PENSOTTI PNCC-32N, Instruction Manual

Page 1: ... 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 This applianc...

Page 2: ...nel 3 1 Reference standard 17 3 2 Unpacking 18 3 3 Installation boiler 19 3 4 Water connections 20 3 5 Piping Diagrams Piping Information 22 3 6 Gas connection 25 3 7 Electrical connections 27 3 8 Venting connections 30 4 Commissioning the appliance authorized personnel 4 1 General warnings 47 4 2 Filling the system 48 4 3 Flushing the system 49 4 4 Starting up the boiler 50 5 Regulating the appli...

Page 3: ...65 6 3 Accessing the boiler 66 6 4 Flushing out the primary side 66 6 5 Draining the central heating and domestic hot water system 67 6 6 Wiring diagrams 68 6 7 Electrical connections Option 69 6 8 Troubleshooting 70 6 9 Function codes 72 6 10 Parts list Exploded Drawings 73 WARRATY INFORMATION 77 ...

Page 4: ...be completely expelled out of the building Do not use this appliance if any part has been underwater Immediately call a 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 bur...

Page 5: ...el burning appliances in rooms or areas where gasoline other 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 re...

Page 6: ...ppliance in any way As dictated by current legislation this appliance must be installed exclusively by qualified personnel Before starting the boiler for the first time make sure that it is connected to a water supply and central heating system compatible with its performance characteristics Prior to start up the central heating pipes should be flushed to remove any residues that could compromise ...

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 ...

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Page 12: ...etc form a compact uniform highly functional unit that is easy to install and simple to operate In its simplicity the wall mounted appliance is equipped with all the appropriate accessories required to make it a fully independent boiler capable of satisfying domestic hot water production and central heating needs This manual must be kept in a safe place and must accompany the boiler at all times G...

Page 13: ...pacity 63 F temperature rise gpm 3 1 D H W temperature setting min max F 95 167 Max Hot water working pressure psi 87 Min Hot water working pressure psi 7 2 Dimensions Boiler casing size Width in 17 7 Height in 31 Depth in 12 9 Weight net lbs 98 Hydraulic connections Central Heating Flow connection Soldier Central heating Return connection Soldier D H W Cold Water Inlet Soldier D H W Hot Water Out...

Page 14: ...INSTALLATION INSTRUCTIONS 11 2 2 Dimensions ...

Page 15: ...INSTALLATION INSTRUCTIONS 12 2 3 Internal parts of the boiler ...

Page 16: ...INSTALLATION INSTRUCTIONS 13 2 5 Water circuit ...

Page 17: ...INSTALLATION INSTRUCTIONS 14 2 5 Circulation pump head flow graph ...

Page 18: ...steps Error History display last 5 errors To switch the boiler OFF press INFO button the symbol appears on the display The central heating frost protection system the circulating pump inactivity protection and 3 way valve inactivity protection functions remain enabled If the boiler was previously ON it is switched OFF and the fan overrun and pump overrun functions are enabled 2 7 Control panel Con...

Page 19: ...NFO Button to display the boiler data Once pressed the parameter number will appear on the left side of the display and the associated parameter value will appear on the centre of the display Use and buttons of Heating Temperature setting to scroll the list of available data Press the INFO button to exit the display mode The list of available display data is the following Parameter Icon Descriptio...

Page 20: ... accordance with the above codes could lead to prosecution It is in the best interest of the installer and for safety reasons that all applicable 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 override in anyway statutory obligations Installation requirements Please refer to local and national stand...

Page 21: ...loor see fig 1 Remove the staples and open the four flaps of the box B Rotate the boiler 90 while supporting it from underneath C Lift the box and remove the packing material Lift the boiler by grasping it from the back part and proceed with the installation D Boiler package includes Boiler Hydronic Valve Kit Outdoor Reset Sensor Mounting Bracket Be sure to secure all of these items before discard...

Page 22: ...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 appliance proceed as follows see fig 2 a Use a level of not less than 24 long to mark a horizontal line on the wall where the appliance is to be fitted b Position the top of the template along the line drawn with t...

Page 23: ...led To facilitate the installation the boiler is supplied with a hydraulic connection kit see fig 2 A pressure relief valve is installed in this dual purpose boiler 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 Boile...

Page 24: ...uired by code Jurisdictions may require the installation of a temperature mixing valve on the domestic hot water piping of this boiler Always refer to and follow all applicable federal state and local codes along with the mixing valve manufacturers instructions Internal Boiler Relief Valve This boiler is equipmed with an intregal 30 psi relief valve It is imperitive that this relief valve be piped...

Page 25: ...INSTALLATION INSTRUCTIONS 22 3 5 Piping Diagrams Preferred piping methods primary secondary Alternate piping method ...

Page 26: ... of pump curves Pensotti recommends you contact your boiler distributor for assistance When using the alternative piping agrrangment be sure the Maximum temperature across the boiler Detlta T does not exceed 30 F When zoning using the alternative piping arangment Pensotti recommends the use of low pressure drop zone valves contact your boiler distributor for assistance Dirt Scale Seperation Along ...

Page 27: ...eck the system water capacity to determine if it is of adequate size for the heating system An external expansion tank may be added if necessary Before filling the system the internal expansion tank pressure must be checked and adjusted if necessary The pressure must match they system s minimum cold water fill pressure as determined by the installer It is required that the air pressure in the expa...

Page 28: ...ng any pressure testing of the gas supply system at test pressures equal to or less then 0 5 psi 14 wc The gas appliance and its gas connections must be leak tested before placing the appliance in operation Leaks can be found 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 a...

Page 29: ... 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 30: ...ergency stand by generator the installation of a surge capacitor surge protector line conditioner or equivalent is required If the boiler 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 gas piping is comple...

Page 31: ... 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 electrician When using an electrical appliance ...

Page 32: ...the earth wire normally coloured green yellow to the terminal marked with the earth symbol Connect the neutral wire normally coloured white to the terminal marked with the letter N Connect the live wire normally coloured black 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 no...

Page 33: ...local Building Official Fire Official or other authority having jurisdiction regarding permits restrictions and installation inspections in your area GENERAL INSTALLATION NOTES Read through these installation instructions before beginning your installation Proper planning for your Concentric Stainless Vent system installation will result in greater safety efficiency and convenience as well as savi...

Page 34: ...CONNECTIONS M G DuraVent s Concentric Vent is connected together by aligning the Alignment Dimples on the male and female vent sections sliding together and twist locking in either direction Fig 1 The joints will only connect and come apart at the point where the Alignment Dimples are aligned The CVS joint section can rotate 360 degrees to allow elbows to point in the desired direction The vent pi...

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Page 36: ...f condensate or buildup of heat in the vent Also make sure you have accommodated any minimum vent height if any that the appliance manufacturer may require The Horizontal Termination Cap must meet the following requirements a Clearance above the ground veranda porch deck balcony and anticpated snow level 12 inches minimum b Clearance to a window operable or fixed closed or door 12 inches minimum c...

Page 37: ...e and weatherization If Telescoping Adjustables are used secure them at the desired length by using 3 screws provided 6 Support Vent Wall Straps are required every 8 ft of horizontal run in order to properly support the vent system Fig 3 If the installation extends through the wall in less than 8 ft of vent pipe a wall strap is not required Wall Straps are designed to provide a 1 standoff from nea...

Page 38: ...e framing Vertical installations of the CVS vent need to be supported A Firestop Support is required where the vent system passes through the first floor and additional Firestops are required at each floor opening except the roof Follow the appliance manufacturer s requirements for minimum clearance to combustibles 4 Install Firestop Support s At each framed floor opening install a Firestop Suppor...

Page 39: ... mounted systems it is recommended that the vent system be enclosed below the roofline to limit condensation and protect against possible incidental damage that may occur to the vent pipe 7 Install Flashing and Vertical Termination Install enough vent pipe through the roof penetration to allow the Adjustable Flashing to fit over the pipe The Adjustable Flashing will fit roofs from 0 12 12 12 pitch...

Page 40: ...ght down the Vent Clean and remove any deposited or foreign material 3 Check for evidence of excessive condensation such as water droplets forming in the inner liner and subsequently dripping out at joints Continuous condensate can cause corrosion of caps pipe and fittings It may be caused by having excessive lateral runs too many elbows and exterior portions of the system being exposed to cold we...

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Page 42: ...Diaphrams 1 51 1 61 FLUE DIAPHRAM B Boiler Vent Adapter w Test Ports PA50 00137 C CVS Adapter PA35CVS AD PS D 90 Elbow PACVS E90 E 12 Vent Pipe PACVS 12 F 8 13 Horizontal Termination PACVS HCR G Wind Guard PACVS HG H Inner Trim Ring PACVS TRI I OutterTrim Ring PACVS TRO ...

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Page 44: ...CTIONS 41 Rough in dimension of coaxial vent pipe is approx 13 from the top of the boiler to the center line of the CVS vent pipe IMPORTANT Secure boiler adapter to the DuraVent CVS adapter with 2 qty screws not provided ...

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Page 46: ...ve amounts of condensate In these cases it is a requirment that the condensate be removed from the vent system by virtue of this condensate drain attachment refer to the pictures on this and the next page Please follow all applicable local state and national codes in regards to condensate disposal Required fittings 1 qty IPS PVC Coupling 1 qty 5 8 Male hose barb X Male adapter 1 piece Necessary le...

Page 47: ...aking a minimum 8 diameter loop in the tubing This condensate loop trap is required to eliminate the possibility of flue gases entering the home Before firing the boiler fill the trap with water Please folow all applicable local state and national codes in regards to condensate disposal ...

Page 48: ... intake exhaust pipes Ø3 5in MAXIMUM FLUE LENGTH linear length FLUE DIAPHRAGM EXHAUST from 3 2 to 6 5 ft INSTALL THE FLUE DIAPHRAGM Ø 1 51 in ON THE FLUE EXHAUST HOLE from 6 5 to 16 4 ft INSTALL THE FLUE DIAPHRAGM Ø 1 61 in ON THE FLUE EXHAUST HOLE MAXIMUM FLUE LENGTH 16 4 ft FLUE DIAPHRAGM EXHAUST ...

Page 49: ...E DIAPHRAGM INTAKE Ø 2 2 in MAXIMUM FLUE LENGTH linear length FLUE DIAPHRAGM INTAKE FLUE DIAPHRAGM EXHAUST from 3 2 3 2 to 13 1 13 1 ft INSTALL THE FLUE DIAPHRAGM Ø 2 2 in ON THE AIR INTAKE INSTALL THE FLUE DIAPHRAGM Ø 1 61 in ON THE FLUE EXHAUST HOLE from 13 1 13 1 to 36 36 ft INSTALL THE FLUE DIAPHRAGM Ø 2 2 in ON THE AIR INTAKE INSTALL THE FLUE DIAPHRAGM Ø 1 61 in ON THE FLUE EXHAUST HOLE MAXIM...

Page 50: ...ing plate corresponds to that of the main supply networks gas electricity water Check that the power supply voltage to the boiler complies with the rating plate 120 V 60 Hz and that the live neutral and earth ground wires are connected properly Also make sure that the earth ground connection is sound Check that the gas supply line is correctly sized for the flow rate required by the boiler and tha...

Page 51: ...izing an external pressure reducing valve and backflow preventer use the pressure gauge M fig 2 to check that the systems pressure reaches the middle of the green area equal to 14 5 psi see fig 3 On completion make sure that the filling tap R is closed Once again unscrew the plug on the pump to remove any trapped air check that the pump is free then re tighten it when water starts to flow out Prop...

Page 52: ...der to flush the system correctly turn off all radiators open the filling loop and drain cock simultaneously and allow the water to flow through the boiler d Open each individual radiator allowing water to flow through then turn that radiator off and repeat for all radiators on the system e Turn off the filling loop and close the drain cock open all radiators and open the filling to fill the syste...

Page 53: ...sec It may be necessary to repeat the operation in order to remove all the air from the pipes To repeat the operation wait approximately 15 seconds from the last ignition attempt before resetting the error code E01 by pressing the reset button To check the inlet gas pressure value allow the boiler to fire Press and hold the reset button for several seconds until F07 appears on the screen indicatin...

Page 54: ...upply cables from the modulator E fig 2 The gas manometer will now indicate the minimum mechanical gas pressure Refer to Gas Data Table above for minimum pressure 7 If the pressure value is different from that of the Gas Data Table turn screw D fig 2 until the gas manometer indicates the correct value Clockwise to increase pressure Counter clockwise to decrease pressure 8 Re connect the modulator ...

Page 55: ... instantaneous boilers w dual circuit exchanger and only heating boilers 00 90 Displayed in multiples of 5 seconds default value 18 x 5 90 P07 Minimum BTU output 00 Max P08 Displayed in P08 Maximum BTU output Min P07 99 Displayed in P09 Sets the ignition sequence 00 99 default 50 Displayed in P10 D H W priority function Not applicable to instantaneous boilers w dual circuit exchanger and only heat...

Page 56: ...s follows 1 Place mode selection button in OFF position indicated by symbol 2 Keep pressed and buttons simultaneously and wait for symbol and P00 to appear on the display 3 Release buttons and 4 Use and buttons of heating temperature setting to select the parameter to modify 5 Adjust the value of the parameter using the procedure described in the following pages 2 P00 P01 1 ...

Page 57: ...agraph 5 2 Accessing the parameters menu steps 1 5 6 Use and buttons D H W temperature setting to modify the value of the parameter 00 Natural Gas 01 LPG 7 Press mode selection button to confirm and to render the new adjustment operative The parameter number P01 will appear on the display 8 To exit from the parameters menu press simultaneously and buttons PARAMETER P02 SETS THE CENTRAL HEATING TEM...

Page 58: ...L HEATING TIMER DIFFERENTIAL This parameter is used to set the minimum time in which the burner is kept switched off once the heating flow temperature has exceeded the temperature set by the user To enter the parameters menu follow the previously described procedure see paragraph 5 2 Accessing the parameters menu steps 1 5 6 Use and buttons D H W temperature setting to modify the value of the para...

Page 59: ...l appear on the display 8 To exit from the parameters menu press simultaneously and buttons PARAMETER P06 D H W STORAGE CYLINDER PUMP OVERRUN TIMER Not applicable to instantaneous boilers w dual circuit exchanger This parameter is used to set the pump functioning time in D H W mode after closing the water tap To enter the parameters menu follow the previously described procedure see paragraph 5 2 ...

Page 60: ... use and buttons D H W temperature setting to modify the value of the parameter The range of settings is 00 80 13 Press mode selection button to confirm and to render the new adjustment operative The parameter number P07 will appear on the display 14 Press simultaneously and buttons until OFF appears on the display 15 Disconnect the manometer from the pressure test port B on the gas valve and care...

Page 61: ...teps 1 5 Select parameter P08 6 Use and buttons D H W temperature setting and adjust the value of the parameter from 99 maximum value of default to the required value 7 Press mode selection button to confirm and to render the new adjustment operative The parameter number P08 will appear on the display 8 To exit from the parameters menu press simultaneously and buttons P08 70 P08 66 ...

Page 62: ...verter valve on D H W mode for a time equal to the post circulation keeping hot the secondary heat exchanger To enter the parameters menu follow the previously described procedure see paragraph 5 2 Accessing the parameters menu steps 1 5 6 Use and buttons D H W temperature setting to modify the value of the parameter 00 Off 01 On 7 Press mode selection button to confirm and to render the new adjus...

Page 63: ...consideration the house insulation degree The values of the flow temperature Tm refer to standard 86 176 F appliances or 77 113 F for under floor heating systems The type of appliance can be set using parameter P02 To enter the parameters menu follow the previously described procedure see paragraph 5 2 Accessing the parameters menu steps 1 5 and select parameter P12 6 Use and buttons D H W tempera...

Page 64: ... P13 will appear on the display 8 To exit from the parameters menu press simultaneously and buttons PARAMETER P14 CENTRAL HEATING MAXIMUM SET POINT This parameter is used to set the central heating maximum user set point To enter the parameters menu follow the previously described procedure see paragraph 5 2 Accessing the parameters menu steps 1 5 6 Use and buttons D H W temperature setting to mod...

Page 65: ...r P15 will appear on the display 8 To exit from the parameters menu press simultaneously and buttons PARAMETER P16 POST VENTILATION This parameter is used to set the fan functioning time after switching off the burner To enter the parameters menu follow the previously described procedure see paragraph 5 2 Accessing the parameters menu steps 1 5 6 Use and buttons D H W temperature setting to modify...

Page 66: ...3 h 3 39 Consumption 15 C 1013 mbar kg h 2 49 Gas pressure adjustment table Pressures in excess of 14 WC may damage the internal components of this boiler Pensotti REQUIRES replacment of the gas valve if it is subjected to pressures in excess of 14 WC Faliure to comply could cause dangerous operating conditions fire explosion bodily injury or possible death NATURAL GAS GAS A LIQUID PROPANE GAS GAS...

Page 67: ...hod to check for gas leaks each time gas connections are dismantled and reassembled 6 select the new gas type by changing parameter P01 see Parameters table 5 1 7 to convert the appliance from L P G to Natural Gas proceed with the min and max gas pressure adjustment see Gas Valve adjustment 5 4 8 to convert the appliance from Natural Gas to L P G proceed as follows remove the modulator plastic cap...

Page 68: ...the primary heat exchanger and clean if necessary using a soft nylon brush and subitle vacum Check the condition and operation of the ignition and gas safety systems Remove and clean the scaling from the ignition and flame detection electrodes paying particular attention to place them at the correct distance from the burner Fig 1 Check the pre fill pressure of the integral expansion tank Check the...

Page 69: ...utwards at the same time rotating the panel downwards Unscrew the four fixing screws see fig 6 and remove the panel back piece 6 4 Flushing out the primary side Fill the boiler 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 boiler In order to flush the system correctly turn off all radiators or fan coils Open th...

Page 70: ...e water from the system Used compressed air to evacuate the pipes of any remaining water Use non toxic antifreeze to protect the DHW system 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 completely drain the boilers heating circuit D H W circuit...

Page 71: ...MAINTENANCE INSTRUCTIONS 68 6 6 Wiring diagrams DIGITECH TR Printed Circuit Board MIAH403 110 V 60 hz ...

Page 72: ...plate removed proceed with the following wires connection install the outdoor temperature sensor on contacts marked as Se Se on the terminal board B install the room thermostat or end switch by removing the jumper Ta Ta from the terminal board B first and then connecting the room thermostat or end switch wires 24 DC at these terminals d When wires have been connected place plate A back to position...

Page 73: ...h THERMOSTAT MALFUNCTION OR OUT OF CALIBRATION i THERMOSTAT CABLE DISCONNECTED h REPLACE PART i CHECK THE WIRING Manual Reset press the Reset button E03 AIR PRESSURE SWITCH j SWITCH OUT OF ORDER k INLET OR OUTLET FLUE PIPES OBSTRUCTED l SWITCH CABLE NOT STABLE j REPLACE PART k CHECK FLUE PIPES l CHECK CABLE Manual Reset press the Reset button E04 NO WATER IN THE SYSTEM m INSUFFICIENT WATER PRESSUR...

Page 74: ... ERROR AUTOMATICALLY Automatic E22 PARAMETER PROGRAMMING REQUEST w LOSS OF MICROPROCESSOR MEMORY w REPROGRAM PARAMETERS Manual Reset Switch off the power supply E35 FLAME DETECTION MALFUNCTION x IONISATION ELECTRODE MALFUNCTION y IONISATION ELECTRODE CABLE MALFUNCTION z PRINTED CIRCUIT BOARD MALFUNCTION x REPLACE OR CLEAN PART y REPLACE PART z REPLACE PART Manual Reset press the Reset button E40 E...

Page 75: ... a temperature of 41 F The boiler operates at minimum gas pressure with the diverter valve in the winter position The function is disabled when the temperature detected by the sensor reaches 86 F F09 Frost Protection function D H W circuit The function is automatically enabled when the D H W sensor detects a temperature of 39 F The boiler operates at minimum gas pressure with the diverter valve in...

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Page 80: ... in excess of published heat exchanger flow rates 10 Improper voltage 11 Use of non factory authorized parts or accessories in conjunction with the boiler 12 Components that are part of the heating system but not supplied by Pensotti Boilers as part of the boiler 13 Contamination of the combustion air including dust dirt environmental particles and construction particles 14 The repair or replaceme...

Page 81: ...Pensotti LLC 34 Coffin Ave Brewer ME 04412 P 207 942 3636 F 207 942 3737 www pensottiboiler com ...