PENSOTTI PCH 34B H Manual

Pensotti ASME Condensing Boilers
Cleaning Procedure
Version 1 - All Models
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Pensotti ASME Condensing Boilers
Table of Contents
Service Requirements Pg. 3
Safety Precautions Pg. 5
Combustion Chamber Cleaning Procedure Pg. 7
Diverter Valve Lubrication Pg. 29
Water Test and Treatment Pg. 30
Version 1

To maintain reliability, efficiency and safe operation, it is imperative that all models of Pensotti
Condensing Gas Boilers be cleaned and inspected by a trained, licensed technician on an annual
basis.
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Service Requirements
Version 1
To maintain the highest possible operating efficiency, the heat exchanger surfaces must be kept clean. Soot and foreign debris will
insulate the heat exchanger surface, reducing the efficient transfer of heat. Failure to inspect and clean the heat exchanger annually
can result in the following problems:
•Plugged combustion passages
•Reduced heating capacity
•Increased flue gas temperatures
•Flue gas thermo-fuse failures, generating an E03 Error Code
•Rough ignition
•Ignition failure, generating an E01 Error Code
•Ignition electrode failure
•Ionization rod failure
•Pulsating combustion
•Heat exchanger failure
Contributing factors to the build up of soot and foreign debris on the heat exchanger surface are:
•Improper burner adjustment
•Improper conversion to the operating fuel
•Combustion air quality
•Cross-contamination of the flue gas and combustion air
•Amount of burner run time
•Frequency of burner on-off cycles
•Amount of condensation generated during operation
•Sulfur content of the fuel

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Service Requirements
Version 1
The quantity and rate of build-up on the heat exchanger will vary with each boiler installation due to the factors mentioned on page 3.
Boilers operating on LP Gas and those installed in environments containing high levels of pollutants or chemical vapors in the
combustion air may need to be cleaned more frequently. The frequency of a cleaning schedule will need to be determined by the
servicing company based on the condition of the heat exchanger at the time of cleaning.
Dirty Heat Exchanger Blocked Heat Exchanger Passages

Safety Precautions
5Version 1
Important Personal Protective Equipment is recommended when handling the insulating material (Refractory Ceramic Fibers)
on the burner door and back wall of the combustion chamber.
Warning Refractory Ceramic Fibers in high temperature applications can result in the formation of Crystalline Silica Dust.
Repeated airborne exposure of Crystalline Silica Dust may result in chronic lung infections, respiratory illness, or
death. Crystalline Silica is listed as a potential, occupational carcinogen by the following organizations: OSHA, NIOSH,
International Agency for Research on Cancer (IARC), and Canadian Centre for Occupational Health and Safety
(CCOHS). Certain components contained within the combustion chamber of this boiler may contain this potential
carcinogen. Improper service, maintenance, alteration, or adjustment can cause property damage, serious illness or
death. Service of this boiler must be performed by a qualified technician, service agency or gas supplier who has
read and understands the instructions and information provided.
Warning Handling Instructions for Refractory Ceramic Fibers
Exposure Risk Precautions and Recommended Personal Protective Equipment
Prevent contact with skin and eyes •Wear safety glasses or googles
•Wear gloves
•Wear long sleeve shirts and pants
•Wear a disposable cover-all
Prevent breathing of silica dust •Wear an approved respirator with N95 rated filter or better
•Use a water mist to minimize airborne dust particles when cleaning and serving the
combustion chamber
•Do not sweep dust particles. Spray with a water mist then collect with damp rags or
a vacuum with a high efficiency filter.
Prevent transfer of silica dust •Transfer Refractory Ceramic Fiber items, both new and used in sealed plastic bags.
•Remove contaminated clothing immediately and store in a sealed plastic bag.
•Launder contaminated clothing separately
•Dispose of disposable articles of clothing correctly
First Aid •Inhalation –Move to fresh air. Sneeze, cough and blow nose to clear irritated
passageways. Drink plenty of water.
•Skin –wash all affected areas with generous amounts of soap and water.
•Eyes –Flush with clean water immediately. Do not rub eyes.
If irritation persists, contact a physician immediately

Safety Precautions
6Version 1
Important Follow all instructions, failure to do so could result in personal property damage, injury or death. Refer to the
installation manual, supplied with the boiler, for additional information.
Warning
Warning
If you smell gas:
•Do not operate any appliance
•Do not attempt to light any gas appliance
•Do not turn any electrical switches on or off
•Do not use any phone in the building, land line or cell
•Leave the building and call the gas supplier from a neighbors phone or from a safe distance with a cell phone
•If the gas supplier can not be reached call the local fire department or dial 911
•Do not re-enter the building
Do not operate this boiler if any part had been under water. Replace each item in the control system that has been
under water. Replace the gas valve if its been under water. Failure to replace these items could result in; personal
property damage, personal injury, explosion or death.
Important Before performing a cleaning and inspection:
•Turn off all electrical power to the boiler
•Remove the power cord from the electrical outlet
•Turn the manual gas shut off valve, in the gas line of the boiler, to the closed position
•Prepare a clean, safe work area around the boiler
Warning Do not operate this boiler if any parts are found to be damaged, corroded or defective. Replace each item before
operating the boiler. Failure to replace these items could result in; personal property damage, personal injury, explosion
or death.
Warning Inspect the venting system:
•Verify the condition of all the vent system components are in good repair
•Inspect the location of the vent termination on the outside of the building
•Verify that all vent system components are secured together with a minimum of 2 screws
•Replace any damaged or defective vent component before operating the boiler
•Failure to replace these items could result in; personal property damage, personal injury, explosion or death.

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Combustion Chamber Cleaning Procedure
Version 1
1. Turn the manual gas shut off valve, for the boiler, to the closed position
2. Disconnect electrical power to the boiler. Remove the electrical cord from the outlet
3. Remove the front cover of the boiler
•Models PCC34, PCH18B, PCH34B and PCI18/8: Remove the 2 Philips head screws on the bottom edge of the front cover (screws face
the floor). Pull the bottom edge of the cover away from the boiler, then lift up to release the top edge.
•Model PCH50B: Remove the single Philips screw from the top edge of the cover (screw faces the ceiling). Grasp both the top and
bottom of the cover firmly and pull. The cover is secured with male/female spring clips.
•Model PCI34/20: Remove the single Philips screw from the top edge of the cover (screw faces the ceiling). Grasp both the top and
bottom of the cover firmly and pull. The cover is secured with male/female spring clips. Remove the 4 Philips head screws that retain
the silver cover. The top 2 screws also secure the front covers retaining bracket. Grasp the right side of the silver cover securely and
pull it away from the boiler at a 45 degree angle, then pull the left side away from the boiler.

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Combustion Chamber Cleaning Procedure
Version 1
4. Disconnect:
•The ionization electrode cable from the electrode - A
•The ignition electrode cable from the ignition transformer - B
•The ground wire from the ignition electrode - C
•The cable on the gas valve - D
•The pressure switch hose from the gas venturi - E
•The 2 cables connected to the fan motor - F
•PCH50B ONLY remove the combustion air tube from the gas venturi by loosening the clamp
F
E
D
C
B
A

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Combustion Chamber Cleaning Procedure
F
F
E
D

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Combustion Chamber Cleaning Procedure
5. Flip the control panel down by spreading the 2 retaining bracket handles

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Combustion Chamber Cleaning Procedure
6. Locate the inlet and outlet gas tube connections to the gas valve and disconnect the nuts. These are gasketed fittings, carefully
remove the gaskets, if in good repair, retain for later use. Replace any damaged gasket.

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Combustion Chamber Cleaning Procedure
7. Locate the gas valve retaining screws. They are located at the inlet side of the gas valve below the sheet metal shelf the gas valve is
mounted on. There are 4 Philips head screws, 2 recessed into the sheet metal and 2 securing the gas valve to the sheet metal shelf. Only
remove the 2 screws securing the gas valve. Retain the screws.
Gaskets
Recessed
Remove

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Combustion Chamber Cleaning Procedure
8. Remove the gas valve. Place it in a safe location to avoid any potential damage.

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Combustion Chamber Cleaning Procedure
9. Using a 10mm wrench or socket, loosen the 4 nuts securing the burner to the main heat exchanger. Once loose, remove 3 of the nuts
and place them in a safe location. Hold the pre-mix burner tube with one hand while removing the final nut. Retain the 4 nuts.
Pre-mix Tube

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Combustion Chamber Cleaning Procedure
9a. Remove the burner assembly. Rotate the left side of the burner assembly a couple of inches away from the main heat exchanger. Now
pull the assembly straight from the boiler. Once free, continue to rotate the burner assembly as you remove it from the boiler.
Warning Caution: Internal components may be hot!

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Combustion Chamber Cleaning Procedure
10. Inspect the internal burner components. Place the burner on a clean, flat surface. Inspect all the burner components, especially, the
refractory, rope gasket and EPDM seal for excessive wear or defect. Replace any worn or defective item.
Burner
Refractory
EPDM Gasket
Rope Gasket
Refractory

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Combustion Chamber Cleaning Procedure
11. Inspect the ignition electrode and measure the spacing. Clean the electrode assembly with a clean soft cloth. Do not use sandpaper,
emery board or coarse steel wool, these may remove the protective coating applied to the electrode. Verify the condition of the electrode,
inspect for excessive wear, broken electrode or ground rod or cracked porcelain insulator. Replace any worn or defective item. Verify the
electrode gap is 4mm and the gap between the electrode and burner surface is 7mm. If necessary, adjust the electrode rods by applying
light pressure with your finger and slowly manipulate the rod to the correct position. If it is found necessary to replace the ignition
electrode it is vital that the electrode gasket is also replaced. Adjust the new electrode as discussed.
4mm
7mm

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Combustion Chamber Cleaning Procedure
12. Inspect the ionization electrode and measure the spacing. Clean the electrode assembly with a clean soft cloth. Do not use
sandpaper, emery board or coarse steel wool, these may remove the protective coating applied to the electrode. Verify the condition of the
electrode, inspect for excessive wear or cracked porcelain insulator. Replace if found to be worn or defective. Verify the gap between the
electrode and burner surface is 7.5mm. If necessary, adjust the ionization rod by applying light pressure with your finger and slowly
manipulate the rod to the correct position. If it is found necessary to replace the ionization electrode, it is vital that the electrode gasket is
also replaced. Adjust the new electrode as discussed.
7.5mm

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Combustion Chamber Cleaning Procedure
13. Inspect the refractory target wall for defects such as large cracks or damaged areas. Replace if necessary. Removal of the existing
target wall will require breaking it into several pieces in order to release the retaining pin and clips. Before attempting the removal, wet the
target wall with water to minimize the amount of air born particles. Refer to the safety precautions section of this manual, beginning on
page 5, before proceeding. To avoid damaging the replacement target wall, install it only after you have completed the cleaning of the heat
exchanger surface.
Permitting any Pensotti Condensing Boiler to operate with a dirty combustion chamber and heat exchanger will
void the warranty.
Warning
Existing Target Wall in Good Condition Replacement Target Wall Retaining Clips - Detail
Important

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Combustion Chamber Cleaning Procedure
14. Clean the heat exchanger surfaces. Refer to the safety precautions section of this manual, beginning on page 5, before proceeding.
Remove the condensate drain hose from the neutralizer and/or drain and place into a bucket to collect the cleaning water. Using a vacuum
with a high efficiency filter, remove all of the loose debris from within the combustion chamber and heat exchanger surfaces.
Warning
Vacuum All Loose Debris From the Heat Exchanger Surfaces