Beretta Power Plus Box 150, Power Plus Box 300 Installation Manual

Installation Manual

THERMAL MODULES | CONDENSING

Power Plus Box

Installation Manual

EN

2

RANGE

MODEL CODE

POWER PLUS BOX 150 20071998
POWER PLUS BOX 200 20071999

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

B boiler. You have

selected a modern, quality product that is designed to give
dependable, efficient 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

The

Power Plus Box

modular condensing systems comply

with:

- Directive 2009/142/EC - Gas Appliances

- Directive 92/42/EEC on efficiency 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

- Delegated Regulation (EU) N. 813/2013

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

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

Furthermore, modular condensing systems

Power Plus Box

fulfil the provisions of chapter R.3.B, collection "R" ISPESL.
See annex.

b

This product must only be used for the purpose
for which it is designed and made, as specified 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.

This manual, Code 20127827 - Rev. 3 (10/16) comprises 60 pages.

3

CONTENTS

The following symbols are used in this manual:

b

CAUTION! =

Identifies actions that require caution

and adequate preparation.

a

STOP! =

Identifies 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 . . . . . . . . . . . . . . . . 4

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

1.5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

1.7 Coupling configuration . . . . . . . . . . . . . . . . . . . . 8

1.8 Technical specifications. . . . . . . . . . . . . . . . . . . . 9

1.9 Water circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.10 Location of sensors . . . . . . . . . . . . . . . . . . . . . . 13

1.11 Wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 14

1.12 Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.13 User interface (master) . . . . . . . . . . . . . . . . . . . 17

1.13.1 Display mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.13.2 Display mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.13.3 Changing the user parameters . . . . . . . . . . . . . 19

1.13.4 Monitor mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.13.5 Installer programming mode . . . . . . . . . . . . . . . 20

1.13.6 Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.13.7 Error mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.13.8 Permanent block . . . . . . . . . . . . . . . . . . . . . . . . 21

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .22

2.1 Unpacking the product . . . . . . . . . . . . . . . . . . . 22

2.2 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3 Overall dimensions and weights . . . . . . . . . . . . 23

2.4 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.5 Installation premises . . . . . . . . . . . . . . . . . . . . . 24

2.6 Installation in older systems and systems

requiring modernisation. . . . . . . . . . . . . . . . . . . 24

2.7 Water connections . . . . . . . . . . . . . . . . . . . . . . . 25

2.8 Flue gas evacuation for installations in a

central heating plant . . . . . . . . . . . . . . . . . . . . . 26

2.9 Condensate evacuation. . . . . . . . . . . . . . . . . . . 27

2.10 Neutralising the condensate . . . . . . . . . . . . . . . 27

2.11 Electrical connections . . . . . . . . . . . . . . . . . . . . 28

2.12 Outdoor sensor installation . . . . . . . . . . . . . . . . 31

2.13 System filling and emptying. . . . . . . . . . . . . . . . 32

2.14 Preparing for initial startup. . . . . . . . . . . . . . . . . 33

3 COMMISSIONING AND MAINTENANCE . . . 34

3.1 Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.2 Checks during and after initial start-up . . . . . . . 35

3.3 Adjusting the functional parameters . . . . . . . . . 37

3.4 Setting the heating parameters . . . . . . . . . . . . . 38

3.5 Setting the DHW parameters . . . . . . . . . . . . . . . 39

3.6 Heat control setting . . . . . . . . . . . . . . . . . . . . . . 39

3.7 Setting addresses for cascade coupling. . . . . . 43

3.8 Error List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.8.1 Master board errors . . . . . . . . . . . . . . . . . . . . . . 45

3.8.2 Slave board errors . . . . . . . . . . . . . . . . . . . . . . . 45

3.9 List of parameters . . . . . . . . . . . . . . . . . . . . . . . 47

3.10 Transformation from one gas type to another . . 49

3.11 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.12 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . 50

3.13 Preparing for extended periods of disuse . . . . . 50

3.14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.15 Cleaning and removing internal components . . 51

3.16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 54

4 WATER IN CENTRAL HEATING SYSTEMS 56

4

1 GENERAL INFORMATION

1.1 General Safety Information

b

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.

b

This product must be installed by a legally qualified
heating engineer. On completion of the installation,
the installer must issue the owner with a declaration
of conformity confirming 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.

b

This product must only be used for the purpose
for which it is designed and made, as specified 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.

b

In the case of water leaks, disconnect the modular
condensing system from the mains electrical supply,
close the water supply and promptly inform the Tech­nical Assistance Centre B or professionally qual­ified personnel.

b

Periodically check that operating pressure in the wa­ter circuit is over 1 bar but below the maximum limit
specified for the boiler. If this is not the case, contact
Technical Assistance Centre B or a professionally
qualified heating engineer.

b

The following operations shall be necessary if the
boiler 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.

b

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

b

This manual is an integral part of the equipment and
therefore must be stored carefully and must ALWAYS
accompany the boiler even if it is sold to another
Owner or User or transferred to another plant. If it is
damaged or lost, request another copy from your lo­cal Technical Assistance Centre B.

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:

a

Do not allow children or infirm persons to operate the
system unsupervised.

a

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 qualified heat­ing engineer.

a

Do not touch the boiler while barefoot or wet.

a

Never clean or service the boiler without first discon­necting it from the mains electricity supply by turning
the main power switch and the control panel switch
OFF.

a

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

a

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

a

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

a

It is prohibited to leave inflammable substances and
containers in the room where the boiler is installed.

a

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.

1.3 Description of the appliance

Power Plus Box

is a modular premixed condensing system
consisting of a set of 3 or 4 heating elements installed in
series.
Every

Power Plus Box

system is closed in a steel plate
containment structure made specifically for outdoor in­stallation. The design was studied to ensure rational use
of space and to make it easier to access the components
during maintenance operations.
In addition to obtaining considerable fuel savings, due to
condensation,

Power Plus Box

systems offer the possibility
to avoid a central heating plant in installations where the
systems can be positioned outside or on the roof of the
building.

5

Depending on the model, the heat input (ref. PCI) of every
modular system reaches 110, 135 or 180 kW, and can be
modulated between 10% and 100%.
Efficiency reaches 107.7% (100% ref. PCI, 50°C-30°C) and
the low flue gas temperatures make it possible to use a fully
integrated plastic flue gas manifold.
The combustion system and the flue gas - water heat ex­change make it possible to reach very high levels of com­bustion and heat to water transfer efficiency.
The gas/comburent air mixture is formed upstream of the
burner, due to the coupled modulating fan with a large
pressure difference, which intakes air from outside based
on the system's heat demand, as well as the pneumatic
regulator that supplies the quantity of gas required for op­timal combustion based on the quantity of aspirated air.
The flue gas produced by combustion passes through the
numerous interspaces created by a winding with a bime­tallic copper/steel corrugated coil that encounters a spe­cial cylindrical turbulator, which stops the free outflow and
constrains it to come into contact, in counter-current, with
the pipe in which the system return pipe passes.
By installing the individual heating elements in series not
only permits classical ignition rotation but can also be set
up so that when the first element reaches a certain power
percentage, the other subsequent elements will start al­ready, all with the same load factor.

The modular systems can be cascade connected (up to

4), placing the antivibration couplings between the de­livery, return and gas manifolds (accessories) and the
polypropylene coupling pipes for the ue gas manifold
and the condensate outlet manifold (supplied).
The ue gas evacuation and condensate outlet mani­folds can have an outlet to the left or to the right.

Power Plus Box

150

Base module consisting of 3 heat generators for heating
and DHW production systems.
Heat input from 15 to

135 kW

Power Plus Box

200

Base module consisting of 4 heat generators for heating
and DHW production systems.
Heat input from 15 to

180 kW

.

1.4 Safety devices

The

Power Plus Box

modular system is equipped with the
following safety devices, installed on every heating ele­ment:

Safety thermostat

with automatic reset, which, when tripped

at 90°, shuts off the burner.

Hydraulic circuit diagnostics

the minimum flow rate of the
carrier fluid for every heating element is controlled by a
differential water pressure switch and an electronic safety
system that controls a delivery sensor and a return sensor.
The equipment is protected if there is no water or in the
case of insufficient circulation.

Safety valve

for the heating system pressure, which trips,
draining the system if circuit pressure exceeds the limit (5.4
bar).

Flue gas evacuation safety

the flue gas sensor, located at
the bottom of the exchanger, provokes a fault in the case
of high flue gas temperature (> 80°C). Furthermore, the
"check valve" present in the flue gas exhaust line prevents
the flue gas from passing between heating elements.

Fan safety

the fan speed is always monitored by a Hall-ef­fect speed indicator device.
The

Power Plus Box

modulating systems are prepared for
cascade-coupling and this makes it possible to implement
compact and extremely flexible central heating plants
thanks to the system's modulating ratio.

b

The tripping of the safety devices indicates a poten­tially hazardous malfunction of the modular system,
therefore contact Technical Assistance Centre imme­diately.

Therefore it is possible to restart the system after waiting a
brief period (see the first start-up chapter).

6

a

The modular system must not be operated, even tem­porarily, if the safety devices are not functioning or
have been tampered with.

b

The safety devices must be replaced by Technical
Assistance Centre, only using original components
from the manufacturer. Refer to the spare parts cata­logue provided with the modular system.

After making the repair, correct that the modular system is
operating properly.

1.5 Identication

The products are identified by:

1

1

2

3

Caldaia regolata per:

G20 20 mbar

Paese di destinazione:

ITALIA

P

aese di destinazione:

Tipo di apparecchio
Caldaia categoria::

B23

II

2H3+

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

1 Gas label

.

It is applied on the front part of the device and indicates the type of gas used by the modular system and the coun-

try of destination.

2 Technical data plate

It indicates the technical and performance data.

3 Serial number plate

This is located on the boiler body and specifies the serial number, model, and furnace power.

b

Spare parts and/or technical operation require the exact identication of the corresponding model. The absence of, tam­pering with or removing the identication plates or other does not make it possible to reliably identify the product, makes
any installation and maintenance operation dif

cult and invalidates the warranty.

7

1.6 System layout

1 2 3 54

6

7

9

8

11

12

10

18

19

20

13

14

22

21

23

24

16

15

25

26

27

28

17

1

Control panel

2

Single heating element

3

Control panel

4

Bus cable passage cable gland for the cascade
connection

5

Flue gas manifold

6

Gas manifold

7

System delivery manifold

8

Condensate drain manifold

9

System return manifold

10

Single heating element flue gas analysis outlet

11

Fan

12

Single heating element flue gas exhaust union

13

Automatic bleed valve

14

Safety thermostat

15

Drain cock

16

Manual diverting valve

17

Circulator (or 2-way valve)

18

Gas valve

19

Comburent air intake union

20

Gas cock

21

Flow probe

22

Ignition/detection electrode

23

Exchanger

24

Return probe

25

Exhaust flue probe

26

Differential water and minimum pressure switch

27

Return detection tap

28

Safety valve 5.4 bar

8

1.7 Coupling conguration

SZ2

VM

SB

PZ1

SZ1

COMPENSATORE

IDRAULICO

COMPENSATORE

IDRAULICO

50°C

30°C

80°C

60°C

SZ1

SZ2

VM

SB

PZ1

PB

SE

PB

SE

PZ2

PZ2

POWER PLUS BOX 200

POWER PLUS BOX 200POWER PLUS BOX 150

SZ1

Delivery manifold sensor

SZ2

Low system temperature sensor

SB

Boiler sensor

SE

Outdoor sensor

PZ1

Zone 1 circulator (high temperature)

PZ2

Zone 2 circulator (low temperature)

PB

Boiler circulator

VM

Mixer valve

NOTE: it is possible to couple up to a maximum of 4

Power Plus Box

with a cascade connection.

9

1.8 Technical specications

MODEL

Power Plus Box

150 200

Fuel G20 - G30 - G31
Device category II2H3+
Device type B23, B53
Furnace heat output ref. PCS (min - max) 16,0 - 150 16,0 - 200 kW
Furnace heat output ref. PCI (min - max) 14,4 - 134,9 14,4 - 179,8 kW
Useful heat output (80°/60°C) 132,5 176,6 kW
Useful heat output (50°/30°C) 145,3 193,6 kW
Useful heat output (60°/40°C) 143,1 190,8 kW
Useful efficiency ref. PCI (80°C/60°C) 98,2 %
Useful efficiency ref. PCI (50°C/30°C) 107,7 %
Useful efficiency ref. PCI Tm=50°C (60°C/40°C) 106,1 %
Useful efficiency at 30% ref. PCI (80°C/60°C) 98,7 %
Useful efficiency at 30% ref. PCI (50°C/30°C) 108,7 %
Useful efficiency at 30% ref. PCI Tm=50°C (60°C/40°C) 106,6 %
Chimney loss with burner operating 1,3 %
Chimney loss with burner off 0,1 %
Casing loss (Tm=70°C) 0,5 %
Flue gas temperature Return temperature + 5 °C °C
CO2 at minimum 9,0 (G20) - 10,4 (G30-31) %
CO2 at maximum 9,0 (G20) - 10,4 (G30-31) %
CO S.A. at minimum - maximum less than 11 - 91 mg/kWh
NOx Class 5
Maximum heating operating pressure 6 bar
Maximum permitted temperature 90 °C
Boiler water temperature selection range (± 3°C) 20 - 80 °C
Water capacity 15 20 l
Power supply 230~50/60 V~Hz
Maximum electric power consumption 684 912 W
Electric degree of protection X4D IP
Quantity of condensate at maximum power 21,6 28,8 kg/h

CONNECTIONS

Delivery manifold 5" DN 125 - PN 6 Ø - DN
Return manifold 5" DN 125 - PN 6 Ø - DN
Gas manifold 3" DN 80 - PN 6 Ø - DN
Flue gas outlet 160 Ø mm
Condensate outlet 50 Ø mm

DIMENSIONS

Height 1500 mm
Width 1250 mm
Depth 650 mm

10

Detail

Power Plus Box

150 200

Maximum rated heat input 150 200 kW
Minimum rated heat input 16,7 16,7 kW
Domestic hot water maximum rated thermal input (80-60) - - kW
Domestic hot water minimum rated thermal input (80-60) - - kW
PARAMETER
Seasonal heating energy efficiency class - ­Water heating energy efficiency class - ­Rated input Prated 132,6 176,8 kW
Seasonal energy efficiency in central heating mode

ηs

92,5 92,5 %
USEFUL HEAT OUTPUT
at rated thermal input and at high temperature rating P4 132,6 176,8 kW
at 30% of rated thermal input and at low temperature rating P1 48,9 65,1 kW
EFFICIENCY
at rated thermal input and at high temperature rating

η4

88,4 88,4 %
at 30% of rated thermal input and at low temperature rating

η1

97,8 97,8 %
ADDITIONAL ENERGY CONSUMPTION
at full load El max 240 320 W
at partial load El min 72 96 W
in stand-by PSB 6 8 W
OTHER PARAMETERS
Heat loss in standby mode Pstby 1326 1768 W
Energy consumption of the pilot light Ping - - W
Annual energy consumption Q HE - - GJ
Level of inner sound power LWA - - dB
Emissions of nitrogen oxides NOx - - mg/kWh
FOR COMBINATION HEATING APPLIANCES
Declared load profile - ­Energy efficiency in DHW mode

ηWH

- - %
Daily electrical energy consumption Qelec - - kWh
Daily fuel consumption Qfuel - - kWh
Annual electrical energy consumption AEC - - kWh
Annual fuel consumption AFC - - GJ

11

1.9 Water circuit

RI

GAS

SC

SF

AA

1

MI

AA AA

2

3

4

8

9

6

5

7

12

1014

11

13 13

1

Fan

2

Automatic bleed valve

3

Burner

4

Heat exchanger

5

Drain cock

6

Differential water and minimum pressure switch

7

Circulator (or 2-way valve)

8

Gas valve

9

Flue gas exhaust union with check valve and flue gas
analysis outlet

10

Manual diverting valve

11

Return shut-off valve

12

Gas cock

13

Delivery sensor traps

14

Safety valve

AA

Air inlet

SF

Exhaust flue duct

SC

Condensate outlet

MI

Central heating flow

RI

Central heating return

GAS

Gas supply

12

WATER SIDE PRESSURE DROP FOR EVERY HEATING ELEMENT

Every heating element of the

Power Plus Box

modular system is equipped with a circulator, whose performance curve is

provided below, in reference to speed 3.

0

Pressure drop (mbar)

Flow rate (l/h)

1200

1100

1000

900

800

700

600

500

400

300

200

100

500

1000 1500 2000 2500 3000 3500 4000

Pressure lost by
the fluid when
crossing the
heating element

P available for
system circulation

1 heating element

Circulator characteristic
curve

Heating element pressure drop at 2000 l/h: 550 mbar.
Flow rate necessary for every heating element: 2000 l/h.

b

At the first 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.

b

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

a

It is prohibited to operate the circulators without wa­ter.

13

1.10 Location of sensors

SZ1

Delivery manifold sensor

SZ2

Low system temperature sensor

SB

Boiler sensor

SE

Outdoor sensor

PZ1

Zone 1 circulator (high temperature)

PZ2

Zone 2 circulator (low temperature)

PB

Boiler circulator

VM

Mixer valve

HEATING
DELIVERY SENSOR

HEATING RETURN
SENSOR

FLUE GAS
SENSOR
(triggering at 80°C)

SAFETY

THERMOSTAT

(triggering at 90°C)

HYDRAULIC

COMPENSATOR

50°C

30°C

80°C

60°C

SZ1

SZ2

VM

SB

PZ1

PB

SE

PZ2

POWER PLUS BOX

b

Install sensors SZ2 and SB in a trap (outside the modular system).

Correspondence table for all sensors

Measured temperatures (°C) - Resistive values of the sensors (Ω).

T (°C)

R (°Ω)

T (°C)

R (°Ω)

T (°C)

R (°Ω)

T (°C)

R (°Ω)

T (°C)

R (°Ω)

T (°C)

R (°Ω)

T (°C)

R (°Ω)

- 20 67739 - 1 28481 18 13062 37 6470 56 3426 75 1925 94 1137

- 19 64571 0 27279 19 12565 38 6247 57 3319 76 1870 95 1108

- 18 61568 1 26135 20 12090 39 6033 58 3216 77 1817 96 1079

- 17 58719 2 25044 21 11634 40 5828 59 3116 78 1766 97 1051

- 16 56016 3 24004 22 11199 41 5630 60 3021 79 1717 98 1024

- 15 53452 4 23014 23 10781 42 5440 61 2928 80 1669 99 998

- 14 51018 5 22069 24 10382 43 5258 62 2839 81 1622 100 973

- 13 48707 6 21168 25 9999 44 5082 63 2753 82 1577 101 948

- 12 46513 7 20309 26 9633 45 4913 64 2669 83 1534 102 925

- 11 44429 8 19489 27 9281 46 4751 65 2589 84 1491 103 901

- 10 42449 9 18706 28 8945 47 4595 66 2512 85 1451 104 879

- 9 40568 10 17959 29 8622 48 4444 67 2437 86 1411 105 857

- 8 38780 11 17245 30 8313 49 4300 68 2365 87 1373 106 836

- 7 37079 12 16563 31 8016 50 4161 69 2296 88 1336 107 815

- 6 35463 13 15912 32 7731 51 4026 70 2229 89 1300 108 796

- 5 33925 14 15289 33 7458 52 3897 71 2164 90 1266 109 776

- 4 32461 15 14694 34 7196 53 3773 72 2101 91 1232 110 757

- 3 31069 16 14126 35 6944 54 3653 73 2040 92 1199

- 2 29743 17 13582 36 6702 55 3538 74 1982 93 1168

14

1.11 Wiring diagrams

gv

J15

4

321

J2

5

m

m

a

a

5

6

J14

J6

gv

gv

J8

3

Fusibile 4A

F1

Terra

Circolatore

Fase

Neutro

Terra

Terra

Ground star pole

gv

Terra

Neutro

Ground star pole

Fase

a

a

a

m

m

m

1

T1

1

gv

J7

al polo stella di terra

g

n

v

b

m

2

4

3

13

45

66

7

J1

a

m

m

a

8

7

J12

n

1

4

3

2

5

b

m

v

g

m

6

5

4

m

a

11

12

21

J11

NTC mandata

NTC di ritorno

Alimentaz. Sens. Hall

Soffiante (-)

Input Sens. Hall

Soffiante (+)

Comune Sens. Hall

Termostato limite

Valvola gas

2

13

a

9

m

J16

NTC fumi

J9

J4

a

10

WD

J5

T3

PC

Main

2

1

1

2

gv

Bus line with female connector for

possible connection to another

slave card for an adjacent

modular system.

230V~50Hz

SLAVE 1

IG1

C

TS

VG

SM

SR

SF

EA/ER

J10

J17

BUS 1

A

B

IG

a

m

13

Pressostato Diff.

PD

CS

Connection by the installer

15

Bus

16

Com.

87

2

1

231

J9

232221

Valv.Mix

OFF

0

20

Alarm

ON

1

18

19

J8

9

17

24V

7

6

8

1314

Input

Analogic

NTC

Circ. 2

10 9

7

6

8

12

Circ.2

11

56

J12

4321

6

234

5

J10

28

27

Pump

252426

Pump 3

Pump

1

254

3

J11

NTC

1

2

NTC

NTC

453

Off - Valv. Mix

a

m

gv

gv

gv

gv

Neutro 230V a.c.

F

ase 230V a.c.

Terra

Terra

Terra

Terra

Fase Pompa circ.1
Neutro Pompa circ.1
Fase Pompa Sanit.
Neutro Pompa Sanit.

Neutro Valv. Mix
Fase Pompa 3
Neutro Pompa 3

J4

J2

J8

J10

R4

2

3

J3

J6

J5

J7

F1

Fuse

3.15 A

1

R6

R5

MC

R3 R2

On - Valv. Mix

Alarm

Comune

J12

2

BUS J14

1

R1

4

3

T1

Ebus contr. remoto

24V contr. remoto

Comune

Analogic Input

Comune

T. A. circ. 1

Comune

T. A. circ. 2

2

Comune

4

J1

PC

BARCODE

NTC climatica

J11 11

Comune

NTC mand. circ. 2

NTC mand. circ. 1

Comune

Comune

NTC bollitore

Comune

MASTER

PB

PZ1

PZ2

VM

SZ1

SB

SE

SZ2

TA1TA2

J11 4

J11 12

J11 5

J11 13

J11 6

J11 14

J11 7

J11 7

J11 14

J11 6

J11 13

J11 5

J11 12

J11

4

J11 11

IACR

J11 3

J11 10

J12 2

J12 3
J12 4

J12 4

J12 3

J12 2

J11

8

J11

1

J11

9

J11

2

J11

10

J11

3

J10 6

J10

5

J10

4

J10

3

J10

2

J10

1

J8

5

J8

4

J8

3

J8

2

J8

1

J10 6

J10 5

J10 4

J10 3

J10 2

J10 1

J9 3

J9 2

J9 1

J8 2

J8 1

1

3

7

14

1

8

J11

MODULAR SYSTEM

IG

Modular system main switch

CS

Contact for external safeties

PB

Boiler circulator

PZ1

Zone 1 circulator (high temperature)

PZ2

Zone 2 circulator (low temperature)

VM

Mixer valve

CR

Remote control (accessory available separately)

IA

Analogue input

SB

Boiler sensor

SZ1

Zone 1 sensor

SZ2

Zone 2 sensor

SE

Outdoor sensor

TA1

Zone 1 room thermostat (high temperature)

TA2

Zone 2 room thermostat (low temperature)

HEATING ELEMENT

C

Heating element circulator (or 2-way valve)

SM

Flow probe

SR

Return probe

SF

Exhaust flue probe

TS

Safety thermostat

VG

Gas valve

PD

Water differential pressure switch

EA/ER

Ignition/detection electrode

IG1..IG4

FIRST...FOURTH heating element switch

J10/J17

Addressing microswitches

15

A

BUS 2

BUS 3

BUS 4

gv

J15

4

321

J2

5

m

m

a

a

5

6

J14

J6

gv

gv

J8

3

Fusibile 4A

F1

Terra

Fase

Neutro

Terra

Terra

1

T1

1

J7

al polo stella di terra

g

n

v

b

m

2

4

3

13

45

66

7

J1

a

m

m

a

8

7

J12

n

1

4

3

2

5

b

m

v

g

m

6

5

4

m

a

11

12

21

J11

NTC mandata

NTC di ritorno

Alimentaz. Sens. Hall

Soffiante (-)

Input Sens. Hall

Soffiante (+)

Comune Sens. Hall

Termostato limite

Valvola gas

213

a

9

m

J16

NTC fumi

J9

J4

a

10

WD

J5

T3

PC

Main

SLAVE 2

IG2

TS

VG

SM

SR

SF

EA/ER

J10

J17

a

m

13

Pressostato Diff.

PD

gv

J15

4

321

J2

5

m

m

a

a

5

6

J14

J6

gv

gv

J8

3

Fusibile 4A

F1

Terra

Fase

Neutro

Terra

Terra

1

T1

1

J7

al polo stella di terra

g

n

v

b

m

2

4

3

13

45

66

7

J1

a

m

m

a

8

7

J12

n

1

4

3

2

5

b

m

v

g

m

6

5

4

m

a

11

12

21

J11

NTC mandata

NTC di ritorno

Alimentaz. Sens. Hall

Soffiante (-)

Input Sens. Hall

Soffiante (+)

Comune Sens. Hall

Termostato limite

Valvola gas

213

a

9

m

J16

NTC fumi

J9

J4

a

10

WD

J5

T3

PC

Main

SLAVE 3

IG3

C

TS

VG

SM

SR

SF

EA/ER

J10

J17

a

m

13

Pressostato Diff.

PD

gv

J15

4

321

J2

5

m

m

a

a

5

6

J14

J6

gv

gv

J8

3

Fusibile 4A

F1

Terra

Fase

Neutro

Terra

Terra

1

T1

1

J7

al polo stella di terra

g

n

v

b

m

2

4

3

13

45

66

7

J1

a

m

m

a

8

7

J12

n

1

4

3

2

5

b

m

v

g

m

6

5

4

m

a

11

12

21

J11

NTC mandata

NTC di ritorno

Alimentaz. Sens. Hall

Soffiante (-)

Input Sens. Hall

Soffiante (+)

Comune Sens. Hall

Termostato limite

Valvola gas

213

a

9

m

J16

NTC fumi

J9

J4

a

10

WD

J5

T3

PC

Main

SLAVE 4

IG4

C

TS

VG

SM

SR

SF

EA/ER

J10

J17

a

m

13

Pressostato Diff.

PD

Circolatore

C

Circolatore Circolatore

Bus line with male

connector for possible

connection to another slave card

for an adjacent modular system.

b

The circulators must be connected with the interposition of suitable contactors with manual emergency actuation.

16

1.12 Control panels

1 2 4 5 6 4 5 6 4 5 6

812 91011

7

13

14 15 16 17

1819202122

4 5 6

3

1

Electric power supply signal

2

Master user interface

3

Slave user interface

4

Slave card operating status signal:

- FLASHES in absence of heat demand

- FLASHES QUICKLY during the ignition cycle

- ON in presence of a flame

5

Single heating element block signalling:

- OFF in absence of errors

- FLASHES QUICKLY in case of errors that can be
deactivated automatically

- ON in case of permanent errors

6

Single heating element slave reset button

7

Instrument panel

8

FOURTH heating element switch (only for

Power Plus

Box

200)

9

THIRD heating element switch

10

SECOND heating element switch

11

FIRST heating element switch

12

Main control panel

13

Modular system main switch (only accessible by
turning the main control panel)

14

Electric power supply signal

15

Modular system block signal

16

Display

17

Value increase button

18

Value decrease button

19

Save button

20

Parameter selection button

21

Operating mode selection button

22

Master reset button

17

Functional notes

The

Power Plus Box

modular system control panel manag-

es:

- The DHW priority function which, in the case of a
DHW demand, the master card can also serve the
high or low temperature circuit.

- The anti-freeze function, also active in stand-by mode,
which starts the high temperature circuit circulator
and the loop circulator if the manifold temperature
drops below 5°C. If there is an outdoor sensor, the
circulators turn on if the outdoor temperature drops
below 3°C. If after 10 minutes the manifold tempera­ture is less than 5°C, a burner turns on at maximum
power until the manifold temperature reaches 20°C.
If after 10 minutes the manifold temperature exceeds
5°C but the outdoor temperature is lower than 3°C the
circulators remain active until the outdoor tempera­ture goes above that value.

- The cascade management function: to manage the
power delivered by the system, it is possible to se­lect between the minimum and maximum quantity of
lit burners.

- The exhaust function: the high and low temperature
circuit pumps remain in operation for 5 minutes after
the last burner is turned off. The waiting time before
the heating element circulator is stopped once the
burner is shut off is 6 minutes. When the last burner
is turned off, the circulator only stops when the room
thermostat demand stops.

- The ignition/shut-off control function: in both cascad­ing management modes there is a burner ignition and
shut-off limitation function in the case of low heat de­mand.

- The system anti-freeze protection function: the

Pow-

er Plus Box

condensing systems are equipped with
freeze protection electronics. The electronics activate
the heating unit if the temperature drops below the
minimum threshold. Therefore the use of particular
anti-freeze fluids are not necessary except in the
case of uses with the equipment completely shut off
for long periods. If using anti-freeze fluids make sure
they are not aggressive for steel.

1.13 User interface (master)

The

Power Plus Box

system control panel buttons have different functions depending on the mode. For example, a combi­nation of two buttons corresponds to a single function. Or a function is activated by pressing the button briefly or waiting
approx. 5 seconds.

Reset

Serves to release the electric board after a permanent ar­rest

Set/esc

Set

: makes is possible to enter the parameter change mode

and monitor mode for the single units

This is used to view the operating status of the various cir­cuits managed by the Master card

and

Are used to increase or decrease a certain value

OK

Press to memorize new values

18

1.13.1 Display mode

The red (error) LED turns on in the case of faults that involve the permanent block of a heating element (normal operation
can be reset by pressing the Master or Slave reset button).
The green (on) LED indicates the presence of the electric power supply.

The 3 digits with seven segments display the system statuses:

SYSTEM STATUS DISPLAY

No demand for heating or hot water.
The two right hand digits display flow temperature T1. E.g. T1 = 30°C

Demand for 1st system or 1st and 2nd system simultaneously.
The two right hand digits display flow temperature T1. E.g. T1 = 80°C

Demand for hot water or simultaneous functioning.
The two right hand digits display flow temperature T1. E.g. T1 = 80°C
The point after the first digit flashes.

Demand for 2nd system.
The two right hand digits display flow temperature T1. E.g. T1 = 80°C

Antifreeze function

1.13.2 Display mode

Temperature values and operating status of the various circuits

Press the button to scroll forward and view the values set for the individual circuits.
The values listed below will be displayed in succession by pressing the button.

POS. VISUALIZED VALUES DISPLAY

1

Manifold delivery temperature T1

(e.g. T1 = 80°C)

2

Hot water T3

(e.g. water tank temp. = 50°C)

3

Outside temperature T4

(e.g. T4 = 7°C)

4 Flow temperature 2nd system or low T6 system

5

1st system room thermostat off or on

(e.g. OFF = contact open; ON = contact closed)

6

2nd system room thermostat off or on

(e.g. OFF = contact open; ON = contact closed)

7

0-10V analogue input

(e.g. 5.5V ; 10V respectively)

8

Mixer valve function status

(e.g. closing, opening, pause)

9

Principal circulator function status.

(e.g. circulator OFF; circulator ON respectively)

10

Function status hot water system circulator.

(e.g. circulator OFF; circulator ON respectively)

11

Second circulator function status

(e.g. circulator OFF; circulator ON respectively)

To exit the value display, press the

"OK"

button.

If no operation is performed within 5 minutes, the card will automatically return to display mode.