installation manual

NOVELLA
24-31-45 RAI
24-31 RAI PV
BOILERS
INSTALLATION MANUAL
CAST IRON
BASE
INSTALLATION MANUAL
Novella boilers conform to the basic requirements of the following directives:
• Gas Appliances Directive 2009/142/CE
• Boiler Efficiency Directive 92/42/CEE (✫✫)
• Electromagnetic Compatibility Directive 2004/108/CE
• Low Voltage Directive 2006/95/CE
Novella boilers are therefore CE marked.
0694
2
The following symbols are used in this manual:
b
CAUTION! = Indicates actions that require caution and adequate preparation
aSTOP! = Identifies actions that you MUST NOT do
CONTENTS
1 SAFETY INFORMATION AND PRECAUTIONS......................................... 4
2 DESCRIPTION OF THE APPLIANCE......................................................... 5
2.1Description of the appliance................................................................................................................5
2.2Optional accessories...........................................................................................................................5
2.3Main parts of the boiler........................................................................................................................6
2.4Control panel.......................................................................................................................................7
2.5Technical specifications.......................................................................................................................7
2.6Identification.........................................................................................................................................8
2.7Material supplied..................................................................................................................................9
2.8Handling...............................................................................................................................................9
2.9Overall dimensions and water fittings................................................................................................10
2.10Water circuit.......................................................................................................................................11
2.11Wiring diagram...................................................................................................................................13
3INSTALLATION.......................................................................................... 14
3.1Installation standards.........................................................................................................................14
3.2Place of installation............................................................................................................................14
3.3Installation in existing systems..........................................................................................................14
3.4Water connections.............................................................................................................................15
3.5Electrical connections........................................................................................................................15
3.6Gas connections................................................................................................................................17
3.7Gas supply conversion......................................................................................................................17
3.8Flue gas vent and air intake..............................................................................................................19
3.9Filling the water circuit.......................................................................................................................19
3.10Emptying the water circuit.................................................................................................................20
4 START-UP AND FUNCTIONING............................................................... 21
4.1Preliminary checks.............................................................................................................................21
4.2Ignition...............................................................................................................................................21
4.3Final checks.......................................................................................................................................23
5SHUT-DOWN ............................................................................................ 24
6MAINTENANCE ........................................................................................ 25
6.1Scheduled maintenance....................................................................................................................25
6.2Extraordinary maintenance................................................................................................................25
7 OPTIONAL ACCESSORIES...................................................................... 26
3
INSTALLATION MANUAL
1 SAFETY INFORMATION AND PRECAUTIONS
bbThis manual and the operation manual
associated with it form integral parts
of the product. Make sure that they are
always kept with the boiler even if it is
transferred to another owner or user, or
re-installed elsewhere. If you damage or
lose this manual, order a replacement
immediately from your local Technical
Assistance Service.
bbThe boiler must only be installed and
serviced by qualified personnel, in conformity to applicable legislation (in Italy,
law 46 of the 05/03/1990) and applicable technical standards (in Italy, UNICIG 7129 and 7131 standards and
subsequent updates thereto).
• Switch the boiler OFF at the control
panel and at the mains power switch
• Close the boiler’s fuel cock, central
heating circuit shut-off cock and domestic hot water circuit shut-off cock
• Empty the central heating circuit and
domestic hot water circuit if there is any
risk of freezing
- The boiler must be serviced at least once
a year. Servicing must be arranged in
advance with the manufacturer’s
Technical Assistance Service
Observe the following precautions to ensure
safe operation of the boiler.
aaDo not allow children or uninformed persons to operate the boiler.
bbThe boiler must only be used for the pur- aaDo not operate any electrical devices or
pose for which it is designed. The manufacturer declines all responsibility, contractual or other, for damage to property
or injury to persons or animals caused
by improper installation, adjustment,
maintenance or use.
bbAs soon as you open the packaging,
check immediately that the contents are
all present and undamaged. Contact the
reseller from whom you purchased the
product if you notice any problems.
4
equipment, including switches or domestic appliances, etc., if you can smell
fuel or fumes. In the event of a gas leak,
thoroughly ventilate the room by opening
wide all doors and windows, close the
gas shut-off valve and call the manufacturer’s Technical Assistance Service
immediately to arrange urgent assistance by professionally qualified personnel.
aaDo not touch the boiler while barefoot or
wet.
bbThe safety valve must be connected to aaNever
a suitable collection and drain system.
The manufacturer declines all responsibility for damage caused by the operation of an improperly connected safety
valve.
bbThe following instructions must be pas
sed on to the user on installation of the
boiler.
- If water leaks from the boiler, turn off the
water supply and contact the manufacturer’s Technical Assistance Service immediately.
- Periodically check that operating pressure in the water circuit is over 1 bar. If
necessary, contact the manufacturer’s
Technical Assistance Service to arrange
servicing by professionally qualified personnel.
- If the boiler is not going to be used for an
extended period of time, contact the
manufacturer’s Technical Assistance
Service to have at least the following operations performed:
clean the boiler without first
disconnecting it from the mains electricity supply by turning the mains power
switch and the control panel switch OFF.
aaDo not tamper with or adjust the boiler’s
safety or control devices without prior
authorisation and instructions from the
manufacturer.
aaDo not pull, disconnect, or twist the elec-
trical cables coming from the boiler even
if it is disconnected from the mains electricity supply.
aaDo
not obstruct or restrict vents in
the room where the boiler is installed.
Adequate ventilation is essential for correct combustion.
aaDo not store containers of flammable
substances in the room where the boiler
is installed.
aaDo not leave items of packaging within
the reach of children.
2 DESCRIPTION OF THE APPLIANCE
2.1 Description of the appliance
Novella boilers are gas fuelled boilers for
domestic heating.
They are equipped with an atmospheric burner and a cast iron primary heat exchanger.
They incorporate an open (type B11BS) combustion chamber and are fitted with a hood
that ensures proper flue gas venting even with
a fluctuating flue draught.
They are also equipped with a flue gas
thermostat, as required by applicable safety
standards.
The burner is a stainless steel unit with stabilised flame and smooth ignition.
The burner is fitted with an ionisation type
flame detection system.
The boiler’s control and safety devices conform to applicable technical and safety standards and are enclosed in a functional control
panel integrated in the body of the appliance.
Novella boilers use total shut-down logic
and do not waste energy because they only
start up when heat is actually needed by the
central heating system (i.e. when the room
thermostat trips).
Novella boilers can be connected to a storage
cylinder to produce domestic hot water, and
can be equipped with temperature controllers
in the form of specific accessories.
Installation, maintenance and access to internal components is facilitated by a large front
panel.
The key features of these boilers include:
-- electronic ignition with ionisation flame
detection
-- adjustable smooth ignition
-- gas supply solenoid valve with built-in pressure stabiliser and double shutter for burner
control
-- domestic hot water temperature control
-- water circuit temperature and pressure
gauge
-- provision for room thermostat or timer.
Novella RAI PV models also feature:
-- central heating circuit pump
-- 12 litre expansion vessel
-- 3 bar central heating circuit safety valve.
2.2 Optional accessories
-- Wall-mounted weekly timer thermostat (part
number 1100279)
-- Pump manifold kit (part number 694769)
-- High head pump kit (part number 1100269)
-- RO120 storage cylinder (part number
696339)
-- Pump or valve controlled multizone central
heating kit with total shut-down function
(part number 696439)
-- Lifting brackets (part number 696429)
5
INSTALLATION MANUAL
2.3 Main parts of the boiler
Novella 24 - 31 RAI PV boilers
Key
1
2
3
4
5
6
7
8
9
10 11 12 Control panel
Temperature sensor sockets
Boiler body
Electronic ignition and flame detection unit
CH pump
Water circuit drain cock
Ignition electrode
Flame detection sensor
Burner
Gas supply solenoid valve
Lifting points
Expansion vessel
11
1
2
3
10
4
9
5
8
6
7
12
6
Fig. 2.1
Novella 24 - 31 - 45 RAI boilers
Key
13 Control panel
14 Temperature sensor sockets
15 Boiler body
16 Electronic ignition and flame detection unit
17 Ignition electrode
18 Water circuit drain cock
19 Flame detection sensor
20 Burner
21 Gas supply solenoid valve
22 Lifting points
22
13
14
15
21
20
16
17
19
18
Fig. 2.2
2.4 Control panel
23
31
24
30
25
26
29
28
Key
23 Main switch
24 Central heating temperature control
25 Water circuit temperature and pressure
gauge
26 Safety thermostat (manual reset)
27 Flue gas thermostat (manual reset)
28 Burner lockout LED warning light
29 Power on LED indicator
30 Quick reference guide
31 Burner reset button
27
30
Fig. 2.3
2.5 Technical specifications
Rated heat input, CH
Rated heat output, CH
Electrical consumption
Boiler class
Power supply voltage
Index of protection
Losses from stack and casing with burner off
Central heating circuit characteristics
Maximum pressure - temperature
CH temperature setting range
Expansion vessel
Gas pressure
Rated gas pressure, methane (G 20)
Rated gas pressure, LPG (G31) (G 30 - G 31)
Water connections
CH flow – return
Gas inlet
Emissions with G 20 gas
CO below
CO2
NOx (according to EN 297)
Flue gas Δt
Boiler dimensions
Height
Width
Depth
Weight of boiler
kW
kcal/h
kW
kcal/h
W
24 RAI
PV
24 RAI
103
15
26,6
22880
24,0
20640
V ~ Hz
IP
%
bar -°C
°C
litres
31 RAI
PV
Ø
Ø
3/4"
1/2"
93
1,23
--
20
28-30/37
°C
15
3 - 100
34-82
12
mbar
mbar
5,6
50,0
43000
45,0
38700
103
II 2H3+
230 ~ 50
40
1,37
--
p.p.m.
%
45 RAI
34,4
29590
31,0
26660
1,65
12
31 RAI
21
5,7
19
5,5
96
113
Class 1
mm
mm
mm
kg
850
450
700
108
675
100
700
126
675
118
600
720
154
7
INSTALLATION MANUAL
8
PARAMETER
Lower Wobbe index
(at 15°C-1013 mbar)
G30
(MJ/m3)
(MJ/m3)
(at 15°C-1013 mbar)
G31
(MJ/m3)
G20
Ø mm
(at 15°C-1013 mbar)
G20
24 RAI
31 RAI
45 RAI
45,5
80,9
70,9
Main burner
Number of nozzles
Nozzle diameter
Nozzle pressure (downstream from valve in central heating only mode)
4
6
2,40
2,40
G30
Ø mm
1,50
1,50
1,45
G31
Ø mm
1,50
1,50
1,45
G20
G30
Maximum gas flow rate, CH (*)
3
2,40
Δp
13,5
13,5
12,7
mm H2O Δp
138
138
129
mbar
Δp
28,4
28,0
27,8
mm H2O Δp
289
285
283
mbar
G31
mbar
Δp
36,5
34,7
35,7
372
354
364
G20
mm H2O Δp
m3/h
2,80
3,50
5,10
G30
kg/h
2,09
2,70
3,92
G31
kg/h
2,05
2,66
3,86
(*) Temperature 15°C; Pressure 1013 mbar.
2.6 Identification
Novella boilers are identified by a product
name plate giving the boiler’s serial number,
model and main technical and performance
data.
bbIt is essential to specify the correct
model of boiler when ordering spare
parts or requesting technical assistance.
If the name plate or any other means of
clearly identifying the product is defaced, removed or lost, proper installation
and servicing may be rendered difficult.
GAS FUELLED BOILER
Model
Serial No.
Code
PIN Code
Year
Heat input at
furnace (Qn/Hi)
Boiler water
capacity
Useful heat
output (Pn)
Heat exchanger
surface area
Maximum working
pressure (mwp)
Maximum admissible
temperature
Power supply
Maximum current
draw
NOx class
Maximum energy
consumption
Gas supply pressure
Index of protection
OBLIGATORY GROUND CONNECTION
CLASS OF BOILER
TYPE OF BOILER
COUNTRY OF DESTINATION
Fig. 2.4
2.7 Material supplied
The boiler is delivered in a wooden cage.
Proceed as follows to remove this.
-- Remove the staples fixing the wooden cage
to the pallet.
-- Lift off the wooden cage.
The following items are delivered in a plastic
bag inside the boiler:
-- Operation manual
-- Installation manual
-- LPG conversion kit (nozzles, label, seals).
Fig. 2.5
Net weight
Gross weight
24 RAI
100
119
24 RAI PV
108
127
MODEL
31 RAI 31 RAI PV
118
126
138
146
45 RAI
154
174
Instruction manuals are integral parts of the
boiler. On unpacking, locate the manuals and
keep them safe.
kg
kg
2.8 Handling
C
Once you have removed the packaging, proceed as follows to handle the boiler.
-- Remove the screws securing the boiler to
the wooden pallet.
-- Remove the front panel (P) and top panel
(C) from the casing (fig. 2.6).
-- Lift the boiler using two 3/4” pipes (1)
pushed through the lifting points (2) (fig.
2.7).
P
Fig. 2.6
2
bbWear
suitable personal protective
equipment and use suitable safety
devices.
aaDo not leave items of packaging within
the reach of children.
1
Fig. 2.7
9
INSTALLATION MANUAL
2.9 Overall dimensions and water fittings
Novella 24, 31 RAI PV boilers
Fig. 2.8
Novella 24, 31, 45 RAI boilers
10
Fig. 2.9
DESCRIPTION
A
B
24 RAI
24 RAI PV
675
700
450
MODEL
31 RAI
31 RAI PV
675
700
45 RAI
154
720
mm
mm
2.10
Water circuit
Novella 24, 31 RAI PV boilers
GAS
RI
MI
E
AB
D
C
F
B
G
A
A Water circuit drain cock
B Water circuit expansion vessel
C Water circuit safety valve
D CH circuit pump
E
CH circuit temperature control sensor
F
Water circuit temperature gauge
sensor
G
Safety thermostat temperature sensor
MI CH flow
RI CH return
AB Storage cylinder connection
GASGas supply
Fig. 2.10
11
Novella 24, 31, 45 RAI boilers
GAS
MI
RI
B
A
C
D
A Water circuit drain cock
B CH circuit temperature control sensor
C Water circuit temperature gauge
sensor
D Safety thermostat temperature sensor
MI CH flow
RI CH return
GASGas supply
Fig. 2.11
Novella RAI PV series boilers are pre-fitted
with a pump to which all water and electrical
connections have already been made. Pump
performance is illustrated by the curves in the
following graph.
The pump is configured in the factory to run at
maximum speed, i.e. speed III. Slower pump
speeds may nevertheless be set with low load
loss systems in order to reduce energy consumption.
5
4,5
Useful head (m approx.)
INSTALLATION MANUAL
Useful head of pump
4
3,5
3
2,5
2
Speed III
1,5
1
0,5
0
Speed II
Speed I
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
Flow rate (l/h)
Fig. 2.12
bbOn initial start-up and at least every year,
aaNever run the pump dry.
Fig. 2.13
Boiler’s water-side pressure drop
Novella RAI boilers come without a pump. A
pump must therefore be provided as part of
the installation. In order to choose a pump of
the right size, bear in mind the boiler’s waterside pressure drop, as shown in the following
graph.
1,4
Pressuredidrop
(m (m.c.a.)
approx.)
Perdite
carico
12
check that all the pumps in the system
rotate freely. Sludge and limescale can
build up and cause seizure, especially
after long periods of disuse.
Novella 24, 31
1,2
1
0,8
Novella 45
0,6
0,4
0,2
0
200
400
600
800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Flow
rate(l/h)
(l/h)
Portata
Fig. 2.14
IG FU LV LR RS TR
TS TF Main switch
Fuse
Green “power on” LED indicator
Red “burner lockout” LED warning light
Burner reset button
CH circuit temperature control
Safety thermostat (manual reset)
Flue gas thermostat (manual reset)
PI AP VG EA ER CH pump
Ignition and flame detection unit
Gas supply solenoid valve
Ignition electrode
Flame detection sensor
2.11
Wiring diagram
Fig. 2.15
13
INSTALLATION MANUAL
3 INSTALLATION
3.1 Installation standards
3.3 Installation in existing systems
The boiler must be only be installed by qualified personnel in conformity to the following
reference standards:
-- UNI-CIG 7129
-- UNI-CIG 7131
-- IEC 64-8.
Installers must also ensure conformity to fire
prevention standards, gas safety standards
and local bylaws.
Perform the following checks before installing
Novella boilers in existing systems.
-- Check that the characteristics of the boiler’s
pump (see the graph on page 12) are suitable for the existing system. Existing pumps
are no longer needed.
3.2 Place of installation
-- Make sure that the central heating circuit
has been flushed out to remove all sludge
and limescale, and that it has been properly
de-aerated.
Novella RAI boilers must be installed in
rooms with vents that conform to applicable
technical standards and safety legislation.
-- Make sure that the system is fitted with
safety and control devices that conform to
applicable legislation and standards.
aaBoilers must be installed indoors. They
are not designed for outdoor use and
are not fitted with automatic frost protection devices.
14
-- Check that the flue is large enough and
suitable for the characteristics of the boiler.
IMPORTANT
Before installing the boiler, thoroughly flush
out all pipes to remove any dirt and deposits
that could compromise the correct functioning
of the boiler.
Install a water collector under the safety valve
and connect it to the nearest drain to evacuate any water coming out of the safety in the
event of overpressure. The domestic hot water
circuit does not require a safety valve but the
installer should nevertheless check that the
water supply pressure does not exceed 6 bar.
If necessary, install a pressure reducer.
Before lighting the burner for the first time,
make sure that the boiler is configured for
use with the type of gas supplied. The type
of gas is specified on the packaging label
and on the boiler’s own name plate.
Make sure that the flue is able to withstand
the temperature of the flue gases and that it
has been designed and made in conformity to
applicable standards. The flue must also be as
straight as possible, sealed, insulated and not
blocked or choked.
-- Check the hardness of the water supply
to ascertain whether a softening system is
required.
Refer to the following values.
REFERENCE VALUES
pH
6-8
Electrical conductivity less than 200 mV/cm (25°C)
Chlorine ions
less than 50 ppm
Sulphuric acid ions
less than 50 ppm
Total iron
less than 0,3 ppm
Alkalinity M
less than 50 ppm
Total hardness
35° F
Sulphur ions
none
Ammonia ions
none
Silicon ions
less than 30 ppm
3.4
Water connections
Novella 24, 31 RAI PV
Novella boilers are designed and made for
use in central heating systems, but can also
be used to generate domestic hot water if
connected to a suitable storage cylinder.
The specifications of the water fittings are as
follows.
MI
RI
Novella 24, 31 RAI PV boilers
MI CH flow 3/4” M
RI CH return 3/4” M
AB Storage cylinder connection 3/4” M
AB
Fig. 3.1
Novella 24, 31, 45 RAI
Novella 24, 31 RAI boilers
MI CH flow RI CH return 3/4” M
3/4” M
Novella 45 RAI boilers
MI CH flow RI CH return 1” M
1” M
bbThe choice of system components and
the method of their installation are left
up to the heating engineer installing the
system. Installers must use their expertise to ensure proper installation and functioning in conformity to all applicable
legislation.
MI
RI
bbCircuits filled with anti-freeze must be fitted with water disconnectors.
DESCRIPTION
A
Fig. 3.2
MODEL
24 RAI
31 RAI
45 RAI
64
28
28
mm
3.5 Electrical connections
Use a multi-pole disconnector with a contact
gap of at least 3 mm to connect the appliance
to the mains electricity supply. The appliance
functions on an alternating current supply
of 230 V, 50 Hz. Consumption is 150 W. The
appliance conforms to EN 60335-1 standard.
bbThe following instructions are mandatory.
-Install a multi-pole magnetic thermal
trip switch and disconnector conforming to IEC-EN standards (with a contact gap of at least 3 mm).
-Respect the polarity of the L1 (Phase) N (Neutral) connections.
-Use cables with insulation and cross
section conforming to applicable standards (minimum cross section 1.5
mm2).
-Always refer to the electrical wiring diagrams in this manual when performing
any electrical work.
-Ensure that an efficient ground connection is provided.
aaIt is strictly forbidden to use fuel and/
or water pipes to ground the appliance.
The manufacturer declines all responsibility for damage caused by failing to
ground the appliance adequately.
15
INSTALLATION MANUAL
-- Unscrew the two fixing screws and remove
the protective cover (A) from the casing
(fig. 3.3).
-- The electrical connection terminals are
located underneath (fig. 3.3).
-- Connect up the (optional) room thermostat
and/or timer as shown in the electrical
wiring diagrams in this manual.
Fig. 3.3
-- Connect up the electrical power supply (fig.
3.4).
16
Fig. 3.4
-- Connect up the room thermostat (TA) (fig.
3.5).
bbIf a room thermostat is connected, remove the bridge from terminals 4-5.
bbThe contacts of the room thermostat
must be able to function at a voltage of
230 V, 50 Hz.
Fig. 3.5
3.6 Gas connections
daia Novella RAI boilers must be connected
to the methane or LPG gas supply in conformity to applicable standards (figs. 3.6 and 3.7).
Perform the following checks before making
the connection.
-- Check that the boiler is compatible with the
type of gas supply.
-- Check that the gas supply pipes are thoroughly clean.
GAS
Fit a suitably sized filter in the gas supply pipe
if the gas supply contains any solid particles.
Fig. 3.6
GAS - Gas supply
bbThe gas supply line must be suitable for
the flow rate demanded by the burner.
The gas supply must also be equipped
with all the necessary safety and control
devices required by applicable legislation and standards.
bbOn completion of the installation, check
that all joints are sealed in conformity to
the relevant installation standards.
GAS
DESCRIPTION
A
GAS - Gas supply
MODEL
24 RAI
31 RAI
45 RAI
50
28
36
mm
Fig. 3.7
3.7 Gas supply conversion
The boiler comes ready for use with methane
gas (G20), but can be converted to work with
LPG (G30/G31) using the conversion kit provided. Conversion must be performed by the
manufacturer’s Technical Assistance Service.
The boiler can be converted even after installation. To do so, proceed as follows.
Fig. 3.8
REPLACING THE NOZZLES
-- Remove the front panel from the casing.
-- Unscrew the two nozzles from the methane
burner and replace them with the LPG nozzles provided in the kit, using the aluminium
seals also provided (fig. 3.8).
17
INSTALLATION MANUAL
DISABLING THE PRESSURE REGULATOR
For the boiler to work with LPG fuel, the pressure regulator on the valve group needs to be
disabled. To do so, proceed as follows:
-- Screw the pressure regulator screw (1) all
the way in (fig. 3.9).
-- Unscrew the pressure measurement point
screw (A) about 3 turns and connect up the
pressure gauge (fig. 3.9).
A
SMOOTH IGNITION
-- Turn the ignition adjuster screw (B) to obtain
the correct pressure for smooth ignition (fig.
3.10).
Fig. 3.9
Start up the boiler as instructed on page 21.
NOZZLE PRESSURE
-- Adjust the pressure regulator on the LPG
supply until the pressure gauge reads out
the value specified in the table below (fig.
3.11):
24 RAI
G30
18
1
31 RAI
G31
G30
G31
B
Fig. 3.10
45 RAI
G30
G31
28,4 36,5 28,8 34,7 27,8 35,7 mbar
-- Disconnect the pressure gauge and close
the pressure measurement point.
Fig. 3.11
-- Check the tightness of all the joints disconnected previously.
-- Apply the LPG label supplied with the boiler
to the inside of the boiler casing (fig. 3.12).
-- Remove any METHANE (G20) labels from
the outside and inside of the boiler casing
(fig. 3.12).
Country of destination:
__
0694
Tipo de aparato
: C13,C33,C43,C53,C63
Categoría del aparato : II2H3P
Boiler configured for:
G30+G32 28-30/37 mbar L.P.G.
Country of destination: ....
Presión alimentación gas:
G20 20 mbar
G31 37 mbar
Regulación realizado por el fabricante:
G20 - 20 mbar - 2H METANO
ATENCIÓN
Leer cuidadosamente el manual de
instrucciones antes de la instalación y
puesta en servicio de la caldera.
Fig. 3.12
3.8 Flue gas vent and air intake
Flues and stack connections must be made in
conformity to all applicable local and national
laws and standards. The use of rigid pipes is
mandatory.
All joints between pipe sections must be hermetically sealed and all parts of the flue must
be resistant to high temperatures, condensate
and mechanical stress.
bbNovella boilers are equipped with a flue
gas thermostat, located inside the hood.
This thermostat shuts down the boiler immediately in the event of flue gas
blowback.
Fig. 3.13
bbUninsulated flue pipes are potentially
dangerous and can cause burns.
MODEL
DESCRIPTION
24 RAI
31 RAI
45 RAI
B
72
77
97
mm
ØI
132
142
182
Ø mm
3.9 Filling the water circuit
Novella RAI boilers must be fitted with a
water circuit filling system connected to the
central heating return line (fig. 3.14).
RI
Fig. 3.14
-- Make sure that the boiler drain cock is
closed before attempting to fill the boiler
(fig. 3.5)
Fig. 3.15
-- Open the water circuit shut-off cocks and
slowly fill the circuit until the pressure gauge
reads out a value of 1.5 bar (cold)
-- Close the water circuit shut-off cocks(fig.
3.16).
RI
Fig. 3.16
19
INSTALLATION MANUAL
20
3.10
Emptying the water circuit
-- Turn the electricity supply off by switching
the boiler’s mains power switch and control panel switch OFF (0) before starting to
empty the boiler (fig. 3.17).
ON
OFF
Fig. 3.17
-- Make sure that the water circuit shut-off
cocks are closed.
-- Connect a rubber hose to the hose union on
the boiler’s drain cock and open the cock
(fig. 3.18).
Fig. 3.18
4 START-UP AND FUNCTIONING
4.1 Preliminary checks
Remove the front panel of the boiler and perform the following checks before switching
the boiler on or testing any of its functions.
-- Check that the fuel and water circuit shut-off
cocks are open
-- Check that the type and pressure of the gas
supply are as specified for the boiler
-- Check that the water circuit pressure gauge
shows a pressure over 1 bar with the system
cold. Check also that the central heating
circuit is properly de-aerated.
-- Check that the pressure in the central heating circuit expansion vessel is sufficient
(about 1 bar).
-- Check that the electrical connections to the
mains supply and to the system’s control
and safety devices have been made correctly.
-- Check that the flue is properly constructed.
4.2 Ignition
Once you have completed all the preparatory
steps, proceed as follows to start up the boiler
for the first time.
-- Turn the boiler’s mains power switch ON
(fig. 4.1).
Fig. 4.1
-- Set the room thermostat to the required
temperature (~ 20°C) or, if the system has
a timer or timer-thermostat, make sure that
this is switched “On” and adjusted to the
required temperature (~ 20°C) (fig. 4.2).
Fig. 4.2
-- Adjust the boiler’s own temperature control
to the desired temperature (not necessary
if the boiler is equipped with a temperature
controller) (fig. 4.3).
Fig. 4.3
-- Switch the boiler on at the control panel
switch and check that the green power indicator lights (fig. 4.4).
Fig. 4.4
21
INSTALLATION MANUAL
The boiler will now start up and the burner will
remain lit until the set temperature is reached.
If any ignition or functioning errors occur, the
boiler enters “LOCK-OUT” and the red LED
on the control panel comes on to indicate this
(fig. 4.5).
Proceed as follows to reset the safety thermostat.
Fig. 4.5
-- Wait for about 1 minute, then press the "burner reset" button (fig. 4.6).
-- Wait for the burner to complete the entire
start-up cycle again, up to the ignition of
the flame.
The boiler will also shut down if the flue gas
thermostat trips. To reset the boiler in this
case, remove the hood and reset the flue gas
thermostat (fig. 4.7).
Fig. 4.6
bbIf the flue gas thermostat trips repeatedly, make sure that the flue gas pipes
are not blocked and that the flue is properly constructed.
22
Fig. 4.7
4.3 Final checks
Once the boiler has started up, make sure that
it shuts down and re-starts properly when the
following actions are taken.
Fig. 4.8
-- The boiler’s temperature control is turned
down (fig. 4.8).
-- The control panel switch is switched OFF
(fig. 4.8).
-- The temperature setting on the room thermostat or timer is reduced (fig. 4.9).
Fig. 4.9
-- Make sure that the pump (if fitted) is free
and rotates in the right direction (fig. 4.10).
-- Turn the mains power switch OFF and make
sure that the boiler shuts down completely.
Provided these conditions are satisfied, restart the boiler.
Fig. 4.10
23
ON
OFF
Fig. 4.11
INSTALLATION MANUAL
5 SHUT-DOWN
If the boiler is not going to be used for an
extended period of time, perform the following
operations.
-- Switch the boiler off at the control panel
switch and check that the green power indicator goes out (fig. 5.1).
Fig. 5.1
-- Turn the mains power switch OFF (fig. 5.2).
ON
OFF
-- Close the boiler’s fuel cock and water circuit
cocks (fig. 5.3).
Fig. 5.2
bbEmpty the boiler if there is any risk of
freezing.
Fig. 5.3
24
6 MAINTENANCE
To maintain maximum functionality and efficiency, and to comply with applicable legislation, have the boiler serviced at regular
intervals.
The frequency at which servicing should be
performed depends on installation and operating conditions.
The boiler should nevertheless be inspected
by specialist personnel from the manufacturer’s Technical Assistance Service at least
once a year.
Always switch the boiler off if any work or
servicing has to be done on other equipment
installed near the flue gas vent pipes and/or
flues and associated accessories.
On completion of work, have the efficiency of
the flue checked by qualified personnel.
bbSwitch the boiler off at its control panel
and at the mains power switch, and turn
the gas supply off by closing the gas
shut-off cock before performing any cleaning or maintenance on the boiler.
6.1 Scheduled maintenance
Scheduled maintenance normally consists of
the following operations:
-- Remove encrustations from the burner.
-- Remove encrustations from the heat
exchangers.
-- Check and clean the flue pipes.
-- Check the efficiency of the external casing.
-- Check the ignition, normal functioning and
shutdown of the boiler in DHW and CH
modes.
-- Check the tightness of the gas and water
pipe joints.
-- Check gas consumption at maximum and
minimum power.
-- Check the position of the ignition electrode
and flame detection sensor.
-- Check the gas failure safety system.
Do not use flammable substances (e.g.
petrol, alcohol etc.) to clean the boiler or any
of its parts.
Do not use paint thinners to clean the casing
or any painted or plastic parts of the boiler.
Use only soapy water to clean the boiler
casing.
6.2 Extraordinary maintenance
Extraordinary maintenance involves actions
designed to restore the functioning of the boiler to its design specifications and to ensure
conformity to legal requirements after a failure
or malfunction.
These actions can be:
-- Replacement of parts
-- Repairs
-- Reconditioning of parts.
These actions generally require special tools
and equipment.
25
INSTALLATION MANUAL
7 OPTIONAL ACCESSORIES
Wall-mounted weekly timer thermostat (fig. 7.1)
(part number 1100279).
Fig. 7.1
Pump or valve controlled multizone central heating kit with total shut-down function (fig. 7.2)
(part number 696439).
Fig. 7.2
RO120 storage cylinder (fig. 7.3)
(part number 696339).
26
Fig. 7.3
Pump manifold (fig. 7.4)
(part number 694769).
Fig. 7.4
High head pump (fig. 7.5)
(part number 1100269).
Fig. 7.5
Cod. 20048744 - 02/12 Ed. 0
Via Risorgimento, 13 - 23900 Lecco (LC)
Servizio Clienti 199.13.31.31*
Assistenza Tecnica Numero Unico 199.12.12.12*
www.berettaclima.it
Beretta is constantly improving its products and therefore reserves the right to modify the characteristics and specifications
of the appliance described in this manual at any time and without prior notice.
The contents of this manual are not contractually binding on the manufacturer.