PENSOTTI PCH 50B-H Instruction Manual Download Page 9

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GENERAL INFORMATION

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Summary of Contents for PCH 50B-H

Page 1: ...s 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 of a properly calibrated electronic combustion analyzer MUST be used to install and or service this appliance Professionally qualified personnel in accordance with current laws and standards and in line with the manufacturer s instru...

Page 2: ... 3 Installation qualified personnel 3 1 Reference standard 17 3 2 Unpacking 18 3 3 Installation boiler 19 3 4 Fixing the boiler to wall 20 3 5 Water connections 21 3 6 Domestic hot water circuit 22 3 7 Piping diagrams 22 3 8 Condensate drain 25 3 9 Gas connections 26 3 10 Electrical connections 28 3 11 Venting 31 3 12 2 Pipe venting system 35 4 Commissioning the appliance qualified personnel 4 1 G...

Page 3: ...Regulating the gas valve offset 54 6 Maintenance qualified personnel 6 1 General warnings 55 6 2 Maintenance 55 6 3 Annual Maintenance 56 6 4 Accessing the boiler 58 6 5 Flushing out the primary side 58 6 6 Draining the central heating and domestic hot water system 59 6 7 Maintenance operations 60 6 8 Wiring diagrams 68 6 9 Troubleshooting 70 6 10 Function codes 72 6 11 Sequence of operations 73 E...

Page 4: ...ely 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 burns instant...

Page 5: ...other 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 avo...

Page 6: ... at the meter or on the cylinder in the case of bottled gas and call a qualified 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 compatible with its p...

Page 7: ...onoxide 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 be met at the time of completion of installation the owner shall have a period o...

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Page 12: ...e 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 Granby Heating Products LLC will not be held responsible for any misinterpretation o...

Page 13: ...n working pressure heating bar psi 0 3 4 29 Dimensions Boiler casing size Width in 19 3 Height in 27 6 Depth in 18 5 Weight net lb 120 Hydraulic connections Central Heating Flow connection Soldier Central heating Return connection Soldier Cold water mains connection Soldier D Hot water connection Soldier Gas connection NPT Flue systems Horizontal Concentric flue system Ø mm in 80 125 3 15 5 Max Fl...

Page 14: ...TECHNICALCHARACTERISTCS 11 2 2 Dimensions ...

Page 15: ...IT GAS MANIFOLD BURNER 5 IONISATION ELECTRODE 6 HEATING SENSOR 7 HEATING SAFETY THERMOSTAT 8 PUMP 9 FAN 10 CONDENSATE TRAP 11 ELECTRONIC GAS VALVE 12 AIR PRESSURE SWITCH 13 IGNITION ELECTRODE 14 IGNITION TRANSFORMER 15 VENTURI 16 DIVERTER VALVE ACTUATOR 17 WATER PRESSURE SWITCH 18 NO RETURN VALVE 19 WATER PRESSURE GAUGE 20 FILLING TAP 21 SAFETY VALVE ...

Page 16: ...VALVE 3 SAFETY THERMOFUSE 320 F 160 C 4 PRIMARY CONDENSING HEAT EXCHANGER 5 BURNER UNIT 6 ELECTRIC FAN 7 SAFETY THERMOSTAT 8 HEATING PROBE 9 GAS VALVE 10 CONDENSATE COLLECTION SIPHON 11 AIR RELIEF VALVE 12 CIRCULATOR 13 SYSTEM DRAINING TAP 14 SAFETY VALVE 15 DOMESTIC CIRCUIT PROBE 16 CYLINDER 17 AIR PRESSURE SWITCH 18 EXPANSION TANK 19 VENTURI 20 WATER PRESSURE SWITCH 21 DIVERTER VALVE 22 NO RETUR...

Page 17: ... 4 13 1 9 8 6 7 3 3 0 0 2 2 4 4 6 6 8 8 11 Water flow US gpm 2 5 2 Hydraulic pressure losses Pressure loss mbar Flow l h 16 4 16 4 9 8 6 7 3 3 2 2 4 4 6 6 8 8 11 Water flow US gpm Hydraulic pressure losses Individual boiler Hydraulic pressure losses Individual boiler storage cylinder installation Head ft Head ft ...

Page 18: ...ower steps Error History display last 5 errors To switch the boiler OFF press INFO button the symbol appears on the display The central heating frost protection system the circulating pump inactivity protection and 3 way valve inactivity protection functions remain enabled If the boiler was previously ON it is switched OFF and the fan overrun and pump overrun functions are enabled 2 7 Control pane...

Page 19: ...play the boiler data Once pressed the parameter number will appear on the left side of the display and the associated parameter value will appear on the centre of the display Use and buttons of Heating Temperature setting to scroll the list of available data Press the INFO button to exit the display mode The list of available display data is the following D03 D09 are not applicable Parameter Icon ...

Page 20: ... 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 destinati...

Page 21: ...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 to installation the Granby Heating Products LLC boilers should be stored in the horizont...

Page 22: ...rtant that 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 P...

Page 23: ... the boiler to wall follow this instruction 1 Check that the spacer A fig 1 is installed in the boiler to ensure the correct installation slope of 4 compared to the installation wall fig 2 and to avoid any condensate stagnation within the condensing exchanger 2 Fix the external part of the mounting bracket to wall fig 1 using proper screw anchors and following the distances shown in fig 3 3 Insert...

Page 24: ...o facilitate the installation the boiler is supplied with a hydraulic connection kit see fig 2 A pressure relief valve is installed in this 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 valv...

Page 25: ...cal 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 The boiler must be installed on a plumb level surface to avoid improper operation 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...

Page 26: ...ired 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 boiler connections between RB AB See page 20 for more information Set parameter P00 to 05 Heat Only PCH 50 B H 1 1 2 Copper 1 1 2 ...

Page 27: ...ies boilers Dirt Scale Separation Along with the application of our Fernox commissioning kit Pensotti highly recommends the installation of a dirt separator in the return piping of all Solenne Series boiler models Follow the manufacturer s instructions when installing these devices PCH 50 B H 1 1 2 Copper 1 1 2 Copper 1 1 2 Copper ...

Page 28: ... reduce 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 app...

Page 29: ...ing 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 ma...

Page 30: ...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 31: ...r or equivalent is recommended to protect the appliance from power surges If a generator is to be used as backup power care must be taken that a line conditioner is used to protect the appliance from erratic voltage If the boiler is to be installed in a structure utilizing an emergency stand by generator the installation of a surge capacitor surge protector line conditioner or equivalent is requir...

Page 32: ...ll not be held liable for any damage or injury caused as a result of an inefficient or faulty ground system Ensure the domestic power supply is checked by a qualified electrician 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 supp...

Page 33: ...s Connect the earth wire normally coloured green 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 ...

Page 34: ... TI boilers are prepared at t h e 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 ALL exhaust vent material must be spec...

Page 35: ...INSTALLATION INSTRUCTION 32 Venting Pictures Illustrations ...

Page 36: ...INSTALLATION INSTRUCTION 33 Part No PAHVK Horizontal Vent Kit ...

Page 37: ...INSTALLATION INSTRUCTION 34 12 Clearance Suggested from The Top of The Appliance to Ceiling 7 Top of Appliance to Center Line of Hole 10 ...

Page 38: ...icensed 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 local state and national codes To ensure continued safe operation of the boiler the venting system must be accessible for inspection once a year by a qualified technician The air intake and flue exhaust ter...

Page 39: ...ll polypropylene pipe exposed to sunlight must be UV approved pipe this includes all sidewall and vertical terminations both air intake and exhaust Both the exhaust and air intake vent pipes must be the same size pipe Clearance to combustibles on the approved polypropylene vent pipe is 0 All interior venting and air intake pipe joints must be secured using the appropriate connector rings indicated...

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Page 41: ...INSTALLATION INSTRUCTION 38 Follow all venting manufacturers guidelines for low profile terminations ...

Page 42: ...INSTALLATION INSTRUCTION 39 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 43: ...corresponds to that of the mains 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 th...

Page 44: ...m the system close the draining tap placed on top of the condensing heat exchanger fig 3 use a pressure gauge M fig 2 to check that the system pressure reaches the middle part of the green zone corresponding to 17 4 psi fig 4 On completion make sure that the filling tap R is perfectly closed R fig 2 Unscrew the plug on the pump to remove any trapped air check that the pump is free then re tighten ...

Page 45: ...pen all 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 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 hosep...

Page 46: ...remove all the air from the pipes To repeat the operation wait approximately 5 seconds from the last ignition attempt before resetting the error code E01 pressing the reset button Check gas pressure at gas valve inlet pressure tap SEE Fig 1 Set gas pressure to proper level at the regulator Refer to section 2 1 Technical Data Gas pressure adjustments must be performed while the appliance is in Flue...

Page 47: ...0 Off 01 On P07 Central heating timer 00 90 Displayed in multiples of 5 seconds default value 36 x 5 180 P08 Central heating pump overrun timer 00 90 Displayed in multiples of 5 seconds default value 36 x 5 180 P09 D H W Storage cylinder pump overrun timer 00 90 Displayed in multiples of 5 seconds default value 18 x 5 90 P10 Minimum fan speed DHW 38 Hz Nat Gas 50 Hz Propane Displayed in hertz 1Hz ...

Page 48: ...g pump and return temperature sensor connected only N A N A P25 T timing T flow T return w modulating pump and return temperature sensor connected only N A N A P26 Outdoor reset function 00 01 00 Standard Operation 86 F 185 F 01 Outdoor sensor NOT connected 86 F 140 F Outdoor sensor IS connected 86 F 176 F default NOTES P04 This parameter allows to modify the time the boiler takes in heating mode ...

Page 49: ...ous table open the parameter settings menu as follows 1 Place mode selection button in the OFF position the symbol will be displayed 2 Keep pressed and buttons simultaneously and wait for symbol and P00 to appear on the display 3 Release buttons and 4 Use and buttons of heating temperature setting to select the parameter to edited ...

Page 50: ...to confirm and to save the new setting The value will blink several times to confirm it is saved 7 Proceed to the next parameter to be edited by using and buttons of heating temperature setting 8 When finished to exit from the parameters menu press simultaneously and buttons The boiler will be in the off position Press the to place the boiler in the proper mode ...

Page 51: ...h the maximum power set during the starting up In cases of boiler short cycling increase this value 00 0 seconds disabled 01 50 seconds default 02 100 seconds 03 200 seconds 04 400 seconds PARAMETER P05 WATER HAMMER PREVENTION FUNCTION Activating this function the D H W contact is delayed for 2 seconds 00 Off 01 On PARAMETER P06 D H W PRIORITY FUNCTION This parameter is used to maintain the divert...

Page 52: ...m fan speed which corresponds to the maximum burner output displayed in Hertz min Value set in parameter P10 max 203 Hz The default value is set according to the output value set in Parameter P00 PARAMETER P12 SETS THE MINIMUM FAN SPEED CENTRAL HEATING This parameter is used to set the minimum fan speed in heating mode which corresponds to the minimum burner output during a heating mode request di...

Page 53: ... compensation curve is determined by the maximum flow temperature Tm and the minimum outdoor temperature Te taking into consideration the house insulation degree The values of the flow temperature Tm refer to standard 95 185 F appliances or 77 113 F for under floor heating systems The type of appliance can be set using parameter P03 or manually adjusting P19 P20 The value corresponds to the graph ...

Page 54: ...167 F PARAMETER P22 T SET POINT T FLOW T RETURN not applicable Value set to 32 Do not change If set to anything other than 32 Error E15 will appear PARAMETER P23 not applicable PARAMETER P24 not applicable PARAMETER P25 not applicable PARAMETER P26 OUTDOOR RESET FUNCTION This parameter is used to set the D H W maximum temperature the user may increase to 00 Standard Operation 86 F 185 F 01 Outdoor...

Page 55: ... A 9 37 Liquid Propane Gas Gas E 10 28 Table no 2 Frequency Gas type Minimum Hz Maximum Hz Natural Gas Gas A 55 188 Liquid Propane Gas Gas E 52 180 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 ...

Page 56: ... see 5 4 Gas Data Select the new gas type by changing parameter P02 on the control panel see 5 3 Setting the parameters When converting from Natural Gas to LPG o Before firing the boiler using a 4mm allen wrench adjust the V screw 3 full turns clockwise This is only a preliminary adjustment A CO2 analyzer must be utilized for final adjustments When converting from LPG to Natural Gas o Before firin...

Page 57: ...t a third silicon pipe on the free connection of the T and connect its end to the negative point of a gas pressure manometer Fig 3 Unscrew the pressure P point screw and connect there the pipe that goes to the positive point of the gas pressure manometer Switch the boiler On at the minimum power The manometer should read a value of 0 02 mbar if you read a different value proceed as follows Fig 4 F...

Page 58: ... 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 burner flame appearance is not satisfactory or debris is visible on the burners remove a...

Page 59: ...nt This appliance contains materials that identify as carcinogenic or possibly carcinogenic to humans Avoid contact with skin and eyes Avoid breathing in silica dust Avoid transferring contaminants Wear long sleeve clothing gloves safety glasses Wear a respirator with a N95 rated filter or better First Aid Measures Skin wash with soap and water Eyes do not rub eyes flush with water immediately Inh...

Page 60: ...mbustion check using an electronic analyzer Check CO2 levels at high fire operation consult manual for proper CO2 values Adjust to required specification Check flue gas temperature If above 172 degrees F or substantially above a previous test result clean the heat exchanger Check for proper error code operation by simulating error code faults EO1 EO2 EO3 etc repair any deficiencies Lubricate the 3...

Page 61: ...me rotating the panel downwards Unscrew the four fixing screws and remove the cover 6 5 Flushing out the primaryside 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 water heater In order to flush the system correctly turn off all radiators or fan coils Open the filling loop and drain cock simultan...

Page 62: ...anger of freezing the domestic hot water system should be drained This can be done as follows Close the mains water supply valve 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 impossible to completely drain the boilers hea...

Page 63: ...ttention not to remove the ceramic fiber 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 fiber C...

Page 64: ...llowing the above procedure in reverse order Switch on the power supply and restart the appliance If the boiler 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 correct to avoid a malfunction POSITIONING THE IGNITION ELECTRODE AND THE IONISATION ELECTRODE 0 30 in 7 5 mm ...

Page 65: ...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 66: ...ter 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 ne...

Page 67: ... the circuit Restart the boiler 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 suppli...

Page 68: ...rn pipes Remove the support brackets and pull out the heat exchanger Remove the regulation sensor from the old heat exchanger and refit it together with the two condensate drainpipes to the new one Replace the heat exchanger and re assemble the components following the above procedure in reverse order Switch on the electricity water and gas supplies and fill the system with water Check for any lea...

Page 69: ...ssel Unscrew the fixing screws and remove the upper mounting bracket Remove the expansion vessel from the left side of the boiler Replace the expansion vessel and re assemble the components following the above procedure in reverse 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 ...

Page 70: ...1 SS SF Key ER Ionisation electrode EA Ignition electrode C Circulating pump VD Diverter valve VG Gas valve PA Air pressure switch TRA Ignition transformer TF Thermo Fuse 216 F 102 C TF max Thermo Fuse 320 F 160 C TS Safety thermostat Pacq Water pressure switch SR Heating sensor SS D H W sensor SF Condensate Trap EV Fan MP Terminal board SE Outdoor temperature sensor TA Room thermostat L Line N Ne...

Page 71: ...phone control removing the jumper Ta Ta from the terminal board B first and then connecting the room thermostat telephone control wires d When 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 mai...

Page 72: ...86006LA l CHECK INTERNAL CIRCULATOR VALVES STRAINERS m CHECK THE WIRING Manual Reset press the Reset button E03 216 F THERMO FUSE TRIPPED n THERMO FUSE BLOWN o THERMO FUSE CABLE OR POWER SUPPLY DISCONNECTED n CLEAN HEAT EXCHANGER VERIFY FLUE GAS TEMP REMAIN BELOW 172 F VERIFY WATER FLOW REPLACE PART o CHECK THE WIRING AND THE POWER SUPPLY CONNECTION Manual Reset press the Reset button E04 NO WATER...

Page 73: ...ART z CLEAN OR REPLACE PART Automatic E21 GENERAL PCB MALFUNCTION aa MICROPROCESSOR MALFUNCTION IT DETECTS A WRONG SIGNAL aa THE PCB RESETS AUTOMATICALLY THE ERROR Automatic E22 PARAMETER PROGRAMMING REQUEST bb LOSS OF MICROPROCESSOR MEMORY bb REPROGRAM PARAMETERS Manual Reset Switch off the power supply E35 FLAME DETECTION MALFUNCTION cc IONISATION ELECTRODE MALFUNCTION dd IONISATION ELECTRODE CA...

Page 74: ... sensor detects a temperature of 40 F The boiler operates at minimum gas pressure with the diverter valve in the summer position The function is disabled when the temperature detected by the sensor is 45 F in the D H W circuit or 86 F in the central heating circuit F28 Legionella Prevention Function Function active for storage boilers only It comes into operation every 7 days It brings the hot wat...

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Page 80: ...er ME 04412 Product Support Note Technical support will only be provided to licensed gas installers or service personnel with proper credentials Hours 8am 4pm EST M F info hitechheat com Visit www hitechheat com for helpful troubleshooting information ...

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