Beretta NOVELLA 55-64-71 RAP User manual

Installation Manual
NOVELLA 55-64-71 RAP
Boilers | Cast Iron Base
EN 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
2.3 Main parts of the boiler............................................................................................................................ 6
2.2 Control panel............................................................................................................................................ 6
2.4 Technical specifications........................................................................................................................... 7
2.5 Identification............................................................................................................................................. 8
2.6 Material supplied ..................................................................................................................................... 8
2.7 Handling................................................................................................................................................... 9
2.8 Overall dimensions and water fittings ..................................................................................................... 10
2.9 Water circuit ............................................................................................................................................. 10
2.10 Wiring diagram ........................................................................................................................................ 12
3 INSTALLATION ............................................................................................. 13
3.1 Installation standards............................................................................................................................... 13
3.2 Place of installation .................................................................................................................................. 13
3.3 Installation in existing system .................................................................................................................. 13
3.4 Water connections ................................................................................................................................... 14
3.5 Electrical connections.............................................................................................................................. 14
3.6 Gas connections...................................................................................................................................... 16
3.7 Flue gas vent and air intake .................................................................................................................... 17
3.8 Filling the water circuit............................................................................................................................. 18
3.9 Emptying the water circuit ....................................................................................................................... 18
4 START-UP AND FUNCTIONING .................................................................. 19
4.1 Preliminary checks................................................................................................................................... 19
4.2 Ignition ..................................................................................................................................................... 19
4.3 Final checks............................................................................................................................................. 21
5 SHUT-DOWN................................................................................................. 23
6 MAINTENANCE ............................................................................................ 24
6.1 Scheduled maintenance.......................................................................................................................... 24
6.2 Extraordinary maintenance...................................................................................................................... 24
7 OPTIONAL ACCESSORIES ......................................................................... 25

4
1 SAFETY INFORMATION AND PRECAUTIONS
bThis 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.
bThe boiler must only be installed and ser-
viced by qualified personnel, in conform-
ity to applicable legislation and applica-
ble technical standards.
bThe boiler must only be used for the pur-
pose for which it is designed. The man-
ufacturer declines all responsibility, con-
tractual or other, for damage to property
or injury to persons or animals caused by
improper installation, adjustment, mainte-
nance or use.
bAs 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.
bThe 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.
bThe 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 manufactur-
er’s Technical Assistance Service imme-
diately.
- 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 heat-
ing 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:
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 RAP boilers are gas fuelled boil-
ers 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
flame detection system is of the thermocou-
ple type.
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
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 inter-
nal components is facilitated by a large front
panel.
The key features of these boilers include:
- piezoelectric ignition with thermocouple
flame control
- gas supply solenoid valve with built-in pres-
sure stabiliser and double shutter for burner
control
- central heating circuit temperature control-
ler
- central heating circuit temperature gauge
- provision for room thermostat or timer.

6
2.2
Control panel
2.3
Main parts of the boiler
Key
1 Control panel
2 Boiler temperature sensor socket
3 Piezoelectric ignition system
4 Safety thermostat
5 Water circuit drain cock
6 Thermocouple
7 Burner
8 Gas supply solenoid valve
9 Name plate
Key
10 Main switch
11 Central heating temperature control
12 Central heating temperature gauge
13 Flue gas thermostat (manual reset)
14 LED indicator (flue gas temperature alarm)
15 LED indicator (mains power)
1
2
3
4
5
6
7
8
9
10 11 12 13
1415

7
Parameter 55 64 71
Liquid gas Liquid gas Liquid gas
G20 G30 G31 G20 G30 G31 G20 G30 G31
Lower Wobbe index
(at 15 °C - 1013 mbar) MJ/m3 45,7 80,9 71,0 45,7 80,9 71,0 45,7 80,9 71,0
Rated supply pressure mbar 20 28 37 20 28 37 20 28 37
mm H2O (203,9) (285,5) (377,3) (203,9) (285,5) (377,3) (203,9) (285,5) (377,3)
Minimum supply pressure mbar 13,5 13,5 13,5
mm H2O (137,7) (137,7) (137,7)
Main burner - 2 nozzles Ø mm 4,60 2,60** 2,60** 5,00 2,85** 2,85** 5,40 3,00** 3,00**
Maximum gas flow rate, CH (*) m3/h 6,40 7,40 8,29
kg/h 4,50 4,50 5,50 5,50 6,20 6,20
Maximum pressure downstream from
valve in central heating mode mbar ∆p 12,5 25,5 34,0 12,8 25,5 34,5 12,5 24,5 34,0
mm H2O ∆p 127 260 346 130 260 351 127 250 346
2.4
Technical specifications
(*) Temperature 15°C; Pressure 1013 mbar
Description
55 64 71
Rated heat input in central heating mode kW 61,0 70,5 79,0
kcal/h 52460 60630 67940
Rated heat output in central heating mode kW 55,0 63,5 71,1
kcal/h 47300 54600 61150
Consumption W 23
Boiler class II 2H3+
Power supply V ~ Hz 230 ~ 50
Index of protection IP 40
Losses from stack and casing with burner off % 1,12 1,26 1,05
Central heating section
Maximum working pressure - Maximum temperature bar - °C 3 - 100
CH water temperature adjustment range °C 34-82
Gas pressure
Rated gas pressure (G20) mbar 20
Rated gas pressure (G30 - G31) mbar 28-30/37
Water connections
CH circuit flow - CH circuit return Ø 1"1/4
Gas supply Ø 1/2" 3/4"
Emissions with G20 gas
CO s.a. below p.p.m. 34 31 52
CO2% 4,90 5,75 5,70
NOx (according to EN 297) class 1
Flue gas ∆t °C 113 123 130
Boiler dimensions
Height mm 850
Width mm 450
Depth mm 712 795 878
Weight kg 190 225 251

8
2.5
Identification
NOVELLA boilers are identified by a product
name plate giving the boiler’s serial number,
model and main technical and performance
data.
bIt 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
2.6
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
- LPG conversion kit (nozzles, label, seals)
- 2 boiler lifting eyebolts.
bInstruction manuals are integral parts of
the boiler. On unpacking, locate the
manuals and keep them safe.
Description 55 64 71
Net weight kg 190 225 251
Gross weight kg 207 243 271
Fig. 2.3

9
2.7
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)
- unscrew the nut (A) from the top front
tie-rod(fig. 2.6)
- fit one of the lifting plates (B) over the end
of the tie-rod (C) (fig. 2.6)
- screw the nut (A) back on (fig. 2.6)
- unscrew the nut (D) from the top rear tie-
rod (fig. 2.7)
- fit the second lifting plate (E) over the end
of the tie-rod (F). Make sure that the sec-
ond lifting plate is diagonally opposite that
fitted previously (fig. 2.7)
- screw the nut (D) back on (fig. 2.7)
- lift the boiler using a 1" pipe (G) inserted
through the two lifting plates (fig. 2.8)
- once the boiler is in its final installation
position, reverse the above steps to remove
the two lifting plates. Securely tighten the
nuts.
bWear suitable personal protective equip-
ment and use suitable safety devices.
Fig. 2.5
Fig. 2.6
Fig. 2.7
Fig. 2.8

10
Description 55 64 71
A mm 712 795 878
B mm 260 302 342
2.8
Overall dimensions and water fittings
Fig. 2.9
2.9
Water circuit
Key
A Water circuit drain cock
B CH circuit temperature control sensor
C Safety thermostat sensor
D CH circuit temperature gauge sensor
MI CH flow
RI CH return
GAS Gas supply
Fig. 2.10
GAS
MI
RI

11
Boiler’s water-side pressure drop
NOVELLA boilers come without a pump. A
pump must therefore be provided as part of
the installation.
Fig. 2.10
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.
Fig. 2.11
bOn 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. 2.12
Pressure drop (m.w.c.)
Flow rate (l/h)

12
2.10
Wiring diagram
Fig. 2.14
Key IG Main switch A/M Mode selector (automatic/manual)
FU Fuse LV LED indicator (mains power) LR LED indicator (flue gas temperature alarm) TR Central heating temperature control
TS Safety thermostat (manual reset) TF Flue gas thermostat (manual reset)
PI CH pump
VG Gas supply solenoid valve
TT Thermocouple

13
3 INSTALLATION
3.1
Installation standards
The boiler must be only be installed by quali-
fied 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 RAP boilers must be installed in
boiler rooms with vents that conform to appli-
cable technical standards and safety legisla-
tion.
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-
tem
Perform the following checks before installing
NOVELLA 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).
Existing pumps are no longer needed.
- Make sure that the central heating circuit
has been flushed out to remove all sludge
and lime scale, and that it has been proper-
ly 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

14
3.4
Water connections
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 CH outlet 1”1/4 F
RI CH return 1”1/4 F
b The “RO120 storage cylinder water con-
nections kit” (cod. 596369) adapts the
boiler’s water connections to a different
diameter:
MI CH outlet 3/4” F
RI CH return 3/4” M
bThe 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.
bCircuits 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 appli-
ance conforms to applicable standards.
bThe 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.
aIt 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.
Fig. 3.1

15
- Remove the control panel (1) by pulling it
towards you.
- Unscrew the fixing screw (3) to release the
control panel from its housing (2) and
access its internal parts.
- Unscrew the two fixing screws and remove
the protective cover (4) from the casing.
- Make the necessary connection to the ter-
minal strip (A).
- 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.
3.4).
- Connect up the room thermostat (TA) (fig.
3.5).
bIf a room thermostat is connected,
remove the bridge from terminals 4-5.
bThe contacts of the room thermostat
must be able to function at a voltage of
230 V, 50 Hz.
1 2
3
4
A
Fig. 3.4
Fig. 3.5
Fig. 3.3
Fig. 3.2

16
3.6
Gas connections
NOVELLA boilers must be connected to the
methane or LPG gas supply in conformity to
applicable standards (fig. 3.6).
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.
bThe 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.
bOn completion of the installation, check
that all joints are sealed in conformity to
the relevant installation standards.
Fig. 3.6
GAS Gas supply
GAS

17
Fig. 3.7
Description 55 64 71
A mm 260 302 342
Ø i mm 182 182 202
3.7
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 resist-
ant to high temperatures, condensate and
mechanical stress.
bNOVELLA 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.
bUninsulated flue pipes are potentially
dangerous and can cause burns.
bTo install the flue gas thermostat, refer
to the instructions given with the back
draught shutter accessory supplied with
the boiler.
NOVELLA boilers must be fitted with a back
draught shutter, available as an accessory.
Refer to the manual provided with the acces-
sory for installation instructions.

18
3.8
Filling the water circuit
NOVELLA series boilers must be fitted with a
water circuit filling system connected to the
boiler return line (fig. 3.8).
- Make sure that the boiler drain cock is
closed before attempting to fill the boiler
(fig. 3.9)
- 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.
3.10).
3.9
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. 3.11)
- 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. 3.12).
Fig. 3.8
Fig. 3.9
Fig. 3.10
Fig. 3.11
Fig. 3.12

19
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 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 (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 indi-
cator lights (fig. 4.4).
Fig. 4.4
Fig. 4.1
Fig. 4.3
Fig. 4.2

20
- Open the boiler’s front panel, then press the
ignition knob on the gas valve and turn it to
the “1” position (fig. 4.9)
- Keep holding down the ignition knob and
simultaneously press the button on the pie-
zoelectric igniter (near the “4” gas valve), a
number if times until the pilot burner lights
(fig. 4.10)
- Hold down the ignition knob on the gas
valve for about another 20 seconds after the
pilot burner lights, then release it
- Turn the ignition knob on the gas valve back
to “2” position (fig. 4.11).
Repeat this operation no more than 2-3 times,
at intervals of at least 3 minutes. If the prob-
lem persists after that, call your local Technical
Assistance Centre. Fig. 4.11
Fig. 4.10
Fig. 4.9