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PENSOTTI PCH 18 Instruction Manual

Wall mounted heat only boiler premix condensing system boiler
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Instruction Manual
for model
PCH 18
Wall mounted heat only boiler
Premix condensing system boiler
This appliance must be installed by a licensed and/or qualified technician. Failure to
properly install this appliance could result in property damage and possible injury or
death to occupents.
Installation, operating, commissioning and maintenance instructions.
RK_18_-_PNA_-_USA_-_MAN.INST_-_1009A_-_DIGITECH
ENGLISH

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Summary of Contents for PENSOTTI PCH 18

  • Page 1 Instruction Manual for model PCH 18 Wall mounted heat only boiler Premix condensing system boiler This appliance must be installed by a licensed and/or qualified technician. Failure to properly install this appliance could result in property damage and possible injury or death to occupents.

  • Page 3: 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 4 CONTENTS Pages 6. Maintenance (authorized personnel) 6.1 General warnings 6.2 Boiler inspection 6.3 Accessing the boiler 6.4 Flushing out the primary side 6.5 Draining the central heating system 6.6 Maintenance operations 6.7 Wiring diagrams 6.8 Troubleshooting 6.9 Diagnostics 6.10 Parts list...

  • Page 5: General Information

    The commissioning of the boiler and any subsequent works carried out on the appliance must be effected by an appropriately qualified technician or an approved Pensotti North America Helpline Service Centre. The appliance must be used solely for the purpose for which it has been designed and manufactured: central heating water production.
  • Page 6 GENERAL INFORMATION The air inflow from adjacent rooms is allowed providing that those rooms are in depression with respect to the atmosphere and that there are not fireplace or fan installed. Check the technical data reported on the packing and on the data plate located on the inside of the front casing. Also check that the burner is appropriate for the type of gas to burn.

  • Page 7: Product Conformity

    GENERAL INFORMATION 1.2 Product conformity Pensotti North America declares that all its products are manufactured to a high specification and in compliance with the relevant standards. All PENSOTTI NORTH AMERICA boilers are CE certified and possess technical and functional characteristics that comply with the following standards: EN 483 for GAS-FIRED CENTRAL HEATING BOILERS TYPE C OF NOMINAL HEAT INPUT ≤...

  • Page 8: Technical Characteristics

    INSTALLATION INSTRUCTIONS 2. TECHNICAL CHARACTERISTICS 2.1 Technical data Model PCH 18 CE Certification n° 0694BN3485 Appliance Type B23p-B33-C13-C33-C43-C53-C63-C83-C93 Appliance Category II2H3B/P 18 – 61419 kW - BTU/hr Heat Input max 23.5 – 80185 kW - BTU/hr Heat Input max - D.H.W. production working (G 20) 4 –...

  • Page 9: Dimensions

    INSTALLATION INSTRUCTIONS 2.2 Dimensions 16.1 12.3 11.2 LEGEND Ø3/4” HEATING RETURN Ø3/4” HEATING FLOW Ø1/2” COLD WATER INLET Ø1/2”...

  • Page 10: Internal Parts Of The Boiler

    INSTALLATION INSTRUCTIONS 2.3 Internal parts of the boiler LEGEND SAFETY THERMOFUSE FLUE HOOD PRIMARY CONDENSING HEAT EXCHANGER IONISATION ELECTRODE PREMIX BURNER UNIT (GAS MANIFOLD + BURNER) CONDENSATE DRAIN PIPE HEATING SENSOR HEATING SAFETY THERMOSTAT VENTURI 10. FAN 11. AUTOMATIC AIR VENT VALVE 12.

  • Page 11: Water Circuit

    INSTALLATION INSTRUCTIONS 2.4 Water circuit LEGEND SAFETY THERMO FUSE AIR PRESSURE SWITCH HEATING SENSOR HEATING SAFETY THERMOSTAT PREMIX BURNER UNIT (GAS MANIFOLD+BURNER) LEGEND IONISATION ELECTRODE EXPANSION VESSEL HEATING RETURN PRIMARY CONDENSING HEAT EXCHANGER HEATING FLOW ELECTRONIC GAS VALVE AUTOMATIC AIR VENT VALVE COLD WATER INLET PUMP CONDENSATE DRAIN...

  • Page 12: Circulation Pump Head/Flow Graph

    INSTALLATION INSTRUCTIONS 2.5 Circulation pump head/flow graph Water flow (US gpm) Pump head I, II, III Pump speed Boiler losses...

  • Page 13: Control Panel

    INSTALLATION INSTRUCTIONS ® printed circuit board – SM20021 2.6 DIGITECH Technical characteristics Adjustments possible by service personnel only Standard (86-176°F) / reduced (77-104°F) central heating temperature Water hammer prevention function Central Heating timer - (adjustable from 0 to 7,5 minutes) Central Heating pump overrun timer Minimum Gas pressure setting Maximum Heating Load...

  • Page 14: Installation (Authorized Personnel)

    INSTALLATION INSTRUCTIONS 3. INSTALLATION (authorized personnel) 3.1 Reference standard Install in accordance with CEC and NEC. All wiring shall conform to CEC, NEC and local building and electrical codes. This appliance meets the requirements of: - EMC DIRECTIVE 89/336 CEE - LVD DIRECTIVE 73/23 CEE - BOILER EFFICIENCY DIRECTIVE 92/42 CEE Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution.

  • Page 15: Unpacking

    STORAGE & HANDLING Please note that prior to installation the Pensotti North America boilers should be stored horizontal position with no more than three boilers to a stack; Ensure that the boilers are...

  • Page 16: Installing The Boiler

    INSTALLATION INSTRUCTIONS 3.3 Installing the boiler ■ The appliance must be installed exclusively on a flat vertical solid wall capable supporting weight. ■ The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse.
  • Page 17 INSTALLATION INSTRUCTIONS Direct Vent Termination Minimum Clearances A = 12” Clearance above grade, snowline, deck, porch or balcony B = 12” Clearance to window or door that may be opened C = 24” Vertical clearance to ventilated and unventilated soffit within a 2’ distance horizontally from center line of DV termination D = 12”...

  • Page 18: 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. Make sure that the central heating pipes are not used to earth the electrical system.

  • Page 19: Condensate Drain

    INSTALLATION INSTRUCTIONS Internal Expansion Tank Size Maximum. System Operating Temperature (F) Maximum System Water Content (gal.)* *Assuming the air pressure in the diaphragm tank is equal to the minimum operating water pressure in the system. Central 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.
  • Page 20 INSTALLATION INSTRUCTIONS 3.5 Condensate drain FAILURE INSTALL CONDENSATE Termination to an internal soil and vent pipe DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE Boiler BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5°...

  • Page 21: Gas Connection

    INSTALLATION INSTRUCTIONS 3.7 Gas Connection The connection to the gas supply must be carried out by professionally qualified personnel in accordance with relevant standards: When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The use of hemp, Teflon tape and similar materials is not allowed.

  • Page 22: Electrical Connections

    The connection to the mains power supply must be carried out by professionally qualified personnel, registered in accordance with current legislation and authorized by Pensotti North America. Always check to make sure that the appliance has an efficient earth ground. This requirement is only satisfied if it has been properly connected to an efficient earth system installed in accordance with the requirements of current safety standards and carried out by professionally qualified personnel.
  • Page 23 INSTALLATION INSTRUCTIONS Wire connections Connect the power supply to the terminal board inside the control panel as follows: a. Switch off the power supply at the main switch. b. Remove the front case panel of the boiler. c. Slacken the screws and remove plate A (see fig. 1). d.

  • Page 24: Flue Connections

    Deluxe 3/5" Vent Kit, includes Termination, Wall sleeve, 90° Ell, 10" Conc. Pipe, 39" Conc. Pipe & 2/4-3/5 Adapter w/ Test ports PA27058LA Pensotti Flat Roof Outlet Flashing PA27059LA Pensotti Pitched Roof Flashing PA27088LA Pensotti 45 Degree Co-Axial Elbow 3/5" PA27089LA Pensotti 90 Degree Co-Axial Elbow 3/5" PA43186LA Pensotti 5" Rubber Wall Plate PA80020LA Pensotti Horizontal Conc.
  • Page 25 INSTALLATION INSTRUCTIONS The standard flue components above are suitable for horizontal and vertical applications. Maximum permissible equivalent flue lengths are; Horizontal: 8 meters / 26 feet Vertical: 8 meters / 26 feet Any additional turns in the flue system must be taken into consideration. Each elbow decreases the equivalent length as shown.

  • Page 26: 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. The boiler leaves the factory pre-set and tested for burning either natural Gas or LPG. Nevertheless, when starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler.

  • Page 27: Filling The System

    INSTALLATION INSTRUCTIONS 4.2 Filling the system Use only clean tap water to fill the system. Once the water pipes have been connected, close the AIR VENT VALVE gas feed valve and fill the system as follows: Check that the circulation pump runs freely; AIR VENT VALVE PLUG Check that the plug of the air vent valve has been PUMP...

  • Page 28: Flushing The System

    INSTALLATION INSTRUCTIONS 4.3 Flushing the system Failure to flush and add inhibitor to the system will invalidate the appliance working. All systems must be thoroughly drained and flushed out using additives – corrosion inhibitors and flushing agents/descalers. To flush out the primary side of this unit. a.

  • Page 29: Starting Up The Boiler

    INSTALLATION INSTRUCTIONS 4.5 Starting up the boiler Once the system has been filled, proceed as Table n°1 follows: Gas type Check that the exhaust flue is free of Methane - G20 obstructions and correctly connected to the boiler; Liquid Propane Gas - G 31 10.1 Switch on the power supply to the boiler;...

  • Page 30: Regulating The Appliance (Authorized Personnel)

    REGULATION INSTRUCTIONS 5. REGULATING THE APPLIANCE 5.1 Parameters table PARAMETER TYPE OF OPERATION PARAMETER VALUE FUNCTION N° Instantaneous Boiler with storage tank Selects the type of boiler B. w/storage tank Comfort (+13°F) D.H.W. Temperature 95-160 °F Natural gas Selects the type of gas Sets the central heating Standard (86-176°F) temperature...

  • Page 31: Setting The Parameters

    REGULATION INSTRUCTIONS 5.2 Setting the parameters To modify the preset 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 O FF position. 110V 60Hz 2. Activate the On/Off switch while keeping P 00 buttons „+‟...
  • Page 32 REGULATION INSTRUCTIONS To enter the parameters menu, follow the previously described procedure (steps 1-5). 1 – T ARAMETER YPE OF BOILER 6. Use buttons „+‟ and „-„ to modify the value of the 110V 60Hz parameter: 00 = Instantaneous boiler 01 = Storage boiler;...
  • Page 33 REGULATION INSTRUCTIONS 4 – C ARAMETER ENTRAL HEATING PUMP 6. Use buttons „+‟ and „-„ to modify the value of the parameter: 110V 60Hz 00 = standard (3” overrun) 01 = permanent (always running) 7. Press and release button „S‟ to confirm. The parameter number (4) will appear on the display.
  • Page 34 REGULATION INSTRUCTIONS 7 – C ARAMETER ENTRAL HEATING PUMP OVERRUN TIMER 6. Use buttons „+‟ and „-„ to modify the value of the parameter within the prescribed limits 110V 60Hz 00 = 0 x 5” = 0” 90 = 90 x 5” = 450” (7.5 min) The default value is 36 = 180”...
  • Page 35 REGULATION INSTRUCTIONS 13 – D.H.W ARAMETER PRIORITY Not applicable 110V 60Hz P 1 3 110V 60Hz 14 – T ARAMETER YPE OF BURNER 6. Use buttons „+‟ o „-‟ to modify the value of the parameter: 110V 60Hz 00 = boiler with atmospheric burner; 01 = boiler with premix burner 25 kW;...
  • Page 36 REGULATION INSTRUCTIONS 17 – M ARAMETER INIMUM PEED ETTING 6. Use buttons „+‟ o „-‟ to modify the value of the parameter between: 110V 60Hz min = 33 Hz ; max = value of parameter 18 The default value is : - 38 Hz for Natural Gas;...
  • Page 37 REGULATION INSTRUCTIONS 21 – I ARAMETER GNITION EQUENCE ETTING 1 1 0 6. Use buttons „+‟ o „-‟ to modify the value of the 110V 60Hz parameter between: min = value of parameter 17; max = value of parameter 18. The default value is: - 90 Hz for Natural Gas;...

  • Page 38: Gas Data

    REGULATION INSTRUCTIONS 5.3 Gas data Technical data tables Table no.1 - CO2 Values Gas type Natural gas - G20 Liquid Propane Gas - G 31 10.1 Table no.2 - Frequency PARAMETRO 20 17-19 ARAMETER ARAMETER Gas type Maximum Central Minimum (Hz) Maximum D.H.W.

  • Page 39: Converting The Boiler To A Different Gas Type

    The conversion of a boiler from burning natural gas to LPG, or vice versa, must be carried out exclusively by professionally qualified personnel, registered in accordance with current legislation and authorized by Pensotti North America. Check that the gas supply pipe is suitable for the new fuel type.

  • Page 40: Boiler Inspection

    6. MAINTENANCE (authorized personnel) 6.1 General Warnings All maintenance operations must be carried out by professionally qualified personnel, authorized by Pensotti North America. The frequency of boiler maintenance must comply with current law and, nevertheless, should be carried out once a year.

  • Page 41: Accessing The Boiler

    MAINTENANCE INSTRUCTIONS 6.3 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 42: Draining The Central Heating System

    MAINTENANCE INSTRUCTIONS 6.5 Draining the central heating system If the need arises to drain the system, this can be done as follows: Switch the system to “WINTER” mode and ignite the boiler. Switch off the power supply to the boiler. Wait for the boiler to cool down.

  • Page 43: Maintenance Operations

    Before carrying out any cleaning or part replacement operations, ALWAYS turn off ELECTRICITY, WATER primary heat supplies to the boiler. exchanger Pensotti North America will not be held responsible for damage to any of the premix burner unit boiler’s components caused non- compliance with this instruction.
  • Page 44 MAINTENANCE INSTRUCTIONS and exhaust joints are tight. Part replacement Ignition and/or flame detection electrodes (see fig. 1) ignition Un-Plug the electrode wires; electrode Slacken the fixing screws; Remove the electrodes. When fitting the new ones, check that the seals are not damaged. Replace if necessary; Reconnect the wires and re-assemble the components following the above procedure in reverse order;...
  • Page 45 MAINTENANCE INSTRUCTIONS Safety thermostat (see fig. 2) Disconnect the connecting wire; Unscrew the fixing screws and remove the thermostat; Replace thermostat re-assemble components following the above procedure in reverse order; Switch on the electricity, water and gas supplies and restart the appliance. heating sensor Heating sensor...
  • Page 46 MAINTENANCE INSTRUCTIONS Electric fan (see fig. 1) Remove and dismantle the entire burner unit (see “Cleaning the burner unit”). venturi Use an 8 mm spanner to unscrew the four nuts securing the electric fan to the gas manifold and then remove the electric fan, noting the positions of the washer and diaphragm.
  • Page 47 MAINTENANCE INSTRUCTIONS Circulating pump (motor body) (see fig. 1) Close the shut-off valves and drain the central heating circuit of the boiler; circulating Use a 5 mm Allen key to unscrew the four screws pump securing the motor body to the impeller body; Remove the motor body and check the condition of the washer.
  • Page 48 INSTALLATION INSTRUCTIONS Primary heat exchanger (see fig. 1) Close the shut-off valves and drain the central primary heat heating circuit of the boiler; exchanger flue connection Switch off the power and gas supply to the boiler; chamber Remove and dismantle the entire burner unit (see “Cleaning the condensation module and burner unit”);...

  • Page 49: Wiring Diagrams

    INSTALLATION INSTRUCTIONS 6.7 Wiring diagrams PRINTED CIRCUIT BOARD KOND DT - SK11003 COD. 76702LA PRINTED CIRCUIT BOARD DIGITECH - SM20021 EXHAUST FAN type RG 128 IG: Main Switch PA: Air Pressure switch TS: Safety thermostat fusibile 2A brown TF: Thermo Fuse 216°F TF max: Thermo Fuse 320°F light-blue SR: Heating sensor...
  • Page 50 INSTALLATION INSTRUCTIONS Connecting the room thermostat (Option) Connect the wires to the terminal board inside the instrument panel as follows: (Example with WEEK digital weekly chronostat): a. switch off the power supply at the main switch. b. remove the front case panel of the boiler. c.
  • Page 51 INSTALLATION INSTRUCTIONS Connecting the remote controller 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 Outside temperature switch. sensor (option) b. remove the front case panel of the boiler.
  • Page 52 INSTALLATION INSTRUCTIONS Remote control and zone valves wiring For the installation of a zone valve p.c.b, it is necessary to access the main p.c.b for electrical connection (see 6.3 “Accessing the boiler” ) and to activate the parameter no. 16 (see 5.1 “Parameters table”).
  • Page 53 INSTALLATION INSTRUCTIONS Remote control, zone valves and telephone control wirings...
  • Page 54 INSTALLATION INSTRUCTIONS Regulating the Flow temperature in accordance with the outdoor temperature The outdoor sensor has to be connected directly to circuit board SM20021. The sensor can thus be managed in one of two ways: In case of remote controller + outdoor temperature sensor installation, the climatic compensation curve is set by the remote itself (see remote control installation and operating manual).

  • Page 55: Troubleshooting

    INSTALLATION INSTRUCTIONS 6.8 Troubleshooting ERROR PROBLEM POSSIBLE CAUSE REMEDY CODE WITH NO IGNITION CHECK GAS SUPPLY. NO GAS. REPLACE PART. IGNITION ELECTRODE BROKEN OR REPLACE PART EARTHED. REGULATE MECHANICAL MINIMUM OR GAS VALVE MALFUNCTION SLOW IGNITION. MECHANICAL MINIMUM ADJUSTMENT CHECK THE MAXIMUM PRESSURE (ON GAS VALVE) SET TOO LOW OR SLOW SETTING.

  • Page 56: Diagnostics

    INSTALLATION INSTRUCTIONS 6.9 Diagnostics ■ Error codes: Ionisation Lock Out Safety Thermostat Tripped Flue Gas Thermofuse Tripped Low Water Pressure Alarm Heating Sensor Malfunction Electric Fan Malfunction Parameter Programming Request Flame Detection Malfunction Fan Speed P.C.B. Malfunction ■ Function codes : Code Function Description...

  • Page 57: Parts List

    INSTALLATION INSTRUCTIONS 6.10 Parts List Main components CODE DESCRIPTION 20082LA ISOTERMIQUE 3+1 COMBUSTION CHAMBER BACK PANEL 21043LA PRIMARY EXCHANGER 3+1 PREMIX 0.70 24060LA PUMP STAR-S-21-ku-RSL- 15-PR6 C3aper.UL/CSA 25-00045 EXPANSION VESSEL 6 lt. SAFETY VALVE 3/4” M- 3/4” F 25-00050 27044LA CONDENSATE TRAP 30-00023 AIR PRESSURE SWITCH 2.14 UL/CSA...
  • Page 58 Pensotti North America 34 Coffin Ave Brewer, ME 04412 P. 207-942-3636 F. 207-942-3737 www.pensotti-pna.com...

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