Beretta NOVELLA 31 RAI User manual

Installation Manual
NOVELLA 31-45 RAI
Boilers | Cast Iron Base
EN
Installation Manual

INSTALLATION MANUAL
2
The following symbols are used in this manual:
b CAUTION! = Indicates actions that require caution and adequate preparation
a STOP! = Identifies actions that you MUST NOT do

3
CONTENTS
1 SAFETY INFORMATION AND PRECAUTIONS ................................................. 4
2 DESCRIPTION OF THE APPLIANCE .......................................................... 5
2.1 Description............................................................................................................................................... 5
2.2 Optional accessories ............................................................................................................................... 5
2.3 Main parts of the boiler............................................................................................................................ 6
2.4 Control panel............................................................................................................................................ 6
2.5 Technical specifications........................................................................................................................... 7
2.6 Identification............................................................................................................................................. 8
2.7 Material supplied ..................................................................................................................................... 8
2.8 Handling................................................................................................................................................... 9
2.9 Overall dimensions and water fittings ..................................................................................................... 10
2.10 Water circuit ............................................................................................................................................. 10
2.11 Multi line wiring diagram.......................................................................................................................... 12
3 INSTALLATION............................................................................................. 13
3.1 Installation standards............................................................................................................................... 13
3.2 Place of installation .................................................................................................................................. 13
3.3 Installation in existing systems ................................................................................................................ 13
3.4 Water connections ................................................................................................................................... 14
3.5 Electrical connections.............................................................................................................................. 14
3.6 Gas connections...................................................................................................................................... 16
3.8 Flue gas vent and air intake .................................................................................................................... 18
3.9 Filling the water circuit............................................................................................................................. 18
3.10 Emptying the water circuit ....................................................................................................................... 19
4 START-UP AND FUNCTIONING .................................................................. 20
4.1 Preliminary checks................................................................................................................................... 20
4.2 Ignition ..................................................................................................................................................... 20
4.3 Final checks............................................................................................................................................. 22
5 SHUT-DOWN................................................................................................. 23
6 MAINTENANCE ............................................................................................ 24
6.1 Scheduled maintenance.......................................................................................................................... 24
6.2 Extraordinary maintenance...................................................................................................................... 24
7 OPTIONAL ACCESSORIES ......................................................................... 25

INSTALLATION MANUAL
4
1 SAFETY INFORMATION AND PRECAUTIONS
b This manual and the operation manu-
al 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.
b The boiler must only be installed and ser-
viced by qualified personnel, in conform-
ity to applicable legislation and applica-
ble technical standards.
b The boiler must only be used for the
purpose for which it is designed. The
manufacturer declines all responsibili-
ty, contractual or other, for damage to
property or injury to persons or animals
caused by improper installation, adjust-
ment, maintenance or use.
b As 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.
b The safety valve must be connected to a
suitable collection and drain system. The
manufacturer declines all responsibility
for damage caused by the operation of
an improperly connected safety valve.
b The following instructions must be
passed on to the user on installation of
the boiler:
- if water leaks from the boiler, turn off
the water supply and contact the man-
ufacturer’s Technical Assistance Service
immediately.
- periodically check that operating pres-
sure in the water circuit is over 1 bar. If
necessary, contact the manufacturer’s
Technical Assistance Service to arrange
servicing by professionally qualified per-
sonnel.
- 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:
• 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 domes-
tic 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:
aDo not allow children or uninformed per-
sons to operate the boiler
aDo not operate any electrical devic-
es or 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
aDo not touch the boiler while barefoot or
wet
aNever clean the boiler without first dis-
connecting it from the mains electrici-
ty supply by turning the mains power
switch and the control panel switch OFF
aDo not tamper with or adjust the boiler’s
safety or control devices without prior
authorisation and instructions from the
manufacturer
aDo not pull, disconnect, or twist the
electrical cables coming from the boiler
even if it is disconnected from the mains
electricity supply.
aDo not obstruct or restrict vents in
the room where the boiler is installed.
Adequate ventilation is essential for cor-
rect combustion.
aDo not store containers of flammable
substances in the room where the boiler
is installed.
aDo not dispose of packaging material
into the environment, or leave it within the
reach of children, since it can become a
potential hazard. Dispose of packaging
material in compliance with applicable
legislation.

5
2 DESCRIPTION OF THE APPLIANCE
2.1
Description
Novella RAI 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) com-
bustion 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 con-
form to applicable technical and safety stand-
ards 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 stor-
age cylinder to produce domestic hot water,
and can be equipped with temperature con-
trollers in the form of specific accessories.
Installation, maintenance and access to inter-
nal 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 pres-
sure stabiliser and double shutter for burner
control
- domestic hot water temperature control
- provision for room thermostat or timer.
2.2
Optional accessories
- wall-mounted weekly timer thermostat (cod.
1100279)
- pump manifold kit (cod. 694769)
- high head pump kit (cod. 1100269)
- RO120 storage cylinder (cod. 696339)
- pump or valve controlled multizone central
heating kit with total shut-down function
(cod. 696439)
- lifting brackets (cod. 696429)

INSTALLATION MANUAL
6
2.3
Main parts of the boiler
Key
11 Main switch
12 Central heating temperature control
13 Water circuit temperature and tempera-
ture gauge
14 Safety thermostat (manual reset)
15 Flue gas thermostat (manual reset)
16 “Burner lockout” LED warning light
17 “Power on” LED indicator
18 Quick reference guide
19 Burner reset button
Key
1 Control panel
2 Temperature sensor socket
3 Boiler body
4 Electronic ignition and flame detection
unit
5 Ignition electrode
6 Water circuit drain cock
7 Flame detection sensor
8 Burner
9 Gas supply solenoid valve
10 Lifting points
29 28
23 24 25 26 27
31 30 30
Fig. 2.2
11 12 13 14 15
161718 1819
19
21
22
20
13
14
15
16
17
18
Fig. 2.1
1
10
9
8
7
2
3
4
5
6
2.4
Control panel

7
31 RAI 45 RAI
Rated heat input, CH kW 34,4 50,0
kcal/h 29590 43000
Rated heat output, CH kW 31,0 45,0
kcal/h 26660 38700
Electrical consumption W 15
Category II 2H3+
Power supply voltage V ~ Hz 230 ~ 50
Index of protection IP 40
Losses from stack and casing with burner off % 1,37 1,23
Central heating circuit characteristics
Maximum pressure - temperature bar -°C 3 - 100
CH temperature setting range °C 34-82
Gas pressure
Rated gas pressure, methane (G20) mbar 20
Rated gas pressure, LPG (G30-G31) mbar 28-30/37
Water connections
CH flow - return Ø3/4"
Gas inlet Ø1/2"
Emissions with G20 gas
CO below p.p.m. 21 19
CO2 % 5,7 5,5
NOx (according to EN 297) class 1
Flue gas Δt °C 96 113
Boiler dimensions
Height mm 850
Width mm 450 600
Depth mm 675 720
Weight of boiler kg 118 154
2.5
Technical specifications
PARAMETER 31 RAI 45 RAI
Lower Wobbe index (at 15°C-1013 mbar) G20 (MJ/m3) 45,5
(at 15°C-1013 mbar) G30 (MJ/m3) 80,9
(at 15°C-1013 mbar) G31 (MJ/m3) 70,9
Main burner
number nozzles 4 6
nozzle diameter G20 Ø mm 2,40 2,40
G30 Ø mm 1,50 1,45
G31 Ø mm 1,50 1,45
Nozzle pressure
(downstream from valve in central heating only mode)
G20 mbar Δp13,5 12,7
mm H2O Δp138 129
G30 mbar Δp28,0 27,8
mm H2O Δp285 283
G31 mbar Δp34,7 35,7
mm H2O Δp354 364
Maximum gas flow rate, CH (*) G20 m3/h 3,50 5,10
G30 kg/h 2,70 3,92
G31 kg/h 2,66 3,86
(*) Temperature 15°C; Pressure 1013 mbar

INSTALLATION MANUAL
8
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.
b It is essential to specify the correct
model of boiler when ordering spare
parts or requesting technical assis-
tance. If the name plate or any other
means of clearly identifying the prod-
uct is defaced, removed or lost, proper
installation and servicing may be ren-
dered difficult.
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:
- instruction manual
- LPG conversion kit (nozzles, label, seals).
Instruction manuals are integral parts of the
boiler. On unpacking, locate the manuals and
keep them safe.
MODEL
31 RAI 45 RAI
Net weight 118 154 kg
Gross weight 138 174 kg
Fig. 2.3

9
C
P
Fig. 2.5
2.8
Handling
Once you have removed the packaging, pro-
ceed 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. 2.5)
- lift the boiler using two 3/4" pipes (1)
pushed through the lifting points (2) (fig.
2.6).
b Wear suitable personal protective
equipment and use suitable safety
devices.
aDo not dispose of packaging material
into the environment, or leave it within
the reach of children, since it can
become a potential hazard. Dispose of
packaging material in compliance with
applicable legislation.
2
1
Fig. 2.6

INSTALLATION MANUAL
10
2.9
Overall dimensions and water fittings
Fig. 2.7
DESCRIPTION MODEL
31 RAI 45 RAI
A 450 154 mm
B 675 720 mm
2.10
Water circuit
MI
GAS
RI
A
B
C
D
A Water circuit drain cock
B Water circuit temperature control
sensor
C Safety thermostat temperature sen-
sor
D Water circuit temperature gauge
sensor
MI CH flow
RI CH return
GAS Gas supply
Fig. 2.8

11
0
0,2
0,4
0,6
0,8
1
1,2
1,4
200 400600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Novella 31
Flow rate (l/h)
Pressure drop (m.w.c.)
Novella 45
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 water-side pressure
drop, as shown in the following graph.
b On initial start-up and at least every year,
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.
aNever run the pump dry.
Fig. 2.10
Fig. 2.9

INSTALLATION MANUAL
12
PI
FU
L1
N
PE
TA
TA
TB-C
TB-1
TB-2
1
2
3 4 5 6
7 8 9
10 11 12
CO1
RS
TR
CO2
PB-N
PB-L1
PB-PE
MO1MO2
LR
LV
1
2
3
4
5
6
7
8
9
10
11
12
ER
EA
VG
AP
0 1
IG TS
PI-L1
PI-PE
PI-N
PE
N
F
VG
TF
G Main switch FU Fuse LV Green “power on” LED indicator LR Red “burner lockout” LED warning light RS Burner reset button
TR Central heating temperature control TS Safety thermostat (manual reset) TF Flue gas thermostat (manual reset) PI CH pump AP Ignition and flame detection unit VG Gas supply solenoid valve
EA Ignition electrode ER Flame detection sensor MO1 Main board terminal strip MO2 Auxiliary terminal strip
2.11
Multi line wiring diagram
Fig. 2.11

13
3 INSTALLATION
3.1
Installation standards
The boiler must be only be installed by qual-
ified personnel in conformity to applicable
standards.
Installers must also ensure conformity to fire
prevention standards, gas safety standards
and local bylaws.
3.2
Place of installation
Novella RAI boilers must be installed in boiler
rooms with vents that conform to applicable
technical standards and safety legislation.
aBoilers must be installed indoors. They
are not designed for outdoor use and
are not fitted with automatic frost protec-
tion devices.
IMPORTANT
Before installing the boiler, thoroughly flush
out all pipes to remove any dirt and deposits
that could compromise the correct function-
ing of the boiler.
Install a water collector under the safety valve
and connect it to the nearest drain to evac-
uate 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.
3.3
Installation in existing sys-
tems
Perform the following checks before installing
Novella RAI boilers in existing systems:
- Check that the flue is large enough and
suitable for the characteristics of the boiler
- Check that the characteristics of any exist-
ing central heating pump are suitable for
the boiler (see the graph on page 11).
- 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.
- Make sure that the system is fitted with
safety and control devices that conform to
applicable legislation and standards.
- 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

INSTALLATION MANUAL
14
MI
RI
3.4
Water connections
Novella RAI 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:
Novella 31 RAI
MI CH outlet 3/4” M
RI CH return 3/4” M
Novella 45 RAI
MI CH outlet 1” M
RI CH return 1” M
b The choice of system components and
the method of their installation are left
up to the heating engineer installing the
system. Installers must use their exper-
tise to ensure proper installation and
functioning in conformity to all applica-
ble legislation.
b Circuits filled with anti-freeze must be fit-
ted with water disconnectors.
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 applicable standards.
b The following instructions are mandato-
ry.
-install a multi-pole magnetic thermal
trip switch and disconnector conform-
ing to IEC-EN standards (with a con-
tact 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);
Fig. 3.1
DESCRIPTION MODEL
31 RAI 45 RAI
A 28 28 mm
- always refer to the electrical wiring dia-
grams in this manual when performing
any electrical work;
- ensure that an efficient ground connec-
tion is provided.
aIt is strictly forbidden to use fuel and/
or water pipes to ground the appliance.
The manufacturer declines all respon-
sibility for damage caused by failing to
ground the appliance adequately.

15
Fig. 3.2
Fig. 3.3
Fig. 3.4
- Unscrew the two fixing screws and remove
the protective cover (A) from the casing (fig.
3.2)
- the electrical connection terminals are
located underneath (fig. 3.2)
- connect up the (optional) room thermostat
and/or timer as shown in the electrical wir-
ing diagrams in this manual
- connect up the electrical power supply (fig.
3.3)
- connect up the room thermostat (TA) (fig.
3.4).
b If a room thermostat is connected,
remove the bridge from terminals 4-5.
b The contacts of the room thermostat
must be able to function at a voltage of
230 V, 50 Hz.

INSTALLATION MANUAL
16
3.6
Gas connections
Novella boilers must be connected to the
methane or LPG gas supply in conformity to
applicable standards (fig. 3.5).
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 thor-
oughly clean
Fit a suitably sized filter in the gas supply pipe
if the gas supply contains any solid particles.
b The 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 legisla-
tion and standards.
b On completion of the installation, check
that all joints are sealed in conformity to
the relevant installation standards.
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 pro-
vided and the LPG gas valve contained in the
relevant kit. 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.
REPLACING THE NOZZLES
- Remove the front panel from the casing.
- Unscrew the two nozzles from the methane
burner and replace them with the LPG noz-
zles, using the aluminium seals provided in
the kit (fig. 3.6).
GAS
Fig. 3.5
Fig. 3.6
GAS - Gas supply
DESCRIPTION MODEL
31 RAI 45 RAI
A 28 36 mm

17
DISABLING THE PRESSURE REGULATOR
For the boiler to work with LPG fuel, the pres-
sure 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. 3.7).
- Unscrew the pressure measurement point
screw (A) about 3 turns and connect up the
pressure gauge (fig. 3.7).
SMOOTH IGNITION
- Turn the smooth ignition adjuster screw (B)
to obtain the correct pressure for smooth
ignition (fig. 3.8).
Start up the boiler as instructed on page 20.
NOZZLE PRESSURE
- Adjust the pressure regulator on the LPG
supply until the pressure gauge reads out
the value specified in the table below (fig.
3.9):
31 RAI 45 RAI
G30 G31 G30 G31
28,8 34,7 27,8 35,7
mbar
- Disconnect the pressure gauge and close
the pressure measurement point
- Check the tightness of all the joints discon-
nected previously
- Apply the LPG label supplied with the boiler
to the inside of the boiler casing (fig. 3.10)
- Remove any METHANE (G20) labels from
the outside and inside of the boiler casing
(fig. 3.10).
B
1
A
Fig. 3.9
Fig. 3.8
Fig. 3.7
Boiler configured for:
Country of destination: ....
G30+G31 28-30/37 mbar L.P.G.
Fig. 3.10

INSTALLATION MANUAL
18
RI
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 her-
metically sealed and all parts of the flue must
be resistant to high temperatures, condensate
and mechanical stress.
b Novella RAI 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.
b Uninsulated flue pipes are potentially
dangerous and can cause burns. Fig. 3.11
DESCRIPTION MODEL
31 RAI 45 RAI
B 77 97 mm
ØI 142 182 Ømm
3.9
Filling the water circuit
Novella RAI series boilers must be fitted with
a water circuit filling system connected to the
boiler return line (fig. 3.12).
- Make sure that the boiler drain cock is
closed before attempting to fill the boiler
(fig. 3.13)
- open the water circuit shut-off cocks and
slowly fill the circuit until the temperature
gauge reads out a value of 1.5 bar (cold)
- close the water circuit shut-off cocks (fig.
3.14).
RI
Fig. 3.12
Fig. 3.13
Fig. 3.14

19
3.10
Emptying the water circuit
- Turn the electricity supply off by switching
the boiler’s mains power switch and control
panel switch OFF before starting to empty
the boiler (fig. 3.15)
- 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. 3.16).
ON
OFF
Fig. 3.15
Fig. 3.16

INSTALLATION MANUAL
20
Fig. 4.1
Fig. 4.2
Fig. 4.3
4 START-UP AND FUNCTIONING
4.1
Preliminary checks
Remove the front panel of the boiler and per-
form 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 temperature
gauge shows a pressure over 1 bar with
the system cold. Check also that the central
heating circuit is properly de-aerated
4.2
Ignition
Once you have completed all the preparatory
steps, proceed as follows to start up the boil-
er for the first time.
- Turn the boiler’s mains power switch ON
(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)
- Adjust the boiler’s temperature control to
the desired temperature (operation not nec-
essary if the boiler has been equipped with
a temperature controller) (fig. 4.3)
- Switch the boiler on at the control panel
switch and check that the green power
indicator lights (fig. 4.4).
- Check that the pressure in the central heat-
ing 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 cor-
rectly
- Check that the flue is properly constructed.
Fig. 4.4