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PENSOTTI PCH 50B-H Instruction Manual

Condensing combination space heating/boiler 170,600 btu/h input
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CONTENTS
Instruction Manual
PCH 50B-H
Condensing Combination
Space heating / Boiler
170,600 BTU/h 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.
-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

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  • Page 1 CONTENTS Instruction Manual PCH 50B-H Condensing Combination Space heating / Boiler 170,600 BTU/h 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. -Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

  • Page 2: Table Of Contents

    CONTENTS Pages 1. General information 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 D.H.W Sensor Connection 6.10 Troubleshooting 6.11 Diagnostics...

  • Page 4: General Information

    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...

  • 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 PCH 50B-H kW – BTU 50 – 170600 Heat Input max kW – BTU Heat Input min 12 - 40900 AFUE% 93.1 Efficiency (Full load) - 122/86°F Efficiency (Full load) - 176/140°F 87.7...

  • Page 14: Dimensions

    TECHNICAL CHARACTERISTCS 2.2 Dimensions RCR RCF CWI 18.5 LEGEND HEATING RETURN Ø 3/4 " Ø 3/4 " HEATING SUPPLY Ø 3/4 " Ø 3/4 " D.H.W. INDIRECT RETURN Ø 3/4 " D.H.W. INDIRECT FLOW Ø 1/2" COLD WATER INLET 19.3 CONDENSATE DRAIN Ø...

  • Page 15: Internal Parts Of The Boiler

    TECHNICAL CHARACTERISTCS 2.3 Internal parts of the boiler LEGEND AIR PRESSURE SWITCH SAFETY THERMOFUSE HEATING SENSOR HEATING SAFETY THERMOSTAT IONISATION ELECTRODE EXPANSION VESSEL IGNITION TRANSFORMER PREMIX BURNER UNIT (GAS MANIFOLD + BURNER) AUTOMATIC AIR VENT VALVE 10. FAN 11. PUMP 12.

  • Page 16: Water Circuit

    TECHNICAL CHARACTERISTCS 2.4 Water circuit OPTIONAL EXTERNAL SENSOR REMOTO LCD EXTERNAL SENSOR STORAGE CYLINDER DHW TEMPERATURE SENSOR code 31368LA (SUPPLIED WITH THE BOILER) REMOTE DHW CYLINDER code 20045LA LEGEND NOTE THERE IS A STRAINER ON THE HEATING CIRCUIT.. THE INSTALLATION OF AN ADDITIONAL STRAINER ON THE SECONDARY CIRCUIT IS RECOMMENDED.

  • Page 17: Circulation Pump Head/Flow Graph

    TECHNICAL CHARACTERISTCS 2.5 Circulation pump head/flow graph...

  • Page 18: Control Panel

    TECHNICAL CHARACTERISTCS ® printed circuit board – SM 20023 2.6 DIGITECH Technical characteristics Adjustments possible by service personnel only Standard (95-185° 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

    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 Pensotti boilers should be stored in the horizontal position with no more than three boilers to a stack;...

  • Page 21: Fixing The Boiler To Wall

    INSTALLATION INSTRUCTIONS 3.4 Fixing the boiler to wall...

  • Page 22: Water Connections

    INSTALLATION INSTRUCTIONS 3.5 Water connections In order to safeguard the heat exchanger and circulation pump, especially in case of appliance replacement, it is recommended that the system is hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators.

  • Page 23: Domestic Hot Water Circuit / Hard Water Warning / Expansion Tank / Piping Diagram

    INSTALLATION INSTRUCTIONS 3.6 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 24 INSTALLATION INSTRUCTIONS These piping diagrams are examples for illustrative purposes only. They are 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 – Consult Local Codes *Must leave 15”...

  • Page 25: Condensate Drain

    INSTALLATION INSTRUCTIONS 3.7 Condensate drain FAILURE TO INSTALL THE CONDENSATE Termination to an internal soil and vent pipe DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE Boiler DUAL PURPOSE BOILER. The condensate discharge pipe MUST NOT RISE at any point along its length.

  • Page 26: 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 27 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"...

  • Page 28: 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 29 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 30 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.

  • Page 31: 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 us es a 3”...
  • Page 32 INSTALLATION INSTRUCTIONS Venting Pictures & Illustrations...
  • Page 33 INSTALLATION INSTRUCTIONS Included With Each Combination Boiler Is A PAHVK Horizontal Kit...
  • Page 34 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 35 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 36 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 37 INSTALLATION INSTRUCTIONS...
  • Page 38 INSTALLATION INSTRUCTIONS Follow all venting manufacturers’ guidelines for low-profile terminations.
  • Page 39 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...

  • Page 40: 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 41: Filling The System

    INSTALLATION INSTRUCTIONS 4.2 Filling the system Check the properties of the water supply and install the appropriate treatment devices if the mains water has a AIR VENT VALVE hardness rating more than 7 grains/gal. (120 ppm) in order to prevent scaling and eventual damage to the D.H.W heat AIR VENT VALVE PLUG exchanger.

  • Page 42: 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 43: 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 appliance;...

  • Page 44: Regulating The Appliance (Authorized Personnel)

    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 Propane Sets the central heating Standard (95-185°...

  • Page 45: 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 46 8. Switch off the appliance and switch it back on again to render the new parameter operative. ^If NOT installing an indirect water heater directly to this PCH 50B-H boiler using the supplied fittings set Parameter 1 to “00”. Refer to section 3.6 “Domestic Water Circuit”...
  • Page 47 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 48 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 49 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 50 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 : - 60 Hz for Natural Gas; - 60 Hz for L.P.G.;...
  • Page 51 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.

  • Page 52: Gas Data

    Natural Gas – Gas A Liquid Propane Gas – Gas E 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 50B-H...

  • Page 53: Converting The Boiler To A Different Gas Type

    *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 54: Regulating The Gas Valve Offset

    MAINTENANCE INSTRUCTIONS 5.5 Regulating the gas valve offset When replacing the gas valve, it is necessary to regulate the offset on the new gas valve to guarantee a correct operation of the boiler. Instructions as follows: Fig. 1 – Disconnect the silicon pipe from its connection onto the venturi air intake point.

  • 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 Operations

    ELECTRICITY, WATER and GAS supplies to the boiler. 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 60 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. Replace if necessary; ignition Reconnect the wires and re-assemble the electrode components following the above procedure in reverse order;...
  • Page 61 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 heating and restart the appliance.
  • Page 62 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 63 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 64 INSTALLATION INSTRUCTIONS Primary heat exchanger (see fig. 1) primary heat flue connection Close the shut-off valves and drain the central exchanger chamber heating circuit of the boiler; Switch off the power and gas supply to the boiler; Remove and dismantle the entire burner unit (see “Cleaning the condensation module and burner unit”);...

  • Page 65: 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 66 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 these terminals. a. switch off the power supply at the main switch. b.
  • Page 67 INSTALLATION INSTRUCTIONS Regulating the water temperature in accordance with the outdoor temperature The outdoor sensor has to be connected directly to the boiler SE terminals. In case of outdoor temperature sensor installation, the climatic compensation curve is set using the central heating control knob.

  • Page 68: Sensor Connection

    INSTALLATION INSTRUCTIONS 6.9 D.H.W sensor connection (INDIRECT FIRED BOILER)

  • Page 69: Troubleshooting

    INSTALLATION INSTRUCTIONS 6.10 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 70: Diagnostics

    INSTALLATION INSTRUCTIONS 6.11 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 71: Parts List

    6.12 Parts List / Available from PENSOTTI Main components CODE DESCRIPTION 20094LA ISOTERMIQUE 8+3 COMBUSTION CHAMBER BACK PANEL 20079LA PLATE EXCHANGER 40 P. EXPANSION VESSEL 6 lt. – 1,58 gal 25-00045 25-00196 WATER PRESSURE GAUGE 25-00247 SAFETY VALVE 30 psi...

  • Page 72: Sequence Of Operations

    6.13 Sequence of operations...
  • Page 74 Pensotti LLC 34 Coffin Ave Brewer, ME 04412 P. 207-942-3636 F. 207-942-3737 www.pensottiboiler.com...

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