HTP Pioneer Installation And Startup Manual Download

Page: 71 / 74

LP- 325 REV. 3.3.15

Summary of Contents for Pioneer

Page 1: ...hout notice and will not be held liable for typographical errors in literature The surfaces of these products contacted by consumable water contain less than 0 25 lead by weight as required by the Safe Drinking Water Act Section 1417 NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE This manual must only be used by a qualified heating installer service technician Read and understa...

Page 2: ...CINITY OF 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...

Page 3: ...ial or electrical inspector or others having statutory authority In some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departmental official may be the AHJ NOTE HTP Inc reserves the right to modify product technical specifications and components without prior notice This manual must only be used by a qualified heating i...

Page 4: ...INTERIZING 9 PART 2 BEFORE YOU START 10 A WHAT S IN THE BOX 10 B HOW THE APPLIANCE OPERATES 10 C OPTIONAL EQUIPMENT 11 PART 3 PREPARE APPLIANCE LOCATION 12 A BEFORE LOCATING THE APPLIANCE 12 B LEVELING 13 C CLEARANCES FOR SERVICE ACCESS 13 D RESIDENTIAL GARAGE INSTALLATION 13 E EXHAUST VENT AND INTAKE PIPE 14 1 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE 14 2 INDOOR COMBUSTION AIR INS...

Page 5: ...NDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 43 I CONDENSATE REMOVAL SYSTEM 45 PART 6 FIELD WIRING 46 A INSTALLATION MUST COMPLY WITH 46 B FIELD WIRING 48 C LINE VOLTAGE WIRING FOR STANDARD APPLIANCE 48 D THERMOSTAT 48 E OUTDOOR SENSOR OPTIONAL 49 F INDIRECT SENSOR OPTIONAL 49 G 0 10 VOLT BUILDING CONTROL SIGNAL OPTIONAL 49 H UL353 LOW WATER CUT OFF INTERFACE KIT OPTIONAL 49 I...

Page 6: ...S 61 B PROGRAM SYSTEM SETTINGS 61 PART 11 SHUTDOWN 64 A SHUTDOWN PROCEDURE 64 B VACATION PROCEDURE 64 C FAILURE TO OPERATE 64 PART 12 TROUBLESHOOTING 64 A APPLIANCE ERROR CODE 64 B APPLIANCE ERROR 64 C APPLIANCE FAULT 64 D NO HOT WATER DHW VERSA FLAME 64 PART 13 MAINTENANCE 69 MAINTENANCE NOTES 73 HTP CUSTOMER INSTALLATION RECORD FORM 74 PART 1 GENERAL SAFETY INFORMATION A PRECAUTIONS This applian...

Page 7: ...merous harmful conditions such as a potential gas leakage causing a fire and or explosion or the release of mold bacteria or other harmful particulates into the air Operating a previously submerged appliance could result in property damage severe personal injury or death NOTE Appliance damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty Be sure t...

Page 8: ...ses failure Addition of oxygen from make up water can cause internal corrosion in system components Leaks in the appliance or piping must be repaired at once F CHECK CONTROL HYDRONIC WATER CHEMISTRY Water pH between 6 0 and 8 0 1 Maintain appliance water pH between 6 0 and 8 0 Check with litmus paper or have chemically analyzed by a water treatment company 2 If the pH differs from above consult lo...

Page 9: ...d as low as 0 to 1 grain per gallon may be under saturated with respect to calcium carbonate resulting in water that is aggressive and corrosive pH of Water pH is a measure of relative acidity neutrality or alkalinity Dissolved minerals and gases affect water pH The pH scale ranges from 0 to 14 Water with a pH of 7 0 is considered neutral Water with a pH lower than 7 is considered acidic Water pH ...

Page 10: ... extracts the last residual amount of energy Modulating Combustion System Modulation during central heating operation is based on the supply temperature The set point used for the control depends upon the programmed central heating curve The slope of the heating curve can be changed by the installer The control monitors the system regulating burner output during operation to match system demand ef...

Page 11: ...all a thermostatic mixing valve could result in property damage The indirect sensor allows the installer to operate the appliance with two temperatures one for central heating and the other for the SuperStor Indirect Water Appliance This allows the user to increase water temperature supplied to the indirect to get faster recovery by prioritizing flow at a higher rate than may be needed for central...

Page 12: ...onditions Ensure ambient temperatures are higher than 32 o F 0 o C and lower than 104 o F 40 o C Prevent the air from becoming contaminated by the products places and conditions listed in this manual Part 3 Section F Avoid continuously high levels of humidity Never close existing ventilation openings Ensure a minimum 1 clearance around hot water and exhaust vent pipes The service life of the appli...

Page 13: ...cate the appliance must be level Location must also fully support the weight of the appliance when filled with water 650 lbs C CLEARANCES FOR SERVICE ACCESS If you do not provide the minimum clearances shown it may not be possible to service the appliance without removing it from the space The space must be provided with combustion ventilation air openings correctly sized for all other appliances ...

Page 14: ...prevent combustion air contamination see Table 1 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE This appliance requires fresh uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air NOTE To prevent combustion air contamination see Table 1 Combustion air from the indoor space can be used if the spa...

Page 15: ...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 building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches laundry detergents and cleaning solvents Garages and workshops Ad...

Page 16: ...n burner 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 b...

Page 17: ...17 LP 325 REV 3 3 15 Figure 3 Dimensions ...

Page 18: ...may require additional external controls B RELIEF VALVE Install supplied pressure and temperature relief valve Connect discharge piping to a safe disposal location following the guidelines on the next page Replacement is available See parts list To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposa...

Page 19: ...on tank SIZING SPACE HEAT SYSTEM PIPING 1 See piping details in this manual Special attention must be paid when connecting an indirect storage tank as temperature delivered to low temperature circuits may be higher than desired The use of thermostatic mixing valves is required to protect these circuits To control the temperature of low temperature heating circuits when using an indirect fired wate...

Page 20: ...iping details this section Make sure the circulator is properly sized for the system and friction loss 7 Install an expansion tank on the system supply Consult manufacturer instructions for specific information relating to expansion tank installation Size the expansion tank for the required system volume and capacity 8 Install supply air vent to remove air when commissioning the appliance 9 The sa...

Page 21: ... volume during a temperature increase from 32 o F to 180 o F while water expands 3 over the same temperature rise Allowances must be made for expansion in system design A 30 mixture of glycol results in a BTU output loss of 15 with a 5 increase in head against the system circulator A 50 glycol mixture results in a BTU output loss of 30 with a 50 increase in head against the system circulator It is...

Page 22: ...liance is 1 25 inch 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 diame...

Page 23: ...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 all circulators 7 Winterization When winterizing put a drain valve on both the supply and return bet...

Page 24: ...estic water connections on this appliance with black iron galvanized steel steel or lead pipe Doing so will result in premature product failure and property damage and WILL VOID the product warranty Domestic water connections must be installed in accordance with all local and national plumbing codes or any applicable prevailing standards The domestic inlet and outlet ports on the brazed plate heat...

Page 25: ...ter at any faucet in the system Be careful whenever using hot water to avoid scalding injury By setting the thermostat on this appliance to obtain increased water temperature you may create a higher potential for scald injury To protect against injury you should install an ASSE approved thermostatic mixing valve a device to limit the temperature of water to protect against scald injury by mixing h...

Page 26: ...please call HTP Technical Support Department Installation of the Mixing Valve 1 Flush all pipe work thoroughly with water only before installing the mixing valve 2 The mixing valve comes complete with union type connections for ease of installation and service 3 The mixing valve must be removed from the pipe work prior to soldering the end connections It is recommended to use a spacer piece while ...

Page 27: ...LVE MAINTENANCE AND SERVICE It is recommended to check the mixing valve annually to ensure proper system capabilities More frequent checks are recommended in adverse water conditions When checking the mixed water supply temperature use the same faucet used in the initial installation temperature adjustment There may be some variation in the water temperature from the mixing valve due to seasonal t...

Page 28: ...28 LP 325 REV 3 3 15 Figure 9 DHW Pack Performance on 199K BTU Models ...

Page 29: ...ors 4 A pressure relief valve or T P valve may be required Check with local codes 5 This drawing refers to DHW piping only For Central Heating piping please refer to Part 5 Section L 6 Winterization When winterizing pump a small amount of food grade glycol FDA rated as GRAS Generally Recognized As Safe into the brazed plate heat exchanger 7 In Massachusetts a vacuum relief valve must be installed ...

Page 30: ...traight pipe upstream of all circulators 4 A pressure relief valve or T P valve may be required Check with local codes 5 This drawing refers to DHW piping only For Central Heating piping please refer to Part 5 Section L 6 Winterization When winterizing pump a small amount of food grade glycol FDA rated as GRAS Generally Recognized As Safe into the brazed plate heat exchanger 7 In Massachusetts a v...

Page 31: ...cuum relief valve must be installed on the cold water line per 248 CMR 8 Recirculator pump must be sized to flow 0 6 GPM or greater to the appliance 9 If a backflow preventer or no return valve is installed a thermal expansion tank is required on the cold water inlet between the water heating appliance and the backflow preventer 10 Versa Flame DHW setting on mixing valve must be set higher 5o F mi...

Page 32: ...mers used to join plastic exhaust vent and intake pipes explosive solvent vapors must be cleared from all vent piping before start up Avoid using excess cement or primer as this may pool in the vent pipes Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance Failure to follow these instructions will result in substantial property damage se...

Page 33: ...00 o F 37 o C or greater such as stove pipes space heaters etc may damage plastic components of the appliance as well as plastic vent pipe materials Such damages ARE NOT covered by warranty It is recommended to keep a minimum clearance of 8 from high heat sources Observe heat source manufacturer instructions as well as local state provincial and national codes laws regulations and ordinances when ...

Page 34: ...s 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 J This vent system shall terminate at least 3 feet 0 9 m above any forced air intake located within 10 ft 3 m NOTE This does not apply to the combustion air intake of a direct vent appliance K When venting with a two pipe s...

Page 35: ...5 total equivalent feet necessary for transition and 200 maximum total equivalent feet for 3 transitioning to 4 pipe including the minimum 15 total equivalent feet necessary for transition b Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe MODEL MAXIMUM TOTAL EQUIVALENT LENGTH AT STANDARD VENT CONNECTION REDUCING COUPLING MAXIMU...

Page 36: ...id PVC or CPVC pipe or a Polypropylene vent system approved for use with Category IV appliances FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS Foam core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be properly cleaned primed and cemented Use only cement and primer approved for use wi...

Page 37: ...NTING DRAWINGS 1 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE If installing a direct vent option combustion air must be drawn from the outdoors directly into the appliance intake and exhaust must terminate outside There are three basic direct vent options detailed in this manual 1 Side Wall Venting 2 Roof Venting and 3 Unbalanced Venting Be sure to locate the appliance such that the ex...

Page 38: ...red by local codes All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for...

Page 39: ...cal codes All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for the firs...

Page 40: ... be glued properly supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for the first three feet from the applian...

Page 41: ... properly supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for the first three feet from the appliance 2 VENT...

Page 42: ...tional concentric vent kits Refer to Concentric Vent Kit installation manual LP 166 for further information on venting with the optional concentric vent kits Concentric venting through an existing system must run vertically through the roof See Table 9 for proper minimum vent sizing Use only the approved venting materials specified in Table 4 for piping the system All instructions listed in Part 5...

Page 43: ...s per 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 connec...

Page 44: ...44 LP 325 REV 3 3 15 Figure 20 ...

Page 45: ...f the condensate line may be necessary to avoid blockage of the condensate flow Figure 21 Condensate Line Detail NOTES 1 Condensate line must be pitched at least 1 4 per foot to properly drain If this cannot be done or a very long length of condensate hose is used you must increase the condensate line to a minimum of 1 ID and place a tee in the line after the condensate neutralizer to properly red...

Page 46: ...ring supplied with the appliance must be replaced use only TEW 105 o C wire or equivalent Appliance must be electrically grounded as required by National Electrical Code ANSI NFPA 70 Latest Edition A INSTALLATION MUST COMPLY WITH 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes...

Page 47: ...47 LP 325 REV 3 3 15 Figure 22 Internal Wiring Diagram ...

Page 48: ... WIRING FOR STANDARD APPLIANCE 1 Connect the incoming power wiring to the line voltage terminal strip in the field connection board 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 8 HOT 2 NEUT 3 GND in Figure 23 The connec...

Page 49: ...ll a thermostatic mixing valve when using an indirect fired water heater could result in damage the heating circuits Such damage IS NOT covered by warranty G 0 10 VOLT BUILDING CONTROL SIGNAL OPTIONAL 1 If a 0 10 volt building management system is not used in the installation move on to Section H 2 A signal from a building management system may be connected to the appliance to enable remote contro...

Page 50: ...The central heating pump must be connected to the appliance Ensure that factory jumper connecting terminals 120 VOLT and 9 remains in place 2 WIRING WITH ZONE CIRCULATOR PUMPS For proper installation of the appliance with zone circulator pumps follow the wiring instructions below Connect the end switch to the TT connection on the appliance Remove the factory jumper from Line Voltage Pin to Pin 9 C...

Page 51: ...ble If you have connected the appliances to each other properly see Figure 6 Cascaded System p 24 two of the appliances will have single open connection ports L CASCADE MASTER PUMP AND SENSOR WIRING PIONEER ONLY 1 Connect the system pump hot wire to the terminal marked 1 2 Connect the system pump neutral to the terminal 2 and the pump ground wire to terminal 3 3 Connect a jumper wire from the 120 ...

Page 52: ...re 27 Cascade Master and Follower Wiring PART 7 GAS CONNECTIONS FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE EXPLOSION OR DEATH The gas supply shall have a maximum inlet pressure of less than 14 water column 350 mm pound pressure 3 5 kPa and a minimum of 3 5 water column The entire piping system gas meter and regulator must be sized properly to prevent pressure drop great...

Page 53: ...inch water column Nominal Iron Pipe Size In Internal Dia In Length of Pipe Feet BTU s Per Hour x 1 000 10 20 30 40 50 60 70 80 90 100 125 150 175 200 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 1 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 100 1 1 380 1 050 730 590 500 440 400 370 350 320 305 275 250 225 210 1 1 610 1 600 1 100 890 760 670 610 560 530 490 460 410 380 350 320 ...

Page 54: ...may result in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO Failure to follow this instruction could result in fire explosion property damage severe pers...

Page 55: ...d by a water treatment company 2 If the pH differs from above consult local a water treatment company for treatment required Hardness less than 7 grains Consult local water treatment companies in circumstances of unusually hard water above 7 grains hardness Chlorine concentration less than 100 ppm 1 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are ...

Page 56: ...his can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of this appliance This scale accumulation can also impede the ability of the heat exchanger to transfer heat into the water A heat exchanger damaged or blocked by lime scale accumulation must be replaced The manufacturer of the appliance has no control of water quality especially TDS levels...

Page 57: ...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 and proceed with the next zone Follow this procedure until all zones are purged 7 Refill to correct pressure G PURGE AIR FROM DHW SYSTEM VERSA FL...

Page 58: ... or explosion 4 Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been damaged 5 The appliance shall be installed so the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service ...

Page 59: ...ure The set point temperature can be set as low as 50 o F or as high 185 o F Changes are directly stored and the display returns to normal mode after one minute 2 Press S3 a second time The appliance will now display Ch and an alternating value of 15 This is the Appliance Differential Set Point This function allows the installer to adjust the activation of the burner based on the differential temp...

Page 60: ... x 10 4100 actual fan speed d7 Actual ionization current read from flame rectification probe d8 Actual status of the central heating circulator Off 0 On 1 d9 Actual status of the indirect fired circulator Off 0 On 1 VERSA FLAME Status of the DHW module pump Off 0 On 1 d10 Actual status of bus communication co connected nc not connected d11 Central heating set point d12 Power on hours in thousands ...

Page 61: ...and the system pump will come on You can use the S1 and S2 keys to toggle between running each pump in the system as required to help bleed 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 10 PROGRAMMING THE APP...

Page 62: ...r shorted FOU error does not prevent the appliance from running 0 No FOU displayed 1 FOU displayed if outdoor sensor is shorted or open 22 100 Maximum appliance output percentage Default 100 This parameter can be adjusted to lower the maximum appliance output if necessary Range 50 100 23 0 Cascade configuration Default 0 Leave as 0 if this is a standalone unit or if the unit is cascaded using the ...

Page 63: ...um outside design temperature Function 8 Table 15 Central Heating Curve Factory Default 2 Design supply water temperature at the minimum design outside temperature Function 9 3 Maximum outside design temperature Function 10 4 Design supply water temperature at the maximum outside temperature Function 11 NOTE Versa Flame minimum set point Function 49 may override the supply temperature for Function...

Page 64: ...e unit will try to re light once every 6 minutes PART 12 TROUBLESHOOTING A APPLIANCE ERROR CODE An error code may occur in the installation of the appliance This condition may lead to a lock out condition of the controller which will need to be manually reset through the S4 button These temporary codes will help the installer correct the problem before going into a lock out condition which will re...

Page 65: ...mperature switch limit exceeded 194o F 1 Try reset If F00 repeats create a demand for hot water DANGER Use caution to prevent burn injury If water is above 194o F test upper and lower temperature sensor with an ohmmeter Refer to resistance chart this section Replace bad sensor If water is below 194o F test high temperature switch and wiring with ohmmeter Switch should be closed at this point If no...

Page 66: ...he flame rectifier probe 6 If the flame rectifier probe continues to read low replace it F11F False flame signal The appliance will lock out if it senses a flame signal when there should be none present 1 Turn the gas off to the unit at the service valve 2 If the flame signal is still present replace the igniter 3 If the flame signal is not present after turning off the gas supply check the gas va...

Page 67: ...67 LP 325 REV 3 3 15 Figure 30 Pioneer and Versa Flame ...

Page 68: ...68 LP 325 REV 3 3 15 Figure 31 Pioneer and Versa Flame ...

Page 69: ...ilures ARE NOT covered under warranty The appliance requires minimal periodic maintenance under normal conditions However in unusually dirty or dusty conditions periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely...

Page 70: ...or LP a gap from single probe to burner Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary Condensate hose Disconnect condensate hose Clean out dirt Fill with water to level of outlet and re install NOTE Verify the flow of condensate making sure that the hose is pro...

Page 71: ...71 LP 325 REV 3 3 15 ...

Page 72: ...72 LP 325 REV 3 3 15 ...

Page 73: ...73 LP 325 REV 3 3 15 MAINTENANCE NOTES _______________________________________________________________________ ___________________________________________________________________________________ ...

Page 74: ...Installation Address 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 co...

Search results

Summary of Contents for Pioneer

Reviews:

Related manuals for Pioneer

Brands by name

Popular brands

HTP Pioneer, Installation And Startup Manual

Search results

Summary of Contents for Pioneer

Reviews:

Related manuals for Pioneer

Brands by name

Popular brands