THERMAL

MODULES
CONDENSING
POWER PLUS
BOX SYS

INSTALLATION MANUAL


RANGE Dear Customer,

Thank you for preferring a B heating unit, a modern,
high-quality product that is able to guarantee your maxi-
MODEL CODE mum well-being for a long period of time, with high levels of
POWER PLUS BOX 85 SYS 20020976 reliability and safety. In particular, if working together with a
Technical Assistance Centre B that is specifically pre-
POWER PLUS BOX 115 HI SYS 20020977
pared and trained to perform periodic maintenance, your
unit will remain at maximum efficiency levels at minimum
ACCESSORIES operating costs and if required, replacements with original
ITEM spare parts can be made.
HT kit (direct circuit) This instruction manual contains important information and
LT kit (mixed circuit) suggestions that must be followed to ensure simple instal-
Water tank kit lation and the best possible use of the Power Plus Box SYS
heating unit.
System connection kit
Remote control
Please accept our renewed thanks for your purchase.
N2 neutraliser kit Beretta
For a complete list of accessories and details of their com-
patibility, refer to the Catalogue.

CONFORMITY

The Power Plus Box SYS 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 Au-
gust 1993 (****)
-- Electromagnetic Compatibility Directive 2004/108/EC
-- Low Voltage Directive 2006/95/EC
-- Boiler and Condensation UNI EN 677 standard.

0085
2 Furthermore, modular condensing systems Power Plus Box
SYS fulfil the provisions of chapter R.3.B, collection "R" ISP-
ESL. See annex.

bbThis 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.

ENGLISH
CONTENTS

1 GENERAL INFORMATION . . . . . . . . . . . . . . . 4 3 COMMISSIONING AND MAINTENANCE . . . 31

1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1 Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.2 Checks during and after initial start-up . . . . . . . . 32
1.3 Description of the appliance . . . . . . . . . . . . . . . . . 4 3.3 Adjusting the functional parameters . . . . . . . . . . 34
1.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.4 Setting the heating parameters . . . . . . . . . . . . . . 35
1.5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.5 Setting the DHW parameters . . . . . . . . . . . . . . . . 36
1.6 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.6 Heat control setting . . . . . . . . . . . . . . . . . . . . . . . 36
1.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.7 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.8 Hydraulic circuit and probe positioning . . . . . . . . . 9 3.8 List of parameters . . . . . . . . . . . . . . . . . . . . . . . . 43
1.9 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.9 Transformation from one gas type to another . . . 45
1.10 Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.10 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.11 User interface (master) . . . . . . . . . . . . . . . . . . . . 14 3.11 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . 46
1.11.1 Display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.12 Preparing for extended periods of disuse . . . . . . 46
1.11.2 Display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.11.3 Changing the user parameters . . . . . . . . . . . . . . 16 3.14 Cleaning and removing internal components . . . 47
1.11.4 Monitor mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.11.5 Installer programming mode . . . . . . . . . . . . . . . . 17
1.11.6 Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4 WATER IN CENTRAL HEATING SYSTEMS . 52
1.11.7 Error mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.1 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.11.8 Permanent block . . . . . . . . . . . . . . . . . . . . . . . . . 18

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Unpacking the product . . . . . . . . . . . . . . . . . . . . 19
2.2 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Overall dimensions and weights . . . . . . . . . . . . . 19
2.4 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Installation premises . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Installation in older systems and systems requiring
modernisation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . 21
2.8 Flue gas evacuation for installations in a central
heating plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3
2.9 Condensate evacuation . . . . . . . . . . . . . . . . . . . . 24
2.10 Condensate neutraliser . . . . . . . . . . . . . . . . . . . . 25
2.11 Electrical connections . . . . . . . . . . . . . . . . . . . . . 26
2.12 Outdoor sensor installation . . . . . . . . . . . . . . . . . 28
2.13 System filling and emptying . . . . . . . . . . . . . . . . . 28
2.14 Preparing for initial startup . . . . . . . . . . . . . . . . . . 30

This booklet code

- Rev.
comprises
The following symbols are used in this manual: pages.
bbCAUTION! = Identifies actions that require caution
and adequate preparation.
aaSTOP! = Identifies actions that you MUST NOT do.

This booklet code 20082434 - Rev. 7 (12/13) comprises 56 pages.



1 GENERAL INFORMATION 1.2 Precautions

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

bbAfter removing the packaging, check the condition aaDo not allow children or infirm persons to operate the
system unsupervised.
and completeness of the supply. If there are any
problems, contact the company B that sold the aaIt is forbidden to use electrical devices or equipment,
equipment. such as switches, appliances, etc. if there is a smell
bbThis product must be installed by a legally qualified -- Ventilate
of gas or un-burnt products. If so:
the room, opening doors and windows
heating engineer. On completion of the installation,
the installer must issue the owner with a declaration -- Close the fuel shut-off cock
of conformity confirming that the installation has been -- Report the fault immediately to the B's Technical
completed to the highest standards in compliance Assistance Centre or a professionally qualified heat-
with the instructions provided by B in this instruc- ing engineer.
tion manual, and that it conforms to all applicable
laws and standards.
aaDo not touch the boiler while barefoot or wet.
bbThis product must only be used for the purpose aaNever clean or service the boiler without first discon-
necting it from the mains electricity supply by turning
for which it is designed and made, as specified by the main power switch and the control panel switch
B. B declines all responsibility, contractual or
OFF.
other, for damage to property or injury to persons or
animals caused by improper installation, adjustment, aaDo not tamper with or adjust the safety or control de-
maintenance or use. vices without prior authorisation and instructions from
bbIn the case of water leaks, disconnect the modular the manufacturer.
condensing system from the mains electrical supply, aaNever pull, disconnect, or twist the electrical cables
close the water supply and promptly inform the Tech- coming from the appliance even if it is disconnected
nical Assistance Centre B or professionally qual- from the mains electricity supply.
ified personnel.
bbPeriodically check that operating pressure in the wa- aaDo not obstruct or restrict the vents in the room where
the boiler is installed. Adequate ventilation is essen-
ter circuit is over 1 bar but below the maximum limit tial for correct combustion.
specified for the boiler. If this is not the case, contact
aaIt is prohibited to leave inflammable substances and
4
Technical Assistance Centre B or a professionally
qualified heating engineer. containers in the room where the boiler is installed.
bbThe following operations shall be necessary if the aaDo not dispose of packaging material into the envi-
boiler is not used for a long period of time: ronment, or leave it within the reach of children, since
-- Switch the boiler OFF at the control panel it can become a potential hazard. Dispose of packag-
-- Turn the main system switch "off" ing material in compliance with applicable legislation.
-- Close the fuel cock and heating circuit water cock
-- Drain the central heating circuit if there is any risk of 1.3 Description of the appliance
freezing.
Power Plus Box SYS is a premixed modular condensing sys-
bbMaintenance must be performed on the boiler at least tem that consists of a set of 2 or 3 series installed heating
once a year. elements.
bbThis manual is an integral part of the equipment and Every Power Plus Box SYS system is closed in a steel plate
containment structure made specifically for outdoor in-
therefore must be stored carefully and must ALWAYS stallation. The design was studied to ensure rational use
accompany the boiler even if it is sold to another of space and to make it easier to access the components
Owner or User or transferred to another plant. If it is during maintenance operations.
damaged or lost, request another copy from your lo- The casing houses a special hydraulic separator with con-
calTechnical Assistance Centre B. nectors that makes it simple to connect the circuits that are
directly managed by the control panel:
-- High temperature (direct circuit)
-- Low temperature (mixed circuit)
-- Hot water system..
The cabinet also contains the hydraulic distribution acces-
sories, which saves additional space.


In addition to obtaining considerable fuel savings, due to

Power Plus Box SYS 115 HI
condensation, Power Plus Box SYS systems offer the possi-
Base module consisting of 3 heat generators for heating
bility to avoid a central heating plant in installations where
and DHW production systems.
the systems can be positioned outside or on the roof of the
Heat input from 14.4 to 115 kW.
building.
The heat input (ref. PCI) of every modular system reaches
76.7 kW (2 heating elements) or 115 kW (3 heating ele-
ments), 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 ex-
change make it possible to reach very high levels of com-
bustion 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 op-
timal 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 bime-
tallic copper/steel corrugated coil that encounters a spe-
cial 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 1.4 Safety devices
percentage, the other subsequent elements will start al-
The Power Plus Box SYS modular system is equipped with
ready, all with the same load factor.
the following safety devices, installed on every heating el-
This makes it possible to divide the delivered power be-
ement:
tween multiple heat exchangers with a power/exchange
Safety thermostat with automatic reset, which, when tripped
surface ratio that is particularly favourable for using the la-
at 90°, shuts off the burner.
tent condensation heat.
Hydraulic circuit diagnostics the minimum flow rate of the

5
The safety devices foreseen by collection R of ISPESL,
carrier fluid for every heating element is controlled by a
for this type of application, are installed on the delivery
differential water pressure switch and an electronic safety
manifold downstream of the last combustion unit.
system that controls a delivery sensor and a return sensor.
The equipment is protected if there is no water or in the
Power Plus Box SYS 85
case of insufficient circulation.
Base module consisting of 2 heat generators for heating
Safety valve for the heating system pressure, which trips,
and hot domestic water production systems.
draining the system if circuit pressure exceeds the limit (5.4
Heat input from 14.4 to 76.7 kW.
bar).
Maximum pressure switch (ISPESL type-approved).
Fuel check valve (ISPESL type-approved).
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-ef-
fect speed indicator device.
bbThe tripping of the safety devices indicates a poten-
tially hazardous malfunction of the modular system,
therefore contact Technical Assistance Centre imme-
diately.

After a short wait, it is possible to try to restart the system

(see the initial start up chapter).


aaThe modular system must not be operated, even tem-

porarily, if the safety devices are not functioning or
have been tampered with.
bbThe safety devices must be replaced by Technical
Assistance Centre, only using original components
from the manufacturer. Refer to the spare parts cata-
logue provided with the modular system.

After making the repair, correct that the modular system is

operating properly.

1.5 Identification
The products are identified by:

Paese di destinazione:

Tipo di apparecchio : B23

1
Caldaia categoria : II2H3+
Temperatura ambiente:
2
min. -10°C max. 50°C
Pressioni di alimentazione gas:
G20 20 mbar
G30 28-30 mbar
G31 37 mbar
Regolazione effettuata dal costruttore:
G20 - 20 mbar - 2H METANO
ATTENZIONE
Questo apparecchio puó essere installato e
funzionare all'aperto o solo in locali
permanentemente ventilati secondo norma
UNI7129.
Leggere attentamente il libretto istruzioni
prima di installare e mettere in servizio
l'apparecchio.
(Laterale DX) 068411_E0

Caldaia regolata per: 1

G20 20 mbar
Paese di destinazione: ITALIA
3

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 Gas label
It is applied on the back of the device and shows the type of fuel the heating unit uses as well as the country of
destination.

bbSpare parts and/or technical operation require the exact identification of the corresponding model. The absence of, tam-
pering with or removing the identification plates or other does not make it possible to reliably identify the product, makes
any installation and maintenance operation difficult and invalidates the warranty.


1.6 System layout

1 2 3 4 5 6 7 8

10

11
12
13

14
15

16

21 20 19 18 15 14 17

22 10 Hydraulic separator
23 11 Minimum pressure switch
41
24 12 Fuel shut-off valve probe pit (to be positioned during
40 installation)
5 39
25 13 System filling unit or expansion tank fitting
26 38 14 CH circuit drain cock
15 Condensate drain manifold

7
27 16 3-way manual valve
28 17 Fuel shut-off cock (supplied)
29 18 Delivery probe pit
19 Water flow manifold
30 20 Water return manifold
37
6 21 Gas manifold
22 Fan
23 Single heating element flue gas analysis outlet
31 24 Single heating element flue gas exhaust union
25 Safety thermostat
36 26 Flow probe
32 27 Burner
35 28 Heating element delivery pipe
29 Safety valve 5.4 bar
30 Non-return valve
31 Relief valve drain
34 32 Differential water and minimum pressure switch
33 Condensate drainpipe
33 34 Circulator
35 Return probe
36 Exhaust flue probe
37 Exchanger
1 Control panel 38 Gas supply pipe
2 Single heating element 39 Gas cock
3 Control panel 40 Comburent air intake union
4 Pressure gauge 41 Gas valve
5 Automatic vent valve
6 Shut-off cock
7 Temperature gauge
8 Fairlead
9 Flue gas manifold


1.7 Technical data

Power Plus Box SYS
MODEL
85 115 HI
Fuel G20 - G30 - G31
Device category II2H3+
Device type B23, B53
Furnace heat output ref. PCS (min - max) 16-85.2 16-127.8 kW
Furnace heat output ref. PCI (min - max) 14.4-76.7 14.4-115 kW
Useful heat output (80°/60°C) 75,3 112,9 kW
Useful heat output (50°/30°C) 82,5 123,8 kW
Useful heat output (60°/40°C) 81,3 122,0 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 %
Combustion efficiency 98,7 %
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 + 2.5 °C (max 80°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 (min/max) 0.5 / 6 bar
Maximum permitted temperature 90 °C
Boiler water temperature selection range (± 3°C) 20 - 80 °C
Water capacity 10 15 l
Electrical supply 230~50 V~Hz
8 Absorbed electric power
Electric degree of protection
370
X4D
555 W
IP
Quantity of condensate at maximum power 11,1 16,6 kg/h


1.8 Hydraulic circuit and probe positioning

SF
AA AA AA
12 12 12
1 1 1
2 2 2
11 11 11

3 3 3

4 4 4
2

19

14 14 14
20
5 5 5
MI
7 7 7 23
6 6 6 20
24
8 8 8
17
9 10 9 10 9 10 25
21
15
RI

16 21
10 10 10
SC
18
13 13 13
10

22
9
GAS

1 Fan 24 Fuel shut-off cock probe

2 Automatic vent valve 25 Heating delivery probe
26 3 Burner 26 Heating element delivery probe
4 Heat exchanger 27 Safety thermostat (triggering at
5 Differential water and minimum 90°C)
27 pressure switch 28 Exhaust flue probe (triggering at
6 Non-return valve 80°C)
7 Circulator 29 Heating return probe
8 3-way manual valve
9 Delivery shut-off cock AA Air inlet
10 Drain SF Smoke outlet
11 Flue gas exhaust union with check SC Condensate outlet
valve and flue gas analysis outlet MI High temperature system deliv-
28 12 Gas valve ery line
13 Gas cock RI High temperature system return
14 Safety valve 5.4 bar line
29 15 Water flow manifold GAS Gas supply
16 Water return manifold
17 Hydraulic separator
18 Drain valve
19 Shut-off cock
20 Connections for additional area
delivery lines (accessories)
21 Connections for additional area
return lines (accessories)
22 Fuel shut-off cock
23 Minimum pressure switch


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

WATER SIDE PRESSURE DROP FOR EVERY HEATING ELEMENT

Every heating element of the Power Plus Box SYS modular system is equipped with a circulator, whose performance curve
is provided below, in reference to speed 3.

1200
1100 1 heating element
1000
900
10
Pressure drop (mbar)

800
700
Circulator
600 characteristic curve
500
P available for
400 system circulation

300
200 Pressure lost by
the fluid when
100 crossing the
heating element

0 500 1000 1500 2000 2500 3000 3500 4000

Flow rate (l/h)

Heating element pressure drop at 2000 l/h: 550 mbar.

Flow rate necessary for every heating element: 2000 l/h.

bbAt the first start-up, and at least once a year, the rota-
tion of the circulator shaft should be checked as, es-
pecially after long periods of not being operated, de-
posits and/or residuals could impede its free rotation.
bbBefore loosening or removing the circulator cap, pro-
tect the electric devices located underneath from any
water that exits.
aaIt is prohibited to operate the circulators without wa-
ter.
 

Ground star pole

gv gv
Connection by the installer
gv

Terra

a
230V~50Hz
Neutro

m
Fase

m
P IG
L0 a
a
m

gv
A
J10 6 Pump NTC J11 7 al polo stella di terra
1.9 Wiring diagrams

6 28 1 1

J10 5 5 PB SZ1 2 2 J11 14

27
J10 4 4 Pump NTC 3 J11 6 EA/ER
26 3
J10
J10 3 3 25
PZ1 SB 4 4 J11 13 gv Terra
J6 IG1
J11 gv Terra
J10 2 2 Pump 3 NTC 5 J11 5 J14
24 5

1
Fusibile 4A gv Terra
J7 J8 J15
J10 1 1 PZ2 SZ2 6 6 J11 12
23 Circ. 2 1 3 Fase
1

m
Valv.Mix
5

J9 3 3 CR IA TA2 TA1 NTC 7 J11 4 F1

0 22 7 T1 a Neutro
2

J9
J9 2 2 17 16 15 14 13 12 11 10 9 8
OFF
3

21 VM SE 8 m Circolatore
Analogic
6

Com.

24V
Bus
J9 1 1 Input Circ.2 J2 C
4

ON 20 a
J8 2
5

2 Alarm
19

J11 11
J8
6

J8 1 1
18
9 8 7 6 J12 5 4 3 2 1 v

Off - Valv. Mix

On - Valv. Mix

Neutro Valv. Mix

Neutro Pompa 3
Fase Pompa 3

Neutro Pompa circ.1

Fase Pompa circ.1

Fase Pompa Sanit.

Neutro Pompa Sanit.
7

m Valvola gas
4 5

g
8

a
6

VG
3

J12 4
J12 3
J12 2
J11 3

J11 8
J11 1
J11 9
5

J12 m Termostato limite

2

J11 2
7

J1 a
1

TS

WD

Comune
Comune

NTC climatica
NTC mand. circ. 2
NTC bollitore
NTC mand. circ. 1
a Pressostato Diff.
2 3 4

n
13

m
PD

J11 3 T. A. circ. 1
J11 4
J11 12 Comune
J11 5
J11 13
J11 6
J11 14 Comune
J11 7

J11 11
4

Analogic Input
T. A. circ. 2

Comune
Comune

Alarm
Comune
J11 10 Comune J11 10
3

6
5
4
3
J11
2

5
4
2
1
SLAVE 1
1

J12 4 24V contr. remoto

J12 3 Comune
J12 2 Ebus contr. remoto

J8

J10
J10
J10
J10
J10 2
J10 1
J8
J8
J8
J8
7 Soffiante (+)
1 2 1 m
J12 14 Input Sens. Hall b
3 4
J11 8
J10 J8 Alimentaz. Sens. Hall v
PC J5 Comune Sens. Hall g
Soffiante (-)
T3 n
m NTC mandata
6
11

a SM
5

T1 J10 NTC di ritorno

4

1 2 m
R6 R5 R4 J9
10

R3 R2 R1 J4 a SR
Fuse
NTC fumi
2

F1 3.15 A m
J17
9

J16 a SF
Fase 230V a.c. Main
m
1
Neutro 230V a.c. a
2
J3
3 BUS 1
Terra gv
J7
BARCODE

J2
MASTER
Terra gv
J6

Terra gv
J5
BUS J14
Terra gv
MC 1 2 3 4
J4
J1
PC

2 1
1

2 B

bbThe circulators must be connected with the interposition of suitable contactors with manual emergency actuation.
11
 

12

IA
IG

L0

SE
SB
PB

CR
VM

TA2
TA1
SZ2
SZ1
PZ2
PZ1

Mixer valve

Boiler sensor
MODULAR SYSTEM

Zone 2 sensor
Zone 1 sensor
Analogue input

Outdoor sensor
Boiler circulator
A

ISPESL pressure switch

al polo stella di terra al polo stella di terra

Modular system main switch

EA/ER EA/ER
gv Terra gv Terra
J6 IG2 J6 IG3
gv Terra gv Terra
J14 J14

1
1
Fusibile 4A gv Terra Fusibile 4A gv Terra
J7 J8 J15 J7 J8 J15

Zone 2 circulator (low temperature)

1 3 Fase 1 3 Fase

1
1

m m

Zone 1 circulator (high temperature)

Master card operating indicator light
5
5

F1 F1
T1 a Neutro T1 a Neutro

2
2

3
Circolatore
3

m m Circolatore

6
6

J2 C J2

4
4

a a C

Zone 2 room thermostat (low temperature)

Zone 1 room thermostat (high temperature)
5
5

6
6

v v

7
7

m Valvola gas m Valvola gas

4 5
4 5

g g

8
8

Remote control (accessory available separately)

a a

6
6

3
3

b VG b VG

5
5

J12 m Termostato limite J12 m Termostato limite

2
2

m m

7
7

J1 a J1 a

1
1

TS TS

WD
WD

a Pressostato Diff. a Pressostato Diff.

2 3 4
2 3 4

n n

13
13

1
1

m m

C
PD PD

TS
SF

PD
SR

VG
SM
4
4

3
3

SLAVE 3
J11

2
J11
2

SLAVE 2 (models 115)

1
1

Soffiante (+) Soffiante (+)

m m
Input Sens. Hall b Input Sens. Hall b
Alimentaz. Sens. Hall v Alimentaz. Sens. Hall v
PC J5 Comune Sens. Hall g PC J5 Comune Sens. Hall g
Soffiante (-) Soffiante (-)
T3 n T3 n

Gas valve
m NTC mandata m NTC mandata

6
6

Flow probe
11
11

a SM a SM
5
5

Return probe
J10 NTC di ritorno J10 NTC di ritorno
4
m
4

1 2 1 2 m

HEATING ELEMENT
J9 J9
10
10

3
3

J4 a SR J4 a SR
NTC fumi NTC fumi
2
2

m m
J17 J17
9
9

Safety thermostat
1
1

J16 a SF J16 a SF

Exhaust flue probe

Main Main

BUS 2 BUS 3

Heating element circulator

EA/ER Ignition/detection electrode

J10/J17 Addressing microswitches

B

Water differential pressure switch

IG1..IG3 FIRST..THIRD heating element switch



1.10 Control panels

4 5 6

1 2 4 5 6 4 5 6 7
3

12 11 10 9 8

13 14 15 16

13

21 20 19 18 17

1 Electric power supply signal 16 Value increase button

2 Master user interface 17 Value decrease button
3 Slave user interface 18 Save button
4 Slave card operating status signal: 19 Parameter selection button
-- FLASHES in absence of heat demand 20 Operating mode selection button
-- FLASHES QUICKLY during the ignition cycle 21 Master reset button
-- 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 THIRD heating element switch (only for Power Plus
Box SYS 115 HI)
9 SECOND heating element switch
10 FIRST heating element switch
11 Main control panel
12 Modular system main switch (only accessible by
turning the main control panel)
13 Electric power supply signal
14 Modular system block signal
15 Display


Functional notes -- The exhaust function: the high and low temperature
The Power Plus Box SYS modular system control panel circuit pumps remain in operation for 5 minutes after
manages: the last burner is turned off. The waiting time before
-- The DHW priority function which, in the case of a the heating element circulator is stopped once the
DHW demand, the master card can also serve the burner is shut off is 6 minutes. When the last burner
high or low temperature circuit. is turned off, the circulator only stops when the room
-- The anti-freeze function, also active in stand-by mode, thermostat demand stops.
which starts the high temperature circuit circulator -- The ignition/shut-off control function: in both cascad-
and the loop circulator if the manifold temperature ing management modes there is a burner ignition and
drops below 5°C. If there is an outdoor sensor, the shut-off limitation function in the case of low heat de-
circulators turn on if the outdoor temperature drops mand.
below 3°C. If after 10 minutes the manifold tempera- -- The system anti-freeze protection function: the Power
ture is less than 5°C, a burner turns on at maximum Plus Box SYS condensing systems are equipped with
power until the manifold temperature reaches 20°C. freeze protection electronics. The electronics activate
If after 10 minutes the manifold temperature exceeds the heating unit if the temperature drops below the
5°C but the outdoor temperature is lower than 3°C the minimum threshold. Therefore the use of particular
circulators remain active until the outdoor tempera- anti-freeze fluids are not necessary except in the
ture goes above that value. case of uses with the equipment completely shut off
-- The cascade management function: to manage the for long periods. If using anti-freeze fluids make sure
power delivered by the system, it is possible to se- they are not aggressive for steel.
lect between the minimum and maximum quantity of
lit burners.

1.11 User interface (master)

The Power Plus Box SYS 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 ar-
rest

14 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 cir-

cuits managed by the Master card

and
Are used to increase or decrease a certain value

OK
Press to memorize new values


1.11.1 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

1.11.2 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

Manifold delivery temperature T1
1 (e.g. T1 = 80°C)
Hot water T3
2 (e.g. water tank temp. = 50°C)
Outside temperature T4
3

15
(e.g. T4 = 7°C)

4 Flow temperature 2nd system or low T6 system

1st system room thermostat off or on

5 (e.g. OFF = contact open; ON = contact closed)
2nd system room thermostat off or on
6 (e.g. OFF = contact open; ON = contact closed)
0-10V analogue input
7 (e.g. 5.5V ; 10V respectively)

Mixer valve function status

8 (e.g. closing, opening, pause)

Principal circulator function status.

9 (e.g. circulator OFF; circulator ON respectively)
Function status hot water system circulator.
10 (e.g. circulator OFF; circulator ON respectively)
Second circulator function status
11 (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.


1.11.3 Changing the user parameters

Pressing displays the following values in succession:
-- manifold delivery temperature T1
-- DHW temperature T3
-- low temperature circuit delivery temperature T6.

To change the relative setpoints:

-- press the “Set/esc” button: the relative value will appear, the two digits on the right will flash
-- if the value should not be changed, press ”Set/esc” again to return to display mode
-- if the value should be changed, press and until the required value appears on the display. Press “OK” to save
the new value. The displayed value stops flashing and the display returns to the display mode

For example’s sake here below is a table showing the procedure for changing the setpoint value of the low temp. heating
system from 50 to 40°C.
POS. PROCEDURE DISPLAY

1 E.g. value read on display for high system 80° C

2 Press button to enter display mode, press again and go to the first of 6 digits to visuali-
ze the set value (e.g. 50° C)

3 Press button ”Set/esc”

4 Press to take the setpoint to the desired value (e.g. 40° C)

5 Press ”OK” to memorize the new value

6 After 3 secs. the display will return to the display mode with the new setpoint

If there is no change after pressing ”Set/esc” for 10 secs. (the desired value corresponding to the set one) the display
returns to display mode function.
If there is no operation after pressing buttons and , after one minute the display will return to display mode. The

16
new selected value is not memorized.

1.11.4 Monitor mode

Press “Set/esc” for 5 seconds to access "Monitor" mode. This mode is used to check the operating values for every sys-
tem unit (addresses from 1 to 60).
POS. OPERATIONS DISPLAY

1 From current T1 position at 80° C

Press ”Set/esc” for 5 secs. The displays shows it is possible to read the values or functio-
2 nal status of unit 1

3 Press or to scroll and read the values of the desired unit (e.g. fig., unit 19)

Pressing the first value of the selected unit will appear. Afterwards by pressing the
4 same button the next values will be visualized.
(e.g. fig., 1st value – flow temperature NTC 70° C).
Press ”Set/esc” to exit monitor mode. The display will return to display mode function if it
5 is not pressed within 5 minutes or if no operation has been done.


The following values for each single unit can be visualized with :
POS. DIMENSIONS DISPLAY

1 Flow temperature (e.g. 70° C)

2 Return temperature (e.g. 50° C)

3 Exhaust flue temperature (e.g. 60° C)

Ionization current (index from 0 to 99).

4 E.g. fig. Ionization current index 44.
Fan PWM signal (%).
5 If PWM = 100%, it corresponds to 99 on the display. E.g. fig. with
66%.
Flowmeter contact open and closed (e.g. fig. contact open then
6 contact closed)
Circulator or motor-driven valve individual unit on/off.
7 (e.g. fig. circulator on then circulator off)
Maximum ionization current (range from 0 to 99) at first attempt.
8 E.g. fig. Maximum ionization current value on display 80.
Hours worked by unit (from 0 to 9999 hours)
9 E.g. fig. 8050 hours: first thousands and hundreds then tens and
units will appear in succession and coupled on the display

1.11.5 Installer programming mode

The installer parameters can be changed by entering the password (22).
The installer level password makes it possible to view and change the user and installer parameters.
Procedure for accessing the programming mode:
POS. PROCEDURE DISPLAY
Manifold delivery temperature T1
1 (e.g. T1 = 80°C)

2 Press “Set/esc” and “OK” . After 5s, the second and third digits will flash 17
3 Use and to enter the second number of the password (the right digit).
E.g: password = X2

4 Press “OK” to save the second number of the password

5 Use and to enter the first number of the password (the central digit).
E.g: password = 22

Press “OK” to confirm the password, if the password is incorrect, the card returns to the
6 Display mode. If it is correct, the first parameter P06 is displayed

Press and to scroll the parameters enabled by the password.

7 Press “Set/esc” to start to modify the parameters.
Now P-XX and the respective value will be shown alternatively on the display.
Press and to change the parameter value.
8 Each time a button is pressed, the alternating display of the parameter and the respective
value stops for 5 seconds and only the value is displayed.
9 Press “OK” to save the new parameter value.

To exit the installer programming mode, press the “Set/esc” button.

See the chapter "Parameter list" for a complete list of the parameters.


1.11.6 Test mode

In test mode it is possible to generate a high temperature heating demand at maximum power and at minimum power.
All system fans must be activated. If the installer turns off the switch for some Slaves, the others, connected to the Master,
must continue to operate.
Proceed as follows to enter Test mode from Display mode:
POS. VISUALIZED VALUES DISPLAY
Press “Set/esc” and at the same time for 5 s.
After 5 s select the maximum speed or the minimum speed with the and buttons.
1 All system fans will operate at the selected speed.
The first digit indicates the selected speed (H = maximum speed; L = minimum speed).
The other two digits display the delivery temperature. E.g: T1 = 80°C.

2 Press “OK” to exit Test mode and return to Display mode.

1.11.7 Error mode

The display starts to flash in case of a fault originating from any heating element.
Follow the procedure indicated for identifying the errors.
POS. PROCEDURE DISPLAY

1 The display starts to flash to indicate one or more errors.

Press : the address of the first unit will appear on the display, alternating with the first
error code.
Press again to display the rest of the errors for this unit.
1.b The errors of the subsequent units that are not functioning will be displayed in succession,
pressing the button. By pressing the button, the errors will be displayed in reverse
order (E.g. unit 2 error code E05). If the errors originate from the Master card, they are
displayed as unit 00 errors (U 00 + error code).

2 Press “Set/esc” to exit Error mode and return to Display mode.

18 See the chapter "Fault list" for a complete list of the errors.

1.11.8 Permanent block

In the case of burners with a permanent block, the “Reset” button must be pressed to reset their operation.
If the “Reset” button is pressed while in Display mode, all the Slave heating elements will be reset.
If the “Reset” button is pressed while displaying the error that caused the permanent block, only the heating element
related to the block will be reset.


2 INSTALLATION aaDo not dispose of packaging material into the envi-

ronment, or leave it within the reach of children, since
it can become a potential hazard. Dispose of packag-
ing material in compliance with applicable legislation.
2.1 Unpacking the product
The Power Plus Box SYS condensing system is supplied on
a pallet, strapped and protected by cardboard packaging. 1
Its condition and compliance with what was ordered must
be checked immediately. The specific characteristics of
the product are indicated on the outside: model, power,
product code and serial number. If there is a discrepancy
between what was ordered and what was received, imme-
diately contact the local agent, warehouse or sales service.
2

5
6
4

2.3 Overall dimensions and weights

2.2 Opening
19
Remove the straps (1) and the cardboard packaging (2). 26
15
1 Strap
2 Cardboard packaging
3 Pallet
4 Modular condensing system
5 Document envelope containing:
12
50

-- Instruction manual
0
65

-- Hydraulic test and warranty certificate

-- Barcode labels
6 Accessory envelope containing:
-- Natural gas to LPG transformation kit Power Plus Box SYS
-- Door key DESCRIPTION UM
85 115 HI
Water drainage system
The following is also supplied: 180 220 Kg
weight
positioned on the base inside the modular system:
-- fuel shut-off valve
-- high temperature system connection kit 2.4 Handling
positioned inside the control panel:
A transpallet or forklift must be used for handling.
-- outdoor sensor.
bbThe document envelope (5) must be kept in a safe
place. Any copies must be requested from B,
who will send the new documentation within 45 days
and who reserves the right to charge for the copies.


2.5 Installation premises

The Power Plus Box SYS systems are designed to be in-
stalled outside If installed inside, they are B23 category
devices and must be installed in permanently ventilated
rooms in compliance with the Technical Standard currently
in force. In this latter case, a suitable system for collecting
condensation and for releasing the flue gas must be pro-
vided (see the specific chapter “Flue gas evacuation for
installations in a central heating station”).
bbTake into consideration the space that is required in
order to access the safety and control devices and
to perform the maintenance operations. If possible,
maintain a distance of approx. 1 metre between the
rear panel and the wall. Note that the front doors can
be removed easily.
bbCheck that the electrical degree of protection of the
modular system is suitable for the characteristics of
To make it easier to position the modular system in the room the installation location.
of installation:
-- place two wooden boards (1) near the pallet (2)
-- slide the modular system above the wooden boards
-- adjust the feet (3) of the modular system until they
rest on the ground
-- slide the wooden boards out.

30
15
≥
1
m

m
1
≥
12
50

0
65
20 3

≥
m

1
1

m
≥

2
1 2.6 Installation in older systems and
3
systems requiring modernisation
If the system is being installed in an old or refurbished sys-
bbThe packaging material must be disposed of care- tem, check that:
-- If installing in a central heating plant, the flue is suit-
fully and must not be abandoned, as it is a source of
able for the condensing equipment, at the tempera-
potential danger.
tures of the products of combustion, calculated and
If it is necessary to hoist the system using a crane, it is ad-
built according to standard. it is as straight as pos-
visable to sling it with elastic straps, as shown in the figure.
sible, air-tight, isolated and not have obstructions or
constrictions
-- The flue has a connection for condensation evacu-
ation
-- The electrical system has been implemented by qual-
ified personnel in compliance with the specific stand-
ards
-- The flow rate, head and flow direction of the circula-
tion pumps is appropriate
-- The gas supply line and tank (if installed) are imple-
mented according to the specific standards
-- The expansion tanks ensure total absorption of the
fluid expansion in the system
-- The system has been cleaned of sludge and depos-
its.


2.7 Hydraulic connections

The Power Plus Box SYS condensing systems are designed and built to be installed in hot water heating systems. They
are used only for this purpose and any other erroneous or unreasonable application is prohibited.
Water fittings have the following specifications:

SF
MS

103 186 140 180 110 110

MI at / MI atk
150
MI btk
MI bt

RI bt

1041
1526
RI at

RI btk
RS 106,5
40

GAS RI atk
286

Sc
433

RS k

255
131

104 140 130 140 1250

65 71
650

Power Plus Box SYS

DESCRIPTION
85 - 115 HI

21
MI at High temperature system delivery line (*) 2" (M) Ø - DN
RI at High temperature system return line (*) 2" (M) Ø - DN
MI bt Low temperature system delivery line 2" (M) Ø - DN
RI bt Low temperature system return line 2" (M) Ø - DN
MS Domestic hot water delivery line 2" (M) Ø - DN
RS Domestic hot water return line 2" (M) Ø - DN
MI btk Low temperature system delivery line (distribution kit) (***) 2" (M) Ø - DN
RI btk Low temperature system return line (distribution kit) (***) 2" (M) Ø - DN
RI atk High temperature system return line (distribution kit) (***) 2" (M) Ø - DN
RS k Domestic hot water return line (distribution kit) (***) 2" (M) Ø - DN
GAS Gas inlet (**) 2" (M) Ø - DN
SF Socketed flue gas outlet 125 Ø mm
Sc Socketed condensate outlet 50 Ø mm
(*) Outlets provided once the system connection kit is installed (supplied).
(**) Inlet provided once the fuel shut-off valve is installed (V) (supplied).
(***) With accessory kits installed.
bbOnce the fuel shut-off valve is installed, (V) insert the probe in the pit (P), second
from the bottom, located in the back on the delivery manifold, and block it by
tightening the specific screw. P

To make it easier to position the modular system in the area of installation, refer to the
"Handling" paragraph.
Adjust the feet of the cabinet if necessary in order to level them, making it easier to V
open and close the doors.
bbProvide the system filling, draining and safety components, expansion tank, etc.


Schematic diagram with FACTORY configuration

Based on the type of system to be connected, identify the connections to be used on the hydraulic separator, located in
the machine.

4 3 5 4 2
4 3 5 4

4
4
6
8 6
4 7 4
EAF 8
4 7 4
EAF
1 1

Position for system connection HIGH TEMPERATURE Position for system connection LOW TEMPERATURE

3 1 Power Plus Box SYS modular system

4 5 4 2 High temperature system users
3 Central heating system pump
4 Check valve
5 Non-return valve
6 Expansion tank

22
10 7 Filter
8 Pressure reducer
9 Low temperature system users
6 10 Remote controlled water tank
4 EAF Water from mains

8
1 4 7 4
EAF

Position for system connection DOMESTIC HOT WATER

bbThe hydraulic separator does not cause a loss of load, therefore select the circulator (3) based only on the loss of
load from the system.
bbThe circulators located in the modular system provide circulation only in the primary circuit, and are sized to work
with a maximum ∆T between the delivery and return lines of 18°C. This value can be increased by moving the cir-
culator selector to the first speed.


Schematic diagram with the ACCESSORIES KIT installed

2
3

1 B
5 R 4
A R

8
5 R
C
6
5 7 5
EAF

1 Power Plus Box SYS modular system EAF Water from mains
2 High temperature system users A High temperature HT kit
3 Low temperature system users B Low temperature LT kit
4 Remote controlled water tank C Water tank kit
5 Check valve R Non-return valve
6 Pressure reducer
7 Filter
8 Expansion tank

bbWhen installing the distribution kits (A, B or C), supplied as an accessory, check that the characteristics of the
circulators and the mixing valves for the low temperature system are suitable for the system (see the characteristic
curves below).
bbDistribution kits are equipped with shut-off valves. These must be installed in appropriate places on the installation.
23
Technical data for the circulator in the distribution kit

900
800
700 2”
600
H (mbar)

500
400
180

III
300
200
100
II
I 2”
0
0 2 4 6 8 10 12
Q (m3/h)


2.8 Flue gas evacuation for 2.9 Condensate evacuation

installations in a central heating Power Plus Box SYS condensation systems produce a
plant condensate flow depending on the operating conditions.
The maximum hourly flow of condensation produced is in-
When constructing evacuation lines for installations in a dicated for every model in the technical data table. The
central heating plant, materials must be used that are re- condensate outlet system must be sized for that value and
sistant to products of combustion (temperature between 40 the cross section may not be smaller in any section than
°C and 100 °C, relative humidity also above 100%), in class the dimension of the connection to the condensate outlet
W1 according to UNI EN 1443, typically stainless steel or manifold (SC).
plastic materials. It is also necessary to guarantee the tight- The condensate outlet manifold is supplied already in-
ness of the entire evacuation line with regard to the perme- stalled. Therefore it is only necessary to connect the out-
ability of condensed steam and gas pursuant to the current let (SC) coming from the modular system to the drainage
regulation (UNI EN 1443). system.
The connection sections between the chimney and the
boiler must have a minimum slope of 3° towards the boiler bbAlways keep the inclination angle “i” greater than 3%
so that any condensate that forms in this line section can and the diameter of the condensate outlet pipe al-
be evacuated using a suitable exhaust device. ways greater than the union on the modular system.
The Power Plus Box SYS modular condensing systems have
been approved complete with a flue gas evacuation line
in self-extinguishing PP or suitable materials based on EN
677 and correlated standards.
The flue gas exhaust system foresees the use of pipes with
the diameters indicated in the table.
All of the indicated diameters refer to lines in self-extin-
guishing polypropylene (class B1), implemented with pipes
with socketed connections or equivalent lines.
The maximum equivalent length of the flue gas evacuation
lines is indicated in the table. Each modular system is pro-
vided with 2 female socketed connections Ø 160 mm for
the exhaust of combustion products to the right and to the
left.
Maximum Loss of load (m)
SC
equivalent i ≥ 3%
length (m) 90° bend 45° bend "T" union
55 5 1,2 4

24 bbThe flue must be sized according to the current

standard UNI 7129 and be as straight as possible
without obstructions or constrictions.
bbA steam trap is mandatory for flue gas lines longer bbThe connection to the drainage system must be
made according to current laws in compliance with
than 3 metres. any local regulations.
bbMake sure that there is a minimum slope of 3° in the bbFill the water pipes (1) for connecting to the con-
horizontal sections of the flue gas manifold to avoid densate outlet manifold in order to avoid products of
the accumulation of condensation. combustion from entering the environment during the
bbIn the event of installation with air intake from the first minutes of modular system ignition.
premises (both in the heating unit and externally)
avoid obstructing the passage of air under the metal
cupboard.

1 1 1


bbIf installing in a central heating plant, it is recommended HN2 TYPE NEUTRALISATION KIT
to direct both the products deriving from the boiler con- The HN2 TYPE neutralisation units were designed for sys-
densate outlet as well as the condensate deriving from tems equipped with the central heating plant condensate
the flue gas manifold to the same exhaust outlet. outlet trap located higher than the boiler condensate outlet.
bbThe boiler base must be horizontal and flat in the area This neutralisation kits does require electric connections.
Description Sizes
of the support frame to prevent problems with con-
densate evacuation. L - Width 400 mm
H - Height 220 mm
bbAny condensate neutralisation devices can be con- P - Depth 300 mm
nected after the siphon. For the calculation of the Quantity of granulate 25 kg
duration of the neutralisation load, the amount of
neutraliser consumption must be evaluated after one
year of operation. The total duration of the load can
be extrapolated from this information.
bbPay particular attention to fixing the condensate evac-
uation pipe from the siphon located on the flue gas ex-
haust manifold and from the condensate outlet mani- 1,5 m
fold. max

2.10 Condensate neutraliser

The N2 and HN2 neutralisation kits are available for con- B
densate neutralisation.

N2 TYPE NEUTRALISATION KIT

The N2 TYPE neutralisation units were designed for sys-
tems equipped with the central heating plant condensate H
outlet trap located lower than the boiler condensate outlet.
P
This neutralisation kits does not require electric connec-
tions. A
Description Sizes
L
L - Width 400 mm
H - Height 220 mm
C

25
P - Depth 300 mm

B Maintenance
Neutralisation device maintenance must be performed at
regular intervals and as required (minimum once per year).
The requirement for maintenance depends on the system
characteristics. For this purpose, the filling level of the dol-
omitic granules must be checked. The minimum filling level
H is equal to 15 cm, starting from the upper edge of the box.
The first filling of neutralisation product is sufficient at least
P for one heating season in the case of maximum formulation
of condensate.
The operation can be checked easily using the pH indica-
A tor cards available commercially. They can be purchased
L from any pharmacy or store selling chemical products. The
condensate that exits must have a pH value between 6.5
and 9. If any deposits are found on the surface of the neu-
tralisation device during maintenance, it is recommended
C to replace the granulate.


2.11 Electrical connections

2 1 3 4 3

ROTATE

ROTATE

Power Plus Box SYS systems leave the factory completely -- Identify the terminal board (6), located inside the
wired and the only connections required are the electric electric panel, and direct the pump and sensor ca-
power supply cable, the room thermostats, the outdoor bles (7) towards it through the holes made in the
sensor and the user circulators, using the dedicated ter- panel casing. Make the connections as shown in the
minals. diagram on the following page, referring to the wiring
Proceed as follows: diagrams.
-- switch the boiler OFF at the mains power switch -- Provide a three-pole cable (8) to supply the
230V~50Hz line, direct it through the hole made in
the casing of the electric panel and connect it to the
switch (9) as indicated on the wiring diagrams.

8 7

26 6

5
Pump 28

27
1

2
NTC

6
4 Pump
26 3 NTC
J10
3 25 4
2 Pump 3 24 5 NTC

1
23 6
Circ. 2
3 Valv.Mix
0 22 7
NTC
J9
2 OFF 21 8
1 r
ON 20
17 16 15 14 13 12 11 10 9
2
Com.

Alarm Analogic
24V

19
Bus

Input Circ.2
J8
1

9
18

-- open the two front doors in the casing

-- loosen the screw (1) and turn the main control panel
(2)
-- loosen the screws (3), turn the instrument panel (4).
Insider, there is the low temperature delivery/boiler
sensor and the outdoor sensor (to be connected).

identify the cable glands (5) located on the rear part of the
modular system and use them to pass the pump, sensor
and electric power supply cables inside the modular sys- bbIf coupling multiple modular systems with a cascade
tem connection, a power supply cable must be provided
for each modular system.

5


TERMINAL BOARD INSIDE THE CONTROL PANEL

28 SZ1 1
Pump NTC

PB (*) High temperature

27 DHW circulator zone 1 sensor 2
26 PZ1 (*) 3
Pump NTC

System circulator SB
Boiler sensor
25 High temperature 4
24 SZ2 5
NTC
Pump 3
PZ2 (*) System circulator Low temperature
23 Low temperature zone 2 sensor 6 Circ. 2
Valv. Mix
22 7 NTC
0
SE
VM (*)
21 Mixer
External sensor
8
OFF
valve

ON
20
TA2 TA1
Alarm 19 Alarm signalling "Room thermostat Room thermostat
contact Low temperature" High temperature
18
IA
Analogue
CR input 0-10V
Remote
control

17 16 15 14 13 12 11 10 9
"Analogue
Com

BUS
24V

Input"
Circ. 2

(*) 230V~50Hz
bbThe following is mandatory: aaIt is prohibited to use gas and/or water pipes for the
-- The use of an omnipolar magnetothermic switch, equipment's earth connection. 27
line disconnecting switch in compliance with CEI-
EN standards (contact opening of at least 3 mm) aaIt is prohibited to pass the power supply and room
-- Respect the connection L (line) - N (neutral). Keep thermostat cables near hot surfaces (delivery
the earth conductor 2 cm longer than the power pipes). If contact is possible with parts that have
supply conductors temperatures above 50°C, use a suitable type of
-- Use cables with a section greater than or equal to cable.
1.5 mm2, complete with cable terminal caps
-- Refer to the wiring diagrams in this manual for all The manufacturer is not responsible for any damage
electric operations caused by failure to earth connect the device and fail-
-- Connect the equipment to an effective earthing sys- ure to comply with what is indicated in the wiring di-
tem. agrams.

bbThe circulators must be connected with the interpo-

sition of suitable contactors with manual emergency
actuation.

NOTE: for sensor positioning, see the "Sensor positioning" chapter.



2.12 Outdoor sensor installation bbIf the outdoor sensor is not connected, set parame-
ters 14 and 22 to “0”.
The correct positioning of the outdoor sensor is of funda-
mental importance for proper climate control operation. See the correspondence table in the chapter "Hydraulic
The sensor must be installed outside the building to be circuit and probe positioning".
heated, at approx. 2/3 the height of the NORTH or NORTH
WEST façade and far from flues, doors, windows and sun-
ny areas.
2.13 System filling and emptying
Fastening the outdoor sensor to the wall The Power Plus Box SYS filling system is not equipped with
-- Unscrew the sensor protection box cover, turning it a filling tap, which must be installed on the system return.
anticlockwise to access the terminal board and fas-
tening holes
-- Trace the fastening points using the box as a tem-
plate
-- Remove the box and drill the holes for the 5x25 ex-
pansion plugs
-- Fasten the box to the wall, using the two supplied
dowels
-- unscrew the cable gland nut, insert a bipolar cable
(with a section between 0.5 to 1mm2, [not included in
the supply]) to connect the sensor to terminals 7 and
8 (see diagram in the "Electric connections" chapter)
-- connect the two cable wires to the terminal board
without identifying the polarities
-- fully tighten the cable gland nut and close the protec-
tion box cover.
FILLING
-- Check that the 3-way valve (1) and the delivery cock
(2) for all heating elements are open

2
28

bbThe sensor must be positioned on a smooth wall sec- 1

tion. If there are exposed bricks or irregular walls, an
area with a smooth contact must be prepared.
bbThe maximum length of the connection between the
outdoor sensor and the control panel is 50 m. In the
case of connections with a cable length that exceeds
50 m, check compliance of the value read on the card
with a real measurement and adjust parameter 39 to
make any necessary correction.
bbThe connection cable between the outdoor sen- -- Open the automatic bleed valve caps (3) on each
sor and the control panel must not have couplings. heating element by two or three turns
If these are necessary, they must be watertight and
suitably protected.
bbAny channelisation of the connection cable must be
separated by live cables (230Vac).


3
6

-- Open the filling tap (4), provided on the system, until

4
the pressure indicated on the pressure gauge (M) is
1.5 bar
-- Close the filling tap (4).

EMPTYING THE HEATING ELEMENT

-- Close the thermal element's delivery cock (2)
-- Connect a plastic pipe to the 3-way valve (1) and po-
M
sition the lever downwards
bbBefore opening the 3-way valve (1) protect the elec-
tric devices located below from any escaping water

bbDeareation of the Power Plus Box SYS modular sys-

tem takes place automatically through the automatic
bleed valves located at the top of every heating ele-
ment. Check that the valve cap is open.
29
EMPTYING
Before emptying, disconnect the electric power supply by
switching the main system switch to "off”.
1

Make sure that the filling tap (4), installed on the hydraulic
system, is closed


SYSTEM EMPTYING -- the system expansion tank preload is sufficient

-- Connect a plastic pipe to the drain tap (6) located on -- the electric connections have been made correctly
the system return line
-- Connect a plastic pipe to the 3-way valve (1) of every bbIt is mandatory to connect the circulators using con-
heating element tactors with manual emergency actuation.
-- Open the delivery cock (2) -- make sure that the bleed valve cap(s) have been un-
-- Open the drain cock (6) and the 3-way valves (1). screwed
-- the circulators can rotate freely: unscrew the inspec-
tion screw and use a flat screwdriver to check that the
main shaft moves without obstructions
bbBefore loosening or removing the circulator cap, pro-
tect the electric devices located underneath from any
water that exits.
6

2.14 Preparing for initial startup -- the combustion product evacuation lines have been
suitably implemented.
Before igniting the Power Plus Box SYS modular system and
performing a functional check, it is important to first check
that:
-- the heating system shut-off and gas taps are open
-- the type of gas and the supply pressure comply with
the features of the modular system

30

-- the hydraulic circuit pressure, when cold, is approx.

1.5 bar and the circuit has been deaerated


3 COMMISSIONING AND
MAINTENANCE

3.1 Initial startup

-- Turn the main system switch "on"

-- press the button: the manifold delivery tempera-

ture will be displayed, preceded by the symbol “1”
-- press “Set/esc”: the relative setpoint is displayed and
the two digits to the right will flash. To change this
value press or . To confirm, press “OK”

-- loosen the screw (1), turn the main control panel (2)
and access the main switch of the modular system
(3), turning it to "on". The green indicator lights (4)
and (5) will turn on
-- turn the switches (6) for each heating element to "on”
-- the green SLAVE electric power supply indicator light
(7) for every heating element will flash. The system
will perform a self-diagnostics cycle, after which it will
switch to DISPLAY mode
-- the display (8) shows the system status and the tem-
perature measured by the "high temperature" circuit
sensor (see the "Display mode" chapter)

If there is a low temperature system, set parameter 34=1. -- press the button four times: the maximum temper-
ature of the low temperature circuit will be displayed,
preceded by the symbol “6”
4 5 8 1 7

31

-- press “Set/esc”: the relative setpoint is displayed and

the two digits to the right will flash. To change this
value press or . To confirm, press “OK”
3 2 6

-- Adjust the room thermostats for the high and low tem-
perature 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)


bbIn the case of low temperature systems, select a

temperature between 20°C and 45°C. By setting the 4
"low temperature" type system, the maximum deliv-
ery temperature setting will be limited to 50°C (Par.
23=T_CH_Low_limit).
bbChanging the delivery temperature involves chang-
ing the climatic curve (see the “Heat control setting”).
This change may only be made by Technical Assis-
tance Centre. Refer to the “DISPLAY mode” chapter for more information
about the system display types.
If the system is connected to a boiler, set parameter 6 (pre-
set to 0=no DHW service). To do so, access the “Installer If there are any ignition or operating faults in any heating
programming” mode and set parameter 6 to: element, the control panel display will start to flash and the
-- 2 = for a boiler with a sensor red LED (5) will turn on.
-- 6 = for a boiler with a thermostat.

Also set parameter 9 (DHW_Priority) to 2 to have absolute

priority.
If the boiler is equipped with an NTC sensor, the required
temperature can be set from the display between 10°C and
50°C.
If the boiler is equipped with a thermostat, the required
temperature is set directly on the boiler, whereas parameter
3 must be left at 50°C.
-- Press the button two times: the domestic hot wa-
5
ter temperature will be displayed, preceded by the
symbol “3”
-- press “Set/esc”: the relative setpoint is displayed and
the two digits to the right will flash. To change this
value press or . To confirm, press “OK”.

There are two types of errors:

-- Type A errors, which can only be turned off by press-

32
ing the RESET button
-- Type E errors, which turn off when the cause that de-
termined them has disappeared (see the "ERROR
mode" chapter and the "Fault code" chapter).

3.2 Checks during and after initial

start-up
After start-up, check that the Power Plus Box SYS system is
carrying out the following correctly:
The system will turn on in DHW mode until the demand is -- the start-up and subsequent shut-off procedures,
satisfied. closing the zone thermostat contacts

When the modular system is in stand-by, the Master unit

display will be in DISPLAY mode and the three digits will be
“1” followed by the delivery temperature. The green LED
(4) will flash.

-- display of the DHW temperature (only with a boiler in-

stalled) and the heating temperature by pressing the
button two times.
If a boiler is installed, check that parameter "6” is set
correctly (2 = boiler with sensor; 6 = boiler with thermo-
stat) and that operation is correct by opening the hot
water tap.


Check that the modular system stops completely when

turning the main system switch to "off".

Electrically power the modular system by turning the main

system switch and the main device switch to "on".
-- generate the heat demand using the room thermo-
stat. The system will operate at maximum power, in-
dicating “H” on the display followed by the delivery
temperature (flue cleaning function)
-- with the burner ignited at maximum power, check that
the gas pressure is the nominal supply pressure indi-
cated in the table

After a few minutes of continuous operation with demand DESCRIPTION G20 G30 G31
from the room thermostat, the binders and manufacturing Wobbe index 45,7 80,6 70,7 MJ/m3
residuals will have evaporated and the following can be Nominal supply pres- 20 28-30 37 mbar
performed: sure
-- supply gas pressure check
-- combustion check. -- stop the heat demand
-- press “OK” to exit TEST mode
SUPPLY GAS PRESSURE CHECK -- disconnect the pressure gauge and tighten the pres-
-- Turn the main system switch "off" sure tapping point (3) upstream of the gas valve.
-- open the two front doors in the casing
-- unscrew the pressure tapping point screw (3) located COMBUSTION CHECK
upstream of the gas valve by two turns and connect electrically power the system by turning the main system

33
a pressure gauge there. switch and the main device switch to "on".

In TEST mode it is possible to generate a high temperature

heating demand at maximum power.
Proceed as follows:
-- press the “Set/esc” and buttons at the same time
for 5 seconds
-- electrically power the system by turning the main sys-
tem switch and the main device switch to "on".

In TEST mode it is possible to generate a high temperature

heating demand at maximum power.
Proceed as follows:
-- press the “Set/esc” and buttons at the same time
for 5 seconds


-- generate the heat demand using the room thermo- 3.3 Adjusting the functional
stat. The system will operate at maximum power, in-
dicating “H” on the display followed by the delivery parameters
temperature (flue cleaning function) The heating functions can be set for the high temperature,
-- combustion can be checked by unscrewing the cap low temperature and DHW circuits based on the system
(4) and inserting the analyser sensor in the foreseen requirements by setting the functional parameters.
position The first three parameters can be accessed on the user
level. The next three require a password (“22”, see the "IN-
STALLER PROGRAMMING mode" chapter in the "User
4 interface" chapter.

To access the user parameters, press the button, and

the following values will be displayed in order:
-- manifold delivery temperature T1
-- DHW temperature T3
-- low temperature circuit delivery temperature T6.

To change the relative setpoints:

-- once the check is complete, stop the flue cleaning -- press the “Set/esc” button: the relative value will ap-
function by pressing “Set/esc” pear, the two digits on the right will flash
-- stop the heat demand -- press and until obtaining the required value.
-- remove the analyser sensor and carefully retighten Press “OK” to save the new value. The displayed val-
the cap (4). ue will stop flashing after 3 sec and will be operative.
FAN SPEED A detailed description of all the parameters and the factory
The fan speed is controlled automatically based on the gas preset values can be found in the "Parameter list" chapter.
type and the length of the flue gas exhaust line (L).
This information is managed by parameter 36.
To make the change:
-- access “INSTALLER PROGRAMMING mode" follow-
ing the procedure described in the "User interface"
chapter and set parameter 36 to:
01 = natural gas and L<15 m
02 = natural gas and L>15 m
03 = LPG and L<15 m
04 = LPG and L>15 m.
34 ThePower Plus Box SYS systems are supplied for operation
with G20 (natural gas), with a flue gas exhaust line with
L<15m (parameter 36=01).

bbAll checks must be performed by Technical Assis-

tance Centre.


3.4 Setting the heating parameters

The following heating parameters can be set:
1 Setpoint_T_CH_High
High temperature circuit setpoint (parameter 1)
If the "fixed point" operating mode is set (par. 14=CH_type_high=0), it is the target temperature.
If the "climatic control" operating mode is set (par. 14=1) , it is the maximum target temperature with minimum outdoor
temperature (T_out_min=par. 37, preset to 0°C).
parameter 18 (T_ch_high_foot, preset to 50°C) defines the minimum setpoint at maximum outdoor temperature (T_out_
max=par. 38, preset to 18°C).

Preset to 70°C and upper value limited by par. 17 (T_ch_high_limit, preset to 80°C).

CLIMATIC CURVE
HIGH TEMPERATURE circuit
100
90
T_CH_High_foot
80 Max heat
Delivery temperature (°C)

requirement
70 T_out_min

60
50 T_out_max
T_CH_High
40
30
20
10
0
25 20 15 10 5 0 -5 -10 -15 -20
External temperature (°C)

2 Setpoint_T_CH_Low
Low temperature circuit setpoint (parameter 3)
If the "fixed point" operating mode is set (par. 22=CH_type_low=0), it is the target temperature. 35
If the "climatic control" operating mode is set (par. 22=1) , it is the maximum target temperature with minimum outdoor
temperature (T_out_min=par. 37, preset to 0°C).
parameter 24 (T_ch_low_foot, preset to 25°C) defines the minimum setpoint at maximum outdoor temperature (T_out_
max=par. 38, preset to 18°C).

Preset to 40°C and upper value limited by par. 23 (T_ch_low_limit, preset to 50°C).

CLIMATIC CURVE
LOW TEMPERATURE circuit
100
90
80
Delivery temperature (°C)

70
60 T_CH_Low_foot

50 Max heat
requirement
40 T_out_min

30
T_out_max
20
T_CH_Low
10
0
25 20 15 10 5 0 -5 -10 -15 -20
External temperature (°C)

Therefore, it is possible to work with a fixed point or set a climatic curve on every circuit.


3 CH_Priority 3.6 Heat control setting

Heating priority (parameter 16)
If set to 0, the system will work without heating priority with 1 Attenuation_High
the high temperature and low temperature circuits served HIGH TEMPERATURE circuit attenuation function
in parallel. (parameter 21)
If set to 1, the demand from the low temperature circuit is There are 2 cases:
ignored and the relative pump remains off. The low tem- -- Fixed point operation Par. 14=0
perature circuit demand is only accepted when the high -- Operation with climatic control Par. 14=1.
temperature circuit demand is inactive. Vice versa, if set to
2, the low temperature circuit has priority. FIXED POINT OPERATION, PAR. 14=0
With the high temperature circuit attenuation disabled,
Preset to 0. Par21=0 when the high temperature circuit thermostat is
closed, the heating demand is activated. When opened,
3.5 Setting the DHW parameters the system turns off.

The following DHW parameters can be set: The Master control unit activates the high temperature cir-
1 Setpoint_DHW cuit pump PZ1 and the system pump PZ2 (if parameter
DHW setpoint (parameter 2) P34=0).
This is the production temperature for DHW.
The maximum limit is indicated by par. 8 (T_DHW_limit, pre- On the Master control unit it is possible to set the high tem-
set to 60°C). perature circuit setpoint, Setpoint_T_CH_High = Par. 1, pre-
set to 70°C and settable from 10°C to T_CH_high_limit=Par
Preset to 50°C. 17, which is in turn preset to 80°C. The setpoint used will be
the one set with parameter 1.
The burner is on when:
2 DHW_Type Manifold temperature <=Setpoint – ignition hysteresis.
Boiler type (parameter 6) Ignition hysteresis can be set, CH_High_hyst_on = Par. 19,
0 = No DHW service preset to 7°C, can be set between 0 and 20°C.
1 = Quick exchanger with sensor The Master control unit converts the heat demand into pow-
2 = Boiler with sensor er demand for each slave control unit.
6 = Boiler with thermostat
The burners are off when:
In the case of a boiler with a thermostat, if the input is a Manifold temperature >=Setpoint + shut-off hysteresis .
closed contact, the DHW demand is activated, if it is an Shut-off hysteresis can be set (CH_High_Hyst_off=Par. 20,
open contact the demand stops. preset to 3, can be set between 0 and 20°C).

36 Preset to 0. With the high temperature circuit attenuation parameter,

Par. 21≠0, the high temperature thermostat contact is ig-
nored and a heat demand is present for the high tempera-
3 DHW_Priority ture circuit when:
DHW priority (parameter 9) Manifold temperature <=Setpoint – ignition hysteresis

0 = Shifting priority A The heat demand stops when:

The purpose of shifting priority function A is that the system Manifold temperature >=Setpoint + shut-off hysteresis .
can also serve heating if the heating demand is low. The setpoint in this case coincides with the value set for
The system responds to the heating demand if: parameter 1 (Setpoint_t_ch_high) if the high temperature
(Setpoint_Ch - 50°C) < Temp_collettore < (Setpoint_Ch + thermostat contact is closed, whereas it is calculated as
1°C) the value set for parameter 1 less the attenuation (Set-
Setpoint_Ch = Setpoint of the high or low temperature cir- point_t_ch_high-Attenuation_high) if the contact is open.
cuit depending on demand.
OPERATION WITH CLIMATIC CONTROL, PAR. 14=1
1 = Shifting priority B If the high temperature circuit attenuation is equal to 0 , At-
The purpose of shifting priority function B is that the system tenuation_high=Par. 21=0, its behaviour is the same as the
never stops the heating service for too much time. previous paragraph, with the exception that the setpoint is
The system responds to the heating demand if: calculated based on the outdoor temperature.
(Setpoint_Dhw+T_Tank_extra) - 50°C < Temp_collettore <
(Setpoint_Dhw + T_tank_extra) + 1°C
T_tank_extra = Par. 10 = preset to 30°C.

2 = Absolute priority (only DHW service)

Preset to 0.


If the outdoor temperature = Tout_min=Par. 37, preset to If the outdoor temperature = Tout_min=Par. 37, preset to
0°C, then setpoint =setpoint_T_Ch_high. 0°C, then setpoint =setpoint_T_Ch_low.
If the outdoor temperature = Tout_max=Par. 38, preset If the outdoor temperature = Tout_max=Par. 38, preset
to 18°C, then setpoint T_ch_high_ foot=Par. 18, preset to to 18°C, then setpoint T_ch_high_ foot=Par. 24, preset to
50°C. 50°C.
The setpoint is calculated linearly between the 2 outdoor The setpoint is calculated linearly between the 2 outdoor
temperature values. temperature values.

Preset to 0. Preset to 0.

2 Attenuation_Low 3 T_out_correct
LOW TEMPERATURE circuit attenuation function Outdoor temperature correction (parameter 39)
(parameter 25) Normally, the displayed value is the value read by the mi-
This paragraph is similar to the previous paragraph for the crocontroller plus or minus a correction value (T_visualizza-
low temperature circuit. ta = T read by the sensor +/- correction).
The read value of the outdoor temperature can be correct-
There are 2 cases: ed by varying the value of parameter 39, (the permitted
-- Fixed point operation Par. 22=0 limit for the correction is +/- 30 °C). In this phase, it is sug-
-- Operation with climatic control Par. 22=1. gested to use a reference thermometer.

FIXED POINT OPERATION, PAR. 22=0 Preset to 0.

With low temperature circuit attenuation disabled, Par.
25=0 at the closure of the low temperature circuit thermo-
stat, heating demand is activated. When opened, the sys- 4 T4_frost_protection
tem turns off. Antifreeze protection (parameter 35)
The Master control unit activates the low temperature cir- The electronic control unit has active antifreeze protection
cuit pump if the parameter for the third pump is set to 1 also in stand-by mode. The antifreeze protection has two
(P34=1). levels, the first that activates the pump and the second that
On the Master control unit, it is possible to set the low tem- activates the pump and the burner.
perature circuit setpoint, Setpoint_T_CH_Low = Par. 3, pre-
set to 40°C and can be set between 10°C and T_CH_low_ If the manifold temperature ≤ 5°C, the high temperature
limit=Par. 23, which in turn is preset to 50°C. The setpoint circuit pump and the system pump (third pump) are active
used will be the one set with parameter 3. or, with CH_type=1 and outdoor sensor connected,
if the outdoor temperature ≤ 3°C (par. 35) the high temper-
The burner is on when: ature pump and the system pump (third pump) are active

37
Manifold temperature <=Setpoint – ignition hysteresis.
Ignition hysteresis can be set, CH_Low_hyst_on = Par. 26, If after 10’ the manifold temperature ≤ 5°C
preset to 5°C, can be set between 0 and 20°C. a burner is on at maximum until the manifold temperature
The Master control unit converts the heat demand into pow- ≥ 20°C.
er demand for each slave control unit.
If after 10’ the manifold temperature ≥ 5°C but, with CH_
The burners are off when: type=1 (Par. 14 or 22) and outdoor sensor connected, the
Manifold temperature >=Setpoint + shut-off hysteresis . outdoor temperature ≤ 3°C (par. 35) the pump continues to
Shut-off hysteresis can be set (CH_Low_Hyst_off=Par. 27, operate until the outdoor temperature ≥ 3°C. Parameter 35
preset to 3, can be set between 0 and 20°C). can be set between -30°C and 15°C.

With the low temperature circuit attenuation parameter, Par. Preset to 3.

25≠0, the low temperature thermostat contact is ignored
and a heat demand is present for the low temperature cir-
cuit when: 5 Power_control_mode
Manifold temperature <=Setpoint – ignition hysteresis Cascading management (parameter 33)
To manage the power delivered by the system, two cas-
The heat demand stops when: cading strategies are possible. In both cases, the Master
Manifold temperature >=Setpoint + shut-off hysteresis . control unit can only add a new burner when another is on.
The setpoint in this case coincides with the value set for pa- If the Master control unit must increase the number of ignit-
rameter 3 (Setpoint_t_ch_low) if the low temperature ther- ed burners, first check that the next burner can be ignited:
mostat contact is closed, whereas it is calculated as the no errors present and modular system temperature below
value set for parameter 3 less the attenuation (Setpoint_t_ the maximum. Otherwise, check another burner. If no burn-
ch_low-Attenuation_low) if the contact is open. er is ready for ignition, the master will decrease the number
of burners to ignite.
OPERATION WITH CLIMATIC CONTROL, PAR. 22=1
If the low temperature circuit attenuation is equal to 0 , At-
tenuation_low=Par. 25=0, its behaviour is the same as the
previous paragraph, with the exception that the setpoint is
calculated based on the outdoor temperature.


MODE: MINIMUM QUANTITY OF BURNERS IGNITED Low load

(PAR. 33=0) The low load function prevents burner ignition and shut off
System power modulation is controlled by a PID regulator, in the case of a low heat demand. The conditions for low
which controls the manifold temperature and the setpoint load operation activation is controlled in every Slave card
is that of the active circuit (high or low temperature circuit that sends the function activation request to the Master.
setpoint or DHW setpoint). The PID has a direct influence During normal operation, the setpoint of the active circuit
on the last 2 burners ignited, whereas the previous ones (high or low temperature circuit setpoint or DHW setpoint)
operate at maximum power. is sent to the Slave cards and is controlled by the tempera-
ture of the heating element by every Slave card:
If the manifold temperature < Setpoint – 5°C the next burn- if the modular system temperature > Setpoint – 8°C or
er is ignited and both are managed by the PID regulator. if the modular system temperature > 85°C - 8°C
The Master control unit waits for 30s and then consent for starting the burner is not given.
if the manifold temperature < Setpoint - 5°C, another burner If the Slave board acquires a modular system temperature
is ignited. greater than 85°C for 3 times with the burner ignited, the
The first burner operates at maximum power, whereas the heating element is turned off and the ignition procedure is
other two are managed by the PID regulator. started again.

If the manifold temperature > Setpoint + 2°C the last burn- Emergency function
er ignited is shut off, the remaining last two burners are In the case of a Master card fault, there are two methods for
managed by the PID regulator and the others operate at manually controlling the Slave cards:
maximum power. The Master control unit waits 30s before -- With eBUS and with the manifold sensor
making another decision. Disconnect the power supply from the system, dis-
connect the BUS. Set the address 000000 on all
MODE: MAXIMUM QUANTITY OF BURNERS IGNITED slave cards (J10 and J17 OFF). Connect a power
(PAR.33=1) supply between 21 and 28 Vac to the BUS.
All burners are controlled by the same PID regulator, which If the manifold temperature < Temp.Emergency
controls the manifold temperature and the setpoint is that (Par.40; preset 70°C; can be set between 10 and
of the active circuit (high or low temperature circuit setpoint 80°C) all the burners will operate at maximum pow-
or DHW setpoint). er.
If the manifold temperature > Temp.Emergency +
If the manifold temperature < Setpoint – 5°C the next burn- 5°C all burners are off.
er is ignited. -- With PC
The Master control unit waits for 30s and then Disconnect the system power supply, disconnect
if the manifold temperature < Setpoint - 5°C, another burner the BUS and connect the PC interface. The burner
is ignited. power can be sent to the Slave card directly with the

38
PC.
If the manifold temperature > Setpoint + 2°C the last burner
ignited is shut off. The Master control unit waits 30s before bbIn the case of error, contact Technical Assistance
making another decision. Centre.

ADDITIONAL CASCADING MANAGEMENT FUNCTIONS Heat demand management for the high temperature circuit
Sequential rotation of burner ignition with analogue input (Par. 14=2 or 3)
When supplying power to the Master control unit, the burn- The room thermostat for the high temperature circuit is
er with address 1 is the first in the sequence. After 24h, the ignored in the case of heat demand and the input signal
first burner will be the one with address 2, whereas the one is used for calculating the system setpoint temperature or
with address 1 will become the last in the sequence. power.
The analogue input (see terminals 13-14 on the wiring dia-
Ignition/shut off limitation gram on page 35) is only for the Master card and can also
In both cascading strategies, after every ignition or shut off, be used for the low temperature circuit (Par.22). The ana-
there is a minimum time during which the Master cannot logue input cannot be used for both circuits.
ignite or shut off burners.
ANALOGUE POWER INPUT, Par. 14=2 (Par. 22=2 for low
Quick start-up and shut off temperature circuits)
In both modes, there is a quick start-up and shut off func- The following rules apply to high temperature (low temper-
tion. ature) circuit demand:
If the manifold temperature < Setpoint - 70°C 0-2Vdc: no demand by the high temperature (low temper-
the burners are ignited at time intervals equal to 2s ature) circuit
If the manifold temperature > Setpoint + 4°C 2-9Vdc: the heat demand is converted into a power de-
the burners are shut off at time intervals equal to 2s. mand for each Slave. A 2V input corresponds to
minimum power, 9V to maximum power (Par.15).
The power is calculated linearly between 2V and 9V.
Hysteresis for the end of demand is 0.2V and there-
fore demand is present above 2V and stops below
1.8V.


The burner shuts off when:

250 -- Delivery temp. > Setpoint_ch_high (Par.1) + Ch_
high_hist_off (Par.20)
200 -- (Delivery temp. > Setpoint_ch_low (Par.3) + Ch_low_
hist_off (Par.27))
Power (kW)

150
MIX VALVE MANAGEMENT
100 The mix valve is controlled by the parameters:
-- Mix_valve_step_open_time: Par.28 preset to 5s
50 -- Mix_valve_step_close_time: Par.29 preset to 7s
-- Mix_valve_interval_time: Par.30 preset to 5s
0 1 2 3 4 5 6 7 8 9 10 -- Mix_valve_p_hyst: Par.31 preset to 2°C
-- Mix_valve_still_hyst: Par.32 preset to 2°C
Voltage (Volt)
Fig. 1
Before opening or closing, the valve waits the period of
time set in Par.30.
The burner ignited when: Opens if:
-- Delivery temp. ≤ Setpoint_ch_high (Par.1) – Ch_high_ T_mandata_bassa < Setpoint_low – Par32
hist_on (Par.19) Closes if:
-- (Delivery temp. ≤ Setpoint_ch_low (Par.3) – Ch_low_ T_mandata_bassa > Setpoint_low + Par32
hist_on (Par.26)) Within the interval, the valve remains in its current position.
The burner shuts off when: If:
-- Delivery temp. > Setpoint_ch_high (Par.1) + Ch_ T_mandata_bassa < Setpoint_low – Par31
high_hist_off (Par.20) opens for a period of time equal to half the value set in Par.
-- (Delivery temp. > Setpoint_ch_low (Par.3) + Ch_low_ 28
hist_off (Par.27)) If:
T_mandata_bassa > Setpoint_low + Par31
ANALOGUE TEMPERATURE INPUT, Par. 14=3 (Par. 22=3 closes for a period of time equal to half the value set in Par.
for low temperature circuits) 29.
The following rules apply to high temperature (low temper-
ature) circuit demand:
0-2Vdc: no demand by the high temperature (low temper- 55
ature) circuit
45
Manifold temperature

2-9Vdc: the heat demand is converted into a power de-

mand for each Slave, using the algorithm PID_CH_ 35
high (PID_CH_low). 2V corresponds to a setpoint
equal to T_Ch_high_foot, Par. 18 (T_Ch_low_foot,
Par. 24), 9V to a setpoint equal to SetPoint_Ch_high,
25
39
Par.1 (SetPoint_Ch_low, Par.3). The setpoint is cal- 15
culated linearly between 2V and 9V. Hysteresis for
5
the end of demand is 0.2V and therefore demand is
present above 2V and stops below 1.8V. -5
0 5 10 15 20
Time (s)
90
Fig. 3
80
70
60 3
Setpoint

50 2
Valve closing-opening (s)

40
Open

1
30
20 0
10 -1
Close

-2
0 1 2 3 4 5 6 7 8 9 10
Voltage (Volt) -3
Fig. 2
-4
20 25 30 35 40 45 50 55 60
The burner ignited when: Mix delivery temperature (°C)
-- Delivery temp. ≤ Setpoint_ch_high (Par.1) – Ch_high_
hist_on (Par.19) default Par. 31 = 10
-- (Delivery temp. ≤ Setpoint_ch_low (Par.3) – Ch_low_ Fig. 4
hist_on (Par.26))


Safety functions of the Slave cards Checking ∆T uses the parameter ∆T_max (preset to 35°C)
If the delivery temperature > 90°C for 5s, the slave card is and limits the burner power as follows:
blocked (no. 46). -- if ∆T_max -5°C > ∆T > ∆T_max –10°C = burner mod-
If the return temperature > 80°C for 5s, the slave card is ulated
blocked (no. 47). -- if ∆T_max > ∆T > ∆T_max –5°C = burner at minimum
If the flue gas temperature > 80°C for 5s, the slave card -- if ∆_T > ∆_T_max = burner off.
is blocked (no. 48) and the fan operates for 10 minutes at
maximum. Furthermore, the presence of a sensor stops the exchanger
if the pressure inside the combustion unit goes below 0.5
The Slave card is able to protect the primary exchanger bar.
from the hazards of low water circulation both using a flow
switch as well as checking the difference between the de-
livery and return temperatures.

3.7 Fault codes

MASTER CARD ERRORS
The following tables provide a description of possible Master card errors.

The errors can be divided into two groups:

-- permanent type-A errors, which can only be turned off by pressing the reset button (see ref. 22 in the "Control pan-
els" chapter)
-- type-E block errors that turn off when the cause that determined them has disappeared.

Permanent type-A errors

N° No. on the PC Cause Troubleshooting
A16 10 Internal error Replace the Master card
A18 12 Internal error Replace the Master card
A20 14 Internal error Replace the Master card

Type-E errors that deactivate automatically

40
The following errors that deactivate automatically can occur.
If any of these errors is detected, the red LED turns on (see ref. 15 in "Control panels") chapter.
N° No. on the PC Cause Troubleshooting
E25 0 Internal error Replace the Master card
E23 28 Internal error Replace the Master card
E24 29 Internal error Replace the Master card
E25 30 Internal error Replace the Master card
E26 31 Internal error Replace the Master card
Check that the bipolar switches of the individual units
are “ON”.
Check the addresses on the slave.
E32 33 Slaves not present Check the slave BUS connection.
Replace the Master.
Replace the slave.
E34 42 Internal 50HZ error The main frequency is not 50Hz
NTC1 open
E02 51 Primary delivery sensor not connected or interrupted.
NTC1: delivery sensor)
NTC3 open
E04 53 DHW sensor not connected or interrupted.
(NTC3: boiler sensor)
NTC1 short circuiting
E18 67 Primary circuit delivery sensor short circuit.
(NTC1: delivery sensor)
NTC3 short circuiting
E20 69 DHW sensor short circuiting.
(NTC3: boiler sensor)


SLAVE CARD ERRORS

Slave error list: manual reset (see ref. 6 in the "Control panels" chapter)
In the case of slave type errors with manual reset, also the Slave reset button can be used.
No. on the
N° Cause Troubleshooting
PC
Check that the gas tap is open.
Check for the presence of electric discharge between the
two ignition electrodes.
Check the ignition cable.
A01 1 5 ignition attempts without success Do not open the gas valve.
Replace the electronic card (Slave).
Make sure the float in the siphon is not stuck.
Make sure the module is not full of condensation.
Check that the VIC (gas shut-off valve) was not tripped.
Multiple unsuccessful attempts due to Clean the electrodes.
A02 2 Replace the igniter plug.
flame ionisation problems Replace the ignition cable.
Water side limit thermostat (> 90°C) Poor circulation in the primary circuit.
A04 4 tripping, version SCHEDA43 Limit thermostat defective.
Gas valve coil interrupted. Replace the gas valve
False gas valve connector contact. Check the gas valve connector
A05 5 Defective gas valve connector. Replace the gas valve connector
Water side limit thermostat tripped Poor circulation in the primary circuit.
(> 90°C) while the burner was on. Limit thermostat defective.
Absent or insufficient earth con- Check the earth connection.
A06 6 nection. Version SCHEDA43. Replace the Slave card.
A07 7 Internal error Replace the Slave card
A08 8 Internal error Replace the Slave card
A09 9 50HZ error The main frequency is not 50Hz
A10 10 Internal error Replace the Slave card
A11 11 Internal software error Press the rest button
A12 12 Internal error Replace the Slave card
Delivery sensor error due to Check the correct flow rate in the water circuit of the indi-
A17 17 exceeding the limit temp. vidual unit. 2 m3/h per unit
Return sensor error due to Check the correct flow rate in the water circuit of the indi-
A18 18 exceeding the limit temp. vidual unit. 2 m3/h per unit
The limit thermostat contact is open Connector disconnected or defective.
41
A16 16 with the burner off Limit thermostat defective.
The flue gas sensor tripped due to Heat exchange insufficient on the flue gas side inside the
A19 19 overtemperature > 80°C ( in this exchanger.
case, the fan turns at max. speed) Clean the flue gas side exchanger.
The flame turned off too later after Check the proper operation of the gas valve.
A20 20 the gas valve closed Replace the gas valve.
"E" type error on the slave card for
A22 22 Check the history of "E" type errors
more than 24 hours
It is an error inside the clock.
It can appear if the current is not present for a few mo-
A23 23 Internal clock error ments.
The error disappears after a few seconds.
The measured fan speed varies too much with the read
speed.
A24 24 Fan error Check the fan.
Check the fan's electrical connection.
Replace the fan.
A25 21 Internal error Replace the Slave card.


Slave error list: automatic reset

No. on the
N° Cause Troubleshooting
PC
E33 33 Line and neutral inverted Restore the correct line-neutral electrical connection
Reset button error. Wait for the error to disappear.
E34 34 It was pressed more than 7 times in If the error did not disappear after max 40 min, replace
30 min. the Slave card.
Water differential pressure switch Check the correct flow rate in the water circuit of the indi-
E35 35 error vidual unit. 2 m3/h per unit.
(contact open) Replace the water pressure switch (tar.500 lt/h).
E36 36 Internal error Replace the Slave card.
Clean the electrodes.
E37 37 Flame detection error Replace the electrode.
Check the flue gas sensor connector.
E38 38 Flue gas sensor short circuiting Replace the flue gas sensor.
Flue gas sensor with contact open Check the flue gas sensor connector.
E39 39 Replace the flue gas sensor.
E40 40 The frequency is not 50 Hz Check the frequency of the electrical network
E41 41 Internal error Replace the Slave card
Check the delivery sensor connector.
E42 42 Flow sensor in short circuit Replace the delivery sensor.
Check the delivery sensor connector.
E43 43 Delivery sensor with contact open Replace the delivery sensor.
Check the return sensor connector.
E44 44 Return sensor short circuiting Replace the return sensor.
E45 45 Return sensor with contact open Check the return sensor connector.
Replace the return sensor.
Delivery sensor error due to excee- Check the correct flow rate in the water circuit of the indi-
E46 46 ding the limit temp. vidual unit. 2 m3/h per unit.
Return sensor error due to exceeding Check the correct flow rate in the water circuit of the indi-
E47 47 the limit temp. vidual unit. 2 m3/h per unit.
Flue gas sensor error due to excee- Check the correct flow rate in the circuit of every unit
E48 48 ding the limit temp. (fan turns at max Approx. 2 m3/h per unit.
with this error). Clean the water side and flue gas side exchanger.
Insufficient or absent earth con-
E49 49 Check the earth connection. Replace the Slave card.
nection.

42


3.8 List of parameters

lower upper factory
N° Name U.M. Description
limit limit settings
USER parameters
If Par14=0 it is the high temperature
circuit setpoint.
1 SetPoint_ch_high 10 Par. 17 70 °C If Par14=1 it is the maximum high tem-
perature circuit temperature.
2 SetPoint_DHW 10 Par. 8 50 °C
If Par22=0 it is the low temperature
circuit setpoint.
3 SetPoint_ch_low 10 Par. 23 40 °C If Par22=1 it is the maximum low tempe-
rature circuit temperature.
INSTALLER parameters accessible with a password: 22
0 = No DHW service
1 = Instantaneous with NTC sensor
6 DHW_type 0 6 0 2 = Boiler with NTC sensor
5 = Instantaneous with flow switch
6 = Boiler with thermostat
7 P_DHW_max 1 255 230 Maximum power/speed in DHW mode
8 T_DHW_limit 10 80 60 Limit for DHW user set
0 = Shifting A
9 DHW_priority 0 2 0 1 = Shifting B
2 = Absolute priority
Modular system temp. in DHW mode =
10 T_tank_extra 0 50 30 °C Par. 2 + Par. 10
11 T_tank_hyst_up 0 20 1 °C Upper DHW differential
12 T_tank_hyst_down 0 20 5 °C Lower DHW differential
13 N°_bruc_DHW 1 60 60 Max. no. of burners in DHW mode
0 = Fixed temperature
1 = Weather with probe outside
14 CH_type_high 0 3 1 2 = 0-10 Vdc power
3 = 0-10 Vdc temperature
15 P_ch_max 1 255 230 Maximum power/speed in CH mode
0 = No circuit priority

43
16 CH_priority 0 2 0 1 = Priority to high temperature circuit
2 = Priority to low temperature circuit
Limit for high temperature circuit user
17 T_CH_high_limit 10 80 80 °C set
Min. high circuit setpoint - at maximum
18 T_CH_high_foot 10 Par. 1 50 °C outdoor temperature (Par. 38)
High temperature circuit ignition hyste-
19 CH_high_hyst_on 0 20 7 °C resis
High temperature circuit shut-off hyste-
20 CH_high_hyst_off 0 20 3 °C
resis
21 Attenuation_high 0 70 0 °C Setpoint attenuation with TA open
0 = Fixed temperature
1 = Weather with probe outside
22 CH_type_low 0 3 1 2 = 0-10 Vdc power
3 = 0-10 Vdc temperature


lower upper factory

N° Name U.M. Description
limit limit settings
23 T_CH_low_limit 10 70 50 °C Limit for low temperature circuit user set
Min. low circuit setpoint - at maximum
24 T_CH_low_foot 10 Par. 13 25 °C outdoor temperature (Par. 38)
25 Attenuation_low 0 70 0 °C Setpoint attenuation with TA open
Low circuit ignition hysteresis calculated
26 CH_low_hyst_on 0 20 5 °C on mix delivery T
Low circuit shut-off hysteresis calculated
27 CH_low_hyst_off 0 20 3 °C on mix delivery T
Mix_valve_step_ At every step, the valve opens 1/2 the
28 0 255 5 s
open_time set value
Mix_valve_step_clo- At every step, the valve closes 1/2 the
29 0 255 7 s
se_time set value
Mix_valve_interval_
30 0 255 5 s Mix valve wait time
time
31 Mixing_p_hyst 0 255 2 °C Hysteresis for maximum valve opening
32 Mixing_still_hyst 0 255 2 °C
0 = Minimum number of burners
33 Power control mode 0 1 1 1 = Maximum number of burners
0 = System/loop
34 3rd pump 0 1 0 1 = Low temperature circuit
35 Frost protection - 30 15 3 °C System
01 = Natural gas with flue gas exhaust
< 15m
02 = Natural gas with flue gas exhaust
36 Gas_type 1 31 01 > 15m
03 = LPG with flue gas exhaust < 15m
04 = LPG with flue gas exhaust > 15m
37 T_out_min - 20 30 0 °C
37 T_out_min - 20 30 0 °C
38 T_out_max 0 30 18 °C
39 T_out_correct - 30 30 0 °C
40 T_emergency 10 80 70 °C
41 Parameter_reset 0 1 0

44 42 Flow switch on slave 0 1 1 0 = The slave does not verify the pressu-
re switch
0 = Eco protocol
43 Protocol 0 1 1 1 = Argus link (new)


3.9 Transformation from one gas

6.75
type to another 6.5

The Power Plus Box SYS system is supplied for operating

with G20 (natural gas). It can however be transformed to
operate with G30-G31 (LPG) using the provided kit.
bbThe transformations may only be carried out by Tech- 4 5
nical Assistance Centre or by personnel authorised
by B, also on already installed modular systems.
-- refit the gas valve
bbOnce the transformation is complete, adjust the mod- -- apply the adhesive (6) for G30-G31, supplied inside
ular system again by following the instructions in the the kit, on the crosspiece located inside the modular
“Adjustments” paragraph. system, and remove the one for G20
-- remove the gas label from the outside.
Before making the transformation:
-- disconnect the electric power supply from the device
by turning the main switch to "off"
-- close the gas shut-off valve
Paese di destinazione:

Tipo di apparecchio : B23

Caldaia categoria : II2H3+
Temperatura ambiente:
min. -10ϒC max. 50ϒC
Pressioni di alimentazione gas:
G20 20 mbar
G30 28-30 mbar
G31 37 mbar
Regolazione effettuata dal costruttore:
G20 - 20 mbar - 2H METANO
ATTENZIONE
Questo apparecchio puó essere installato e
funzionare all'aper to o solo in locali
permanentemente ventilati secondo norma
UNI7129.
Leggere attentamente il libretto istruzioni
prima di installare e mettere in servizio
l'apparecchio.
(Laterale DX) 068411_E0

To install the kit:

-- open the two front doors in the casing
-- set parameter 36 to 03 or 04, depending on the length Gruppo termico regolato per:
(L) of the flue gas exhaust line (03 = L < 15 m; 04 =
G30 - G31 28-30/37 mbar
L > 15 m). The fan speed is adjusted automatically.
Paese di destinazione:

For every heating element:

-- disassemble the gas valve from the van unit, loosen-
ing the three screws (3)
bbAfter installing the kit, check the tightness of all con-
nections made.
45
3
Perform all the calibration operations described below in
the “Adjustments” chapter.

3.10 Adjustments
The Power Plus Box SYS system is supplied for operation
with G20 (natural gas) according to what is indicated on
the technical plate and was already adjusted in the factory
by the manufacturer.
However, if it is necessary to repeat the adjustments, for
example after non-scheduled maintenance, replacing the
-- identify the gas passage hole with the relative gas- gas valve or after transformation from G20 gas to G30-G31
ket that, in the case of natural gas, does not have a gas, or vice versa, proceed as described below.
diaphragm
-- insert the diaphragm (4) marked with “6.5” without
bbAdjustments to maximum and minimum power must
be performed in the indicated sequence and only by
removing the gasket. Only for the case if the boiler
Technical Assistance Centre.
is supplied with a gas mixture that can cause ignition
problems, use the other diaphragm (5) marked with bbAll the operations described below must be carried
“6.75” out for every individual heating element, while oper-
ating only the heating element involved with the ad-
justment and turning off other others using the proper
switch (see ref. 8-11 in the "Control panels" chapter).


CO2 ADJUSTMENT AT MAXIMUM POWER 3.11 Temporary shutdown

-- Press the “Set/esc” and buttons at the same time
for 5 seconds In the case of temporary absences, weekends, short trips,
-- use and to select the maximum fan speed etc., proceed as follows:
-- generate the heat demand using the room thermo- -- set the room thermostats to approx. 10°C
stat. The modular system will operate at maximum -- set parameter 2 to “10” or adjust the boiler thermostat
power, indicating “H” on the display followed by the to 10°C.
delivery temperature (flue cleaning function)
-- unscrew the cap (1) and insert the combustion With the electric power supply remaining active, as sig-
analyser sensor nalled by the flashing green LED and the supply of the gas,
-- adjust the CO2 using a screwdriver to turn the ad- the modular system is protected.
justing screw (2) located on the fan unit (turning it
clockwise the CO2 value decreases), in order to obtain The electronic control unit has active antifreeze protection
a value of 9.0% for G20 and 10.4% for G30-G31. also in stand-by mode.
There are two levels of antifreeze protection:
CO2 ADJUSTMENT AT MINIMUM POWER the first activates the pump
-- Press the “Set/esc” and buttons at the same time -- if the manifold temperature ≤ 5°C, or, with CH_type=1
for 5 seconds and the outdoor sensor connected
-- use and to select the minimum fan speed The -- if the outdoor temp. ≤ 3°C (Par. 35=Frost_protection)
modular system will operate at minimum power, in- the high temperature circuit pump and system pump
dicating “L” on the display followed by the delivery (third pump) are activated.
temperature the second that activates the pump and burner
-- adjust the CO2 using a screwdriver to turn the adjust- -- if after 10’ the manifold temperature ≤ 5°C, a burner
ing screw (3) located on the fan unit (turning it anti- is ignited at maximum until the manifold temperature
clockwise the CO2 value decreases), in order to obtain ≥ 20°C
a value of 9.0% for G20 and 10.4% for G30-G31. -- if after 10’ the manifold temperature ≥ 5°C, but with
CH_Type = 1 and outdoor sensor connected, the out-
door temperature ≤ 3°C, the pump continues to oper-
ate until outdoor temperature is ≥ 3°C.

1 2 3
3.12 Preparing for extended periods
of disuse
The following operations shall be necessary if the Power
Plus Box SYS modular system is not used for a long period

46
of time:
-- loosen the screw (1) and turn the control panel (2)
-- position the main switch of the modular system (3)
and the main system switch to "off" and check that the
green indicator light turns off (4)

4 2 1

CHECKING THE CALIBRATION

Press the “Set/esc” and buttons at the same time for 5
seconds and check the max CO2 value (9.0% for G20 and
10.4% for G30-G31).
The press the “Set/esc” and buttons for 5s and check
the minimum CO2 value (9.0% for G20 and 10.4% for
G30-G31). 3

When the checks are complete:

-- stop the flue cleaning function by pressing the “OK”
button -- Close the heating and domestic hot water system fuel
-- stop the heat demand and water cocks.
-- remove the analyser sensor and carefully retighten
the cap (1).

bbIn this case, the antifreeze system is deactivated.

Empty the heating and DHW circuit if there is a freez-
ing hazard.


3.13 Maintenance Access to the control panel and the internal modular
system parts
Period maintenance is "mandatory', required by Presiden- -- open the two front doors in the casing
tial Degree 26 August 1993 no. 412, and is also essential -- loosen the screw (1) and turn the main control panel
for device safety, efficiency and duration It makes it possi- (2)
ble to reduce consumption, polluting emissions and keep -- loosen the screws (3), turn the instrument panel (4).
the product reliable over time.
Remember that device maintenance can be performed by
Technical Assistance Centre or by professionally qualified 2 1 4 3
personnel.
Remember that performing a combustion analysis prior to ROTATE
starting maintenance provides useful information about the
operations to perform.
Before performing any operation:
-- disconnect the electric power supply by turning the
main system switch to "off"
-- close the gas shut-off valve.

ROTATE

3.14 Cleaning and removing internal -- at this point, it will be possible to access the terminal
board (5), the Master card (6) and the Slave cards
components (7).
Before any cleaning operation, disconnect the electric
power supply by switching the main system switch to "off”. 5

6 Pump 28 NTC
1
5
27 2
4 Pump
26 3 NTC
J10
3 25 4
2 Pump 3 24 5 NTC

1
23 6
Circ. 2
3 Valv.Mix
0 22 NTC
J9 7
2 OFF 21 8

47
1 r
ON 20
17 16 15 14 13 12 11 10 9
2
Com.

Alarm Analogic
24V

19
Bus

Input Circ.2
J8
1
18

6
7
OUTSIDE
Clean the casing, the control panel, the painted parts and
plastic parts with cloths moistened with soap and water. In Once the maintenance operations are complete, refit the
the case of stubborn stains, moisten the cloth with a 50% components working in the opposite direction of what was
water and alcohol mixture or specific products. described.

aaDo not use fuels, sponges impregnated with abrasive Accessing the Master card
solutions or powder detergents. -- open the two front doors in the casing and access the
inside of the control panel (see the steps described
INSIDE above)
Before starting internal cleaning operations: -- remove the screws (8) and then the rear cover (9) of
-- close the gas shut-off valves the control panel
-- close the system taps. -- for possible substitutions, remove the card's wiring
connectors and unscrew the fastening screws to re-
move it.
bbIf replacing the Master card, refer to the wiring dia-
gram when restoring the connections.


8 6

5
Pump 28

27
1

2
NTC

4 Pump 26 3 NTC
J10
3 25 4
2 Pump 3 24 5 NTC

1
23 6
Circ. 2
3 Valv.Mix
0 22 7
NTC
J9
2 OFF 21 8
1 r
ON 20
17 16 15 14 13 12 11 10 9
2

Com.
Alarm Analogic

24V
19

Bus
Input Circ.2
J8
1
18

14 15

Once the maintenance operations are complete, refit the

Once the maintenance operations are complete, refit the components working in the opposite direction of what was
components working in the opposite direction of what was described.
described.
Disassembling the fan
Accessing the Slave cards -- open the two front doors in the casing
-- open the two front doors in the casing and access -- disconnect the wiring (16) of the fan (17)
the inside of the control panel (see the previously de- -- unscrew the two screws (19) that fix the fan (17) to the
scribed steps) air conveyor (20)
-- remove the screws (V) and then the upper cover (10) -- use a box spanner to unscrew the four screws (18)
of the Slave card relative to the first heating element. that fix the fan (17) to the exchanger
To access the other Slave cards, repeat the same op- -- remove the fan (17).
eration for covers (11) and (12)
-- for possible substitutions, remove the card's wiring 17
connectors and unscrew the fastening screws to re- 16
20
move it.
bbIf replacing the Slave card, refer to the wiring diagram
when restoring the connections.

48
19

18
10
11
12 Once the maintenance operations are complete, refit the
components working in the opposite direction of what was
described.
Once the maintenance operations are complete, refit the
components working in the opposite direction of what was
described.
bbCheck that the gas connection is leak proof.
Disassembling the circulator Disassembling and cleaning the burner and exchanger
-- open the two front doors in the casing -- open the two front doors in the casing
-- disconnect the electric power supply connector -- disconnect the wiring (16) of the fan (17)
close the delivery and return taps for the heating element -- unscrew the two screws (19) that fix the fan (17) to the
(ref. 16-27 of the "Structure" chapter) air conveyor (20)
empty the heating element as described in the "System fill- -- use a box spanner to unscrew the four screws (18)
ing and emptying" chapter that fix the fan (17) to the exchanger
loosen the upper and lower ring nuts (14) and remove the -- remove the gasket (21) and remove the burner (22)
circulator (15). -- remove the electrode support plate (23), check the
condition of the electrode and replace it if necessary.


Disassembling the doors

In particular operations must be carried out inside the mod-
ular system, the two front doors can be disassembled.
Proceed as follows:
-- open the two front doors
-- working from inside, remove the pin (24) and the door
(25)

24

17
25

21

22

23

Once the maintenance operations are complete, refit the

components working in the opposite direction of what was
described.

bbCheck that the gas connection is leak proof.

Once the maintenance operations are complete, refit the

49
components working in the opposite direction of what was
described.


3.15 Troubleshooting

FAULT CAUSE SOLUTION

--Check the seal of the gaskets and

There is a smell of gas Gas supply circuit. the closure of the pressure tapping
points
--Check the gasket seals
Odour of unburnt gas Flue gas circuit --Make sure there are no obstructions
--Check the combustion quality

Burner gas pressure --Check the temperature setting

Diaphragm installed --Check the diameter

Irregular combustion Clean the burner and exchanger --Check the conditions

Exchanger passages obstructed --Check passage cleaning

Faulty fan --Check operation

Burner gas pressure --Check the temperature setting

Ignition delays with pulsations to
the burner
Ignition electrode --Check the positioning and conditions

The modular system becomes dirty --Check the flame colour

Combustion
very quickly --Check the combustion controls
--Check for the presence of 230Vac
The burner does not start upon con-
Gas valve voltage on the gas valve terminals,
sent of the modular system control
check wiring and connections

50 The modular system does not start No electric power supply (no messa-
ge on the display)
--Check the electric connections
--Check the condition of the fuse

Boiler dirty --Clean the combustion chamber

The modular system does not arrive Burner capacity insufficient --Check and adjust the burner
at temperature

--Check correct functioning.

Modular system adjustment
--Check the temperature setting
--Check correct functioning.
--Check the temperature setting
No water --Check the electrical wiring
The generator triggers a thermal --Check the position of the sensor
safety block bulbs
--Check the bleed valve
Modular system adjustment
--Check the heating circuit pressure

Presence of air in the system --Bleed the system

The generator is at temperature but --Check/unseize the pump
the heating system is cold --Replace the circulator.
Pump malfunctioning
--Check the electrical connection of
the circulator


FAULT CAUSE SOLUTION

--Check/unseize the pump

--Replace the circulator.
The circulator does not start Pump malfunctioning
--Check the electrical connection of
the circulator

System safety valve --Check calibration or efficiency

Frequent tripping of the system --Check the circuit pressure

safety valve System circuit pressure
--Check pressure reducer functioning
--Check the efficiency of the expansion
CH expansion vessel
vessel

51


4 WATER IN CENTRAL HEATING General note on water used to top up systems:

-- if softened water is used to top up a system, 8 weeks
SYSTEMS of functioning after topping up, verify that the water in
the system respects the above limits, in particular for
INTRODUCTION electrical conductivity.
-- this check is not necessary if demineralised water is
Water used in central heating systems MUST be suitably used to top up the system.
treated to ensure the correct functioning of those systems
and to guarantee an extended working life for boilers and 2. Central heating systems
all other system components. This applies not only to exist-
ing systems but to newly installed systems too. bbDo not use automatic filling devices to add water to
Sludge, lime-scale and pollutants present in the water can central heating systems. Use a manual device in-
cause permanent damage to the heating unit, also within stead and record top-ups in the system service book.
a short time and regardless of the quality standards of the
materials used. bbIf there are more than one boiler, they must all be put
Contact the Technical Assistance Centre for any further in- into service either contemporarily or with a very low
formation on type and use of additives. rotation time during the initial period of service, so as
to evenly distribute the limited quantity of initial lime-
bbAlways conform to the standards and legislation ap- scale.
plicable in the country of installation.
bbA flushing cycle must be programmed after the plant
WATER IN CENTRAL HEATING SYSTEMS. has been installed to flush out any installation debris.
INSTRUCTIONS FOR THE DESIGN, INSTALLATION AND
MANAGEMENT OF CENTRAL HEATING SYSTEMS.
bbWater used to fill a system for the first time and water
used to top it up must always be filtered (using syn-
thetic or metal mesh filters with a filtration rating of no
1. Chemical and physical characteristics of water
less than 50 microns) to prevent sludge from forming
The chemical and physical characteristics of water used in
and triggering deposit corrosion.
central heating systems must conform to the requirements
of EN 14868 standard and to the following tables: bbThe heating system must be flushed out and cleaned
with good workmanship before filling up the existing
STEEL BOILERS systems. The boiler may not be filled until after the
with furnace power < 150 kW heating system has been flushed out.
Regular ser-
Initial filling vice water 2.1 New central heating systems
water (*)
The system must be filled up slowly the first time; once it is
ph 6-8 7,5-9,5

52
filled and the air expelled it should never need to be topped
Hardness °fH < 10° < 10° up again.
Electrical Systems should also be operated at maximum working
conductivity μs/cm < 150
temperature the first time they are started up, in order to
Chlorides mg/l < 20 facilitate de-aeration. (Gas is not released from the water at
Sulphides mg/l < 20 low temperatures).
Nitrides mg/l < 20
Iron mg/l < 0,5 2.2 Reconditioning old central heating systems
If a boiler has to be replaced, do not refill the entire cen-
tral heating circuit if the quality of water in it conforms to
STEEL BOILERS requirements. If the quality of water fails to conform to re-
with furnace power > 150 kW quirements, either recondition the old water or separate the
Regular ser- water circuits (water in the boiler circuit must conform to
Initial filling vice water
water requirements).
(*)
ph 6-8 7,5-9,5
3. Corrosion
Hardness °fH < 5° < 5°
Electrical 3.1 Deposit corrosion
conductivity μs/cm < 100
Under-deposit corrosion is an electrochemical process,
Chlorides mg/l < 10 due to the presence of sand, rust, etc., inside the mass
Sulphides mg/l < 10 of water. These solid substances generally deposit on the
Nitrides mg/l < 10 bottom of the boiler (sludge), on tube and pipe heads or in
Iron mg/l < 0,5 the gaps between pipes and tubes.
(*) values for water in system after 8 weeks of functioning Micro-corrosion phenomena may be triggered off owing
to the difference in electrochemical potential coming to be
created between the material in contact with the impurity
and the surrounding one.


3.2 Stray current corrosion

Corrosion from stray currents can occur due to the differ-
ing electrical potentials between water in the boiler and the
metallic mass of the boiler or piping. This process leaves
unmistakeable traces i.e. small regular conical holes.
bbAll metallic parts should be grounded by an efficient
earth cable for this reason.

4. Eliminating air and gas from central heating systems

If oxygen enters a circuit continuously or even intermittently
(e.g. in under-floor heating systems whose pipes are not
protected by impermeable synthetic sheaths, in circuits
with open expansion vessels, or in circuits that require fre-
quent top-ups) always separate the boiler’s water circuit
from the central heating circuit.

Mistakes to avoid and precautions.

From what we have seen it is therefore important to avoid
two factors possibly leading to the above mentioned pro-
cesses i.e. contact between air and water in the installation
and regular topping up with fresh water.
To eliminate contact between air and water (and to prevent
the latter from becoming oxidized), it is necessary:
-- For the expansion system to be a closed vessel type,
correctly scaled and with the correct pre-loading
pressure (to be regularly checked)
-- For the installation to always be at a higher pressure
than that of the atmosphere at any point (comprising
the pump suction side) and under all running con-
ditions (all the water sealing and couplings in the
installation are designed to resist pressure towards
outside, but not for depression)
-- That the installation will not be made with materials
permeable to gas (e.g. plastic pipes for floor systems
without anti-oxygen barrier).
bbLastly we would remind you that the warranty does 53
not cover breakdowns incurred by the boiler due to
deposits and corrosion.


4.1 Appendix
DECLARATION

With regard to the fulfilments specific in chapter R.3.B of collection "R", the following is declared:

The Power Plus Box SYS B devices are modular premixed condensing heat generators for heating, fully managed by
a microprocessor. Due to their design and structure, they can be used as modules for the creation of high capacity heat
generators, with the purpose of having an optimal installed power both for overall system efficiency as well as in order to
comply with environmental pollution standards.

In that regard, as each heating element or module has all the devices foreseen by the provisions in R.3.F. of collection "R"
transmitted by ISPLELS memorandum no. 102/99 dated 13.12.99,

taking into account the positive results of the checks and tests carried out at the manufacturer's laboratory,

we believe that multiple elements or modules specified above, installed individually or in a series, in any combination of
the models indicated above, can be considered as a single heat generator and the safety, protection and control devices
specified in chapters R.3.A. and R.3.B. of collection "R" can be located within 1 metre of the hot water circuit delivery pipe
immediately downstream of the last element or module. The safety valve with the CE marking according to directive 97/23/
EC will be installed directly on each module by the manufacturer on the delivery manifold and therefore does not require
any additional safety valve downstream of the last module.

Beretta

54


55
 20082434 - Rev. 7 (12/13)

Via Risorgimento, 13 - 23900 Lecco (LC) - Italy

Customer Service 199.13.31.31
www.berettaclima.it

The manufacturer strives to continuously improve all products. Appearance, dimensions, technical specifications, standard equipment
and accessories are therefore liable to modification without notice.