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HTP Pioneer PHR100 Installation, Start-Up And Maintenance Instructions

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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.
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.
HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical
errors in literature.
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.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
272 Duchaine Blvd.
This Manual For Use With Appliances Manufactured After
April 10, 2017
New Bedford, MA 02745
Pioneer
Heating Appliance
www.htproducts.com
LP-325 Rev. 4.4.17

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Summary of Contents for HTP Pioneer PHR100

  • Page 1 California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
  • Page 2 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS •...
  • Page 3 AHJ. levels or to important product information. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice. DANGER indicates an imminently hazardous situation...

  • Page 4: Table Of Contents

    Table of Contents H. Wiring of an Appliance Alarm (Optional) Part 1 - General Safety Information I. Wiring of the Cascade System Communication Bus A. Improper Combustion J. Cascade Master Pump and Sensor Wiring B. Gas K. Cascade Follower Pump and Sensor Wiring C.

  • Page 5: Part 1 - General Safety Information

    The appliance can be damaged by build- NOTE: Install all system components and piping in such a up or corrosion due to sediment. HTP recommends a suction manner that does not reduce the performance of any fire strainer in all systems.

  • Page 6: Freeze Protection And Winterizing

    NOTE: Damages resulting from incorrect installation or from Modulating Combustion System use of products not approved by HTP, Inc. ARE NOT covered by The combustion system modulates the output of the burner warranty. during operation to match system demand and achieve F.

  • Page 7: Optional Equipment

    (Part # 554200, available from Part 3 - Prepare the Appliance HTP). In addition, local authorities may require a condensate neutralizer to neutralize the condensate. Condensate Remove all sides of the shipping crate to allow the appliance to neutralizers are made up of lime crystals, marble, or phosphate be moved into its installation location.

  • Page 8: Leveling

    freeze and leak • Incorrectly sized expansion tank This appliance has a condensate disposal system that may 6. Clean and flush system when reinstalling a appliance. freeze if exposed to sustained temperatures below 32 NOTE: When installing in a zero clearance location, it may Precautions should be taken to protect the condensate trap and not be possible to read or view some product labeling.

  • Page 9: Residential Garage And Closet Installations

    The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the appliance. For power venting installations using room air for combustion, refer to the venting section, this manual, for descriptions of confined and unconfined spaces. Do not install the appliance in an attic.

  • Page 10: Carbon Monoxide Detectors

    there is adequate combustion and ventilating air. NOTE: To a. In the event that the vented gas fueled appliance is prevent combustion air contamination, see Table 2. installed in a crawl space or attic, the hard wired carbon Combustion air from the indoor space can be used if the space monoxide detector with alarm and battery back-up shall be has adequate area or when air is provided through a duct or installed on the next adjacent floor level.

  • Page 11: Removing An Appliance From A Common Vent System

    H. Removing an Appliance from a Common Vent System 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. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
  • Page 12 to lime scale build-up throughout the system. Water • Total Dissolved Solids (TDS) less than 500 ppm below 5 grains/gallon (85 mg/L) may be over softened. (mg/L) • Total dissolved solids are minerals, salts, metals, and • Consult local water treatment companies for unusually charged particles that are dissolved in water.

  • Page 13: Part 4 - Piping

    HTP offers 30/45/60/80/119 gallon of pressure relief. Discharge 6” above the drain. Provide piping size indirect storage tanks in Stainless Steel or 50/80/119 in that is the same size as the safety relief valve outlet.

  • Page 14: Relief Valve

    scalding injury or property damage. 2. The expansion tank must be located as shown in Applications, FAILURE TO COMPLY WITH THE ABOVE GUIDELINES this manual, or following recognized design methods. See expansion tank manufacturer’s instructions for details. COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY 3.

  • Page 15: Fill And Purge Heating System

    Approximate Time / Temperature Relationships in Scalds More than 5 minutes For installation that incorporates standing iron radiation and systems with manual vents at high points, follow above section 1 1/2 to 2 minutes and, starting with the nearest manual air vent, open until water About 30 seconds flows out.

  • Page 16: Central Heating Applications (All Models)

    K. Central Heating Applications (All Models) NOTES: 1. This drawing is meant to show system piping concept only. Installer 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.
  • Page 17 Figure 6 - Cascaded System NOTES: 1. This drawing is meant to show system piping concept only. Installer 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.

  • Page 18: Part 5 - Venting And Condensate Removal

    Part 5 - Venting and Condensate Removal The appliance must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual.

  • Page 19: Approved Materials For Exhaust Vent And Intake Pipe

    B. Approved Materials for Exhaust Vent and Intake Pipe Standards for Installation In: Item Material United States Canada PVC Schedule 40/80 ANSI / ASTM D1785 PVC, CPVC, and PP Venting Must PVC-DWV* ANSI / ASTM D2665 be ULC-S636 Certified. IPEX is Exhaust Vent or Intake an approved manufacturer in CPVC Schedule 40/80...

  • Page 20: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location INSIDE CORNER DETAIL FIXED OPERABLE CLOSED FIXED CLOSED OPERABLE LP-179-CC 03/28/17 Intake Pipe Terminal Exhaust Vent Terminal Area Where Intake Terminal Is Not Permitted Figure 7 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DESCRIPTION CANADA Clearance above grade, veranda, porch, deck, or balcony...

  • Page 21: Exhaust Vent And Intake Pipe Sizing

    equivalent length cannot be increased beyond 200 feet. E. Exhaust Vent and Intake Pipe Sizing b. Transitions should always be made in vertical sections 1. The exhaust vent and intake pipe size is 2” for 100 and of pipe to prevent the condensate from pooling in the vent 130kBTU models and 3”...

  • Page 22: Applications

    16. A screened inlet air tee is provided with the heater to be used The following table lists optional exhaust/intake terminations as an outside intake termination. available from HTP: 17. Maximum Snow Level Determination: These installation Description Stock Code instructions reference snow levels in establishing a minimum 2”...

  • Page 23: Sidewall Venting

    must be taken to utilize uncontaminated combustion air. Sidewall Venting NOTE: To prevent combustion air contamination, see Table 2. with Kit Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated piping could result in property damage, serious injury, or death.

  • Page 24: Venting Through An Existing System

    SIDE VIEW FRONT VIEW Figure 11 - Unbalanced Venting - Roof Exhaust and Sidewall Intake NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. All vent pipes must be glued, properly supported, and the exhaust pitched a minimum of 1/4”...

  • Page 25: Power Venting, Indoor Combustion Air In Confined Or

    Unconfined space is space with volume greater than 50 cubic HTP’s optional concentric vent kits. Refer to Concentric Vent feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total Kit installation manual (LP-166) for further information on input rating of all fuel-burning appliances installed in that space.
  • Page 26 INDOOR COMBUSTION AIR (SINGLE PIPE) DO NOT PLACE DRYER NEAR WATER HEATER OR BOILER BOILER OR HEATER LP-325-X Figure 13 - Do Not Place Appliance Near Dryer OUTDOOR COMBUSTION AIR (SINGLE PIPE) BOILER HEATER Figure 14 - Indoor and Outdoor Combustion Air - Single Pipe LP-325 Rev.

  • Page 27: Condensate Removal System

    If the appliance condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP). If required by local authorities, a condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate.

  • Page 28: Part 6 - Wiring

    required to be externally mounted and connected according Part 6 - Wiring to local codes that may apply. 2. Connect the central heating pump to the terminals marked 8 (HOT), 2 (NEUT), 3 (GND) in Figure 22. The connections To avoid electrical shock, turn off all power to the appliance shown are suitable for a maximum continuous pump draw prior to opening an electrical box within the unit.

  • Page 29: Outdoor Sensor (Optional)

    See the instruction manual of G. UL353 Low Water Cut-Off Kit (Optional) connected devices for further information. 1. If an HTP 7450P-255 UL353 Low Water Cut-Off (LWCO) Kit is not used, move on to Section I. D. Outdoor Sensor (Optional) 2.

  • Page 30: Wiring Of The Cascade System Communication Bus

    Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends the maximum length Figure 17 - Cascade Wiring of communication bus cables not exceed 200 feet.
  • Page 31 CASCADE MASTER CASCADE FOLLOWER CAT3/CAT5 CONNECTION POINTS CAT3/CAT5 CONNECTION POINTS Figure 18 - Cascade Master and Cascade Follower Wiring LP-325 Rev. 4.4.17...

  • Page 32: Internal Wiring Diagram

    PIONEER INTERNAL CONNECTION DIAGRAM L. Internal Wiring Diagram 120 VAC J6-2 J6-1 LINE NEUTRAL GROUND WHITE BLACK BLACK POWER SWITCH GREEN DISPLAY BOARD ASSEMBLY J6-3 X6-1 X6-4 X6-2 X4-12 BLUE THERMISTOR X8-2 PROTECTED BY BLUE AN INTERNAL X4-13 6.3 AMP FUSE RELAY X8-1 COMBINATION SUPPLY/HIGH...

  • Page 33: Part 7 - Gas Connections

    Part 7 - Gas Connections Support gas supply piping with hangers, not by the appliance or its accessories. The appliance gas valve and blower will not support the weight of the piping. Make sure the gas piping is Failure to follow all precautions could result in fire, explosion, protected from physical damage and freezing, where required.

  • Page 34: Gas Valve

    C. Gas Valve Do not do a gas conversion on this appliance without an officially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the appliance to fire on Natural or Propane gas will result in extremely dangerous burner operation, leading to fire, explosion, severe personal injury, or death.

  • Page 35: Part 8 - Start-Up Preparation

    Clean system to remove sediment* Part 8 - Start-Up Preparation 1. You must thoroughly flush the system (without appliance connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to Thoroughly clean and flush any system that has used glycol sediment.

  • Page 36: Fill And Test Water System

    This may be done by the installer or It is important to purge the system of air to avoid damage to you may purchase a condensate neutralizer from HTP (7450P- the appliance. 212).

  • Page 37: Part 9 - Start-Up Procedure

    NOTE: The Master Appliance MUST be addressed as 0. Part 9 - Start-Up Procedure e. Set parameter 23 from 0 to 1. f. Exit the Installer Menu. These settings designate this appliance as the Master Appliance. FOR YOUR OWN SAFETY READ BEFORE OPERATING 3.

  • Page 38: Status Menu

    Set Point. This function allows the installer to adjust the |d16| — This function only becomes active when appliance activation of the burner based on the differential temperature is set as the Master. It allows the user to monitor the System setting of the appliance.

  • Page 39: Program System Settings

    - - - in the display. The display will show |1| alternating to |de|. Programs a 0-10 volt directly from a This first function verifies that the control will function with Building Management System. the SuperStor Indirect Fired Water Heater. To activate, change value to 2.
  • Page 40 0 = There will be no extra appliance on the Cascade Master. 1 = Extra appliance is connected to the Cascade Master. N/A, Do not change. Activates control for use with HTP Modbus Board 0 = Modbus Disabled (Default) 1 = Modbus Enabled 2 = Modbus Auto (enables automatic...

  • Page 41: Combustion System Test Mode

    Control Program Reference Chart Natural Gas Propane (LP) Function Default Setting Programmed Setting Ignition High Ignition High Speed Do Not Change Carbon Do Not Change Monoxide 1 - 10 2 - 15 2 - 20 1 - 10 2 - 15 2 - 20 (CO) PPM Do Not Change...

  • Page 42: Displayed Error And Fault Codes

    2. Inspect low level switch and wiring for damage and repair if necessary. 1. Check line voltage. Must be between 100 – 128 volts. 2. If available, connect a PC and, using HTP service software, check the 24v supply display in the lower left corner of the screen. The number displayed here must be greater than 128 and should be greater than 250.
  • Page 43 If the display flashes a code other than F01, follow the troubleshooting guide for that code. 7. If the flue temperature increases to over 190 F, consult HTP for further assistance. Interrupted or shorted upper (supply) temperature sensor 1.

  • Page 44: Part 12 - Maintenance

    Code Description Corrective Action Combustion fan speed incorrect – The 1. Check the combustion air fan wiring. appliance will lock out if it senses that the 2. Replace the combustion air fan. fan speed is less than 70% of expected rate 3.
  • Page 45 Supply Sensor (7100P-192) Outdoor Sensor Return Sensor (7250P-319) (7100P-005) Clip-On Sensor (7100P-172) Outside High / Low Resistance Resistance Temperature Temp Sensor (ohms) (Ohms) Temp. ( 171800 32550 129800 25340 98930 19870 76020 15700 58880 12490 45950 10000 36130 8059 28600 6535 22800 5330...
  • Page 46 LP-325-W 03/23/17 03/23/17 Item Replacement Description Part # LOW WATER CUT-OFF SENSOR 7000P-852-1 COMBINATION SUPPLY/HIGH TEMP SENSOR 7450P-192 CUSTOMER CONNECTION BOARD 7350P-070 THERMISTOR 7100P-004 3/4" NPT DRAIN VALVE 2500P-0090 3/4" NPT - 30 PSI RELIEF VALVE 7100P-279 CONTROL DISPLAY 7350P-009 CONTROL BOARD 7450P-122 120 VOLT WIRE HARNESS (LOCATION SHOWN)
  • Page 47 LP-325-R 04/03/17 Item Replacement Part Item Replacement Part Description Description GASKET - MOUNTING PLATE 7100P-139 COMBUSTION BLOWER (w/GASKET, SIGHT GLASS) 7100P-518 MOUNTING PLATE 7100P-007 SCREWS - 10-32 x 1/2 7700P-094 GASKET - PROBES 7100P-155 ADAPTER PLATE 7250P-644 FLAME RECTIFICATION PROBE 7100P-082 FLAT HEAD SCREW - ADAPTER PLATE 7100P-045...

  • Page 48: Part 14 - Installation Checklist

    Part 14 - Installation Checklist Before Installing Is there enough space to ensure proper installation? Does installation location allow for proper service clearances? Are water and gas lines properly sized and set at proper pressures for the installation? Is appliance location as near the exhaust vent / intake pipe terminations as possible? Have combustible materials been cleared from the installation location? Is there a drain close to the appliance? Water Piping...

  • Page 49: Part 15 - Maintenance Report

    Start-Up, Adjust, and Test Has the appliance been started? If necessary, has the appliance gas valve been adjusted? Has the installation been customized per installation location requirements? Have all customized system parameters been tested? Has proper appliance operation been confirmed? Final Installation Approvals Signed by Technician Date...
  • Page 50 Inspection Activities Date Last Completed Piping 1st Year 2nd Year 3rd Year 4th Year* Near appliance Check appliance and system piping for any sign of leakage; make sure piping pipes are properly supported. Check condition of all vent pipes and joints. Ensure the vent piping Vent terminations are free of obstructions and blockages.

  • Page 51: Limited Warranty

    COVERAGE 2. Ensure all related heating components are properly maintained A. During the first year after the date of installation, HTP and kept in good operating condition. warrants that it will repair or replace, at its option, any defective 3.
  • Page 52 If all warranty conditions are satisfied, HTP will provide replacement parts to the retailer. If you have questions about the coverage of this warranty, please contact HTP at the following address or phone number: HTP, 272 Duchaine Blvd, New Bedford, MA, 02745, Attention: Warranty Service Department, 1(800) 323-9651.

  • Page 53: Maintenance Notes

    Maintenance Notes LP-325 Rev. 4.4.17...

  • Page 54: Customer Installation Record Form

    Customer Installation Record Form The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document. Customer’s Name Date of Installation Installation Address...

This manual is also suitable for:

Pioneer phr130Pioneer phr160Pioneer phr199

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