Pensotti PCI 18-8-H User Manual
MAINTENANCE INSTRUCTIONS
6. MAINTENANCE (authorized personnel)
6.1 General Warnings
All maintenance operations must be carried out by professionally qualified personnel, authorized by
PENSOTTI
The frequency of boiler maintenance is REQUIRED to be carried out once a year.
In order to guarantee the long life of the appliance and in accordance with the current gas safety
regulations, only use original replacement parts
Before carrying out any type of maintenance operation, disconnect the appliance from the electrical supply
and shut off the gas valve.
Warranty will not be offered if required maintenance is not followed.
Keep appliance area clear and free from combustible material, gasoline and other flammable vapors and
liquids.
In order to safeguard all waterside components the supplied Fernox Commissioning Kit must be used in
its entirety.
6.2 Maintenance
Periodic examination of the entire venting system is REQUIRED. Make sure all the venting
connections/joints are tight and in good condition.
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.
Visually inspect the burner flame. The flame must burn with a clean, stable flame. If the burner flame
appearance is not satisfactory or debris is visible on the burners, remove and clean with a vacuum
cleaner.
All electric motors are permanently lubricated and do not need oiling. Remove the combustion air blower
and clean wheel and housing with soft brush or vacuum.
Verify proper operation after any servicing using a properly calibrated electronic combustion analyzer.
Verify proper operation of safety circuits.
Wipe the outside surface with a wet cloth; then dry the surface. Use a neutral detergent to clean any stains.
Vent termination should be inspected for blockage during maintenance checks.
Check for blockage at the drain pipe and condensate trap.
Clean condensate trap and check for correct level of water.
Check for water leaks from the equipment and piping.
Warranty will not be offered if required maintenance is not followed.
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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:
■ Check the condition of the gas seals and replace where necessary.
■ Check the condition of the water seals and replace where necessary.
■ Visually inspect the condition of the combustion chamber and flame.
■ Check that the combustion is correctly regulated and if necessary proceed in line with section “Commissioning
the boiler”.
■ Remove and clean any oxidation from the burner.
If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system.
Contact a qualified plumber to correct this situation. DO NOT PLUG THE RELIEF VALVE.
■ Check that the seal of the room-sealed chamber is undamaged and positioned correctly.
■ Check the primary heat exchanger and clean if necessary.
■ Check the maximum and minimum modulation pressures and the modulation itself.
■ Check the condition and operation of the ignition and gas safety systems. If necessary, remove and clean the
scaling from the ignition and flame detection electrodes, paying particular attention to replace them at the
correct distance from the burner.
■ Check the heating safety systems: temperature limit safety thermostat, pressure limit safety device.
■ Check the pre-fill pressure of the expansion tank (see expansion tank rating plate).
■ For safety reasons, periodically check the integrity and operation of the exhaust system.
■ Check that the connection to the mains electricity supply complies with that reported in the boiler’s instruction
manual.
■ Check the electrical connections inside the control panel.
■ Check the D.H.W flow rate and temperature.
■ Check that the condensate drain system is working correctly, including any parts of the system outside the boiler
such as condensate collection devices along the length of the exhaust vent and/or any acid neutralizing devices.
■ Check that the condensate flows freely and that there are no exhaust fumes present within the appliance.
Warranty will not be offered if required maintenance is not followed.
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MAINTENANCE INSTRUCTIONS
Fig. 1
Fig. 2
Fig. 5
Fig. 6
Fig. 3
Fig. 4
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.
Grasp the lower part of the panel and pull
it outwards (fig. 1) and then up.
Left and right side panel:
Remove the fixing screws at the front and
lower edge of the side panel to remove.
Grasp the bottom of the panel, move it
sideways and then upwards to remove
it.
To access the electrical connections of the
control panel, proceed as follows:
Remove the front panel (see fig. 1).
Grasp the left and right control panel support
brackets and pull them outwards, at the
same time rotating the panel downwards.
Unscrew the four fixing screws and remove
the cover.
6.5 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 the filling
loop and drain cock simultaneously and allow
the water to flow through the boiler.
Open each individual radiator or fan coil,
allowing water to flow through. Then turn that
radiator or fan coil off and repeat for all
radiators or fan coil on the system.
Turn off the filling loop and close the drain cock open all radiators and open the filling to fill the system.
Continue to fill the system until the pressure gauge reads in the Green section of the gauge (14.5 psi = 1
bar)
In order to safeguard all waterside components the supplied Fernox Commissioning Kit must be used in its
entirety.
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MAINTENANCE INSTRUCTIONS
Fig. 1
Fig. 2
6.6 Draining the central heating system
If the need arises to drain the system, this can be done as follows:
Switch the system to “HEAT” mode and ignite the boiler.
Switch off the power supply to the boiler.
Wait for the appliance to cool down.
Connect a hosepipe to the system drain point R and
locate the other end of the hose in a suitable drainage
system.
Open the system drain valve (fig. 1).
Open the manual air vent located on the primary heat
exchanger.
Open the air vents on the radiators, starting with the
highest and moving down the system to the lowest.
When the system has been drained, close the radiator
air vents and the drain valve.
If only the boiler needs to be drained, close the
flow/return isolating valves on the heating circuit
and open the drain valve R located at the bottom of
the boiler on the pump manifold (see fig. 1 );
Draining the domestic hot water system
If there is a danger of freezing, the domestic hot water
system should be drained. This can be done as follows:
Close the main water supply valve.
Joint the water draining pipe and open the cylinder
draining tap (see fig. 2)
Open all the hot and cold water taps.
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 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.
System winterization (operating system)
Pensotti boilers are certified for indoor use ONLY. Proper precautions for freeze protection are
recommended for boilers and associated piping in areas where the danger of freezing exists. Do not use
automotive antifreeze. Pensotti recommends the use of inhibited glycol concentrations between 20-35%
glycol. Glycol products must be maintained properly so they do not become inactive or corrosive, consult
glycol specifications for more information.
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MAINTENANCE INSTRUCTIONS
Fig. 3
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. A non correct
maintenance will invalidate the cylinder
warranty.
To check the anode, unscrew the anode nut
located on the top of the cylinder (see fig.3)
by turning it counter-clockwise. If, at the
opening of the valve, water comes out of the
valve, the anode is worn and needs to be
replaced; if no water comes out of the valve,
the anode is not worn and therefore still
functioning. Once this operation has been
completed, close the small valve.
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MAINTENANCE INSTRUCTIONS
premix burner unit
burner
ionisation
ignition
primary heat
exchanger
B
A
primary
heat
flue
connection
stainless steel
pipe coil
ceramic fibre
washer
Fig. 1
Fig. 2
6.7 Maintenance operations
All maintenance operations must be carried out
by professionally qualified personnel,
authorised by Granby/Pensotti LLC.
The frequency of boiler maintenance must
comply with current law and, nevertheless,
should be carried out once a year.
In order to guarantee the long life of the
appliance and in accordance with the current
gas safety regulations, only use original spare
parts
Before carrying out any type of maintenance
operation, disconnect the appliance from the
main electricity supply and close the gas valve.
For all maintenance operations requiring removal of the
boiler casing, refer to the procedures described in
paragraph 6.4 “Accessing the boiler”.
Cleaning the main exchanger module and combustion unit
(fig. 1)
Disconnect the electrical connections of the electric fan.
Disconnect the joint and remove the pipe linking the gas
valve to the injector unit (venturi).
Disconnect the joint and remove the gas feed pipe from
the gas valve.
Un-plug the ignition electrode and flame detection wires
from the ignition control unit.
Unscrew the ring-nut at the bottom of the room-sealed
chamber and remove the gas valve.
Unscrew the nuts securing the burner unit (consisting of a
fan, manifold and burner) to the primary heat exchanger.
Remove the burner unit, paying particular attention not to
remove the ceramic fibre protection from the bottom of
the heat exchanger.
Check that the burner is not affected by deposits, scaling
or excessive oxidation. Check that all the holes in the
burner are free.
Clean the electrodes carefully without altering their
positions with respect to the burner.
Clean the burner cylinder using a non-metal brush and
without damaging the ceramic fibre.
Check the integrity of the gasket on the cover of the
burner.
Clean the heat exchanger using a household detergent for stainless steel, distributing the product on the spirals of
the exchanger using a brush. Do not wet the ceramic fibre coating. Wait a few minutes then remove the deposits
using a non-metal brush. Then remove the residues under running water.
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