Beretta Power Plus Box 1001 INT User manual

Installation Manual
CONDENSING
Power Plus Box 1001 INT-EXT
Installation Manual
EN

This manual, Code 20073959 - Rev. 4 (12/15) comprises 40 pages.
2
RANGE
MODEL CODE
Power Plus Box 1001 INT 20067835
Power Plus Box 1001 EXT 20067836
CERTIFIED COMPANY
UNI EN ISO 9001:2008
UNI EN ISO 14001:2004
This manual, Code
- Rev.
comprises
pages.
ENGLISH
Contents
CONTENTS
The following symbols are used in this manual:
b
CAUTION! = Identifies actions that require caution
and adequate preparation.
a
STOP! = Identifies actions that you MUST NOT do.
1 GENERAL INFORMATION ................3
2 WARNINGS ............................3
3 TECHNICAL FEATURES .................4
3.1 Main features ............................ 4
3.2 Advantages.............................. 5
3.3 Safety devices............................ 5
3.4 Components ............................. 6
4 INSTALLATION.........................9
4.1 Product packaging and identification.......... 9
4.2 Installation premises ....................... 9
4.3 System cleaning and water treatment ........ 10
4.4 General instructions ...................... 10
4.5 New heating systems ..................... 10
4.6 Upgrading existing systems ................ 10
4.7 Corrosion............................... 10
4.8 Positioning and preparation for installation..... 11
4.9 Condensate outlet........................ 11
4.10 Water circuit ............................ 12
4.11 Exhaust flue............................. 12
5 INSTALLATION DIAGRAMS .............12
6 ELECTRICAL SYSTEM .................14
6.1 Power supply ........................... 14
6.2 Electrical connections..................... 14
6.2.1 Connection to mains ...................... 14
6.2.2 Connection to thermoregulators ............. 15
6.2.3 Connection to pumps ..................... 15
6.2.4 Connection to room thermostats (on/off) ...... 15
6.2.5 Connection to weather temperature probe..... 15
6.2.6 Frost protection .......................... 16
6.2.7 Connection to 0-10v external thermoregulator .. 17
6.2.8 Connection to alarm device ................ 17
6.3 Emergency mode ........................ 17
7 GAS VALVE CALIBRATION ..............18
8 USE AND ADJUSTMENT ................19
8.1 Control panel: description.................. 19
8.2 Display mode ........................... 20
8.3 Display mode ........................... 20
8.4 Changing the user parameters .............. 21
8.5 Monitor mode ........................... 21
8.6 Installer programming mode................ 22
8.7 Test mode .............................. 23
8.8 Error mode ............................. 23
8.9 Permanent block ......................... 23
9 SETTING FUNCTIONING PARAMETERS ...24
9.1 Setting the heating parameters.............. 24
9.2 Setting the DHW parameters ............... 25
9.3 Heat control setting....................... 26
10 LIST OF PARAMETERS .................31
11 ERROR LIST ..........................33
11.1 Master board errors ...................... 33
11.2 Slave board errors ....................... 33
12 WIRING DIAGRAMS....................35
13 TECHNICAL SPECIFICATIONS ...........37

3
1 GENERAL INFORMATION
Dear Customer,
congratulations on your choice and thank you for placing
your confidence in our products. With Power Plus Box 1001
you have chosen technology that is the very essence of
energy saving and functionality.
Moreover, all Bproducts conform to the strictest
directives and European standards in force.
This product was produced, amongst others, in conformity
to the following directives and standards:
- Directive 2009/142/EC - Gas Appliances
- Directive 92/42/EEC on efficiency requirements
and Annex E and Pres. Republic Decree n. 412, 26
August 1993 (****)
- Electromagnetic Compatibility Directive 2004/108/EC
- Low Voltage Directive 2006/95/EC
- Ecodesign Directive 2009/125/CE for energy-related
products
- Delegated Regulation (EU) N. 813/2013
- EN 15417 Gas-fired central heating boilers - Specific
requirements for condensing boilers with a nominal
heat input greater than 70 kW but not exceeding
1000 kW
- EN 13836 Gas fired central heating boilers - Type B
boilers of nominal heat input exceeding 300 kW, but
not exceeding 1000 kW.
The Power Plus Box 1001 condensing modular systems
moreover conform to the regulatory provisions pursuant to
the INAIL “R” File, section R.3.B.
Bhas been certified with UNI EN ISO 9001/2000 since
22.07.2004.
Power Plus Box 1001 is furthermore a product having to its
credit:
- European Conformity Mark (based on Directive
92/42/CEE) issued by the authorized German
certification organization ;
- Maximum energy efficiency class (according to
Directive 92/42/EEC) identified by the symbol ****;
- Classified in the strictest class for nitrogen oxide-
related pollution (fifth grade according to UNI EN
297)
- Patented heat exchanger.
2 WARNINGS
b The heating unit must be used for the purpose for
which it was specifically designed and produced. Any
whatsoever contractual or extra-contractual liabilities
for damages caused to persons, animals or objects
due to errors in installation, adjustment, maintenance
and improper usage are to be excluded.
b Installation must fully comply with provisions of
the law in force and instructions provided by the
manufacturer to ensure safety and correct functioning,
always calling upon professionally qualified technical
personnel who will issue the declaration of conformity
for the installation accomplished with good
workmanship, in compliance to regulatory provisions
in force and guidelines given in this handbook. The
appliance must be installed in appropriate premises
and together with the specific systems installed
according to the law.
b Commissioning will be carried out by personnel from
the authorized Technical Assistance Centre only and
within 8 days from when the appliance was installed.
After initial ignition the Technical Assistance Centre
will fill in the warranty certificate, leaving the user their
part to be kept, marking the beginning of the period
of guarantee at the terms and conditions specified
on the relative slip.
The appliance in its original packing
may be exposed to temperatures between 4°C and 40°C.
Do not expose the appliance to bad weather conditions
after it has been unpacked, anyhow to temperatures
below 4°C or above 40°C until it has been connected
up to the water, gas and electricity mains so as to be
able to activate the frost protection systems described in
paragraph 6.2.6.
b
Check that the product is complete, undamaged
and as ordered as soon as you receive it. Report any
discrepancies or damage to the Bdealer who sold it.
b
In case of leaks, disconnect the heating unit from the
mains, close the water from the mains and promptly
contact the Technical Assistance Centre.
b
Regularly check that the condensate drain is free from
obstruction.
b
Regularly check that the working pressure of the water
circulation system, when cold, is below the maximum limit
specified for the appliance. If not, contact the Technical
Assistance Centre.
b
Maintenance jobs on the heating unit must be carried out
by personnel from the authorized Technical Assistance
Centre. Maintenance must be performed at least once a
year. Correct maintenance is essential for safety as well
as for the efficiency and long working life of the product.
Proper maintenance keeps consumption and emissions
down, and ensures that the product continues to operate
reliably over time. Analyse the combustion fumes before
commencing maintenance. The results of fume analysis
can give a clear idea of what servicing or repairs are
needed.
b
We recommend cleaning inside the exchanger once
a year, extracting jet and burner and removing any
installation debris by suction. This operation will be done
by personnel from the Technical Assistance Centre only.
b
The warranty slip endorsed during the course of
commissioning will have to be produced for any servicing
required during the guarantee period. The manufacturer
shall not be held liable for any damages caused by
mishandling, improper use or errors in installation, use
and maintenance work on the appliance. In the event
of breakdown or malfunction switch off the appliance,
avoiding to make any attempt to repair it and contact the
Technical Assistance Centre.
b
This manual must be read carefully for the boiler to be
used rationally and safely, and must be kept with care
so as to be on hand where required by the technician or
installer, to facilitate the appropriate installation, running
and maintenance of the boiler. Bwill not be held
liable for any translations possibly giving rise to wrong
interpretation. This manual is an integral part of the
heating unit and must consequently be kept with care
and must ALWAYS accompany the boiler even when
passed on to another owner or user or transferred to
another installation. Ask the Technical Assistance Centre
for another copy if it should be lost or damaged.

4
a
Children and people with disabilities or without
experience and specific knowledge are forbidden to use
the heating unit unless they are assisted by a qualified
person responsible for their safety. It is forbidden to use
electrical devices or equipment, such as switches,
appliances, etc. if there is a smell of gas or un-burnt
products. If so:
- ventilate the room, opening doors and windows;
- close the gas valve at the mains;
- immediately call in the Technical Assistance Centre
or professionally qualified personnel.
a It is forbidden to touch the heating unit with bare feet
or parts of the body wet.
a It is forbidden to start on any technical or cleaning
jobs before disconnecting the heating unit from the
power mains.
a It is forbidden to alter the safety and adjustment
devices without permission and instructions from the
heating unit manufacturer.
a It is forbidden to obstruct the condensate drain.
a It is forbidden to pull, detach, twist the wiring coming
out of the heating unit, even if unplugged from the
power supply.
a It is forbidden to obstruct or reduce the size of air
vents.
a It is forbidden to expose the boiler to atmospheric
agents (if it is not a specific unit for outdoors).
a It is forbidden to leave containers or flammable
substances in the premises 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.
a The user is forbidden to open the cupboard containing
the heating unit. Any jobs on the inside of the latter
must be done by the Technical Assistance Centre or
by qualified personnel.
a It is forbidden to discard the product as household
waste. At the end of its service life, it can be
consigned to specific selected waste centres
provided by the local authorities or else to dealers
providing this service. Disposing of a domestic
appliance separately will prevent possible harmful
consequences for environment and health derived
from inappropriate disposal, likewise making it
possible to recuperate the materials it is made of with
substantial savings in energy and resources.
3 TECHNICAL FEATURES
3.1 Main features
Power Plus Box 1001 is a modular condensing, premixed,
jet heating unit, comprising a modular unit at 26 to 128 kW
equipped with weather adjustment device.
The efficiency of the generators reaches 109% based
on the lower heat potential of natural gas (Hi) making it
possible to use a flue manifold entirely made of plastic
(PP). The system also enables continual modulation of the
gas and combustion air flow.
The
Power Plus Box 1001 heating unit is the optimum as far
as operating costs (up to 109% efficiency per Hi, see Figure
1), reliability and flexibility is concerned. Rapid connection
to any type of heating and domestic hot water system
with accumulation is in fact possible owing to a special
more powerful heat exchanger, new electronic control,
modulating electronic circulator and high efficiency.
Furthermore, the “master” board, supplied with each
heating unit, ensures the latter a simple conFiguretion and
enables it to be adapted to any type of system, optimizing
its performance in terms of creating comfort and cutting
down on consumption.
All the safety devices provided in the INAIL “R” File for
this particular application, have been installed on the flow
manifold, downstream from the last combustion unit.
A special water compensator is housed inside the hood
with attachments for simple connection to the systems
directly controlled by the master board which is supplied
with the heating unit:
- Direct system (high temperature)
- Mixed system (low temperature)
- Hot water system.
Distribution units are available as an accessory for each of
the above mentioned systems.
The heating unit thus becomes a complete, versatile
functional “system” to install in a variety of plant typologies.
All the systems and relevant functional components
(circulators, mixer valve and temperature probe) are
entirely controlled by the master board and are connected
up to the latter, without the help of additional boards.
Room thermostats in the unit’s system-related areas can
also be connected up to said board.
The system can also be extended to numerous additional
zones by a board called “zone master”, which is not
included in this manual.

5
Figure 1
3.2 Advantages
- Totally pre-mixed micro-flame jet burner;
- condensing stainless steel exchanger, with efficiency
up to 109% (see Figure 1);
- maximum exhaust flue exit temperature 80°C;
- PPS plastic exhaust flue manifold, self-extinguishing
(see paragraph 4.11);
- modulating electronic primary circulator at low
consumption;
- weather temperature adjustment device supplied;
- hot water and systems control at different
temperatures, with or without function priority;
- automatic summer/winter switch-over;
- minimum flow capacity of thermal carrier fluid
controlled by a differen-tial pressure switch;
- compensator with inner partition for connection to
three systems;
- INAIL safety organs mounted in factory;
- appliance complete and ready to be connected up to
the installation.
3.3 Safety devices
All the heating unit functions are electrically controlled and
any fault will cause arrest of the heating unit and the gas
valve to automatically close.
The water circulation system includes:
- automatic resetting safety thermostat;
- differential water pressure switch acting as a
flowmeter;
- temperature probe on flow and return controlled
by a certified electronic device to carry out safety
functions with dual-processor technology. The
flow temperature is continually controlled by these
devices as well as the Δt between flow and return by
acting on the primary circulator modulation;
- modular flow temperature adjustment.
The combustion system includes:
- gas solenoid valve in B+C class with pneumatically
compensated gas flow dependent on air intake flow
capacity (air/gas ratio 1:1);
- ionization electrode for continual flame control;
- exhaust flue duct temperature control.
Protective actions and therefore closure of gas valves on
each heating unit are activated in the following cases:
- flame burnt out;
- over-temperature in exchanger system;
- high temperature of exhaust fumes;
- reduced air flow.
a The appliance must not be started up, even
temporarily, where the safety devices have been
mishandled or excluded.
b Safety devices must be replaced by the authorized
Technical Assistance Centre only, exclusively using
original parts.

6
3.4 Components
Power Plus Box 1001 comprises a metal cupboard
containing the condensing combustion unit connected to
a separator, also acting as a distribution organ to three
distinct systems (high T, low T and hot water), see diagram
in Figure 2.
Figure 2
1 Heat exchanger
2 Burner
3 Jet
4 Venturi tubes
5 Gas valve
6 Vent valve
7 Safety thermostat
8 Min. and differential pressure
9 Flow temperature control
10 Return temperature control
11 Flue temperature control
12 Return pipe
13 Flow pipe
14 Gas pipe
15 Air inlet
16 Exhaust flue duct
17 Condensate outlet
18 Condensate manifold
19 Two-way gas valve
20 Fuel check valve
21 Separator
22 Separator drain cock
23 Separator vent valve
24 Modulating circulator
25 VIC probe pit
26 Safety valve
27 Max. INAIL pressure gauge
28 INAIL gauge
29 INAIL thermometer
30 Expansion tank opening

7
DIMENSIONS AND CONNECTION POSITIONS
Power Plus Box 1001 INT
Figure 3
Power Plus Box 1001 EXT
Figure 4
1 Flow low temperature
2 Return low temperature
3 Flow high temperature
4 Return high temperature
5 Return high temperature
6 Return hot water
7 Flow low temperature*
8 Return low temperature*
9 Return high temperature*
10 Return hot water*
11 Condensate outlet
12 Exhaust flue duct
13 Gas inlet

8
SYSTEM COMPONENTS
Figure 5
1 Hydraulic separator
2 Flow pipe
3 Return pipe
4 Gas pipe
5 Vent valve
6 Cock
7 Drain cock
8 Temperature gauge
9 Gauge fitting with cock
10 Damper device for gauge
11 Pressure gauge
12 Thermometer pit
13 Maximum pressure switch
14 Fuel check valve
15 5.4 bar safety valve
16 Expansion tank/filling fitting
17 Flow probe pit
18 Exchanger
19 Burner
20 Fan
21 Venturi tubes
22 Air inlet pipe
23 Gas valve
24 Exhaust flue duct
25 Condensate drainpipe
26 Vent valve
27 Ignition detection electrode
28 Safety thermostat
29 Gas cock
30 Diff. Pressure switch
31 Condensate drain manifold
32 Return probe
33 Exhaust flue probe
34 Master board
35 Slave board
36 Pump control board
37 Flow hot water system connection
38 Return hot water system connection
39 Flow high temperature connection
40 Return high temperature connection
41 Flow low temperature connection
42 Return low temperature connection
43 Modulating circulator

9
4 INSTALLATION
b
Power Plus Box 1001 heating units must be installed
in conformity to the latest provisions of the law
and standards in force concerning heating units,
condensing boilers and/or other applicable regulatory
provisions.
4.1 Product packaging and
identication
The Power Plus Box 1001 heating unit is supplied, packed
and protected by a strapped carton.
Figure 6
1 Boiler
2 Control panel
3 EC marking/Symbol cartouche
4 Packaging
5 Polyester corners
6 Polyester protection panel
7 Strap
Details of the product are written on the outside: model,
power, version and type of fuel. Contact your local dealer
in case of any differences with the order.
Ensure the goods are intact and complete after unpacking
them.
b Do not leave the packaging within the reach of
children as it could be a potential source of danger.
The tag on the front side of the boiler’s electrical board,
contains the following information:
- Product name
- Serial number
- Product identification code
- CE certification number
- Gas type and pressures from mains
- Power type from mains
- Rated heat capacity (Qn)
- Rated working power (Pn)
- Efficiency according to 92/42/EEC Directive (η)
- Max pressure and temperature (Pms)
- Primary system (T)
- NOx class (NOx)
Figure 7
a It is forbidden to remove or mishandle the identification
plates, markings and any other making it difficult to
safely identify the product.
CONNECTION DIMENSION
CONNECTION
TYPE
REMARKS
Water
distribution 2” Threaded
Flow/return
connections
for hot water,
high/low
temperature
systems
Gas fitting 1” Threaded
Exhaust flue
duct Ø110 Socked
Piping in
plastic
material
allowed
Condensate
outlet 50 mm Socked
See
paragraph
4.1.8
4.2 Installation premises
The heating unit must be installed in premises used
exclusively for the latter conforming to standards and
legislation in force and where combustion exhaust
products and combustion air intake is conveyed out of said
premises. Where combustion air is instead taken from the
installation premises then the latter must be equipped with
suitably sized vents conforming to standards.

10
b The space required to reach the safety and
adjustment devices and to carry out maintenance
must be considered. We recommend leaving a space
of at least 500 mm at the back of the appliance.
b Ensure that the degree of the heating unit’s electrical
protection is compatible with the characteristics of
the installation premises.
b Electrical parts must be placed at a height of no less
than 500 mm from the ground where heating units are
supplied with fuel gas with specific weight exceeding
that of air.
b Heating units may not be installed out in the open
(unless they are not specific outdoor units).
b The heating unit is equipped with a frost protection
function, useful for installations where the temperature
of the environment could be below 0°C. Gas and
electricity must be supplied for this system to work,
apart from a correctly pressurized water circulation
system and the system must not be in shutdown due
to any type of error.
4.3 System cleaning and water
treatment
It is ABSOLUTELY NECESSARY to treat the water system
for the heating unit to work properly and to guarantee its
service life together with all its components.
This not only applies to jobs carried out on existing
installations but also on new installations.
Sludge, lime-scale and pollutants present in the water can
cause permanent damage to the heating unit, also within
a short time and regardless of the quality standards of the
materials used.
Contact the Technical Assistance Centre for any further
information on type and use of additives.
Chemical-physical characteristics of the water must
conform to the European CSN EN 14868 standard and to
the table given here below:
Initial
filling
water
Regular
service
water (*)
ph 6-8 7,5-9,5
Hardness < 10° < 10° °fH
Electrical
conductivity < 150 μs/cm
Chlorides < 20 mg/l
Sulphides < 20 mg/l
Nitrides < 20 mg/l
Iron < 0,5 mg/l
(*) Value of water in circulation system after functioning for
8 weeks.
b Where softened water is used it is compulsory
to re-check conformity to tolerances for water in
regular service after 8 weeks from topping up and in
particular the electrical conductivity.
b No controls are required when using de-mineralized
water.
4.4 General instructions
b An automatic filling system may not be used for
topping up, which must be done manually and
recorded in the unit handbook.
b If there are more than one boiler, they must all be
put into service either contemporarily or with a very
low rotation time during the initial period of service,
so as to evenly distribute the limited quantity of initial
lime-scale.
b A flushing cycle must be programmed after the plant
has been installed to flush out any installation debris.
b Water used for filling or for eventually topping up the
system must always be filtered (synthetic or metal
mesh filters with filtering capacity of no less than
50 micron) to avoid deposits possibly triggering off
under-deposit corrosion.
b The heating system must be flushed out and cleaned
with good workmanship before filling up the existing
systems. The boiler may not be filled until after the
heating system has been flushed out.
4.5 New heating systems
b The system must be filled up slowly the first time;
once it is filled and the air expelled it should never
need to be topped up again.
b The system must be turned to maximum service
temperature during the initial ignition to facilitate
deaeration (a too low temperature prevents the gas
from coming out).
4.6 Upgrading existing systems
Where the boiler has to be replaced it is not recommended
to fill up again if the quality of the water in the existing
systems conforms to specifications. If the quality of water
fails to conform to specifications, we recommend either
re-treating it or separating the systems (the water quality
requirements must be respected in the boiler system).
4.7 Corrosion
Under-deposit corrosion
Under-deposit corrosion is an electrochemical process,
due to the presence of sand, rust, etc., inside the mass
of water. These solid substances generally deposit on the
bottom of the boiler (sludge), on tube and pipe heads or in
the gaps between pipes and tubes.
Micro-corrosion phenomena may be triggered off owing
to the difference in electrochemical potential coming to be
created between the material in contact with the impurity
and the surrounding one.
Corrosion from stray currents
Corrosion from stray currents can occur due to the differing
electrical potentials between water in the boiler and the
metallic mass of the boiler or piping. This process leaves
unmistakeable traces i.e. small regular conical holes.