Pensotti PNCH-32 Installation Manual

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 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 standards.

17

INSTALLATION

INSTRUCTIONS

B

C

A

Fig 1

3.2 Unpacking

■ The materials (cardboard) used for packing the

appliance are fully recyclable.

■ It is recommended that the packing material is only

removed prior to installing the boiler. The
manufacturer will not be held responsible for
damage caused by incorrect storage of the product.

■ Packing materials (plastic bags, polystyrene, nails,

etc.) must not be left within reach of children, in
that these items represent a potential hazard.

A. Place the packed appliance on the floor (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 discarding
any packing material)

STORAGE & HANDLING

Please note that prior to installation the Pensotti LLC
boilers should be stored in the horizontal position with no
more than three boilers to a stack;
Ensure that the boilers are stored in dry conditions and be aware that the carton is a two-man lift;

18

INSTALLATION

INSTRUCTIONS

MINIMUM DISTANCES [INCHES]

H

A

X

L

Y

Model

PCNH 32

X Y L H

40

16

2.52.5

B

A B

14 12

Fig. 2

Fig. 1

3.3 Installing the boiler

The appliance must be installed

exclusively on a plumb, vertical solid wall
capable of supporting its weight.

■ The boiler should be fitted within the building
unless otherwise protected by a suitable
heated enclosure i.e. garage or outhouse.
(The boiler may be fitted inside a cupboard)

■ It is recommended to always leave the
ON/OFF switch always in ON position to give
frost protection.

■ If the boiler is installed in a room containing a
bath or shower reference must be made to the
relevant requirements.

■ Appliance is approved for installation on
combustible walls.

In order to allow access to the interior of the
boiler for maintenance purposes, it is important
that the minimum distances indicated in figure 1
are 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 the level, respecting the distances
indicated. Then mark the center position of
the two wall screws or anchors. Finally, mark
the positions of the water and gas pipes.
Position the boiler with consideration of the
venting requirements.

c. Remove the template and install the

domestic hot and cold water pipes, the gas
supply pipe and the central heating pipes
using the fittings supplied with the unit.

Fix the boiler to the wall using the bracket and
connect the pipes.

19

INSTALLATION

INSTRUCTIONS

LEGEND

HR

HEATING RETURN

Ø 3/4"

HF

HEATING SUPPLY

Ø 3/4"

G

GAS

Ø 1/2"

RCR

REMOTE D.H.W. CYLINDER RETURN

Ø 3/4"

RCF

REMOTE D.H.W. CYLINDER FLOW

Ø 3/4"

CWI

COLD WATER INLET

Ø 1/2"

4.9

2.2

2.5

7.53.96.3

4.02.85.92.5

RCF

HFG

RCR

HR CWI

Fig. 1

HR

RCR

RCF

CWI

HF

3.4 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.

In order to safeguard all waterside components the

supplied Fernox Commissioning Kit MUST be used
in its entirety.

Make sure that the domestic water and central

heating pipes are not used to earth the electrical
system. The pipes are totally unsuitable for this
purpose.

Isolation Valves must be installed on the heating

and D.H.W circuits. This will facilitate all
maintenance and service operations when the
appliance needs to be drained.

 To prevent vibration and noise coming from the system, do not use pipes of reduced diameter, short radius elbows

or severe reductions in the cross sections of the water passages.

 In order to guarantee the reliability of the boiler a pressure reducing valve and backflow preventer must be installed.
 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 Boilers).The relief valve must be installed such that
the discharge will be conducted to a suitable place for disposal when relief occurs. The discharge line must be installed
to allow complete drainage of both the valve and the line. If this unit is installed with a separate storage vessel, the
separate vessel must have its own temperature and pressure relief valve. This valve must also comply with The
Standard for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems. AINSI Z21.22 (in the U.S.
only). A temperature relief valve is not required but if one is used, do not install the valve with the probe directly in the
flow of water. This may cause unwarranted discharge of the valve.

Internal Boiler Relief Valve

This boiler is equipmed with an intregal 30 psi relief valve. It is
imperitive that this relief valve be piped out of the boiler cabinet
to a safe location as defined by local code.

Any water damage incurred to this boiler by the release of
water from an improperly or nonexistent relief valve drain
pipe will NOT be covered under the warranty.

20

INSTALLATION

INSTRUCTIONS

IMPORTANT

When installing the PNCH-32

without an indirect water

heater you MUST set

Parameter POO to a value of

5 – “Heating Only Boiler”

3.4 Piping Diagrams and Information

Preferred piping methods (primary-secondary)

21

INSTALLATION

INSTRUCTIONS

PNCH-32

1 -1/4” Copper

11/4” Copper

Water feeder

Ball valves and purge valves

Ball valve

Purge valve

If required

¾”

¾” ¾”

¾”

Gas Line Installed Per Local Code

Air Eliminator

>1

>1 External Low Water Cut-Off if required by local code

1” Copper

1” Copper

Indirect
Water
Heater

IMPORTANT

When installing the PNCH-32

without an indirect water

heater you MUST set

Parameter POO to a value of

5 – “Heating Only Boiler”

Alternate piping method

22

INSTALLATION

INSTRUCTIONS

Alternative piping method

The above graph details the circulator energy available for the heating system piping and accessories.
(Between the supply and return taps of the boiler).

CAUTION:
Detailed heating system design is required to determine if the available circulator energy is adequate for proper/safe
system performance. If you are unfamiliar with heating system design, piping pressure drops and the use 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 with the application of our Fernox commisioning kit Pensotti highly recommends the installation of a dirt
seperator in the return piping of all Solenne Series boiler models. Follow the manufacturers instructions when
installing these devices.

23

INSTALLATION

INSTRUCTIONS

Max. System Operating

Temperature (°F)

Maximum System Water

Content (Gals.)*

100

114

110

85

120

65

130

52

140

43

150

36

160

30

170

26

180

24

Central heating circuit

Pensotti requires the
installation of a pressure
reducing valve & backflow
preventor with all Solenne
Series boilers.

In order to prevent scaling or deposits in the primary heat exchanger, the main supply water to the heating
circuit must be treated according to the requirements of local standards.
This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often
either partially or fully drained.

In order to safeguard all waterside components and ensure warranty coverage the supplied Fernox
Commissioning Kit MUST be used in its entirety.

Expansion Tank Capacity

This boiler is equiped with an internal heat circuit expansion tank. You must check 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 expansion tank be checked on an annual basis.

When installing this boiler without an indirect water heater the following precautions must be taken.

• Install the supplied piping spurs for an indirect water heater.

• Using ¾” copper pipe, connect the supply and return together. Reference piping diagrams on

page 21 & 22.

• Change parameter 00 (P00) to a value of “5” – “Heating only boiler”.

Internal Boiler Relief Valve

This boiler is equipmed with an intregal 30 psi relief valve. It is imperitive that this relief valve be piped out of the boiler
cabinet to a safe location as defined by local code.

Any water damage incurred to this boiler by the release of water from an improperly or nonexistent relief valve
drain pipe will NOT be covered under the warranty.

24

INSTALLATION

INSTRUCTIONS

3.6 Gas Connection

3.6.1 Gas Piping Guidelines

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.

Follow all local codes and/or the most recent edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in
the USA or the Natural Gas and Propane Installation Code in Canada (CAN/CSA B149.1).

The installation and use of flexable appliance connectors is prohibited.

3.6.2 Gas Supply Lines Pressures

The minimum and maximum inlet gas pressures are Natural Gas Min. 6.00”WC – Max. 14.00”WC. and

Propane Gas Min. 11.00”WC – Max. 14.00”WC.

Gas pressures over and above the specified range will result in adverse performance and
dangerous operating conditions; any damage resulting from extreme gas supply pressures will not
be covered by the limited warranty.

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 (14”wc).

The appliance must be isolated from the gas supply piping system by closing its individual manual
shut-off valve during any pressure testing of the gas supply system at test pressures equal to or less
that 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 any debris before connecting to the boiler gas inlet.
Never use an open flame to test for gas leaks as property damage, personal injury or death could result.
The maximum inlet gas pressure must not exceed 14”wc.
The connection to the gas supply must be carried out by professionally qualified personnel in accordance with

the relevant standards.

■ Check the internal and external seals of the gas supply system.

■ A gas shut-off valve and sediment trap must be installed upstream of the appliance .

■ Before starting up the boiler, make sure that the type of gas corresponds to that for which the appliance has

been set-up.

■ The gas supply pressure must be between the values reported
on the rating plate.

■ Conversion of the appliance from natural gas to LPG or vice
versa must be carried out by qualified personnel.

■ 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, a few fundamental rules

must be observed: Do not touch the appliance with damp or

wet parts of the body or when barefoot. Do not pull on the
electric wires.
Do not allow the appliance to be used by children or anyone

unfamiliar with its operation.

25

INSTALLATION

INSTRUCTIONS

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

108

230

387

793

1237

2259

20

75

160

280

569

877

1610

30

61

129

224

471

719

1335

40

52

110

196

401

635

1143

50

46

98

177

364

560

1041

60

42

89

159

336

513

957

70

38

82

149

317

476

896

80

36

76

140

239

443

840

90

33

71

133

275

420

793

100

32

68

126

266

411

775

125

28

60

117

243

369

700

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

2394

80

89

185

346

724

1086

2047

100

78

162

307

630

976

1811

125

69

146

275

567

866

1606

150

63

132

252

511

787

1496

Natural Gas Pipe Sizing Chart

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" of water column. (Typical machine supply 5" -7")

Pipe length must include additional length for all fittings. Add approximately 5 feet of pipe per fitting

Natural Gas 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

LP Gas flow is given in thousands of BTU/ hr. - One cubic foot of LP gas - 2516 BTU

This chart refers to low pressure LP, after regulation Standard nominal pressure at the burner for

Liquid Propane Gas is 11" of water column.

Pipe length must include additional length for all fittings. Add approxi mately 5 feet of pipe per fitting

LP Example: A machine with a burner that requires 440,000 BTU would need a 1" pipe for a 20' long run.

26

INSTALLATION

INSTRUCTIONS

3.7 Electrical connections

3.7.1 General warnings

Follow the electrical code requirements of the local authority having jurisdiction. In the absence of
such requirements, follow the latest edition of the National Electrical Code (NFPA 70) in the U.S.
or the latest edition of CGA C22.1 Canadian Electrical Code – Part 1 in Canada.

3.7.2 Electric Wiring: Ground and Surges

All units come with factory installed 3-pronged (grounded) plug end. The boiler must be plugged
into a dedicated electrical outlet and circuit. The use of extension cords are prohibited.

If the local jurisdiction requires the unit to be wired directly, remove and discard the factory installed plug. An
ON/OFF switch controlling the main power between the breaker and the Boiler should be provided to facilitate
end-user maintenance and servicing. This should be done by a qualified electrician.

The boiler must be electrically grounded. Ensure the electrical receptacle, in which the boiler will be plugged
into, is properly grounded; if wiring directly, do not attach the ground wire to either the gas or the water
piping as plastic pipe or dielectric unions may isolate the boiler electrically.

The use of a surge protector, surge capacitor, line conditioner or equivalent is recommended to protect the
appliance from power surges.

If a generator is to be used as “backup” power a line conditioner must be installed to protect the appliance from
erratic voltage and Hz.

If the boiler is to be installed in a structure utilizing a emergency 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 complete and the boiler has been
filled with water and all air has been properly purged for the boiler and heating system.

The electrical supply required by the boiler is 120VAC at 60Hz with a maximum 4A rating with proper
grounding. Protection must be in place to prevent the Boiler from being exposed to voltage in excess of
130VAC Max or 95VAC Min.

Damage caused by excessive voltage is not covered under warranty.

DO NOT connect 220-240VAC 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.

If there is a power failure in cold weather areas, the freeze prevention system in the boiler will not operate
and may result in freezing of the heat exchanger; in cold weather areas where power failures are common,
you must completely drain the unit to prevent damage if the power will be off for any extended period of
time.

Damage caused by freezing is not covered under warranty.

CAUTION : Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after servicing.

The connection to the main power supply must be carried out by professionally qualified electrical personnel,
registered in accordance with current legislation and local authorities.

27

INSTALLATION

INSTRUCTIONS

Always check to make sure that the appliance has an efficient earth 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. Have
the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any
damage or injury caused as a result of an inefficient or faulty earth ground system.

■ Ensure the domestic power supply is checked by a qualified electrician to ensure that it can support the
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, a few fundamental rules must be observed:

Do not touch the appliance with damp or wet parts of the body or when barefoot.
Do not pull on the electric wires.
Do not allow the appliance to be used by children or anyone unfamiliar with its operation;

If the unit fails to re-start after any fault and you have already pressed the reset “R” button,
unplug the unit for 30 seconds, then re-plug in the unit and try to restart with the on/off switch.
If the unit fails to restart, call a qualified Technician for service. DO NOT ATTEMPT ANY
REPAIRS ON YOUR OWN.

28

INSTALLATION

INSTRUCTIONS

A
B

Se

Se

Ta

N

L

Ta

yellow/green

blue

brown

Fig. 1

white

black

Electrical Connections

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. Loosen the screws and remove plate A (see fig. 1).
d. With the plate removed, connect the wires to the terminal board B as follows:

 Connect 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 non-power robbing, battery operated thermostat or dry set of contacts can be installed
on the Ta terminals.

When the wires have been connected, place plate “A" back to position. Switch the power supply back on.

29

INSTALLATION

INSTRUCTIONS

APPLICATIONS

M&G DuraVent’s Concentric Stainless (CVS)
vent pipe is listed to UL1738 as a double-wall
vent system for Category II, III, and IV gas
Appliances.

CVS is pressure rated to 10 in-w.c. for the inner pipe.
CVS can also be used as a direct vent
system, where the inner pipe is the exhaust
vent; the outer pipe supplies the combustion
air for the appliance. When installing CVS with
direct vent appliances, the vent is considered
a component of the appliance, and is listed
in conjunction with the appliance to the
corresponding appliance standard. Check with
your appliance manufacturer or look in the
appliance installation instructions to verify that
M&G DuraVent’s CVS has been listed as a
direct vent for use with your appliance.

CLEARANCES

CVS is listed to 0" clearance as a doublewall
vent system for Category II, III, and IV
appliances, for flue temperature of up to
400-degrees F for horizontal enclosures,
and up to 480-degrees F for vertical
enclosures.

When CVS is used as a concentric/direct vent
system on gas and installed on a Pensotti Solenne
CLASSIC boiler, clearance to combustibles is 0” .
Never fill any required clearance space with insulation or
any other materials. Combustible materials include, but
are not limited to, lumber, plywood, sheetrock,
plaster and lath, furniture, curtains, electrical wiring, and
building insulation.

PERMITS

Before installation, check with your 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
saving time and money. You must use only
authorized M&G DuraVent parts, or other
parts specifically authorized and listed by the
appliance manufacturer in order to maintain a
safe, approved system. Do not mix parts or try
to match with other products or use improvised
solutions. Do not install damaged or modified
parts. Practice good workmanship. Sloppy
work could jeopardize your vent’s safety. Keep
electrical wiring and building insulation away
from all chimneys and vents. When deciding
the location of your installation, try to avoid
modifications to structural components of the
building. If you have any questions, contact
either your dealer or M&G DuraVent directly.
Check with the appliance manufacturer for
the maximum and minimum allowed vent
runs for your specific appliance model,
including maximum number elbows allowed
in the system. The total vent length from the
appliance to the termination shall not
be greater than what is specified by the
appliance manufacturer. For condensing
appliances, always follow the appliance

manufacturer’s recommendation for handling condensate

drainage.

Before connecting the venting system to
the boiler, be sure to install the correct
Flue Diaphragm into the boiler exhaust
outlet. (see section 3.10 on page 45).

3.8 Venting connections

Concentric

30

INSTALLATION

INSTRUCTIONS

Plan the layout of the vent system:

• Consider the length of horizontal runs,
elbows, clearance requirements, and location
of terminations.

• For horizontal vent runs, maintain at least
a ¼” rise per foot away from the appliance to

prevent collection of condensate or buildup of
heat in the vent.

• Consider condensate drainage, if needed
for your appliance. Refer to the appliance
manufacturer’s installation instructions for
requirements of condensate drainage.

• The CVS system must not be routed into,
through, or within any other vent or chimney,
with the exception of running the vent through
an otherwise unused masonry chimney.

• The vent system must terminate in
accordance with local code requirements and
appropriate National Codes:
o For the US (Gas): NFPA 54 / ANSI Z223.1
National Fuel Gas Code or the International
Fuel Gas Code
o For the US (Pellet): NFPA 211 Standard for
Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances
o For Canada: CAN/GGA-B149.1 Natural
Gas Installation Code or CAN/CGA-149.2
Propane Installation Code.

JOINT 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 pipe
sections cannot be cut. Telescoping Adjustable
lengths are available to accommodate specific
installation length requirements. Screws are not required
for joint connection, except as where indicated for
Telescoping Adjustable lengths and Horizontal
Termination Caps.

APPLIANCE CONNECTION

Connect CVS vent pipe to the appliance adapter
Pensotti Part #: PA50-00137 via the DuraVent
Part #: 35CVS-AD-PS.

CONDENSATE DRAINS- GAS FUEL

CVS has an available Condensate Drain if
required by the appliance, and has a 5/8” ID
outlet which can be attached to an appropriate
size plastic tube for drainage. The Condensate
Drain can be used in either horizontal or
vertical orientation. When installing the
Condensate Drain, always create a siphon
loop in the plastic tube to prevent the leakage
of exhaust gases. Follow all local and national
codes for draining acidic condensate.

31