)

- Remove the gasket (10) and the burner (11).

- Replace the gaskets (7-10) with the new ones.

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

Check that the gas connection is leak proof.

Page 51

Disassembling of the fan and burners models POWER MAX 100 - POWER MAX 110 - POWER MAX 130 - POWER MAX 150

- Remove the locking screws and the panel's front side

- Remove cables (1) and (2) for the fan (3)

- Remove the air pipe from the fan if the thermal mod-

ule is type C (C type conguration non standard but obtained with specic accessory)

- Unscrew the swivel nut (4) and disconnect the gas pipe

- Unscrew the four screws with a pipe wrench (5) xing

the fan (3) to the ange (6)

- Take the fan (3) and the gasket (7) out

- Unscrew the 4 screws (8) that x the ange (6) to the

lower ange (9)

- Remove the gasket (10) and the burner (11).

- Replace the gaskets (7-10) with the new ones.

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

Check that the gas connection is leak proof.

Removing the top closing for cleaning the heat exchangers models POWER MAX 50 P DEP - POWER MAX 50 P

- Remove the locking screws and the panel's front side

- Remove cables (1) and (2) for the fan (3)

- Remove the air hose from the fan if the thermal mod-

ule is of type C (type C conguration not standard but

obtained with a special accessory)

- Unscrew the swivel nut (4) and disconnect the gas pipe

- Use a socket wrench to unscrew the nuts (8) xing the burner assembly (9) to the heat exchanger

- Remove the fan and the entire burner body (9)

- Remove the electrode plate (10), check the electrode's condition and replace it if necessary

- Unscrew screw (11)

- Open the lever catch (12)

- Lift and remove the top closure (13) with the relative insulating pad and gasket.

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

Check that the gas connection is leak proof.

Page 52

disassembling of the ange for cleaning up the heatexchanger models POWER MAX 65 P - POWER MAX 80 P

- Remove the locking screws and the panel's front side

- Remove cables (1) and (2) for the fan (3)

- Remove the air hose from the fan if the thermal mod-

ule is of type C (type C conguration not standard but

obtained with a special accessory)

- Unscrew the swivel nut (4) and disconnect the gas pipe

- Unscrew the six screws (8) that secure the burner unit (9) to the heat exchanger with a socket wrench

- Remove the fan and the entire burner body (9)

- Remove the electrode plate (10), check the electrode's condition and replace it if necessary

Remove the seal (11), the insulation mat (12) and the bracket (13).

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

Check that the gas connection is leak proof.

Disassembling the ange for cleaning the exchanger

models POWER MAX 100 - POWER MAX 110 - POWER MAX 130 - POWER MAX 150

- Remove the locking screws and the panel's front side

- Remove cables (1) and (2) for the fan (3)

- Remove the air hose from the fan if the thermal mod-

ule is of type C (type C conguration not standard but

obtained with a special accessory)

- Unscrew the swivel nut (4) and disconnect the gas pipe

- Unscrew the six screws (8) that secure the burner unit (9) to the heat exchanger with a socket wrench

- Remove the fan and the entire burner body (9)

- Remove the electrode plate (10), check the electrode's condition and replace it if necessary

Remove the seal (11), the insulation mat (12) and the bracket (13).

Once the maintenance operations are complete, ret the

components working in the opposite direction of what was described.

Check that the gas connection is leak proof.

Page 53

3.11 Troubleshooting

FAULT CAUSE SOLUTION

There is a smell of gas

Gas supply circuit

- Check the seal of the gaskets and the closure of the pressure tapping points

Odour of unburnt gas

Flue gas circuit

- Check the gasket seals

- Make sure there are no obstructions

- Check the combustion quality

Irregular combustion

Burner gas pressure - Check the temperature setting

Diaphragm installed - Check the diameter

Clean the burner and exchanger - Check the conditions

Exchanger passages obstructed - Check passage cleaning

Faulty fan - Check operation

Ignition delays with pulsations to

the burner

Burner gas pressure - Check the temperature setting

Ignition electrode - Check the positioning and conditions

The modular system becomes dirty

very quickly

Combustion - Check the combustion controls

The burner does not start upon con-

sent of the modular system control

Gas valve

- Check for the presence of 230Vac voltage on the gas valve terminals, check wiring and connections

The modular system does not start

No electric power supply (no mes-

sage on the display)

- Check the electric connections

- Check the condition of the fuse

The modular system does not arrive

at temperature

Boiler dirty - Clean the combustion chamber

Burner capacity insufcient - Check and adjust the burner

Modular system adjustment

- Check correct functioning

- Check the temperature setting

The generator triggers a thermal

safety block

No water

- Check correct functioning

- Check the temperature setting

- Check the electrical wiring

- Check the position of the sensor bulbs

Modular system adjustment

- Check the bleed valve

- Check the heating circuit pressure

The generator is at temperature but

the heating system is cold

Presence of air in the system - Bleed the system

Pump malfunctioning

- Check/unseize the pump

- Replace the circulator

- Check the electrical connection of the circulator

The circulator does not start

Pump malfunctioning

- Check/unseize the pump

- Replace the circulator

- Check the electrical connection of the circulator

Frequent tripping of the system

safety valve

System safety valve - Check calibration or efciency

Frequent tripping of the system

safety valve

Incorrect circuit pressure

- Check the circuit pressure

- Check pressure reducer functioning

Frequent tripping of the system

safety valve

CH expansion vessel

- Check the efciency of the expansion vessel

Page 54

SYSTEM MANAGER

4 SYSTEM MANAGER

4.1 Putting into service

The appliance must be maintained and adjusted at least once a year by Technical Assistance Centre or

by professionally qualied staff in compliance with all

applicable National and Local provisions.

Incorrect maintenance or adjustment may damage the appliance and cause damage to people or create a hazard.

The system manager is forbidden from opening and removing the appliance's casing. These activities must be carried out only by Technical Assistance

Centre or by professionally qualied personnel.

The thermal module

POWER MAX

B must be commissioned by Technical Assistance Centre B, after which step the appliance may operate automatically.

However, the system manager may be required to restart the appliance independently, without involving Technical Assistance Centre; for example after a long period of absence. To do so, perform the following checks and operations:

- Check that the gas cock and heating water cock are open

- While the system is still cold, check that working pressure in the central heating circuit is over 1 bar

but below the maximum limit specied for the boiler

- Adjust the room thermostats for the high and low temperature zones to the required temperature (~20°C) or, if the systems are equipped with timer thermostats or a time programming unit, make sure it is on and adjusted (~20°C)

- Switch the system's master switch to the ON position and the thermal module's master switch to (I).

The appliance will go through the switch-on stage and, after starting, it will continue to operate until set temperatures are achieved. The burner will then switch off and on automatically to maintain the set temperature without further operator action.

In the event of ignition or operation faults, the display will show a numeric error code that will enable the user to interpret the possible cause as detailed in Paragraph "Error List".

In the event of a permanent error, to reset starting conditions press the "RESET" key and wait for the thermal module to restart.

Repeat this operation 2-3 times at the most. If the problem persists after that, call B’s Technical Assistance Centre.

System manager

Page 55

SYSTEM MANAGER

4.2 Temporary or short-term shutdown

In the event of temporary or short-term shut-down (e.g. due to holidays), proceed as follows:

- Disconnect the power supply by positioning the thermal module switch and the system's main switch to "off".

- If there is a danger of frost, keep the system on. To reduce fuel consumption, set the heating set point to the minimum allowed value.

4.3 Preparing for extended periods of disuse

The following operations shall be necessary if the POWER MAX modular system is not used for a long period of time:

- Turn the main switch of the thermal modules and the main system switch to “off”

- Close the fuel and water valves for the heating and domestic hot water system.

Empty the thermal and sanitary system if there is a danger of frost.

4.4 Cleaning

Use a cloth damped in soapy water to clean the boiler’s external casing. To remove stubborn marks, use a cloth damped in a 50% mix of water and denatured alcohol or a suitable cleaning product. Carefully dry after cleaning.

Do not use abrasive cleaning pads or powder detergents.

Never clean the boiler without rst disconnecting it

from the mains electricity supply by turning the mains power switch and the control panel switch OFF.

The combustion chamber and ue pipes must be

cleaned periodically by the manufacturer’s Technical

Assistance Centre or by a qualied heating engineer.

4.5 Maintenance

Please remember that THE PERSON RESPONSIBLE FOR SYSTEM MANAGEMENT MUST ENSURE THAT PROFESSIONALLY QUALIFIED HEATING ENGINEERS UNDERTAKE PERIODIC MAINTENANCE AND COMBUSTION EFFICIENCY MEASUREMENTS.

B’s Technical Assistance Centre is qualied to satisfy

these legal requirements and can also provide useful information on MAINTENANCE PROGRAMMES designed to guarantee:

- Greater safety

- Compliance with applicable legislation

- Freedom from the risk of nes in the event of spot checks.

Regular maintenance is essential for the safety, efciency

and durability of the boiler. Servicing is a legal requirement and must be performed

at least once a year by a professionally qualied heating

engineer.

Page 56

SYSTEM MANAGER

4.6 Useful information

Seller:...................................................................................

Mr.: .......................................................................................

Address: ..............................................................................

Tel.: ......................................................................................

Technical Assistance Centre: ............................................

Mr.: .......................................................................................

Address: ..............................................................................

Tel.: ......................................................................................

Installer:...............................................................................

Mr.: .......................................................................................

Address: ..............................................................................

Tel.: ......................................................................................

Date Work done

Fuel oil supplier: .................................................................

Mr.: .......................................................................................

Address: ..............................................................................

Tel.: ......................................................................................

Date

Quantity supplied

Date

Quantity

supplied

Date

Quantity supplied

Date

Quantity

supplied

Page 57

SYSTEM MANAGER

5 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.

Adequate sorted waste collection, processing and environmentally-friendly disposal contribute to preventing possible negative impacts on the environment and health and promote the reuse and/or recycling of the materials of which the appliance consists.

Illegal disposal of the product by the owner shall be subject to administrative nes provided for by applicable laws.

Page 58

SYSTEM MANAGER

Page 59

SYSTEM MANAGER

Page 60

20133145 - Rev. 3 (06/18)

Via Risorgimento, 23 A 23900 - Lecco (LC)

www.berettaboilers.com

The manufacturer strives to continuously improve all products. Appearance, dimensions, technical

specications, standard equipment and accessories are therefore liable to modication without notice.

Beretta POWER MAX 50 P DEP, POWER MAX 50 P, POWER MAX 100, POWER MAX 130, POWER MAX 110 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual