Pioneer PHR100-55 User Manual Download

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120 Braley Rd. P.O. Box 429

East Freetown, MA 02717-0429

www.htproducts.com

Pioneer

INSTALLATION

START-UP

MAINTENANCE

PARTS

Pioneer Water Heater Models*

PHR100-55 / 130-55 / 160-55 / 199-55

*A suffix of “LP” denotes propane gas

NOTICE:

HTP reserves the right to make product changes or updates without notice and will not be held

liable for typographical errors in literature.

This manual must be used by a qualified installer/service technician. Read all instructions in this manual
before installing. Perform steps in the given order. Failure to comply could result in substantial property
damage, severe personal injury, or death.

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Summary of Contents for PHR100-55

Page 1: ...opane gas NOTICE HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature This manual must be used by a qualified installer service technician Read all instructions in this manual before installing Perform steps in the given order Failure to comply could result in substantial property damage severe personal injury o...

Page 2: ... THIS OR ANY OTHER APPLIANCE WHAT TO 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 must be provided by a qualified installer service ...

Page 3: ...out the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage FOREWORD This manual is intended to be used in conjunction with other literature provided with the heater This includes all related control information It is important that this manual all other documents included with this system and additional publications including the Nati...

Page 4: ...ical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5N6 Code for the installation of Heat Producing Appliances latest version from American Insurance Association 85 John Street New York NY 11038 The latest version of the National Electrical Code NFPA No 70 This product is for installation in closed loop systems ONLY Use of this product in...

Page 5: ...LLATION 14 E EXHAUST VENT AND INTAKE AIR VENT 14 1 DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE 15 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 15 F PREVENT COMBUSTION AIR CONTAMINATION 16 G REMOVING A HEATER FROM A COMMON VENT SYSTEM 16 PART 5 PREPARE THE HEATER 17 PART 6 HEATER PIPING 18 A GENERAL PIPING INFORMATION 18 B RELIEF VALVE 18 C BACKFLOW PREVENTER 19 D SYSTEM ...

Page 6: ...37 H EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION 39 I REMOVING AN EXISTING WATER HEATER 39 J CONDENSATE REMOVAL SYSTEM 40 PART 8 FIELD WIRING 41 A INSTALLATION MUST COMPLY WITH 41 B FIELD WIRING 41 C LINE VOLTAGE WIRING FOR STANDARD HEATER 42 D THERMOSTAT 42 E OUTDOOR SENSOR OPTIONAL 43 F INDIRECT SENSOR OPTIONAL 43 G 0 10 VOLT BUILDING CONTROL SIGNAL OPTIONAL 43 H UL353 LOW WATER CUT OFF INTERF...

Page 7: ...mbustible materials 0 top bottom sides and back Front must have room for service 24 recommended A combustible door or removable panel is acceptable front clearance This appliance has been approved for closet installation Do not install this appliance directly on carpeting For installation on combustible flooring Category IV vent systems only INSTALLER Read all instructions in this manual before in...

Page 8: ...isconnect electrical supply before performing maintenance To avoid severe burns allow heater to cool E WATER QUALITY Do not use petroleum based cleaning or sealing compounds in a heater system Gaskets and seals in the system may be damaged This can result in substantial property damage Do not use homemade cures or heater patent medicines Substantial property damage damage to heater and or serious ...

Page 9: ...ontrol unit The heater uses data gathered by these sensors to intelligently deliver highly efficient hydronic heating Heat Exchanger The highly efficient combustion heat exchanger flows exhaust gas through the primary section into the secondary heat exchanger section where the coldest water on the bottom of the tank extracts the last residual amount of energy Modulating Combustion System Modulatio...

Page 10: ...in you must use a condensate removal pump kit 554200 available from HTP A condensate filter if required by local authorities can be made up of lime crystals marble or phosphate chips and will neutralize the condensate This can be purchased from HTP 7450P 212 and installed in the field It is also very important that the condensate line is not exposed to freezing temperatures or any other type of bl...

Page 11: ...PMENT Below is a list of optional equipment available from HTP System Sensor Part 7250P 324 Indirect Tank Sensor Part 7250P 325 3 Stainless Steel Outside Termination Vent Kit V1000 4 Stainless Steel Outside Termination Vent Kit V2000 2 PVC Concentric Vent Kit Part KGAVT0501CVT 3 PVC Concentric Vent Kit Part KGAVT0601CVT U L 353 Compliant Low Water Cut Off Interface Kit with Manual Reset Part 7450P...

Page 12: ...12 PART 3 DIMENSIONS AND CLEARANCES Figure 1 LP 325 L ...

Page 13: ...ation of the heater A BEFORE LOCATING THE HEATER Check for nearby connections to System water piping Venting connections Gas supply piping Electrical power Condensate drain Check area around heater Remove any combustible materials gasoline and other flammable liquids Failure to keep heater area clear and free of combustible materials liquids and vapors can result in substantial property damage sev...

Page 14: ...y with the above warnings could result in substantial property damage severe personal injury or death D RESIDENTIAL GARAGE INSTALLATION If the heater is located in a residential garage per ANSI Z223 1 Mount the bottom of the heater a minimum of 18 above the floor of the garage to ensure the burner and ignition devices are well off the floor Locate or protect the heater so it cannot be damaged by a...

Page 15: ...ere indoor air is contaminated see Table 1 it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection Unconfined space is space with volume greater than 50 cubic feet per 1 000 Btu hour 4 8 cubic meters per kW of the total input rating of all fuel burning appliances installed in that space Room...

Page 16: ...cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric or Muriatic acid Furniture refinishing areas and establishments Cements and glues New ...

Page 17: ...rner operation Use the flame of a match or candle or smoke from a cigarette 6 After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be co...

Page 18: ...r scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length Di...

Page 19: ...ection at the same point as the expansion tank connection to the system 4 Most chilled water systems are piped using a closed type expansion tank E CIRCULATOR PUMPS DO NOT install automatic air vents on closed type expansion tank systems Air must remain in the system and return to the tank to provide an air cushion An automatic air vent would cause air to leave the system resulting in improper ope...

Page 20: ...d outlet temperature from the heater Install the heater so the gas ignition system components are protected from water dripping spraying etc allowing clearance for basic service of circulator replacement valves and other parts Observe minimum 1 clearance around all hot water pipes not protected by non combustible materials On a heater installed above radiation level some states and local codes req...

Page 21: ...ction prior to opening valves manually so as not to damage any valves Manually operate fill valve regulator When water runs out of the hose while it s connected to the balance and purge valve or drain you will see a steady stream of water without bubbles Close balance and purge valve or drain to stop the water from flowing Disconnect the hose and connect it to next zone to be purged Repeat this pr...

Page 22: ... inhibitor reduction etc You must carefully figure the additional friction loss in the system as well as the reduction in heat transfer coefficients I ZONING WITH ZONE VALVES 1 Connect heater to system as shown in the Piping Details diagrams Properly size circulators for friction loss of zone valves and piping for proper operation 2 Connect DHW domestic hot water piping to indirect storage water h...

Page 23: ...4 Circulators are shown with isolation flanges and integral check valves The alternative is standard flanges with full port ball valves and a separate flow check valve Purge valves can be used with the circulator flanges as an alternative 5 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 6 Install a minimum of 12 diameters of straight pip...

Page 24: ...are shown with isolation flanges and integral check valves The alternative is standard flanges with full port ball valves and a separate flow check valve Purge valves can be used with the circulator flanges as an alternative 5 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 6 Install a minimum of 12 diameters of straight pipe upstream of ...

Page 25: ...e shown with isolation flanges and integral check valves The alternative is standard flanges with full port ball valves and a separate flow check valve Purge valves can be used with the circulator flanges as an alternative 5 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 6 Install a minimum of 12 diameters of straight pipe upstream of al...

Page 26: ... severe personal injury or death 1 Install the water heater venting system in accordance with these instructions and with the National Fuel Gas Code ANSI Z223 1 NFPA 54 CAN CGA B149 and or applicable provisions of local building codes 2 This water heater is a direct vent appliance and is listed as a Category IV appliance with Underwriters Laboratories Inc VENT AND INTAKE AIR VENT B APPROVED MATERI...

Page 27: ...eters gas meters gas regulators relief equipment exhaust fans and inlets In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained g When adjacent to a public walkway locate exit terminal at least 7 feet above grade h Do not locate the exhaust directly under roof overhangs to prevent icicles from forming i Provide 4 feet c...

Page 28: ...AUST AND INTAKE AIR VENT SIZING 1 The exhaust and intake vent size is 2 for the PH100 and PH130 and 3 for the PH160 and PH199 2 The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet ...

Page 29: ...efore the total combined equivalent length is 46 feet which is well below the maximum of 85 feet c The intake air vent pipe and the exhaust vent are intended to penetrate the same wall or roof of the building d Effort should be made to keep a minimum difference in equivalent length between the intake air vent pipe and the exhaust vent 3 The minimum combined equivalent length is 16 equivalent feet ...

Page 30: ...2564 for PVC and ASTM F493 for CPVC pipe 4 Horizontal lengths of exhaust vent must slope back towards the water heater not less than per foot to allow condensate to drain from the vent pipe 5 All piping must be fully supported Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form 6 Do not use the heater to support any piping 7 A screened straigh...

Page 31: ...perly terminated Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure see Optional Equipment in Venting Section The air intake and exhaust vent piping lengths routing and termination methods must all comply with the methods and limits given in the Venting section Part 8 of this manual When installing a combustion air intake from outdoors ca...

Page 32: ...32 Figure 10 NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 33: ...33 Figure 11 NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 34: ...34 Figure 12 Roof Vent with Tee NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 35: ...35 Figure 13 NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 36: ...36 Figure 14 NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 37: ...r kW of the total input rating of all fuel burning appliances installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space Confined space is space with volume less than 50 cubic feet per 1 000 Btu hour 4 8 cubic meters per kW of the total input rating of all fuel burning appliances installed in that space Rooms connected ...

Page 38: ...38 Figure 16 NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 39: ...ater for use as an outside exhaust termination 8 A screened inlet air tee is provided with the heater to be used as an outside intake termination 9 The following information on Table 5 8 lists optional intake air exhaust vent terminations available from HTP DESCRIPTION STOCK CODE 2 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0501CVT 3 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0601CVT 2 STAINLESS STEEL...

Page 40: ...itially started It is very important that the condensate line is sloped down away from the heater and to a suitable drain If the heater condensate outlet is lower than the drain you must use a condensate removal pump kit 554200 available from HTP If required by local authorities a condensate filter of lime crystals marble or phosphate chips will neutralize slightly acidic condensate This can be in...

Page 41: ...afety turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death Wiring must be N E C Class 1 If original wiring supplied with the heater must be replaced use only TEW 105 o C wire or equivalent Heater must be electrically grounded as required by National Elec...

Page 42: ...oard at terminals 120V Neutral Ground A line voltage fused disconnect switch may be required to be externally mounted and connected according to local codes that may apply 2 Connect the central heating pump to the terminals marked 1 HOT 2 NEUT 3 GND in Figure 18 The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts If the pump requires more current or voltage...

Page 43: ...rol will automatically detect its presence and a demand for heat from the indirect water tank will be generated when the tank temperature falls below the user set point by more than the user selectable offset Demand will continue until the sensor measures that the indirect water tank temperature is above the set point Connect the indirect tank sensor 7250P 325 or mechanical aquastat to the termina...

Page 44: ...2 It is recommended to use the shortest length cable that will reach between the heaters and create a neat installation Do not run unprotected cables across the floor where they may become wet or damaged Avoid running communication cables parallel and close to or against high voltage 120 volt or greater wiring HTP recommends that the maximum length of communication bus cables not exceed 200 feet 3...

Page 45: ...9 4 Connect the heater pump to the terminals marked 1 2 and 3 5 Connect the system pipe sensor to the terminals marked 10 and 11 6 Connect the outdoor sensor if used to the terminals marked 12 and 13 7 Connect the signal to start the system to the terminals marked 14 and 15 NOTE This signal can come from a room thermostat or a dry contact closure No power of any voltage should be fed into either o...

Page 46: ...wer for the device to terminal 8 Connect the alarm device hot wire to terminal 9 Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device 4 To connect a device that should be powered off during a heater lockout condition follow the same instructions as above except use terminal 7 rather than terminal 9 NOTE In a cascade system the alarm output of...

Page 47: ... of 200 ppm Clean system to remove sediment 1 You must thoroughly flush the system without the heater connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment 2 For zoned systems flush each zone separately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean the system 3 Flu...

Page 48: ... drain and be seen 2 Close the heater or system isolation valve between the purge valve and fill connection to the system 3 Close zone isolation valves 4 Open quick fill valve on cold water makeup line 5 Open purge valve 6 One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves ...

Page 49: ... is any indication of a gas leak Repair any leaks at once This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand A OPERATING INSTRUCTIONS If you smell gas STOP Follow listed safety instructions If you do not smell gas follow the next steps 1 Turn on all electrical power to the appliance IF THE INFORMA...

Page 50: ...heaters has an indirect fired water heater connected to it the address of this heater must be 2 or greater It is recommended but not necessary to address heaters in the order that they are wired No two heaters can have the same address It is not required to use all consecutive address numbers Example In a 2 heater system with an indirect connected to the follower the follower address would be 2 ad...

Page 51: ...180 To adjust press either S1 Decrease Value or S2 Increase Value 4 Press S3 a fourth time to access dh the Indirect Differential Set Point This function allows the installer to adjust the activation of the DHW call based on the differential temperature setting for the indirect tank The pump will not start until the indirect water temperature reaches a temperature equal to the setting for the indi...

Page 52: ...eater Alternating 0 100 Percentage firing rate P1 Follower Heater 1 Alternating 0 100 Percentage firing rate P2 Follower Heater 2 Alternating 0 100 Percentage firing rate P3 Follower Heater 3 Alternating 0 100 Percentage firing rate P4 Follower Heater 4 Alternating 0 100 Percentage firing rate P5 Follower Heater 5 Alternating 0 100 Percentage firing rate P6 Follower Heater 6 Alternating 0 100 Perc...

Page 53: ...eed out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet Press S1 and S2 together at any time to return the control to normal operation PART 11 PROGRAMMING THE HEATER The control allows the installer to set system limits and the heat curve for the Heater These system limits should not be changed by...

Page 54: ... F to 185 o F 12 68 o F Sets the lowest temperature on the heater for central heating Range 32 o F to 185 o F 13 0 min Changes central heating circulator post purge time once thermostat is satisfied Range 0 to 10 minutes 14 30 min Sets maximum run time for the indirect water heater and minimum run time for central heating Range 0 to 60 minutes 15 0 Bus address 0 zone master 1 8 cascade slave 16 0 ...

Page 55: ...modulation Parameter set on 1 DHW will begin modulation on low fire rather than high fire 30 0 Parameter set on 0 There will be no extra appliance on the Cascade Master Parameter set on 1 Extra appliance is connected to the Cascade Master 31 Do not change Table 11 Central Heating Curve Function Central heating demand is detected when the room thermostat closes When an outside sensor is also connec...

Page 56: ... an error condition occurs the controller will display an error code on the display module 2 These error codes and several suggested corrective actions are included in Table 15 C HEATER FAULT 1 When a fault condition occurs the controller will illuminate the red fault indication light and display a fault code in the format Example F00 on the display module 2 Note the fault code and refer to Table ...

Page 57: ... see if appliance circulator is functioning Repair as necessary 2 Be sure water is flowing in the system Check for valves that should be open plugged filter screens etc 3 Check flow switch and wiring Repair as necessary Table 15 926 Control Board FAULT Codes Description Remedy F00 High temperature switch limit exceeded 194o F 1 Try reset If F00 repeats create a demand for hot water DANGER Use caut...

Page 58: ...the flame is stable when lit 3 Check to see if the green light on the display module is out while the heater is running 4 If the green light doesn t come on or goes off during operation check the flame signal on the status menu 5 If the signal reads less than 1 microampere clean the flame rectifier probe 6 If the flame rectifier probe continues to read low replace it F11F False flame signal The he...

Page 59: ...59 Figure 22 ...

Page 60: ...60 Figure 23 ...

Page 61: ...rly Change batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit breaker CHAMBER BURNER Combustion Chamber Check burner tube If dirty clean with compressed air Clean chamber with vacuum Spark Electrode Clean Set gap at For natural between probes For LP a gap from single probe to burner Flame Probe Clean Check ionization in uA d7 on status...

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Page 63: ...63 ...

Page 64: ...64 MAINTENANCE NOTES ...

Page 65: ...s Date of Installation Installer s Code Name Product Serial Number s Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make contact please contac...

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