PENSOTTI PCC 34-H Instruction Manual Download | Manualshive

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INSTALLATION INSTRUCTIONS

16

3. INSTALLATION

(authorized personnel)

3.1 Reference standard

Install in accordance with local building and electrical codes.

Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution. It is
in the interest of the installer and safety that the codes are complied with.

The manufacturer

’s instructions form an integral part of the installation and should be left with the appliance but do

not over ride in anyway statutory obligations.

Installation requirements

Please refer to local and national standards in force with the Country of destination of the product.

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Summary of Contents for PCC 34-H

Page 1: ...e WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service be performed by a qualified installer service agency or the gas supplier Use ...

Page 2: ... 3 Installation boiler 18 3 4 Water connections 19 3 5 Domestic Hot Water Circuit Hard Water Warning Expansion Tank 20 3 6 Piping Diagram 21 3 7 Condensate Drain 22 3 8 Gas connection 23 3 9 Electrical connections 25 3 10 Venting connections 28 4 Commissioning the appliance authorized personnel 4 1 General warnings 37 4 2 Filling the system 38 4 3 Flushing the system 39 4 4 Filling the condensate ...

Page 3: ... 52 6 4 Accessing the boiler 53 6 5 Flushing out the primary side 53 6 6 Draining the central heating and domestic hot water system 54 6 7 Maintenance operations 55 6 8 Wiring diagrams 61 6 9 D H W sensor connection 64 6 10 Troubleshooting 65 6 11 Diagnostics 66 6 12 Parts list 67 6 13 Cycle Sequence Flow Chart 68 ...

Page 4: ...be completely expelled out of the building Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and replace any part of the control system and any gas control which has been underwater Be sure not to reverse the water and gas connections as this may damage the gas valves Water temperatures over 125 F can cause severe bur...

Page 5: ... flammable liquids or engine driven equipment or vehicles are stored operated or are repaired Flammable vapors are heavy and travel along the floor and may be ignited by the igniter or main burner flames causing fire or explosion Some local codes permit operation of gas appliances if installed 18 inches or more above the floor This may reduce the risk if location in such an area cannot be avoided ...

Page 6: ...upply valve at the meter or on the cylinder in the case of bottled gas and call an authorized service center Do not attempt to interfere with the appliance in any way As dictated by current legislation this appliance must be installed exclusively by qualified personnel Before starting the boiler for the first time make sure that it is connected to a water supply and central heating system compatib...

Page 7: ... of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision cannot ...

Page 8: ...GENERAL INFORMATION 5 ...

Page 9: ...GENERALInformation 6 ING ...

Page 10: ...GENERALInformation 7 ...

Page 11: ...GENERALInformation 8 ...

Page 12: ...etc form a compact uniform highly functional unit that is easy to install and simple to operate In its simplicity the wall mounted appliance is equipped with all the appropriate accessories required to make it a fully independent boiler capable of satisfying domestic hot water production and central heating needs This manual must be kept in a safe place and must accompany the boiler at all times G...

Page 13: ... 29 Domestic Hot Water circuit D H W temperature setting min max C F 35 70 95 160 Max Hot water working pressure bar psi 6 86 Min Hot water working pressure bar psi 0 5 7 16 Dimensions Boiler casing size Width in 16 1 Height in 28 7 Depth in 12 2 Weight net lb 88 Hydraulic connections Central Heating Flow connection Soldier 3 4 Central heating Return connection Soldier 3 4 Central heating flow con...

Page 14: ... 2 28 7 HF CWI G HR HWO 2 7 1 9 3 1 3 2 4 1 2 12 2 28 7 4 4 7 3 4 4 1 9 12 3 1 9 4 9 2 2 Dimensions LEGEND HR HEATING RETURN Ø 3 4 HF HEATING FLOW Ø 3 4 G GAS Ø 1 2 CWI COLD WATER INLET Ø 1 2 HWO HOT WATER OUTLET Ø 1 2 SC CONDENSATE DRAIN Ø 0 98 in ...

Page 15: ... VENTURI 10 FAN 11 AUTOMATIC AIR VENT VALVE 12 PUMP 13 SAFETY VALVE 3 4 14 SYSTEM DRAIN VALVE 15 AUTOMATIC BY PASS 16 AIR PRESSURE SWITCH 17 EXPANSION VESSEL 18 IGNITION TRANSFORMER 19 IGNITION ELECTRODE 20 ELECTRONIC GAS VALVE 21 ROOM SEAL CHAMBER BACK SIDE 22 LOW WATER CUT OUT SWITCH 23 CONDENSATE TRAP 24 DIVERTER VALVE ACTUATOR UL CSA 25 NO RETURN VALVE 26 WATER PRESSURE GAUGE 27 FILLING TAP 4 ...

Page 16: ... SAFETY THERMOFUSE 2 AIR PRESSURE SWITCH 3 HEATING SAFETY THERMOSTAT 4 HEATING SENSOR 5 PREMIX BURNER UNIT GAS MANIFOLD BURNER 6 PRIMARY CONDENSING HEAT EXCHANGER 7 EXPANSION VESSEL 8 FAN 9 ELECTRONIC GAS VALVE 10 AUTOMATIC AIR VENT VALVE 11 PUMP 12 AIR VENT VALVE 1 4 13 SAFETY VALVE 3 4 14 FLUE HOOD 15 16 IGNITION TRANSFORMER 17 IGNITION ELECTRODE 18 IONISATION ELECTRODE 19 DIVERTER VALVE ACTUATO...

Page 17: ...TECHNICAL CHARACTERISTCS 14 Water flow US gpm 0 2 4 6 8 10 12 14 16 18 20 0 1 2 3 4 5 6 7 8 9 Head ft 2 5 Circulation pump head flow graph ...

Page 18: ... mode selection Operation Functions display Lock Out Water deficiency indicator Temperature display When the boiler is switched off at the switch on the control panel the word OFF appears on the display The D H W and central heating frost protection system nevertheless remain enabled If the boiler was previously on it is switched off and the post ventilation pump overrun circulation pump and three...

Page 19: ...h the above norms could lead to prosecution It is in the interest of the installer and safety that the codes are complied with The manufacturer s instructions form an integral part of the installation and should be left with the appliance but do not over ride in anyway statutory obligations Installation requirements Please refer to local and national standards in force with the Country of destinat...

Page 20: ...a potential hazard A Place the packed appliance on the floor see fig 1 making sure that the up arrow is facing down Remove the staples and open out the four flaps of the box B Rotate the boiler 90 while manually supporting it from underneath C Lift the box and remove the protections Lift the boiler by grasping the rear part and proceed with the installation STORAGE HANDLING Please note that prior ...

Page 21: ...t the minimum distances indicated in figure 1 are respected To make the installation easier the boiler is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall To install the appliance proceed as follows see fig 2 a Use a level of not less than 24 long to mark a horizontal line on the wall where the appliance is to be fitted b Position t...

Page 22: ...tion kit see fig 2 A pressure relief valve is installed in this dual purpose boiler that is rated in accordance with and complying with either The Standard for relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems AINSI Z21 22 or The ANSI ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve must be installed such that the discharge will be conducted t...

Page 23: ...ding to the requirements of local standards This treatment is indispensable in the case where the circuit is frequently topped up or when the system is often either partially or fully drained In order to safeguard all waterside components the supplied Fernox Commissioning Kit Must be used in its entirety Condensate drain Refer to the city town or municipality have jurisdiction for codes regarding ...

Page 24: ...iameters between tees External Low Water Cut Off if required by local code Tempering Valve May be Required Consult Local Codes Must leave at least 15 of straight pipe on either side of closely spaced tees If NOT installing an indirect water heater directly to the boiler you must install a by pass using the supplied indirect water heater connections See page 20 for more information ...

Page 25: ...educe the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and cause appli...

Page 26: ...sing a gas leak detection device or by applying soapy water to all gas fittings Should bubbles occur tighten those connections and re test Always purge the gas line for any debris before connecting to the boiler gas inlet Never use an open flame to test for gas leaks as property damage personal injury or death could result The maximum inlet gas pressure must not exceed the valve specified by the m...

Page 27: ...1 2 3 4 1 1 1 4 1 1 2 2 10 275 567 1071 2205 3307 6221 20 189 393 732 1496 2299 4331 30 152 315 590 1212 1858 3465 40 129 267 504 1039 1559 2992 50 114 237 448 913 1417 2646 60 103 217 409 834 1275 2394 80 89 185 346 724 1086 2047 100 78 162 307 630 976 1811 125 69 146 275 567 866 1606 150 63 132 252 511 787 1496 LP Gas flow is given in thousands of BTU hr One cubic foot of LP gas 2516 BTU This ch...

Page 28: ... a structure utilizing a emergency stand by generator the installation of a surge capacitor surge protector line conditioner or equivalent is required If the boiler is to be installed in a structure where frequent power outages are experienced the installation of a surge capacitor surge protector line conditioner or equivalent is required Do not energize electric power to the unit until all plumbi...

Page 29: ...cian to ensure that it can support the maximum power absorption of the appliance as indicated on the rating plate In particular make sure that the cable sizes are adequate for the power absorbed by the appliance The power supply cable must be replaced by a qualified electrician If the cable is damaged in any way switch off the appliance and have the cable replaced by a suitably qualified electrici...

Page 30: ...reen yellow to the terminal marked with the earth symbol Connect the neutral wire normally coloured blue to the terminal marked with the letter N Connect the live wire normally coloured brown to the terminal marked with the letter L Terminals identified by the letters Ta Room thermostat or End Switch Se Outside temperature sensor Ta terminals are 24V DC Only a non power robbing battery operated th...

Page 31: ...red at the factory to be direct vent sealed combustion units which draw all of their required combustible air directly from outside the building All PENSOTTI boilers use a 3 5 concentric vent or a 2 pipes system that uses a 3 diameter exhaust and a 3 diameter air intake pipe Use only vent and air intake systems certified with the boiler The air intake vent materials can be made of ABS CPVC PVC mat...

Page 32: ...INSTALLATION INSTRUCTIONS 29 Venting Pictures Illustrations ...

Page 33: ...INSTALLATION INSTRUCTIONS 30 Included With Each Combination Boiler Is A PAHVK Horizontal Kit ...

Page 34: ...INSTALLATION INSTRUCTIONS 31 12 Clearance Suggested From The Top Of The Appliance To Ceiling 7 Top of Appliance to Center Line Of Hole 10 ...

Page 35: ...e below A maximum of 7 90 elbows may be installed in the complete intake air exhaust vent system When using PVC or CPVC fittings long sweep elbows are recommended The venting system must be installed by a licensed professional heating contractor who is familiar with the installation and operation of heating appliances and venting systems The venting system must be installed in accordance with all ...

Page 36: ...may be installed in the entire venting system Fittings equivalent length table Material 90 Elbow Long Sweep 45 Elbow 87 Elbow Polypropylene 2 3 PVC CPVC 5 3 If standard 90 PVC CPVC elbows are used the equivalent length is 8 per 90 elbow FOR EXHUAST VENT PIPE MATERIAL USE ONLY APPROVED POLYPROPYLENE EXHAUST PIPE DO NOT USE GALVANIZED PIPE PLASTIC PIPE OR CHIMNEY LINERS RIDGED OR FLEXIBLE OF ANY KIN...

Page 37: ...INSTALLATION INSTRUCTIONS 34 ...

Page 38: ...INSTALLATION INSTRUCTIONS 35 ...

Page 39: ...INSTALLATION INSTRUCTIONS 36 The termination shall be located no less than 48 above or to the side of the exhaust for any other oil gas or solid fuel appliance ...

Page 40: ... supply networks gas electricity water Check that the power supply voltage to the boiler complies with the rating plate 120 V 60 Hz and that the live neutral and ground wires are connected properly Also make sure that the ground connection is sound Check that the gas supply is correctly sized for the flow rate required by the boiler and that it is fitted with all the safety and control devices sti...

Page 41: ...completely from the air vent valve positioned on the top of the condensing exchanger fig 3 Open the air vents on the radiators and monitor the air evacuation process When water starts to flow out of the radiators close the air vents Use the pressure gauge M fig 2 to check that the system pressure reaches the middle of the green section 14 5 psi 1 bar and that the code H2O does NOT appear on the co...

Page 42: ...ll radiators and open the filling to fill the system f Continue to fill the system until the pressure gauge reads in the Green section of the gauge 14 5 psi 1 bar To flush out domestic hot water circuit a Open all hot water outlets b Turn on inlet group supply so water enters the boiler leave to fill until water is released from the hot water outlets Turn off all hot water outlets c Connect a hose...

Page 43: ...e repeated until all the air has been removed from the gas piping Check the water pressure in the system If the pressure has fallen introduce water into the appliance until the code H2O disappears on the display and the pressure gauge reads in the Green section of the gauge 14 5 psi 1 bar on completion Check gas pressure at gas valve inlet pressure tap SEE Fig 2 Set gas pressure to proper level at...

Page 44: ...t applicable for premix boilers 13 D H W priority function 2 min delay on D H W function 00 01 Off default On 14 Selects the type of burner 00 01 02 03 Atmospheric not premix 18 kW 34 kW 50 kW 15 Zone management activation Not Applicable 00 01 Off On 16 Telephone control Not Applicable 00 01 Off On 17 Minimum fan speed setting 60 Hz Natural Gas 60 Hz Propane To set the minimum frequency value Hz f...

Page 45: ...ff switch while keeping buttons and pressed Wait for P 00 to appear on the display 3 Release buttons and 4 Keep button S pressed and use button and to select the parameter to modify 5 Release button S then re press and release it The display will indicate the value of the parameter to modify Adjust the value of the parameter using the procedure described in the following pages P00 S S S S O FF P00...

Page 46: ... 00 Refer to section 3 6 Domestic Water Circuit for important information PARAMETER 2 GAS SUPPLY 6 Use buttons and to modify the value of the parameter 00 natural gas 01 lp gas 7 Press and release button S to confirm The parameter number 2 will appear on the display 8 Switch off the appliance and switch it back on again to render the new parameter operative PARAMETER 3 CENTRAL HEATING TEMPERATURE ...

Page 47: ... 7 Press and release button S to confirm The parameter number 5 will appear on the display 8 Switch off the appliance and switch it back on again to render the new parameter operative PARAMETER 6 CENTRAL HEATING TIMER Electronically timed heating differential 6 Use buttons and to modify the value of the parameter within the prescribed limits 00 0 x 5 sec 0 sec 90 90 x 5 sec 450 sec 7 5 min The def...

Page 48: ...the value of the parameter within the prescribed limits 00 0 x 5 sec 0 sec 90 90 x 5 sec 450 sec 7 5 min The default value is 18 90 sec 1 5 min 7 Press and release button S to confirm The parameter number 8 will appear on the display 8 Switch off the appliance and switch it back on again to render the new parameter operative PARAMETER NO 9 Not applicable for premix burner only for atmospheric burn...

Page 49: ...meter 00 boiler with atmospheric burner 01 PCH18B H or PCI 18 8 H 02 PCH 34B H PCI 34 20 H or PCC 34 H 03 PCH 50B H 7 Press and release button S to confirm The parameter number 14 will appear on the display 8 Switch off the appliance and switch it back on again to render the new parameter operative PARAMETER 15 ZONED SYSTEM NOT APPLICABLE KEEP SET TO 00 OFF If set to 01 the boiler will become a te...

Page 50: ...the new parameter operative PARAMETER 19 MINIMUM FAN SPEED SETTING CENTRAL HEATING MODE 6 Use buttons o to modify the value of the parameter max value of parameter 20 The default value is 56 Hz for Natural Gas 52 Hz for L P G 7 Press and release button S to confirm The parameter number 19 will appear in the display 8 Switch off the appliance and switch it back on again to render the new parameter ...

Page 51: ...ch off the appliance and switch it back on again to render the new parameter operative PARAMETER 22 FAN FREQUENCY VALUE DISPLAY 6 Use buttons o to modify the value of the parameter 00 Off 01 On If parameter value 01 is selected during the boiler operation the display will show the fan frequency value for 10 min 7 Press and release button S to confirm The parameter number 22 will appear in the disp...

Page 52: ... Gas Gas E 10 3 Table no 2 Frequency Gas type Minimum Hz Maximum Hz Natural Gas Gas A 55 164 Liquid Propane Gas Gas E 52 160 NATURAL GAS GAS A LIQUID PROPANE GAS GAS E Heating Value BTU Cubic Feet BTU FT 1000 2516 Nominal supply gas pressure wc 7 11 Heating Power kW Fan frequency Hz diagram LP Gas Nat Gas PCC 34 H PCH 34B H PCI 34 20 H ...

Page 53: ...meters 2 17 18 19 20 and 21 to the values fund in the corresponding installation manuals 9 Turn the appliance off using the power button 10 As a preliminary adjustment using a 4mm allen wrench or properly sized slotted screwdriver turn the V screw clockwise 4 turns PCH 18B H PCI 18 8 H 2 to 3 turns Leave the wrench or screwdriver in the V screw to make the final adjustment 11 Turn on all available...

Page 54: ...re all the venting connections joints are tight and in good condition where visible Clean the burner cylinder using a non metal brush and without damaging the ceramic fiber Clean the heat exchanger using a recommended detergent from PENSOTTI for the stainless steel Do not wet the ceramic fiber coating Visually inspect the burner flame The flame must burn with a clear blue stable flame If the burne...

Page 55: ...m and minimum modulation pressures and the modulation itself Check the condition and operation of the ignition and gas safety systems If necessary remove and clean the scaling from the ignition and flame detection electrodes paying particular attention to replace them at the correct distance from the burner Check the heating safety systems temperature limit safety thermostat pressure limit safety ...

Page 56: ...ing the panel downwards Unscrew the four fixing screws see fig 6 and remove the panel back piece 6 5 Flushing out the primary side Fill the boiler as per the filling instructions Using a drain off cock on the lowest point of the system allow the water to drain from the system and boiler In order to flush the system correctly turn off all radiators or fan coils Open the filling loop and drain cock ...

Page 57: ...water system should be drained This can be done as follows Close the main water supply valve Joint the water draining pipe and open the cylinder draining tap see fig 2 Open all the hot and cold water taps On completion close all the previously opened taps Freeze Protection Glycol must not be used in Domestic Hot Water applications System winterization non operative system Because it may be impossi...

Page 58: ...emove the ceramic fibre protection from the bottom of the heat exchanger Check that the burner is not affected by deposits scaling or excessive oxidation Check that all the holes in the burner are free Clean the electrodes carefully without altering their positions with respect to the burner Clean the burner cylinder using a non metal brush and without damaging the ceramic fibre Check the integrit...

Page 59: ...assemble the components following the above procedure in reverse order Switch on the power supply and restart the appliance If the appliance does not restart check the positions of the electrodes especially the ignition electrode Make sure that original position and distances between the electrodes and the burner are respected to avoid a malfunction POSITIONING THE IGNITION ELECTRODE AND THE IONIS...

Page 60: ...ntral heating circuit Then restart the appliance remembering to discharge any air that may be trapped in the system Gas valve see fig 2 Unscrew the screws connecting the gas valve to the venturi Disconnect the gas feed pipe and valve ring nut at the bottom of the room sealed chamber Remove the flanged elbow coupling of the existing valve and fit it to the new valve also fit a new cork washer and a...

Page 61: ...ater and gas supplies and check the soundness of the joint by measuring the CO2 levels using an electronic combustion analyzer Circulating pump motor body see fig 2 Close the shut off valves and drain the central heating circuit of the boiler Use a 5 mm Allen key to unscrew the four screws securing the motor body to the impeller body Remove the motor body and check the condition of the washer If n...

Page 62: ...oiler Modulating circuit board see fig 2 3 Open the control panel see 6 4 Accessing the boiler Disconnect all the connectors remove the regulating knobs unscrew the four fixing screws and remove the modulation circuit board Replace the circuit board and re assemble the components following the above procedure in reverse order Switch on the electricity water and gas supplies and regulate the boiler...

Page 63: ... order Switch on the electricity water and gas supplies and fill the system with water Check for any leaks from the joints and bleed off any air from the circuit Restart the boiler making sure that there are no gas leaks Expansion vessel see fig 2 Close the shut off valves and drain the central heating circuit of the boiler Use a 19 mm spanner to unscrew the pipe coupling to the vessel Unscrew the...

Page 64: ... fusibile 2A brown brown light blue green light blue brown orange orange light blue light blue brown white light blue black red black orange orange Heating D H W brown brown brown black black light blue orange black light blue light blue brown light blue black TF max Key IG Main Switch PA Air Pressure switch TS Safety thermostat TF Thermo Fuse 216 F 102 C TF max Thermo Fuse 320 F 160 C SR Heating ...

Page 65: ...nnect the room thermostat end switch wires When the wires have been connected place plate A back to position and then the front case panel Connecting the included outside temperature sensor Connect the wires to the terminal board inside the instrument panel as follows a switch off the power supply at the main switch b remove the front case panel of the boiler c slacken the screws and remove plate ...

Page 66: ...1 are displayed The factors governing the correction are reported in figure 1 The selection of the compensation curve is determined by the maximum delivery temperature Tm and the minimum outdoor temperature Te N B The y axis values of the delivery temperature Tm refer to standard 185 95 F appliances or 104 77 F floor mounted appliances The type of appliance can be programmed using parameter 3 see ...

Page 67: ...INSTALLATION INSTRUCTIONS 64 INDIRECT FIRED WATER HEATER 6 9 D H W sensor connection ...

Page 68: ...MOSTAT MALFUNCTION OR OUT OF CALIBRATION n THERMOSTAT CABLE DISCONNECTED m REPLACE PART n CHECK THE WIRING E03 FLUESAFETY THERMOFUSE o THERMOFUSE BROKEN p THERMOFUSE CABLE DICONNECTED q THERMOFUSE LOCK OUT HIGH FLUETEMPERATURE o REPLACE PART p CHECK THE ELECTRICAL CONNECTION q RESTART AND CHECK THE THERMOFUSE H20 NO WATER IN THE SYSTEM r INSUFFICIENT WATER PRESSURE IN THE SYSTEM STOPS AT 0 3 bar s...

Page 69: ...r at the maximum heating pressure for 15 minutes without any modulation The function is useful for combustion testing 08 Frost Protection Central heating circuit The function is activated when the heating sensor senses a temperature of 41 F The boiler operates at minimum gas pressure with the 3 way diverter valve in the winter position The function is deactivated when the temperature detected by t...

Page 70: ... PRESSURE SWITCH HUBA 605 99851 0 004 0 003 psi 30 20 Pa 36072LA VENTURI MINIFOLD 36075LA GAS VALVE UL CSA 37033LA FAN UL CSA 40 00086 MAIN PRINTED CIRCUIT BOARD DT UL CSA USA SM20023 59015LA LOW WATER CUT OUT SWITCH PC 5411 BRASS 73516LA HTG CLIP SENSOR FOR PIPE 17 18 mm BLUE T7335D1123B 73517LA THERMO FUSE 102 C RED ISOTHERM 1 4 4X45 76702LA PRINTED CIRCUIT BOARD KOND DT SK11003 86006LA SAFETY T...

Page 71: ...68 6 13 Cycle Sequence of Operations ...

Page 72: ...69 Pensotti LLC 34 Coffin Ave Brewer ME 04412 P 207 942 3636 F 207 942 3737 www pensottiboiler com ...

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