HTP Pioneer PHR100 Installation, Start-Up, Maintenance, Parts, Warranty Download

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Pioneer

Heating Appliance

Installation

Start-Up

Maintenance

Parts

Warranty

PHR100 / 130 / 160 / 199 Models*

* “LP” Denotes Propane Gas Operation

This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before installing.

Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.

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

in literature.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

272 Duchaine Blvd.

New Bedford, MA 02745

www.htproducts.com

LP-325 Rev. 009 Rel. 004 Date 12.2.20

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property

damage, severe personal injury, or death.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth

defects, or other reproductive harm.

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required

by the Safe Drinking Water Act, Section 1417.

This Manual For Use With Appliances Manufactured After

April 10, 2017

Summary of Contents for Pioneer PHR100

Page 1: ... in literature NOTETO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 272 Duchaine Blvd New Bedford MA 02745 www htproducts com LP 325 Rev 009 Rel 004 Date 12 2 20 Improper installation adjustment alteration service or maintenance could void product warranty and cause property damage severe personal injury or death California Proposition 65 Warning This product contains chemicals known ...

Page 2: ...e 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 agency or the gas supplier Improper installation adjustment alteration service or mainten...

Page 3: ...stalled by qualified and licensed personnel The installer should be guided by the instructions furnished with the appliance and by local codes and utility company requirements In the absence of local codes preference should be given to the National Fuel Gas Code ANSI Z223 1 in the United States and the Natural Gas and Propane Installation Code B149 1 in Canada latest versions Installations Must Co...

Page 4: ...d Space 11 F Carbon Monoxide Detectors 11 G Prevent Combustion Air Contamination 12 H Removing an Appliance from a Common Vent System 12 I Technical Specifications 13 Part 4 Piping 14 A General Plumbing Information 14 B Backflow Preventer 15 C Expansion Tank 15 D Piping the Appliance 15 E Circulator Pumps 15 F Relief Valve 16 G Zoning with Zone Valves 16 H Zoning with Circulators 16 I Multiple App...

Page 5: ... that a CO level of no more than 150 ppm is exceeded at any time during operation WARNING This appliance must be installed by a qualified service technician Improper installation and or operation can cause a potentially hazardous situation which if not avoided will void the warranty and could result in serious injury or death Themanufacturercannotanticipateeverycircumstancethatmight involve a pote...

Page 6: ...p water to the system when the appliance is hot Thermal shock can potentially cause cracks in the heat exchanger Such damage IS NOT covered by warranty F Water Chemistry Requirements Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment Water quality must be professionally analyzed to determine whether it is necessary to trea...

Page 7: ... increased water temperatures By setting the thermostat on this appliance or the indirect water heater to obtain the increased water temperature required by these appliances you may create the potential for scald injury The risk of scalding increases when raising DHW temperature Use a water tempering or mixing valve when raising DHW temperature to lessen the chance of scalds Consult codes for conf...

Page 8: ...the shipping crate Take care to place the appliance and accessories in a safe location prior to installation to prevent damage to the mechanical connections To control the temperature of low temperature heating circuits when using an indirect fired water appliance a thermostatic mixing valve is required Failure to install a thermostatic mixing valve could result in property damage severe personal ...

Page 9: ...o sustained temperatures below 32 o F Precautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions Failure to take precautions could result in property damage severe personal injury or death Failure to keep the appliance area clear and free of combustible materials liquids and vapors can result in substantial property damage severe personal injury o...

Page 10: ...ation opening must be located within 6 in of the floor while the upper opening must be located 6 in from the top of the space If the appliance area has a volume less than 150 ft3 it is considered a Closet or Alcove In the US Canada PVC vent pipe and fittings SHALL NOT BE USED within the closet or alcove Only approved CPVC Polypropylene or Stainless Steel vent pipe and fittings may be used See Tabl...

Page 11: ... 4 8 cubic meters 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 See Venting Section for details Confined space is space with volume less than 50 cubic feet per 1 000 BTU hr 4 8 cubic meters per kW of the total input rating of all fuel burning a...

Page 12: ...e gas spillage and carbon monoxide emissions causing severe personal injury or death Do not install the appliance into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible substantial property damage severe personal injury or death When removing an existing appliance follow the steps below 1 Seal any unused openings in the common v...

Page 13: ...Materials3 PVC CPVC PP Stainless Steel Shipping Weight lbs 260 lbs Gas Supply Pressure NG LP 3 5 to 14 WC Manifold Pressure Min Max NG LP 0 01 WC Power Supply 120V 60Hz 6A General Operating Conditions Ambient Temperature Range 33 104oF 0 6 40oC Ignition System Direct Electronic Spark Ignition Flame Rectification Burner System Premixed Fuel Modulation Stainless Steel Metal Fiber Burner Gas Valve Sy...

Page 14: ...m must meet or exceed the piping requirements in this manual The appliance control module uses temperature sensors to provide both high limit protection and modulating temperature control The control module also provides low water protection by sensing the water level in the appliance Some codes jurisdictions may require additional external controls The National Standard Plumbing Code the National...

Page 15: ...ackflow preventer specifically designed for hydronic installations This valve should be installed on the cold water fill supply line per local codes C Expansion Tank Expansion Tank and Make Up Water 1 Ensure that the expansion tank is sized to correctly handle applianceandsystemwatervolumeandtemperature Theappliance volume is 55 gallons 2 The expansion tank must be located as shown in Applications...

Page 16: ...aced if necessary by a licensed plumbing contractor or qualified installer service technician to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occuring conditions may corrode the valve and its components over time rendering the valve inoperative Such cond...

Page 17: ...s with manual vents at high points follow above section and starting with the nearest manual air vent open until water flows out Then close vent Repeat procedure working your way toward furthest air vent NOTE It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present Annual cleaning of strainer may be necessary Upon completion make sure that...

Page 18: ...aller is responsible for all equipment detailing required by local codes 2 The minimum pipe size for connecting a SuperStor Ultra Indirect Water Appliance is 1 inch 3 The minimum pipe size for connecting the appliance 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 P...

Page 19: ... the appliance 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 ...

Page 20: ...njury or death Due to the extreme flammability of most glues cements solvents and primers 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 applian...

Page 21: ...may be used PVC CPVC pipe and fittings of the same diameter are considered interchangeable The use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in exhaust venting systems is prohibited Covering non metallic vent pipe and fittings with thermal insulation is prohibited When installing AL29 4C vent piping DO NOT mix AL29 4C piping from different manufacturers unless us...

Page 22: ...at may be opened Direct Vent 1 foot 3 feet 91 cm Power Vent 4 ft below or to side of opening 1 ft above opening C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Cle...

Page 23: ...nces ABS pipe material 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 with the pipe material Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is loc...

Page 24: ...on Avoid venting in areas that will affect neighboring buildings or be considered objectionable DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe DO NOT vent near soffit vents crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage DO NOT vent where condensate vapor could cause damage or cou...

Page 25: ...IN 12 MINIMUM CLEARANCE ABOVE HIGHEST OR GRADE WHICHEVER IS VENT KIT EXHAUST ANTICIPATED SNOW LEVEL EXTERIOR WALL 06 23 15 LP 505 A Sidewall Venting with Kit 05 26 15 LP 505 C INTAKE IMPORTANT EXHAUST INTAKE LEG MUST BE FACING UP CONCENTRIC VENT KIT MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP 1 MIN Sidewall Venting with Concentric Kit NOTE T...

Page 26: ...us snow allowance above grade Exhaust Air inlet Wall Brackets Figure 11 Venting Below Grade For installations that exit the wall below grade 1 Excavate the site to a point where the pipes are to exit as shown in Figure 11 2 Ensure the wall is fully sealed where the pipes penetrate 3 The exhaust vent air intake piping MUST be secured to the side of the building above grade as shown to provide rigid...

Page 27: ...ting must be readily accessible for visual inspection from the first three feet from the appliance INTAKE SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING EXHAUST OR 24 WHICHEVER IS GREATER 12 OVER MAXIMUM SNOW LEVEL LP 325 Z 06 18 13 LEFT SIDE VIEW UNBALANCED VENT WITH TEE INTAKE AND COUPLING EXHAUST All vent pipes must be glued properly supported and the exhaust pitched a mini...

Page 28: ...haust Intake 07 22 13 LP 325 NN INTAKE EXHAUST 24 SEAL EXISTING VENT CAP SEAL Exhaust Intake Chase Venting through an Existing System 3 Figure 16 1 2 Concentric Venting Through an Existing System 3 Chase Venting Through an Existing System NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes 3 Power Ven...

Page 29: ...ace Appliance Near Dryer ROOM OPENING ROOM OPENING 6 6 EXHAUST LP 325 S 09 29 11 Boiler Water Heater or Appliance Indoor Combustion Air Single Pipe EXHAUST UPPER AIR DUCT LOWER AIR DUCT LP 325 T 8 5 2010 Boiler Water Heater or Appliance Outdoor Combustion Air Single Pipe Figure 18 Indoor and Outdoor Combustion Air Single Pipe ...

Page 30: ...e line included with the appliance 6 A frozen condensate line could result in a blocked vent condition It is very important to protect the condensate line from freezing temperatures or any type of blockage In installations that may encounter sustained freezing conditions the use of heat tape is recommended to avoid freezing of the condensate line Longer condensate runs are more prone to freezing 7...

Page 31: ...nal Electrical Code NFPA 70 and or CSA C22 1 Electrical Code Part 1 in Canada Failure to follow all applicable local state and national regulations mandates and building supply codes for guidelines to install the electrical power supply could result in property damage serious personal injury or death Jumping out control circuits or components WILL VOID product warranty and can result in property d...

Page 32: ...uter network patch cables to connect the communication bus to each of the appliances These cables are readily available at any office supply computer electronic department or discount home supply store in varying lengths If you possess the skills you can also construct custom length cables 2 It is recommended to use the shortest length cable that will reach between the appliances and create a neat...

Page 33: ...ect fired water tank connected directly to the follower appliance connect the pump for it to the 4 5 and 6 terminals 2 An alarm bell or light can be connected to the alarm contacts of the follower appliance In the event of an alarm the normally open alarm contact may be used to turn a device on The normally closed alarm contact may be used to turn a device off if the appliance goes into lockout mo...

Page 34: ...TIONAL CUT OFF LOW WATER WHT RED RED BRN RED WHT LWCO WHT BRN RED LWCO CONNECTOR JUMPER CONNECTION SHOWN B A 0 10 VOLT 0 10 VOLT J5 5 J5 10 J5 6 J5 7 J5 8 J5 4 J5 3 J5 1 J5 2 J4 4 RS485 BUS RS485 BUS J4 4 J4 3 J3 5 J3 4 J3 3 TT TERMINALS J1 15 J1 14 J1 13 J1 12 DHW TANK OUTDOOR BLOCKED VENT AS SHIPPED BLUE YEL RED RED RED RED PINK PINK LT GRN LT BLUE RED BLUE GREY GREY GRN LT BLUE RED LT BLUE BLK ...

Page 35: ...the appliance on Natural Gas or LP gas with average sulfur rates greater than 30 mg m3 Doing so could result in improper product operation and failure and WILL VOID the appliance warranty Failure to follow these instructions could result in property damage gas leakage fire explosion serious personal injury or death It is very important that the appliance is connected to the gas type noted on the r...

Page 36: ...ply pipe size Run the gas supply line in accordance with all applicable codes 5 TheNationalFuelGasCode NFPA54 requiresthatasedimenttrap dripleg beinstalledinthegaslineonappliancesnotsoequipped The drip leg must be accessible a minimum of 3 in length and not subject to freezing conditions See Figure 24 6 A manual gas shut off valve should be installed in the gas supply line close to the appliance L...

Page 37: ...ere 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 personal injury or death E Checking Gas Pressure at the Appliance for Proper Op eration NOTE Refer to Figure 25 when che...

Page 38: ...lime scale buildup Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section of this manual Test replace freeze protection fluid 1 Forsystemsusingfreezeprotectionfluids followfluidmanufacturer s instructions to verify inhibitor level and that other fluid characteristics are satisfactory 2 Freeze protection fluid must be replaced periodically due to degradation of inhi...

Page 39: ... within this manual for proper steps to start appliance See Startup Report to record steps for future reference 2 Verify appliance and system are full of water and all system components are correctly set for operation 3 Fill condensate trap with water 4 Verify electrical connections are correct and securely attached 5 Inspect exhaust vent and intake piping for signs of deterioration from corrosion...

Page 40: ...r Menu These settings designate this appliance as the Master Appliance 3 Follower Appliances NOTE Read the notes below before programming follower appliances The appliance addressed as 1 will share its alarm output with the Master Appliance If one of the follower appliances has an indirect fired water appliance connected to it the address of this appliance must be 2 or greater It is recommended bu...

Page 41: ...of the system reaches 119oF 130 10 120 E Purge Air from System Manually Operating CH DHW Pumps to Commission System Disconnect wires connected to the THERMOSTAT terminals on the field connection board Power the appliance The display will show the appliance water temperature Press the S1 and S3 keys simultaneously and hold for 1 second The display will begin alternating between SEP and CH and the c...

Page 42: ...sion 3 module Change to 1 if the appliance is part of a cascaded system not using the Vision 3 module 24 24 Power on hours for cascade priority change over This sets how many power on hours will go by before the priority appliance will be rotated in the cascade system 25 0 N A must be 0 26 System Pump Freeze Protection Default Disabled On a cascade master this function activates the system pump if...

Page 43: ...NG CURVE SUPPLY OUTLET TEMPERATURE F 167 104 77 59 68 86 95 131 113 122 149 158 194 176 185 203 212 Table 14 Heating Curve NOTE The user can adjust the heat curve down by lowering the central heating temperature Control Program Reference Chart Function Default Setting Programmed Setting 1 de Do Not Change 2 149oF Do Not Change 3 160oF 4 36oF Do Not Change 5 7oF 6 0 7 68oF 8 5oF 9 180oF 10 68oF 11 ...

Page 44: ... sure to observe the operation of the unit to prevent a recurrence of the fault When servicing or replacing components that are in direct contact with appliance water be certain that There is no pressure in the appliance Pull the release on the relief valve Do not depend on the pressure gauge reading The appliance water is not hot The electrical power is disconnected The gas is shut off Failure to...

Page 45: ...hen the problem is with external sensor wiring Examine external sensor wiring for shorts to ground repairing as necessary If LOU code is still present and the appliance is so equipped disconnect high gas pressure switch then low gas pressure switch then UL 353 low water cutoff in this order one at a time to see if LOU code clears Replace faulty part Check low voltage wire harness in appliance for ...

Page 46: ...er temperature replace bad sensor F06 Lower return temperature sensor exceeds 210oF F09 No flame detected Appliance will make three attempts at ignition before the control goes into this lockout condition Will reset in 1 hour 1 Watch the igniter through the observation window provided 2 If there is no spark check the spark electrode for the proper gap 3 Remove any corrosion from the spark electrod...

Page 47: ...ases are purged from the system This should take a maximum of 40 to 90 seconds After combustion gases are purged turn off electrical power to the appliance B Vacation Procedure If there is danger of freezing change the set point to 70oF DO NOT turn off electrical power If there is no danger of freezing follow Shutdown Procedure C Failure to Operate Should the burner fail to light the control will ...

Page 48: ...nations been installed at least one foot above exterior grade and one foot above normal snow accumulation level Is vent piping properly supported Has vent piping been checked for leaks Has the exhaust vent line been pitched back to the appliance at a rate of 1 4 per foot Have the exhaust vent and intake pipes been properly installed to the appliance Install Condensate Piping Tubing and Components ...

Page 49: ...ubmerged Attempting to operate an appliance that has been submerged could create numerous 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 Appliancedamageduetofloodorsubmersionisc...

Page 50: ...mbers cloth to remove oxides Flame Probe Check ionization uA see Status Menu Record high fire and low fire Clean probe with plumbers cloth to remove oxides Condensate 1st Year 2nd Year 3rd Year 4th Year Neutralizer Check condensate neutralizer Replace if necessary Condensate Pipe Disconnect condensate pipe Clean out dirt Fill with water to level of outlet and reinstall NOTE Verify the flow of cond...

Page 51: ... P T N E V D E K C O L B 0 1 11 LOW VOLTAGE WIRING HARNESS LOCATION SHOWN 7100P 280 4 5 1 P 0 5 2 7 B R A B E S O H S S 2 1 3 4 0 P 0 0 1 7 E S O H E T A S N E D N O C 3 1 5 1 2 P 0 5 2 7 E S O H E T A S N E D N O C P M A L C E S O H 4 1 0 1 2 S V H C T I W S P M E T E U L F H G I H 5 1 16 2 COUPLING w NUT AIR LINET 100 130K BTU 7100P 114 3 COUPLING w NUT AIR INLET 160 199K BTU 7100P 103 17 SENSOR...

Page 52: ... 1 4 LOCK WASHERS 7100P 268 15 GASKET BLOWER TO AIR CHANNEL 7500P 075 Item Description Replacement Part 16 COMBUSTION BLOWER 7100P 330 17 SCREWS 10 32 x 1 2 7700P 094 18 ADAPTER PLATE 7250P 644 19 FLAT HEAD SCREW ADAPTER PLATE 7100P 045 20 AIR INTAKE ADAPTER BLOWER SIDE 7500P 185 21 SWIRL PLATE BLACK 100 130K BTU 7100P 042 SWIRL PLATE WHITE 160 199K BTU 7500P 092 22 AIR INTAKE ADAPTER VALVE SIDE 7...

Page 53: ...ty period for the appliance shall then be deemed to have commenced thirty 30 days after the date of manufacture of the appliance and NOT the date of installation of the appliance and be covered by the unexpired portion of the warranty detailed above G This warranty extends only to appliances utilized in closed loop heating applications that have been properly installed based upon the manufacturer ...

Page 54: ...ted information is provided HTP will respond within three 3 business days The claim will be automatically closed if requested information is not provided within thirty 30 days Claims will not be reopened without HTP Warranty Supervisor approval During the claims process a product that must be replaced will be given a designation of either a field scrap or b return to HTP If the product must be ret...

Page 55: ...LP 325 Rev 009 Rel 004 Date 12 2 20 55 Maintenance Notes ...

Page 56: ...tallation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Customer Please only sign after the qualified installer service technician has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the quali...

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