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Related Manuals for PENSOTTI PCH 34B H
Summary of Contents for PENSOTTI PCH 34B H
- Page 1 Pensotti ASME Condensing Boilers Cleaning Procedure Version 1 - All Models...
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Page 2: Table Of Contents
Pensotti ASME Condensing Boilers Table of Contents Service Requirements Pg. 3 Safety Precautions Pg. 5 Combustion Chamber Cleaning Procedure Pg. 7 Diverter Valve Lubrication Pg. 29 Water Test and Treatment Pg. 30 Version 1... -
Page 3: Service Requirements
Service Requirements To maintain reliability, efficiency and safe operation, it is imperative that all models of Pensotti Condensing Gas Boilers be cleaned and inspected by a trained, licensed technician on an annual basis. To maintain the highest possible operating efficiency, the heat exchanger surfaces must be kept clean. Soot and foreign debris will insulate the heat exchanger surface, reducing the efficient transfer of heat. - Page 4 Service Requirements The quantity and rate of build-up on the heat exchanger will vary with each boiler installation due to the factors mentioned on page 3. Boilers operating on LP Gas and those installed in environments containing high levels of pollutants or chemical vapors in the combustion air may need to be cleaned more frequently.
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Page 5: Safety Precautions
Safety Precautions Personal Protective Equipment is recommended when handling the insulating material (Refractory Ceramic Fibers) Important on the burner door and back wall of the combustion chamber. Refractory Ceramic Fibers in high temperature applications can result in the formation of Crystalline Silica Dust. Warning Repeated airborne exposure of Crystalline Silica Dust may result in chronic lung infections, respiratory illness, or death. - Page 6 Safety Precautions Follow all instructions, failure to do so could result in personal property damage, injury or death. Refer to the Important installation manual, supplied with the boiler, for additional information. If you smell gas: Warning • Do not operate any appliance •...
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Page 7: Combustion Chamber Cleaning Procedure
Combustion Chamber Cleaning Procedure 1. Turn the manual gas shut off valve, for the boiler, to the closed position 2. Disconnect electrical power to the boiler. Remove the electrical cord from the outlet 3. Remove the front cover of the boiler •... - Page 8 Combustion Chamber Cleaning Procedure 4. Disconnect: • The ionization electrode cable from the electrode - A • The ignition electrode cable from the ignition transformer - B • The ground wire from the ignition electrode - C • The cable on the gas valve - D •...
- Page 9 Combustion Chamber Cleaning Procedure Version 1...
- Page 10 Combustion Chamber Cleaning Procedure 5. Flip the control panel down by spreading the 2 retaining bracket handles Version 1...
- Page 11 Combustion Chamber Cleaning Procedure 6. Locate the inlet and outlet gas tube connections to the gas valve and disconnect the nuts. These are gasketed fittings, carefully remove the gaskets, if in good repair, retain for later use. Replace any damaged gasket. Version 1...
- Page 12 Combustion Chamber Cleaning Procedure 7. Locate the gas valve retaining screws. They are located at the inlet side of the gas valve below the sheet metal shelf the gas valve is mounted on. There are 4 Philips head screws, 2 recessed into the sheet metal and 2 securing the gas valve to the sheet metal shelf. Only remove the 2 screws securing the gas valve.
- Page 13 Combustion Chamber Cleaning Procedure 8. Remove the gas valve. Place it in a safe location to avoid any potential damage. Version 1...
- Page 14 Combustion Chamber Cleaning Procedure 9. Using a 10mm wrench or socket, loosen the 4 nuts securing the burner to the main heat exchanger. Once loose, remove 3 of the nuts and place them in a safe location. Hold the pre-mix burner tube with one hand while removing the final nut. Retain the 4 nuts. Pre-mix Tube Version 1...
- Page 15 Combustion Chamber Cleaning Procedure 9a. Remove the burner assembly. Rotate the left side of the burner assembly a couple of inches away from the main heat exchanger. Now pull the assembly straight from the boiler. Once free, continue to rotate the burner assembly as you remove it from the boiler. Warning Caution: Internal components may be hot! Version 1...
- Page 16 Combustion Chamber Cleaning Procedure 10. Inspect the internal burner components. Place the burner on a clean, flat surface. Inspect all the burner components, especially, the refractory, rope gasket and EPDM seal for excessive wear or defect. Replace any worn or defective item. Burner Rope Gasket Refractory...
- Page 17 Combustion Chamber Cleaning Procedure 11. Inspect the ignition electrode and measure the spacing. Clean the electrode assembly with a clean soft cloth. Do not use sandpaper, emery board or coarse steel wool, these may remove the protective coating applied to the electrode. Verify the condition of the electrode, inspect for excessive wear, broken electrode or ground rod or cracked porcelain insulator.
- Page 18 Combustion Chamber Cleaning Procedure 12. Inspect the ionization electrode and measure the spacing. Clean the electrode assembly with a clean soft cloth. Do not use sandpaper, emery board or coarse steel wool, these may remove the protective coating applied to the electrode. Verify the condition of the electrode, inspect for excessive wear or cracked porcelain insulator.
- Page 19 Combustion Chamber Cleaning Procedure Permitting any Pensotti Condensing Boiler to operate with a dirty combustion chamber and heat exchanger will Important void the warranty. Warning 13. Inspect the refractory target wall for defects such as large cracks or damaged areas. Replace if necessary. Removal of the existing target wall will require breaking it into several pieces in order to release the retaining pin and clips.
- Page 20 Combustion Chamber Cleaning Procedure Warning 14. Clean the heat exchanger surfaces. Refer to the safety precautions section of this manual, beginning on page 5, before proceeding. Remove the condensate drain hose from the neutralizer and/or drain and place into a bucket to collect the cleaning water. Using a vacuum with a high efficiency filter, remove all of the loose debris from within the combustion chamber and heat exchanger surfaces.
- Page 21 Combustion Chamber Cleaning Procedure 15. Protect the refractory target wall by covering it with a piece of heavy duty plastic, such as a plastic container lid or the bottom of a 5 gallon pail cut to size. This will reduce the potential of damage caused by the cleaning brush or water spray. 16.
- Page 22 Combustion Chamber Cleaning Procedure 17. Protect the electrical components within the boiler by covering them with a plastic bag or plenty of dry rags. This will eliminate the possibility of damage to these items from sprayed or dripping water. 18. Using a garden hose with a trigger spray nozzle or similar device, direct pressurized water in the space between the heat exchanger tubes.
- Page 23 Combustion Chamber Cleaning Procedure 19. Repeat step 16 and brush the wetted heat exchanger to remove additional debris from the heat exchanger surface. 20. Again, using a garden hose with a trigger spray nozzle or similar device, direct pressurized water in the space between the heat exchanger tubes.
- Page 24 Combustion Chamber Cleaning Procedure 21. Remove the plastic cover protecting the refractory target wall. Using dry rags, wipe up any water overspray that may have occurred during the cleaning process. 22. Remove the plastic bag used to protect the electrical components 23.
- Page 25 Combustion Chamber Cleaning Procedure 24. Reinstall the burner assembly. Apply a very small amount of Never Seize to each burner stud. Reattach the 4 – 10mm nuts, leaving them loose to aid in the installation of the gas valve. 25. Reinstall the gas valve. Fit the inlet side of the gas valve into the cut-out provided in the sheet metal shelf. Manipulate the position until the 2 screws at the gas valve manifold drop into the cut-outs provided for them.
- Page 26 Combustion Chamber Cleaning Procedure 27. Reconnect • The ionization electrode cable - A • The ignition electrode cable - B • The ground wire to the ignition electrode - C • The gas valve cable - D • The pressure switch hose at the gas venturi - E •...
- Page 27 Combustion Chamber Cleaning Procedure 28. Check for combustion leaks. With the gas still turned off, reconnect electrical power to the boiler. Remove the 4 wire cable from the combustion blower motor. The fan will now run continually on high speed. Temporarily block the exhaust vent only. Using a soap and water solution, inspect for leaks throughout the burner assembly and it’s connection to the heat exchanger.
- Page 28 32. Perform a combustion test. Using an electronic combustion analyzer, verify the high fire CO2 reading equals the value in the table below. Adjust if necessary. Refer to the boiler’s installation manual, section 5, for procedural information. Boiler Model Gas Type PCH 34B H 10.3 PCH 50B H 10.3 PCC 34 H 10.3...
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Page 29: Diverter Valve Lubrication
Diverter Valve Lubrication 33. Lubricate the diverter valve. Remove the right-hand side panel. Using a spray can of PTFE lubricant* with a precision spray straw attached, spray a small amount of lubricant directly onto the drive shaft of the diverter valve. Wipe away any excess lubricant. Failure to lubricate the diverter will result in premature failure and may void the warranty of this item. -
Page 30: Water Test And Treatment
Water Test and Treatment 34. Test the heating system boiler water. When purchased, every Pensotti condensing boiler is supplied with a Fernox Express Water Treatment Kit. Within it is a water test kit, along with instructions. Following those instructions; test the water and if necessary, treat as required.