Beretta Novella MAXIMA 129 N RAI User manual

Installation Manual
NOVELLA MAXIMA
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.
MODEL Body code
(pack 1)
Casing and flue
gas hood
(pack 2)
Control panel and
gas valve code
(pack 3)
Novella MAXIMA 129 N RAI 20047061 20047069 20047077
Novella MAXIMA 151 N RAI 20047062 20047070 20047079
Novella MAXIMA 172 N RAI 20047063 20047071 20047080
Novella MAXIMA 194 N RAI 20047064 20047072 20047081
Novella MAXIMA 215 N RAI 20047065 20047073 20047082
Novella MAXIMA 237 N RAI 20047066 20047074 20047083
Novella MAXIMA 258 N RAI 20047067 20047075 20047084
Novella MAXIMA 279 N RAI 20047068 20047076 20047085
RANGE
The boiler must be installed by a qualified heating engineer in conformity to applicable laws and standards.
At the end of its useful life, the boiler must be disposed of in conformity to applicable laws and standards.
The proper separation of components for disposal reduces impact on the environment and risks to health.
The recycling of materials also generates savings in economic terms.

3
CONTENTS
1 SAFETY INFORMATION AND PRECAUTIONS ...................................................5
2 DESCRIPTION OF THE APPLIANCE ........................................................ 6
2.1 Description ..........................................................................................................................................6
2.2 Main parts of the boiler .......................................................................................................................7
2.3 Technical specifications ......................................................................................................................8
2.4 Control panel ......................................................................................................................................9
2.5 Wiring diagram..................................................................................................................................10
2.6 Identification......................................................................................................................................12
2.7 Unpacking the product......................................................................................................................13
2.8 Overall dimensions and weights.......................................................................................................14
2.9 Handling............................................................................................................................................14
2.10 Place of installation...........................................................................................................................15
2.11 Installation in older systems and systems requiring modernisation .................................................16
2.12 Central heating system water quality requirements .........................................................................16
3 INSTALLATION......................................................................................... 17
3.1 Assembling the boiler .......................................................................................................................17
3.1.1 Assembling the flue gas box.......................................................................................................17
3.1.2 Moving the flow-return fittings to the other side..........................................................................17
3.1.3 Reversing the water distributor ...................................................................................................18
3.1.4 Fitting the burner manifold ..........................................................................................................18
3.1.5 Fitting the burner tubes ...............................................................................................................18
3.1.6 Fitting the casing and gas valve .................................................................................................19
3.2 Water connections ............................................................................................................................21
3.3 Gas connection.................................................................................................................................22
3.4 Flue gas vent and air intake .............................................................................................................23
3.5 Fitting the control panel ....................................................................................................................23
3.6 Fitting the flue gas thermostat ..........................................................................................................24
3.7 Electrical connections .......................................................................................................................25
3.8 Filling and emptying the system .......................................................................................................26
4 STARTUP AND FUNCTIONING ............................................................... 27
4.1 Preliminary checks............................................................................................................................27
4.2 Start-up .............................................................................................................................................27
4.3 Final checks......................................................................................................................................29
4.4 Settings .............................................................................................................................................30
4.5 Conversion from one gas type to another ........................................................................................31
4.5.1 Adjusting gas pressure................................................................................................................32
5 SHUTTING DOWN THE BOILER ............................................................. 33
5.1 Temporary shut-downs .....................................................................................................................33
5.2 Extended shut-downs .......................................................................................................................33
6 MAINTENANCE ........................................................................................ 34
6.1 Boiler maintenance ...........................................................................................................................34
7 TROUBLESHOOTING .............................................................................. 36

4
Dear Customer,
Thank you for choosing a Novella MAXIMA boiler. You have purchased a modern, high effi-
ciency, quality product that is designed to give dependable and safe service and to provide
comfort in the home for many years to come. Arrange for your boiler to be serviced regularly by
an authorised Technical Assistance Centre. Their personnel are specially trained to keep your
boiler efficient and cheap to run. Technical Assistance Centres also stock any spare parts you
might need.
This instruction manual contains important instructions and precautions that must be observed
to ensure the trouble-free installation and efficient functioning of your Novella MAXIMA boiler.
Please accept our renewed thanks for your purchase.

5
b As soon as you open the packaging, check
immediately that the contents are all present
and undamaged. Contact the dealer from
whom you purchased the product if you
notice any problems.
b Novella MAXIMA boilers must be installed
by a legally qualified heating engineer. On
completion of the installation, the installer
must issue the owner with a declaration of
conformity confirming that the installation has
been completed to the highest standards in
compliance with the instructions provided in
this instruction manual, and that it conforms
to all applicable laws and standards.
b The boiler must only be used for the purpose
for which it is designed.
The manufacturer declines all responsibility,
contractual or other, for damage to prop-
erty or injury to persons or animals caused
by improper installation, adjustment, mainte-
nance or use.
b If you notice any water leaking from the boiler,
disconnect it immediately from the mains
electricity supply, shut off the water sup-
ply, and call your local Technical Assistance
Centre or a qualified heating engineer imme-
diately.
b Periodically check that operating pressure in
the central heating circuit is over 1 bar but
below the maximum limit specified for the
boiler.
If water pressure is consistently low, call your
local Technical Assistance Centre or a profes-
sionally qualified heating engineer.
b If the boiler is not going to be used for an
extended period of time, perform the follow-
ing operations.
- Switch the boiler OFF at the control panel
and at the mains power switch.
- Close the boiler’s fuel shut-off cock and
water shut-off cock.
- Empty the boiler if there is any risk of
freezing.
b The boiler must be serviced at least once a
year.
b This instruction manual is an integral part
of the boiler. It must be kept safe and must
ALWAYS accompany the boiler, even if it
is sold to another owner or transferred to
another user or to another installation. If you
damage or lose this manual, order a replace-
ment immediately from your local Technical
Assistance Centre.
Observe the following precautions to ensure
safe operation of the boiler.
a Do not allow children or infirm persons to
operate the boiler unsupervised.
a Do not operate any electrical devices or
equipment, including switches or domes-
tic appliances, etc., if you can smell fuel
or fumes. If you detect any suspicious
smells:
- Ventilate the room by opening all doors
and windows.
- Close the fuel shut-off cock.
- Report the fault immediately to your local
Technical Assistance Centre or a profes-
sionally qualified heating engineer.
a Do not touch the boiler while barefoot or wet.
a Never clean or service the boiler without first
disconnecting it from the mains electricity
supply by turning the mains power switch
and the control panel switch OFF.
a Do not tamper with or adjust the safety or
control devices without prior authorisation
and instructions from the boiler’s manufactur-
er.
a Never pull, disconnect, or twist the electrical
cables coming from the boiler even if it is dis-
connected from the mains electricity supply.
a Do no obstruct or restrict the vents in the
room where the boiler is installed. Adequate
ventilation is essential for correct combus-
tion.
a Do not expose the boiler to the elements. It
is not designed to work outdoors and is not
fitted with the necessary automatic anti-frost
systems to do so.
a Do not switch the boiler off if outdoor temper-
ature drops below ZERO (risk of freezing).
a Do not store containers of flammable sub-
stances in the room where the boiler is
installed.
a Do not dispose of packaging material into
the environment, or leave it within the reach
of children, since it can become a potential
hazard. Dispose of packaging material in
compliance with applicable legislation.
1 SAFETY INFORMATION AND PRECAUTIONS

6
2 DESCRIPTION OF THE APPLIANCE
2.1
Description
Novella MAXIMA 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 come complete with:
- gas valves
- a flue gas thermostat, as required by appli-
cable safety standards
- a minimum gas pressure switch that pre-
vents functioning under unsuitable condi-
tions
- a burner controller reset button on the sec-
ondary control panel
- an ionisation type flame detection system.
The burner is a stainless steel unit with mul-
ti-ramp control, stabilised flame and smooth
ignition. The burner controller incorporates
all the safety and control devices required by
current technical standards and also contains
electrical connections for system devices. The
burner controller is installed and integrated in
the outer casing of the boiler.
Installation, maintenance and access to inter-
nal components is facilitated by a large front
panel.
b The intervention of a safety device indicates
a potentially dangerous malfunction in the
boiler, and means that you must contact your
local Technical Assistance Centre immedi-
ately.
b A tripped flue gas thermostat indicates that
fumes are being discharged into the room
in which the boiler is installed. This is an
extremely dangerous condition.
Do not re-start the boiler. Open the
windows and call your local Technical
Assistance Centre or a qualified heat-
ing engineer immediately.
a Never start the boiler up even for a short
period if the safety devices are not function-
ing correctly or have been tampered with.
b Safety devices must only be replaced by a
Technical Assistance Centre using original
spare parts. Refer to the spare parts cata-
logue supplied with the product.
Always check that the boiler is functioning
correctly after repairs have been made.

7
2.2
Main parts of the boiler
Fig. 2.1
1 - Central heating flow
2 - Flue gas hood
3 - Control panel
4 - Top front panel
5 - Flue gas vent
6 - Top panel
7 - Front base
8 - Bottom front panel
9 - Gas supply fitting
10 - Flame inspection window
11 - Boiler drain cock
12 - Flue gas thermostat
13 - Boiler sensor sockets
14 - Ignition electrode
15 - Boiler body
16 - Burner
17 - Nozzle gas pressure measurement
fitting
18 - Gas supply line
19 - Boiler base profiles
20 - Ionisation flame detection sensor
21 - Three part union
22 - Secondary electric power panel
23 - Top rear side panel
24 - Bottom rear side panel
25 - Central heating return
26 - Front side panel
Gas valve:
27 - Inlet pressure measurement fitting
28 - Solenoid valve EVG1
29 - Min. pressure adjuster screw
30 - Solenoid valve EVG2
31 - Outlet pressure measurement fitting
32 - Max. pressure adjuster screw
33 - Vent valve
34 - Minimum valve EVM
35 - Minimum gas pressure switch
1 2 3
29 3230 31
4 5 6
781011151619
35 34
2526 91718
12
13
23
24 14
33
20
21
27
28
22
13
10

8
2.3
Technical specifications
Description 129 151 172 194 215 237 258 279
Fuel G20
Gas supply pressure (nominal) 20
mbar
Boiler class II2H3P
Type of boiler B11BS
Max. heat input at furnace 145,9 170,0 194,2 218,2 242,1 266,0 290,0 313,6
kW
Rated useful heat output 129,0 150,6 172,2 193,7 215,2 236,5 257,8 279,1 kW
Useful efficiency at Pn 89,1 %
Useful efficiency at 30% Pn 86,7 86,9 87,1 87,3 87,5 87,6 87,7 87,8 %
Min. combustion efficiency 94,22 94,36 94,47 94,57 94,67 94,75 94,82 94,89 %
Constant pressure drop 0,8 0,7 1,1 0,6 0,8 0,9 0,7 1,2 %
Losses from stack with burner on 10,8 10,7 10,8 10,6 10,3 10,2 10,1 9,8 %
Flue gas temperature (ΔT) (at Pn) 134 150 153 133 140 123 128 134 °C
Maximum flue gas flow rate (*) 154 170 173 153 160 143 148 154 °C
CO2 5,5 6,3 6,8 5,6 6,1 5,3 5,6 6,1 %
NOx class 3
Boiler water capacity 67,5 77,0 86,5 96,0 105,5 115,0 124,5 134,0
l
Maximum working pressure 5 bar
Maximum admissible temperature 110 °C
Minimum return temperature 47 °C
Power supply 230~50 Volt~Hz
Maximum power consumption 105 W
Index of protection 20 IP
Nozzles size 4,30
Ø mm
number 6 7 8 9 10 11 12 13 n°
Values achieved with G20 gas.
(*) Parameters refer to 0% residual O2 in the products of combustion and atmospheric pressure at sea level.
IMPORTANT!
For functioning with G30 or G31 gas, see the "Conversion from one gas type to another" section on page 31.

9
2.4
Control panel
Fig. 2.2
1 - Main switch
0 Off
I On
2 -
x Manual reset for safety thermostat
Allows you to reset the boiler if the safety thermostat trips.
Unscrew the protective cap to access the reset button.
3 - Housing for additional controls (accessories)
4 - Boiler temperature gauge
Displays the temperature of the central heating water.
5 - v Boiler thermostat
Allows you to set the temperature of the central heating water.
6 - Plug
7 - Gas pressure switch tripped indicator
Lights if incoming gas pressure is insufficient.
8 - Burner controller lockout indicator
Comes on if the controller locks out the burner.
1 2 3 4
5678

10
CONTROL PANEL
2.5
Wiring diagram
Fig. 2.3

11
Legend L Phase N Neutral FA EMI filter A SM 191.1 controller F Fuse (T 4A) PG Gas pressure switch EVG Gas valve ER Flame detection sensor EA Ignition electrode EVM Minimum valve IG Main power switch SB Lockout indicator SG Low gas pressure indicator PA Water pressure switch (accessory) TF Flue gas thermostat (not supplied)
TC 2-stage control thermostat
TS Safety thermostat PI Central heating pump (not supplied) PB Storage cylinder pump (not supplied) C Control unit connectors SF Flue gas damper (not supplied) CO Hour counter (not supplied) NOTE: Remove the bridge from terminals 1-4 on terminal strip MC if a control unit is used to connect the room thermostat TA. Remove the bridges from terminals 12-13 and 15-16 if an RVA 43.222 control unit or temperature control interface kit is installed. Remove the bridge from terminals 22-23 if the flue gas damper is installed. Connect up the pumps (PB-PI) as shown in the wiring diagram only if an RVA 43.222 control unit or temperature control interface kit is installed.

12
2.6
Identification
b If these plates or any other means of clearly identifying the product are defaced, removed or lost, proper instal-
lation and servicing may be rendered difficult.
Data plate
This lists the boiler’s technical specifications and perfor-
mance. It is located in the document bag supplied with the
boiler, and must be applied at the top front of one of the side
panels.
Gas plate
Must be applied near the data plate and specifies the type
of gas used by the boiler, and the country in which the boiler
is destined for use.
Serial number plate
This is located on the boiler body and specifies the serial
number.
Fig. 2.4
Novella MAXIMA boilers are identified by:
G4SK99999999
WEEK OF PRODUCTION
0123456789

13
Fig. 2.5
Fig. 2.6
Fig. 2.7
2.7
Unpacking the product
Novella MAXIMA boilers are delivered in
three separate packs, containing:
PACK no. 1 (Fig. 2.5)
The cast iron boiler body, strapped to a pallet.
Documentation envelope.
PACK no. 2 (Fig. 2.6)
A wooden crate containing:
- the flue gas hood, to be assembled
- casing panels
- a number of burner tubes correspond-
ing to the number of elements in the
body minus one
- burner manifold
- a plastic bag containing:
- 13 screws (M5 x 8) for fixing the burn-
er tubes to the burner manifold
- 32 x self-tapping screws (12E x 1/2”)
for assembling the various parts of
the flue gas box and casing
- 4 x bolts (M8x30) with bracket, flat
washer and M8 nut for fixing the flue
gas box to the boiler body
- 1 x 3/4” drain cock complete with
plug.
PACK no. 3 (Fig. 2.7)
A cardboard box containing:
- preassembled gas valve
- electric power panel
- control panel
- flue gas thermostat.
b The instruction manual is an integral
part of the boiler. Once located, read it
thoroughly and keep it safe.

14
2.8
Overall dimensions and weights
P
L
H
P1
Fig. 2.8
Fig. 2.9
2.9
Handling
bUse equipment adequate for the weight
involved to move the boiler to the place
of installation.
bMake sure that the boiler does not strike
rigid surfaces like floors or walls when it
is being moved.
- Remove the straps securing the cast iron
boiler body to its pallet.
- Pass lifting slings through the cast iron
body. Lift carefully and position at the place
of installation.
b Wear suitable personal protective equip-
ment and use suitable safety devices.
b The boiler is supplied without a base.
Place a suitable sheet of metal under
the boiler to protect the floor surface.
Description 129 151 172 194 215 237 258 279
L 810 920 1030 1145 1255 1370 1480 1580 mm
P 1110 1110 1110 1140 1140 1190 1190 1190 mm
P1 880 880 880 880 880 880 880 880 mm
H 1365 1365 1365 1365 1365 1365 1365 1365 mm
Net weight of boiler 542 612 682 757 829 904 974 1044 kg

15
≥0,6 m P≥0,6 m
≥0,6 m L
≥0,6 m
H
≥
2,30 m
2.10
Place of installation
Novella MAXIMA boilers must be installed in rooms with vents that conform to applicable tech-
nical standards and safety legislation.
b When installing the boiler, allow sufficient
space around it to access all safety and con-
trol devices and to permit easy maintenance.
b Make sure that the boiler’s index of elec-
trical protection is adequate for the char-
acteristics of the room where it is to be
installed.
b The boiler must be installed in a room
with adequate ventilation, in conformity
to applicable standards.
b If the specific weight of the gas supply to the
burner is greater than the specific weight of
air, all electrical parts must be installed at
least 500 mm above floor level.
a These boilers must be installed indoors.
They are not designed for outdoor use.
NOTE: See the table on the previous page for boiler dimensions.
Fig. 2.10

16
2.11
Installation in older systems
and systems requiring mod-
ernisation
2.12
Central heating system water
quality requirements
When installing Novella MAXIMA boilers in
older systems or systems requiring moderni-
sation, always perform the following checks.
- Make sure that the flue is able to withstand
the temperature of the combustion gases
and that it has been designed and made
in compliance with applicable standards.
The flue must also be as straight as possi-
ble, sealed, insulated and not blocked or
choked.
- Make sure that the electrical supply system
has been installed by a qualified electrician
in compliance with applicable standards.
- Make sure that the fuel supply line and
fuel storage tank (if present) are made
and installed in compliance with applicable
standards.
- Make sure that expansion vessel is big
enough to contain the additional volume
generated by thermal expansion.
- Make sure that flow rate, head and direction
of flow of the circulation pumps are suitable
and correct.
- Make sure that the central heating circuit has
been flushed out to remove all sludge and
lime scale, and that it has been bled and
seal tested.
b The manufacturer declines all responsi-
bility for damage caused by incorrectly
constructed flue systems.
If your Novella MAXIMA boiler is to be
installed in an older system or a system
requiring modernisation, make sure that a
suitable water treatment system is installed
if the quality of the supply/recirculation water
so demands. (Refer to the values listed in the
table.)
aIt is forbidden to fill or top up the central
heating circuit while the boiler is func-
tioning. Doing so may cause serious
damage to the boiler.
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 less than 35°F
Sulphur ions none
Ammonia ions none
Silicon ions less than 30 ppm

17
3 INSTALLATION
3.1
Assembling the boiler
Lift the boiler and manoeuvre it into position
in the room where it is to be installed (see the
"Handling" section on page 14).
b The boiler is supplied without a base.
Place a suitable sheet of metal under
the boiler to protect the floor surface.
3.1.1 Assembling the flue gas
box
The flue gas box comes in four parts and
must be assembled using the screws provid-
ed (Fig. 3.1). Fix the right hand side panel (2)
to the top panel (1) with nine self-tapping hex
head screws (12E x 1/2”).
Repeat this operation to fit the left panel (3).
Finally, fit the cleaning access panel (4). On
completion of assembly, install the flue gas
box on top of the cast iron boiler body.
Fix the flue gas box to the cast iron body
using the four brackets (6), four M8 x 30 hex
head bolts (5), four M8 nuts (8) and ø 8.4
washers (7) (Fig. 3.2).
3.1.2 Moving the flow-return fit-
tings to the other side
The boiler comes with the flow and return
fittings on the right side of the cast iron body.
If you need to move the fittings to the left side
of the body, simple remove the nuts (9) and
reverse the positions of the fittings and the
plugs on the other side of the cast iron body
(Fig. 3.3).
b The water distributor must then be repo-
sitioned as described in the next sec-
tion.
b To ensure efficient water distribution
inside the cast iron boiler body, the cen-
tral heating flow and return pipes must
both be connected to the same side of
the boiler.
9
5
7
8
6
1
2
4
3
Fig. 3.1
Fig. 3.2
Fig. 3.3

18 1
3
4
5
2
16 17
18
10
11
13
14
15
12
12
3.1.3 Reversing the water distrib-
utor
The water distributor on the central heating
return line comes fitted to the right of the cast
iron body.
If you need to move it to the left side of the
body, make sure that the two rows of holes in
the distributor face upwards and towards the
front of the boiler (Fig. 3.4).
Novella Maxima model 129 N RAI does not
have a water distributor.
3.1.4 Fitting the burner manifold
To fit the burner manifold (16), screw the four
M8 x 16 hex head screws (17) into the thread-
ed tabs in the two heads of the boiler body
(18) (Fig. 3.6).
3.1.5 Fitting the burner tubes
Once the burner manifold (3) is in place,
insert one of the burner tubes (2) into the boil-
er’s combustion chamber (1), so that the slots
face up. Push the support (5) of the burner
tube into the hole in the cast iron wall between
the elements (Fig. 3.5).
Fix the burner tube to the manifold with one
flat head M5 x 8 screw (4).
Fig. 3.5
Fig. 3.4
Fig. 3.6
LEGEND
10 Boiler body
11 Stud, M12 x 60
12 Seal, ø 65/95 x 2
13 Distribution pipe
14 Collar flange, DN50 2”
15 Nut, M12

19
1
2
3
4
8
5
10
11
9
6
12
7
Fig. 3.8
Fig. 3.7
3.1.6 Fitting the casing and gas
valve
Perform the following operations (Fig. 3.7, Fig.
3.8, Fig. 3.9, Fig. 3.10) to assemble the boiler
casing and gas valve.
- Fix the two panels (1) and (2) to the flow
and return plugs using the plugs’ own fixing
nuts.
- Fit the cock (3) in the return plug.
- Place the front and rear supports of the
casing base (4) between the feet of the two
boiler heads.
- Fix the side supports (5) and (6) to the front
and rear of the casing base (4) using the M6
nuts provided.
- Fix panel (7) to panel (8) and fix panel (10)
to panel (11) by means of their push-fit pins.
- Fix panels (7-8) to panel (9) and fix panels
(10-11) to panel (12) by means of their
push-fit pins, and secure them with two
self-tapping 7SP x 1/2” screws.
- Fix panels (7) and (9) to the base (6) using
the push-fit pins. Fix panels (10) and (12) to
the base (5) in the same way.

20
20 20
21
22
23
4
8
16
14
5
10
13
18
19
17
15 11
9
6
12
7
Fig. 3.9
Fig. 3.10
- Fit the bottom front partition (14) between
the screws in the burner manifold brackets
and the cast iron body. Fix the partition to
the panels (9) and (12) using two self-tap-
ping 7SP x 1/2” screws.
- Fix the top front partition (15) to panels
(8-11) and partition (14) using four self-tap-
ping 7SP x 1/2” screws.
- Fix the rear partition (16) to panels (7-8) and
(10-11) using the eight self-tapping 7SP x
1/2” screws provided.
- Unscrew the three part union (22) to release
the pipe (21) from the gas valve (23) and
connect it to one of the two fittings (20) of
the burner manifold. Fit the gas valve (23)
and the pipe (21) using the three part union
(22) (Fig. 3.9).
b If the gas valve is fitted on the left of
the manifold, remove the gas valve and
rotate it through 180°, so that the con-
trols can be accessed from the front.
- Fix the base (17) to the panels (9) and (12)
by means of the push-fit pins.
- Fit the top front panel (19) in the same way.
- Fit the top panel (13) and bottom front panel
(18).