Table of Contents
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Homeowner: Retain these instructions for future reference
WARNING
If the information in these instructions is not followed exactly, a fire or explosion may
result, causing property damage, personal injury or death.
- Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.
- 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 of a properly calibrated electronic combustion analyzer MUST be used to install and/or service
this appliance.
Approved in accordance with:
ANSI Z21.13b-2010 / CSA 4.9b (2010) Low Pressure Boiler
Manufactured/Distributed by : Granby Furnaces Inc.
12118 Hwy 209, Parrsboro, NS, Canada
Instruction Manual
Installer: Affix these instructions adjacent to the boiler
Condensing Direct Vent Gas Boiler
CONTENTS
PCI 34/20-H
116,000 BTU INPUT
1.
Gener
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Table of Contents
Related Manuals for PENSOTTI PCI 34
Summary of Contents for PENSOTTI PCI 34
- Page 1 CONTENTS Instruction Manual Installer: Affix these instructions adjacent to the boiler Homeowner: Retain these instructions for future reference PCI 34/20-H Condensing Direct Vent Gas Boiler 116,000 BTU INPUT WARNING If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury or death.
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Page 2: Table Of Contents
CONTENTS al information Pages 1.1 General warnings 1.2 Product conformity 2. Technical characteristics 2.1 Technical data 2.2 Dimensions 2.3 Internal parts of the boiler 2.4 Water circuit 2.5 Circulation pump head/flow graph 2.6 Printed circuit board – Technical characteristics 2.7 Control panel 3. - Page 3 CONTENTS Pages 6. Maintenance (authorized personnel) 6.1 General warnings 6.2 Maintenance 6.3 Boiler inspection 6.4 Accessing the boiler 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 Troubleshooting 6.10 Diagnostics 6.11 Parts list...
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Page 4: General Warnings
The appliance should be located in an area where leakage within the unit or at its connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure. PENSOTTI will not be responsible for any damage resulting from leaking if adequate drainage is not provided. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. - Page 5 Check the Rating Plate PENSOTTI units come from the factory configured for use with natural gas. Prior to installation, check the rating plate of the boiler to ensure the unit matches gas type, gas pressure, water pressure and electrical supply. If the unit does not match the requirements, do not install.
- Page 6 GENERAL INFORMATION The “operating instructions” chapter of this manual must be read carefully as it provides information on the operation and the operating limits of the appliance. After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not attempt to use the product but refer to the supplier.
- Page 7 Many jurisdictions require the installation of carbon monoxide detectors in building where a side wall vented fuel burning appliance is installed. Installers must abide by local code requirements regarding the installation of CO detectors. The use of a certified carbon monoxide detector is recommended but not required by PENSOTTI. “In the State of Massachusetts only”...
- Page 8 GENERAL INFORMATION...
- Page 9 GENERAL Information...
- Page 10 GENERAL Information...
- Page 11 GENERAL Information...
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Page 12: Product Conformity
GENERAL INFORMATION 1.2 Product conformity All Granby/Pensotti LLC boilers are ETL certified and possess technical and functional characteristics that comply with the following standards: Gas fired Low Pressure Hot Water Boiler: American National Standard/CSA Standard for Gas Fired Low Pressure Steam and Hot W ater Boiler . -
Page 13: Technical Characteristics
TECHNICAL CHARACTERISTCS 2. TECHNICAL CHARACTERISTICS 2.1 Technical data Model PCI 34/20-H CE Certification n° 0694BN3485 Appliance Type B23p-B33-C13-C33-C43-C53-C63-C83-C93 Appliance Category II2H3B/P kW - BTU/hr 34 - 116013 Heat Input max kW - BTU/hr 35 - 119445 Heat Input max - D.H.W. production working... -
Page 14: Dimensions
TECHNICAL CHARACTERISTCS 2.2 Dimensions HR HWO G RC 5.5 10.9 10.7 18.9 LEGEND HEATING RETURN Ø 3/4" HEATING FLOW Ø 3/4" Ø 1/2" Ø 1/2" COLD WATER INLET Ø 1/2" HOT WATER OUTLET CONDENSATE DRAIN Ø 0.98 in 19.3... -
Page 15: Internal Parts Of The Boiler
TECHNICAL CHARACTERISTCS 2.3 Internal parts of the boiler LEGEND SAFETY THERMO FUSE FLUE HOOD IONISATION ELECTRODE CONDENSATE DRAIN PIPE HEATING SENSOR HEATING SAFETY THERMOSTAT EXPANSION VESSEL D.H.W. AUTOMATIC AIR VENT VALVE 10. PUMP 11. SAFETY VALVE 3/4 - HTG CIRCUIT "... -
Page 16: Water Circuit
TECHNICAL CHARACTERISTCS 2.4 Water circuit LEGEND AIR PRESSURE SWITCH HEATING SAFETY THERMOSTAT HEATING SENSOR PRIMARY CONDENSING HEAT EXCHANGER PREMIX BURNER UNIT (GAS MANIFOLD+BURNER) IONISATION ELECTRODE EXPANSION VESSEL ELECTRONIC GAS VALVE 10. NO-RETURN VALVE 11. AUTOMATIC AIR VENT VALVE 12. PUMP 13. -
Page 17: Circulation Pump Head/Flow Graph
TECHNICAL CHARACTERISTCS 2.5 Circulation pump head/flow graph Water flow [US gpm]... -
Page 18: Control Panel
TECHNICAL CHARACTERISTCS ® printed circuit board – SM 20023 2.6 DIGITECH Technical characteristics Adjustments possible by service personnel only Standard (86-176° F) / reduced (77-104° F) central h e a t i n g temperature Water hammer prevention function Central Heating timer - (adjustable from 0 to 7,5 minutes) Central Heating pump overrun timer Domestic Hot W ater pump overrun timer Minimum Gas pressure setting... -
Page 19: Installation (Authorized Personnel)
INSTALLATION INSTRUCTIONS 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. -
Page 20: Unpacking
STORAGE & HANDLING Fig 1 Please note that prior to installation the Pensotti North America boilers should be stored in the horizontal position with no more than three boilers to a stack;... -
Page 21: Installing The Boiler
INSTALLATION INSTRUCTIONS 3.3 Installing the boiler. The appliance must be installed exclusively on a vertical solid wall capable of supporting its weight. ■ The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard) ■... -
Page 22: Water Connections
INSTALLATION INSTRUCTIONS 3.4 Water connections In order to safeguard the heat exchanger and circulation pump, especially in case of boiler replacement, it is recommended that the system is hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators. In order to safeguard all waterside components the supplied Fernox Commissioning Kit Must be used in its entirety. - Page 23 INSTALLATION INSTRUCTIONS D.H.W. circulating loop In order to joint the D.H.W out loop pipe, proceed as follows: a) unscrew the ½” cap A and insert a ½” nipple; b) joint the nipple to the D.H.W. circulating pipe;...
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Page 24: Domestic Hot Water Circuit / Hard Water Warning / Expansion Tank
INSTALLATION INSTRUCTIONS 3.5 Domestic Hot Water Circuit ■ In order to prevent scaling and eventual damage to the D.H.W heat exchanger, the mains water supply must not have a hardness rating of more than 7 grains/gal (120 ppm). It is nevertheless advisable to check the properties of the water supply and install the appropriate treatment devices where necessary. -
Page 25: Piping Diagram
INSTALLATION INSTRUCTIONS 3.6 Piping Diagram This piping diagram is an example for illustrative purposes only. It is not designed to be used as a piping schematic. *Max. 4 pipe diameters between tees *External Low Water Cut-Off if required by local code *Tempering Valve May be Required –... -
Page 26: Condensate Drain
INSTALLATION INSTRUCTIONS 3.7 Condensate drain FAILURE INSTALL CONDENSATE Termination to an internal soil and vent pipe DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE Boiler DUAL PURPOSE BOILER. condensate discharge pipe MUST NOT RISE at any point along its length. -
Page 27: Gas Connection
Until pressure testing of the main gas supply line is completed, ensure the gas line to the PENSOTTI Boiler is disconnected to avoid any damage to the boiler. The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 0.5 psi (3.5 kPa).. - Page 28 INSTALLATION INSTRUCTIONS Natural Gas Pipe Sizing Chart Size of Schd. 40 Black Iron Pipe in Inches Length of Pipe In Feet 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 1237 2259 1610 1335 1143 1041 Natural Gas flow is given in thousands of BTU/hr. - One cubic foot of natural gas = 1000 BTU Nominal pressure at the burner for Natural Gas is 3.5"...
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Page 29: Electrical Connections
130VAC Max or 95VAC Min. Damage caused by excessive voltage is not covered under warranty. DO NOT connect 220-240VAC and any other voltage to this PENSOTTI Boiler. This will damage the boiler and void the warranty. Do not disconnect the power supply when the unit is in normal operation. - Page 30 INSTALLATION INSTRUCTIONS Always check to make sure that the appliance has an efficient ground system. This requirement is only satisfied if it has been properly connected to an efficient ground system installed in accordance with the requirements of current safety standards and carried out by professionally qualified personnel. This basic safety measure must be checked, verified and carried out by professionally qualified personnel.
- Page 31 INSTALLATION INSTRUCTIONS Remote control connection Connect the power supply to the terminal board inside the control panel as follows: a. Switch off the power supply at service switch or breaker. b. Remove the front case panel of the boiler. c. Slacken the screws and remove plate A (see fig. 1). d.
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Page 32: Venting Connections
All PENSOTTI b o i l e r s use a 3/ 5” c o nc e nt r ic v e nt or a 2 p ip es s ys t em t ha t u s es a 3”... - Page 33 INSTALLATION INSTRUCTIONS Venting Pictures & Illustrations...
- Page 34 INSTALLATION INSTRUCTIONS Included With Each Combination Boiler Is A PAHVK Horizontal Kit...
- Page 35 INSTALLATION INSTRUCTIONS 12” Clearance Suggested From The Top Of The Appliance To Ceiling 10” 7 ¾” Top of Appliance to Center Line Of Hole...
- Page 36 INSTALLATION INSTRUCTIONS 3.11 2 Pipes Venting system Pictures & Illustrations The two pipes direct vent system can be installed in one of the following configurations. 1. Air Intake & Exhaust Pipes on an outside horizontal wall (intake and vent adjacent) 2.
- Page 37 100’ ( 50” air intake + 50’ exhaust) PCH 18B-H, PCI 18/8-H 2” 85’ (42.5’ air intake + 42.5’ exhaust) PCH 34B-H, PCC 34-H, PCI 34/20-H 2” 85’ (42.5’ air intake + 42.5’ exhaust) PCH 50B-H The vent system must be balanced (the air intake pipe and the exhaust pipe must be as close to equal in length as possible). A maximum of 7 elbows is may be installed in the entire venting system.
- Page 38 INSTALLATION INSTRUCTIONS...
- Page 39 INSTALLATION INSTRUCTIONS Follow all venting manufacturers’ guidelines for low-profile terminations.
- Page 40 INSTALLATION INSTRUCTIONS 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...
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Page 41: Commissioning The Appliance (Authorized Personnel)
INSTALLATION INSTRUCTIONS 4. COMMISSIONING THE APPLIANCE 4.1 General warnings The following operations must be carried out by professionally qualified personnel, registered in accordance with current legislation. Use of a properly calibrated electronic combustion analyzer MUST be used when installing, servicing or converting this Boiler from Natural Gas to LP or from LP to Natural Gas. The boiler leaves the factory pre-set and tested for burning either Natural Gas or LPG. -
Page 42: Filling The System
INSTALLATION INSTRUCTIONS 4.2 Filling the system AIR VENT VALVE PLUG Check the properties of the water supply and install the appropriate treatment devices if the mains water has a hardness rating more than 7 grains/gal. (120 ppm) in order to PUMP prevent scaling and eventual damage to the D.H.W heat exchanger. -
Page 43: Flushing The System
All systems must be thoroughly drained and flushed using additives – corrosion inhibitors and flushing agents/descalers. Pensotti requires the use of the supplied Fernox Commissioning Kit or individual containers of Fernox F3 or F5 cleaner and F1 protector. Follow Fernox installation instructions. -
Page 44: Starting Up The Boiler
REGULATION INSTRUCTIONS 4.5 Starting up the boiler Once the system has been filled, proceed as follows: Table n°1 Check that the exhaust flue is free of obstructions and correctly Gas type connected to the boiler; Switch on the power supply to the Natural Gas - G20 9.18 appliance;... -
Page 45: Regulating The Appliance (Authorized Personnel)
TYPE OF OPERATION FUNC TION N° VALUE PCC 34-H PCI 18/8-H or PCI 34/20-H Selects the type of boiler PCH 34B-H, PCH 18B-H or PCH 50B-H D.H.W. Temperature 95-160 ° F (PCC 34-H only) Natural gas Selects the type of gas... -
Page 46: Setting The Parameters
MAINTENANCE INSTRUCTIONS 5.2 Setting the parameters To modify the pre-set values of the parameters reported in the previous table, open the parameter settings menu as follows: 1. Place the On/Off switch in the OFF position. O FF 110V 60Hz 2. Activate the On/Off switch while keeping buttons ‘+’ and “-“... - Page 47 6. Use buttons ‘+’ and ‘-‘to modify the value of the 110V 60Hz parameter: 00 = PCC 34-H; 01 = PCI 18/8-H or PCI 34/20-H; 02 = PCH 34B-H, PCH18B-H or PCH 50B-H; 03 = DHW Temperature 95-160°F – PCC 34 Only P 01 7.
- Page 48 MAINTENANCE INSTRUCTIONS 4 – C ARAMETER ENTRAL HEATING PUMP 6. Use buttons ‘+’ and ‘-‘to modify the value of the parameter: 110V 60Hz 00 = standard (3 minute default overrun) 01 = permanent (always running) 7. Press and release button ‘S’ to confirm. The parameter number (4) will appear on the display.
- Page 49 MAINTENANCE INSTRUCTIONS 7 – C ARAMETER ENTRAL HEATING PUMP OVERRUN TIMER 110V 60Hz 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 default value is 36 = 180 sec = 3 min P 07 7.
- Page 50 00 = boiler with atmospheric burner; 110V 60Hz 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) P 1 4 will appear on the display.
- Page 51 MAINTENANCE INSTRUCTIONS 17 – M ARAMETER INIMUM PEED ETTING 6. Use buttons ‘+’ o ‘-’ to modify the value of the parameter: 110V 60Hz max = value of parameter 18 The default value is : - 55 Hz for Natural Gas; - 52 Hz for L.P.G.;...
- Page 52 MAINTENANCE INSTRUCTIONS 21 – I ARAMETER GNITION EQUENCE ETTING GNITION POINT IN 1 1 0 110V 60Hz 6. Use buttons ‘+’ o ‘-’ to modify the value of the parameter between: min = value of parameter 17; max = value of parameter 18.
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Page 53: Gas Data
NATURAL GAS – GAS A LIQUID PROPANE GAS – GAS E Heating Value (BTU/Cubic Feet) 2516 BTU/FT³ 1000 “wc Nominal supply gas pressure Heating Power (kW) – Fan frequency (Hz) diagram PCH 34B-H, PCC 34-H & PCI 34/20-H LP Gas Nat Gas... -
Page 54: Converting The Boiler To A Different Gas Type
8. Switch off the appliance and switch it back on again to render the new parameter operative. *When Converting model numbers PCC 34-H, PCH 34B-H, PCI 34/20-H and PCH 50B-H it is only necessary to change Parameter “P02”. If converting models numbers PCH 18B-H or PCI 18/8-H it is necessary to change Perimeters 2, 17, 18, 19, 20 and 21 to the values fund in the corresponding installation manuals. -
Page 55: Maintenance (Authorized Personnel)
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. -
Page 56: Boiler Inspection
MAINTENANCE INSTRUCTIONS 6.3 Boiler inspection In order to ensure that the boiler operates efficiently and safely, it is recommended that the appliance is inspected by a suitably competent technician at least once a year. The following operations should be carried out annually: ■... -
Page 57: Accessing The Boiler
MAINTENANCE INSTRUCTIONS 6.4 Accessing the boiler All maintenance operations require one or more of the boiler casing panels to be removed. The side panels can only be removed after the front panel has been removed. Front panel: Remove the fixing screws at the lower edge of the front panel. -
Page 58: Draining The Central Heating System
System winterization (non-operative system) Because it may be impossible to completely drain the boilers heating circuit, D.H.W circuit and distribution system. Pensotti recommends the introduction of the proper type antifreeze to protect these systems from freezing damage. Glycol must not be used in Domestic Hot Water applications. - Page 59 MAINTENANCE INSTRUCTIONS glycol specifications for more information. STORAGE CYLINDER MAINTENANCE AND MAGNESIUM ANODE REPLACEMENT Check the magnesium anode inside the D.H.W. storage cylinder for erosion, a minimum of every 12 months or more frequently in case of hard water or continuous operation. If it is worn-out, replace it immediately.
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Page 60: Maintenance Operations
ELECTRICITY, WATER and GAS supplies to the exchanger boiler. premix burner unit Pensotti LLC will not be held responsible for damage to any of the boiler’s components caused by non-compliance with this instruction. For all maintenance operations requiring removal of the boiler casing, refer to the procedures described in paragraph 6.4 “Accessing the boiler”. - Page 61 MAINTENANCE INSTRUCTIONS Part replacement Ignition and/or flame detection electrodes (see fig. 2) Un-Plug the electrode wires; Slacken the fixing screws; Remove the electrodes. When fitting the new ones, check that the seals are not damaged. ignition Replace if necessary; electrode Reconnect the wires and re-assemble the components following the above procedure in reverse order;...
- Page 62 MAINTENANCE INSTRUCTIONS Safety thermostat (see fig. 1) Disconnect the connecting wire; Unscrew the fixing screws and remove the thermostat; Replace the thermostat and re-assemble the components following the above procedure in reverse order; Switch on the electricity, water and gas supplies and restart the appliance.
- Page 63 INSTALLATION INSTRUCTIONS Electric fan (see fig. 1) Remove and dismantle the entire burner unit (see “Cleaning the burner unit”). Use an 8 mm spanner to unscrew the four nuts venturi securing the electric fan to the gas manifold and then remove the electric fan, noting the positions of the washer.
- Page 64 INSTALLATION INSTRUCTIONS Diverter valve (see fig. 1) Replacing the motor Unscrew the fixing screws securing the transparent cover of the diverter valve and remove the cover; Unscrew the two motor fixing screws and disconnect the wires; Replace the motor and re-assemble the components following the above procedure in reverse order;...
- Page 65 INSTALLATION INSTRUCTIONS Primary heat exchanger (see fig. 1) Close the shut-off valves and drain the central primary heating circuit of the boiler; heat flue exchanger Switch off the power and gas supply to the connection chamber boiler; Remove and dismantle the entire burner unit (see “Cleaning the condensation module and burner unit”);...
- Page 66 INSTALLATION INSTRUCTIONS D.H.W heat exchanger (see fig. 1) Close the shut-off valve and drain the domestic hot water circuit and central heating circuit of the boiler. D.H.W heat exchanger Use a 4 mm Allen key to unscrew the four screws securing the heat exchanger to the multiplex unit.
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Page 67: Wiring Diagrams
INSTALLATION INSTRUCTIONS 6.8 Wiring diagrams PRINTED CIRCUIT BOARD KOND DT - SK11003 COD. 76702LA PRINTED CIRCUIT BOARD DIGITECH - SM20023 EXHAUST FAN type RG 128 PRINTED CIRCUIT BOARD - SK16504 - COD. 40-00073 IG: Main Switch green PA: Air Pressure switch TS: Safety thermostat fusibile 2A brown... - Page 68 INSTALLATION INSTRUCTIONS Connecting the room thermostat (Option) Connect the wires to the terminal board inside the instrument panel as follows: TA terminals are 24volt DC. Accordingly only a non-power stealing device can be installed to the these terminals. a. switch off the power supply at the main switch. b.
- Page 69 INSTALLATION INSTRUCTIONS Regulating the water temperature in accordance with the outdoor temperature The outdoor sensor has to be connected directly to circuit board. In case of outdoor temperature sensor installation, the climatic compensation curve is set using the central heating control knob. As the knob (see fig. 2) is rotated, the numbers corresponding to the curve shown in figure 1 are displayed The factors governing the correction are reported in figure 1.
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Page 70: Troubleshooting
INSTALLATION INSTRUCTIONS 6.9 Troubleshooting ERROR PROBLEM POSSIBLE CAUSE REMEDY CODE WITH NO IGNITION WITH NO IGNITION NO GAS. CHECK MAINS SUPPLY. IGNITION ELECTRODE BROKEN OR GROUNDED. REPLACE PART. GAS VALVE MALFUNCTION REPLACE PART MECHANICAL MINIMUM ADJUSTMENT (ON GAS REGULATE MECHANICAL MINIMUM OR VALVE) SET TOO LOW OR SLOW IGNITION SLOW IGNITION. -
Page 71: Diagnostics
INSTALLATION INSTRUCTIONS 6.10 Diagnostics ■ Error codes: Ionization Lock Out / Air Pressure Switch Tripped Safety Thermostat Tripped Flue Gas Thermofuse Tripped Low Water Pressure Alarm Heating Sensor Malfunction 110V 60Hz D.H.W Storage Cylinder Sensor Malfunction Electric Fan Malfunction Parameter Programming Request Flame Detection Malfunction Fan Speed P.C.B. -
Page 72: Parts List
6.11 Parts List / Available from PENSOTTI Main components CODE DESCRIPTION 20047LA PLATE EXCHANGER 20 P. 25-00108 CYLINDER 20 lt 25-00110 PRESSURE RELIEF VALVE 8 BAR - HOT WATER 25-00196 WATER PRESSURE GAUGE 25-00247 SAFETY VALVE 30 psi 25-00248 PUMP UPS 15-58 CACAO ETL Molex... -
Page 73: Sequence Of Operations
6.13 Sequence of Operations... - Page 75 Pensotti LLC 34 Coffin Ave Brewer, ME 04412 P. 207-942-3636 F. 207-942-3737 www.pensottiboiler.com...