PENSOTTI PCI 18 Instruction Manual Download Page 3

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CONTENTS

6. Maintenance

(authorized personnel)

Pages

6.1 General warnings

6.2 Maintenance

6.3 Water heater inspection

6.4 Accessing the water heater

6.5 Flushing out the primary side

6.6 Draining the central heating and domestic hot water system

6.7 Maintenance operations

6.8 Wiring diagrams

6.9 D.H.W Sensor Connection

6.10 Troubleshooting

6.11 Diagnostics

6.12 Parts list

6.13 Sequence of operations

Summary of Contents for PCI 18

Page 1: ...liance 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...

Page 2: ...alling the water heater 18 3 4 Water connections 19 3 5 Domestic Hot Water Circuit Hard Water Warning Expansion Tank 21 3 6 Piping Diagram 22 3 7 Condensate Drain 23 3 8 Gas connection 24 3 9 Electrical connections 25 3 10 Venting connections 28 4 Commissioning the appliance authorized personnel 4 1 General warnings 33 4 2 Filling the system 34 4 3 Flushing the system 35 4 4 Filling the condensate...

Page 3: ...on 49 6 4 Accessing the water heater 50 6 5 Flushing out the primary side 50 6 6 Draining the central heating and domestic hot water system 51 6 7 Maintenance operations 53 6 8 Wiring diagrams 60 6 9 D H W Sensor Connection 61 6 10 Troubleshooting 63 6 11 Diagnostics 64 6 12 Parts list 65 6 13 Sequence of operations 66 ...

Page 4: ... 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 instantly or death from scalding If the proposed water heater outlet temperature is above 125 F a thermostatically c...

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 F...

Page 6: ...ny other equipment that may cause sparks Open doors and windows immediately to create a current of air and ventilate the room Shut off the main gas supply 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 q...

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: ...imple to operate In its simplicity the wall mounted appliance is equipped with all the appropriate accessories required to make it a fully independent water heater capable of satisfying domestic hot water production and central heating needs All water heaters are fully inspected and are accompanied by a quality certificate signed by the inspector and a guarantee certificate This manual must be kep...

Page 13: ...ature C F 80 176 Expansion vessel capacity litres gal 8 2 11 Max working pressure heating bar psi 2 1 30 Min working pressure heating bar psi 0 3 4 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 D H W 40 C water supply DT 30 C for 1 hour litres gal 696 183 9 Max D H W 40 C ...

Page 14: ...C HF CWI G HR HWO 2 85 12 2 85 29 7 2 5 3 1 2 7 3 2 4 2 2 5 1 HR HWO G CWI HF 2 2 Dimensions LEGEND HR HEATING RETURN Ø 3 4 HF HEATING SUPPLY 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: ...VE 3 4 HTG CIRCUIT 13 SYSTEM DRAIN VALVE 14 MAGNESIUM ANODE 15 AIR PRESSURE SWITCH 16 PRESSURE RELIEF VALVE 8 BAR HOT WATER 17 IGNITION TRANSFORMER 18 AUTOMATIC AIR VENT VALVE 19 IGNITION ELECTRODE 20 D H W SENSOR 21 EXPANSION VESSEL 22 CYLINDER 23 ELECTRONIC GAS VALVE 24 CYLINDER DRAINING TAP 25 LOW WATER CUT OUT SWITCH 26 PLATE EXCHANGER 27 3 WAY VALVE 28 ELECTRONIC FLOWSWITCH 29 NO RETURN VALVE...

Page 16: ...N ELECTRODE 19 CONDENSATE DRAIN PIPE 20 VENTURI 21 ROOM SEAL CHAMBER BACK SIDE 22 LOW WATER CUT OUT SWITCH 23 CONDENSATE TRAP 24 CONDENSATE DRAIN PIPE 25 PLATE EXCHANGER 26 ELECTRONIC FLOWSWITCH 27 DIVERTER VALVE ACTUATOR UL CSA 28 FLOW LIMITER 29 WATER PRESSURE GAUGE 30 FILLING TAP 31 PRESSURE RELIEF VALVE 7 BAR HOT WATER 32 MAGNESIUM ANODE 33 D H W SENSOR 34 CYLINDER 35 CYLINDER DRAINING TAP 36 ...

Page 17: ...TECHNICAL CHARACTERISTCS 14 2 5 Circulation pump head flow graph Pump head I II III Pump speed Boiler losses I II III 0 5 10 15 20 25 30 0 2 4 6 8 10 Water flow US gpm Head ft ...

Page 18: ...selection Operation Functions display Lock Out Water deficiency indicator Temperature display When the water heater 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 water heater was previously on it is switched off and the post ventilation pump overrun circulation pump and...

Page 19: ...stantaneous Conforms to ANSI STD Z21 10 3 certified to CSA STD 4 3 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 anyw...

Page 20: ...d 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 combination water heater 90 while manually supporting it from underneath C Lift the box and remove the protections Lift the combination water heater by grasping the rear part and proceed with the installation STORAGE HANDLING Please note that prior ...

Page 21: ...heater for maintenance purposes it is important 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 boiler proceed as follows see fig 2 a Use a level of not less than 24 long to mark a horizontal line on the wall ...

Page 22: ...ation the water heater is supplied with an hydraulic connection kit see fig 2 A pressure relief valve is installed in this dual purpose water heater 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 va...

Page 23: ...INSTALLATION INSTRUCTIONS 20 D H W circulating loop In order to joint the D H W out loop pipe proceed as follows a unscrew the cap A and insert a nipple b joint the nipple to the D H W circulating pipe ...

Page 24: ...l heating circuit In order to prevent scaling or deposits in the primary heat exchanger the mains supply water to the heating circuit must be treated according 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 su...

Page 25: ...INSTALLATION INSTRUCTIONS 22 3 6 Piping Diagram ...

Page 26: ...entire condensate discharge pipe should be treated as an external run 9 In alI cases discharge pipe must be installed to aid disposal of the condensate To 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 ...

Page 27: ...d by using 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 water heater 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 specif...

Page 28: ... Example A machine with a burner that requires 440 000 BTU would need a 1 1 4 pipe for a 20 long run Liquid Propane Gas Pipe Sizing Chart Length of Pipe in Feet Size of Schd 40 Black Iron Pipe in Inches 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...

Page 29: ...ilizing a emergency stand by generator the installation of a surge capacitor surge protector line conditioner or equivalent is required If the water heater 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 plumbing and ga...

Page 30: ...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 31: ...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 32: ...et of horizontal run and every 5 feet of vertical run PENSOTTI and Direct Vent All PENSOTTI Combination Water Heaters are prepared 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 Combination Water Heaters use a 3 5 concentric vent polypropylene inner exhaust pipe with a painted aluminum outer ...

Page 33: ...INSTALLATION INSTRUCTIONS 29 Venting Pictures Illustrations ...

Page 34: ...INSTALLATION INSTRUCTIONS 30 Included With Each Combination Water Heater Is A PAHVK Horizontal Kit ...

Page 35: ...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 36: ...INSTALLATION INSTRUCTIONS 32 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 37: ...the mains supply networks gas electricity water Check that the power supply voltage to the water heater 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 water heater and that it is fitted with all the safety an...

Page 38: ...or 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 14 psi 1 bar and that the code H2O does NOT appear on the control panel display see 2 7 section Control Panel If after the above operations there is a reduction in the pressure re open the filling tap R until the pressure gauge re...

Page 39: ...tors 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 water heater leave to fill until water is released from the hot water outlets Turn off all hot water outlets c Connect a hosepi...

Page 40: ...nited if the system still emits noises the operations must be 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 inle...

Page 41: ...ters 13 D H W priority function 2 min delay on D H W function 00 01 Off On Recommended 14 4 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 38 Hz Natural Gas 50 Hz Propane To set the minimum frequency value Hz for the fan operation ...

Page 42: ...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 43: ... 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 Displayed in C only 6 Use buttons and to modify the value of the parameter 00 standard 86 176 F 01...

Page 44: ... 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 45: ...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 46: ... boiler with atmospheric burner 01 PCH 18 PCH18 B or PCI 18 8 02 PCH 34 B PCI 34 20 or PCC 34 03 PCH 50 B 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 combination water heater will bec...

Page 47: ...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 38Hz for Natural Gas 50 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 o...

Page 48: ...h 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 displ...

Page 49: ... no 1 CO2 Values Gas type CO2 Natural Gas Gas A 9 1 Liquid Propane Gas Gas E 10 1 NATURAL GAS GAS A LIQUID PROPANE GAS GAS E Lower Wobble Index 59 F 14 5 psi 3 MJ Nm 45 67 70 69 Nominal supply gas pressure wc 7 11 Heating Power kW Fan frequency Hz diagram LP Gas Nat Gas ...

Page 50: ... Perimeters 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 18 PCH 18B PCI 18 8 2 to 3 turns Leave the wrench or screwdriver in the V screw to make the final adjustment 11 Turn on all a...

Page 51: ... sure 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 bu...

Page 52: ...imum 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 safe...

Page 53: ...el downwards Unscrew the four fixing screws and remove the cover 6 5 Flushing out the primary side Fill the water heater 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 simultaneously and a...

Page 54: ...hould 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 impossible to complet...

Page 55: ...n out replace it immediately A non correct maintenance will invalidate the cylinder warranty To check the anode unscrew the anode nut located on the top of the cylinder see fig 3 by turning it counter clockwise If at the opening of the valve water comes out of the valve the anode is worn and needs to be replaced if no water comes out of the valve the anode is not worn and therefore still functioni...

Page 56: ...ar attention not to remove 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 fib...

Page 57: ...semble the components following 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 respected to avoid a boiler malfunction POSITIONING THE IGNITION ELECTRODE AND THE ION...

Page 58: ...e shut off valves and fill the central 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...

Page 59: ... Remove the motor body and check the condition of the washer If necessary replace the washer Replace the circulation pump or cartridge only 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 all air from the circuit Restart the water heater Cl...

Page 60: ...r heater 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 wat...

Page 61: ... 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 water heater 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 water heater Use a 19 mm spanner to unscrew the pipe coupling to the vessel Unscr...

Page 62: ...h water and check for any leaks from the joints Storage Cylinder see fig 2 Close the shut off valves and drain the central heating circuit of the boiler Use a 30 mm key to unscrew the heating flow and return pipes fig 2 pos A Use a 24 mm key to unscrew the D H W flow and return pipes fig 2 pos B Lift the storage cylinder by releasing it from the boiler frame fig 2 pos C Remove the storage cylinder...

Page 63: ...INSTALLATION INSTRUCTIONS 59 6 8 Wiring diagrams ...

Page 64: ...onnect 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 outside temperature sensor Option 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 water heater c slacken the screws and remove p...

Page 65: ...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 176 86 F appliances or 104 77 F floor mounted appliances The type of appliance can be programmed using parameter 3 see ...

Page 66: ... REPLACE PART o CHECK THE ELECTRICAL CONNECTION p RESTART AND CHECK THE THERMOFUSE H20 NO WATER IN THE SYSTEM q INSUFFICIENT WATER PRESSURE IN THE SYSTEM STOPS AT 4 5 PSI 0 3 BAR r WATER PRESSURE SWITCH CABLE DISCONNECTED s WATER PRESSURE SWITCH MALFUNCTION q FILL THE SYSTEM r CHECK THE WIRING s REPLACE PART E05 HEATING SENSOR t SENSOR MALFUNCTION OR OUT OF CALIBRATION RESISTANCE VALUE 10 kOhms AT...

Page 67: ...function is activated when the heating sensor senses a temperature of 41 F The water heater operates at minimum gas pressure with the 3 way diverter valve in the winter position The function is deactivated when the temperature detected by the sensor reaches 86 F 09 Frost Protection D H W circuit The function is activated when the sensor senses a temperature of 40 F The water heater operates at min...

Page 68: ...ECTRODE 35032LA IONISTATION ELECTRODE 36068LA VENTURI MINIFOLD 36075LA GAS VALVE UL CSA 37033LA FAN UL CSA 59015LA LOW WATER CUT OUT SWITCH PC 5411 BRASS 73507LA D H W HEATING 1 8 WHITE SENSOR S011001 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 76719LA MAIN PRINTED CIRCUIT BOARD UL CSA SM20...

Page 69: ...65 6 13 Sequence of operations ...

Page 70: ...66 Pensotti LLC 34 Coffin Ave Brewer ME 04412 P 207 942 3636 F 207 942 3737 www pensottiboiler com ...

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