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

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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.
Heating Appliance
This Manual For Use With Appliances Manufactured After
New Bedford, MA 02745
Pioneer
April 10, 2017
www.htproducts.com
LP-325 Rev. 009 Rel. 004 Date 12.2.20

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  • 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. DANGER indicates an imminently hazardous situation which, if NOTE: HTP reserves the right to modify product technical specifications not avoided, will result in serious personal injury or death. and components without prior notice.

  • Page 4: Table Of Contents

    K. Cascade Follower Pump and Sensor Wiring Table of Contents L. Internal Wiring Diagram Part 1 - General Safety Information Part 8 - Gas Connections A. Operation and Installation Warnings A. Gas Pipe Sizing Tables B. Improper Combustion 1. Gas Pipe Sizing C.

  • Page 5: Operation And Installation Warnings

    Failure to follow these instructions will result in property damage, severe personal injury, or death. DO NOT alter or modify the appliance or appliance controls. Altering any HTP appliance with parts not manufactured by HTP WILL WARNING INSTANTLY VOID the appliance warranty and could result in property damage, personal injury, or death.

  • Page 6: Improper Combustion

    NOTE: DO NOT add cold make up water to the system when the NOTICE appliance is hot. Thermal shock can potentially cause cracks in the heat exchanger. Such damage IS NOT covered by warranty. This appliance provides an overheat shutdown limit. In the event the appliance water temperature exceeds the setpoint of the control F.

  • Page 7: Freeze Protection And Winterizing

    I. High Elevation Installations loop CH applications. This appliance is designed to operate at its maximum listed capacity NOTE: HTP DOES NOT WARRANT THE APPLIANCE AGAINST FREEZE- in installations located at 0 - 2000 ft above Sea Level. Since the density RELATED DAMAGE.

  • Page 8: Part 2 - Before You Start

    Neutralizers can be UNCRATING THE APPLIANCE - Any claims for damage or shortage installed in the field by the installer and purchased from HTP (7450P- in shipment must be filed immediately against the transportation 212).

  • Page 9: Part 3 - Prepare The Appliance

    Part 3 - Prepare the Appliance COLD WEATHER HANDLING - If the appliance has been stored in Failure of the appliance or components due to incorrect operating a very cold location (BELOW 0 F) before installation, handle with conditions IS NOT covered by product warranty. care until the components come to room temperature.

  • Page 10: Residential Garage And Closet Installations

    Appliance Area Ventilation Air Openings - Closet Installations C. Clearances for Service Access If the appliance is installed in a closet or alcove the appliance area/ room must be ventilated. EXCEPTION: If the appliance area/room has a volume of 150 ft All appliances eventually leak.

  • Page 11: Exhaust Vent And Intake Pipe

    Confined space is space with volume less than 50 cubic feet per E. Exhaust Vent and Intake Pipe 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of The appliance is rated ANSI Z21.10.3 Category IV (pressurized vent, all fuel-burning appliances installed in that space.

  • Page 12: Prevent Combustion Air Contamination

    Close all fireplace dampers. G. Prevent Combustion Air Contamination 4. Place in operation the appliance being inspected. Follow the Install intake air piping for the appliance as described in the Venting lighting instructions. Adjust the thermostat so the appliance will Section, this manual.

  • Page 13: Technical Specifications

    I. Technical Specifications Model PHR100-55 PHR130-55 PHR160-55 PHR199-55 Installation Indoor, Floor Model, Fully Condensing Minimum / Maximum Input (Btu/Hr) 35,000 / 100,000 35,000 / 130,000 40,000 / 160,000 40,000 / 199,000 Thermal Efficiency Flue System Category IV, Sealed Combustion Direct Vent, Power Vent Min Combined Vent Run 16 feet Max Combined Vent Run...

  • Page 14: Part 4 - Piping

    Failure to follow the instructions in this section WILL VOID the domestic hot water. HTP offers indirect water heaters in a wide range warranty and may result in property damage, severe personal injury, of gallon sizes in either stainless steel or glass lined construction.

  • Page 15: Backflow Preventer

    • The pipe must be cleaned and without blemish before any This appliance is designed to function in a closed loop 15 PSI System. A connections are made. factory installed low water cut off will ensure that you have adequate •...

  • Page 16: Relief Valve

    F. Relief Valve G. Zoning with Zone Valves Install supplied temperature and pressure relief valve. Connect 1. Connect appliance to system as shown in the Applications discharge piping to a safe disposal location, following the guidelines diagrams. Properly size circulators for friction loss of zone valves and on the next page.

  • Page 17: Fill And Purge Heating System

    Glycol in hydronic applications includes inhibitors that prevent it from attacking metallic system components. Make certain that system fluid is checked for the correct glycol concentration and inhibitor level. ASSE 1017 or ASSE 1070 temperature limiting or mixing valves do The glycol solution should be tested at least once a year, or as not eliminate the risk of scalding.

  • Page 18: Central Heating Applications

    L. Central Heating Applications NOTES: ZONE CIRCULATORS 1. This drawing is meant to show with IFC CENTRAL HEATING (TYP) system piping concept only. Installer responsible equipment & detailing required by TO SYSTEM local codes. RETURN 2. The minimum pipe size for connecting SuperStor Ultra...
  • Page 19 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 20: Part 5 - Venting

    Part 5 - Venting 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 21: 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 Pipe and Fittings Approved for Intake ONLY ABS* ANSI/ASTM D2661 ANSI/ASTM D2661 PVC Schedule 40/80 UL-1738 or ANSI/ASTM D1785 PVC-DWV Schedule 40/80 UL-1738 or ANSI/ASTM D2665 UL-1738 or ULC-S636 Pipe Approved for...

  • Page 22: 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 23: Exhaust Vent And Intake Pipe Sizing

    Standard E. Exhaust Vent and Intake Pipe Sizing Increased Vent Size Vent Connection and Reducing 1. The exhaust vent and intake pipe size is 2” for 100 and 130kBTU and Maximum Total Maximum Total Coupling models and 3” for 160 and 199kBTU models. Equivalent Length Equivalent Length 2.

  • Page 24: Applications

    However, improper location or installation can result in The following table lists optional exhaust/intake terminations available severe damage to the structure or exterior finish of the building, from HTP: and increase the opportunity for vent blockages and nuisance Description Stock Code shutdowns.
  • Page 25 Sidewall Venting Options - Direct Vent Installation Sidewall Venting with Kit EXTERIOR WALL VENT KIT Sidewall Venting with Tee (Intake) and Exhaust EXHAUST 1" MIN. 12" MIN. EXHAUST MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL INTAKE 12"...
  • Page 26 Venting Below Grade Snorkel Venting (Two Pipe Sidewall Venting Termina- For installations that exit the wall below grade: tions Beneath an Overhang) Excavate the site to a point where the pipes are to exit as shown in Figure 11. Ensure the wall is fully sealed where the pipes penetrate. The exhaust vent / air intake piping MUST be secured to the side of the building above grade, as shown, to provide rigidity.

  • Page 27: Venting Through An Existing System

    Roof Venting Options - Direct Vent Installation Unbalanced Venting - Roof Exhaust Termination EXHAUST 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 28: Power Venting, Indoor Combustion Air In Confined Or Unconfined Space

    NOTE: The following instructions refer only to venting through an Unconfined space is space with volume greater than 50 cubic feet existing vent system, and not to venting with HTP’s optional concentric per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input vent kits.
  • Page 29 Indoor Combustion Air (Single Pipe) DO NOT INSTALL WATER HEATER, BOILER, OR APPLIANCE NEAR DRYER EXHAUST Outdoor Combustion Air (Single Pipe) LP-325-X Figure 17 - Do Not Place Appliance Near Dryer UPPER AIR DUCT Boiler, Water Heater, or Appliance LOWER AIR DUCT LP-325-T 8/5/2010...

  • Page 30: Part 6 - Condensate Removal

    (p/n 7450P-212 available from HTP). Follow all the installation The condensate line must remain unobstructed. If allowed to freeze instructions included with the neutralizer. If a neutralizer is installed,...

  • Page 31: Part 7 - Wiring

    Part 7 - Wiring volts. If the pump requires more current or voltage other than 120 volts, an external motor starter or contactor will be required. 3. If using DHW, connect the domestic hot water pump as shown to the Install wiring and electrically ground appliance in accordance terminals marked 4 (HOT), 5 (NEUT), 6 (GND).

  • Page 32: Outdoor Sensor (Optional)

    G. UL353 Low Water Cut-Off Kit (Optional) 1. If an HTP 7450P-255 UL353 Low Water Cut-Off (LWCO) Kit is not used, move on to Section I. 2. The control box of the kit should be mounted to the left side of the appliance near the low water cut-off probe, which is located near the outlet nipple of the appliance.

  • Page 33: Cascade Master Pump And Sensor Wiring

    J. Cascade Master Pump and Sensor Wiring K. Cascade Follower Pump and Sensor Wiring 1. Connect the system pump hot wire to the terminal marked 1. 1. Connect the appliance pump to the terminals labeled 8, 2, and 3. 2. Connect the system pump neutral to the terminal 2 and the pump If you are using an indirect fired water tank connected directly to the ground wire to terminal 3.

  • Page 34: 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 35: Part 8 - Gas Connections

    Part 8 - Gas Connections If an in-line regulator is used, it must be installed a minimum of 10 feet WARNING from the heater. It is very important that the gas line is properly purged by the gas supplier or utility. Improper line sizing or failure to properly FIRE AND/OR EXPLOSION HAZARD purge the lines will result in ignition failure.

  • Page 36: Gas Pipe Sizing Tables

    A. Gas Pipe Sizing Tables 1. Gas Pipe Sizing This information is for reference use only. Refer to gas pipe manufacturer specifications for actual delivery capacity. The DOE standard for Natural Gas is 1100 BTU/ft . Contact the local gas supplier for actual BTU/ft rating.

  • Page 37: Gas Valve

    Do not do a gas conversion on this appliance without an officially 1. The appliance and its individual shutoff valve must be disconnected approved conversion kit and instructions supplied by HTP. Failure from the gas supply piping system during any pressure testing of the to use a conversion kit when converting the appliance to fire on system at pressures greater than ½...

  • Page 38: Part 9 - Start-Up Preparation

    *NOTE: It is recommended you clean heat exchanger at least once a Part 9 - Start-Up Preparation year to prevent lime scale buildup. Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section of this manual. Test/replace freeze protection fluid Thoroughly clean and flush any system that has used glycol before 1.

  • Page 39: System Water Fill And Test

    HTP (554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow, which, if not corrected, could cause property damage.

  • Page 40: Part 10 - Start-Up Procedure

    • The appliance addressed as 1 will share its alarm output with Part 10 - Start-Up Procedure 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.

  • Page 41: Status Menu

    DHW call based on the differential temperature setting for the indirect E. Purge Air from System tank. The pump will not start until the indirect water temperature Manually Operating CH/DHW Pumps to Commission System reaches a temperature equal to the setting for the indirect, minus the Disconnect wires connected to the THERMOSTAT terminals on indirect differential.
  • Page 42 Range: 0 - 3 Cascade Master. Controls the 0-10 volt input N/A, Do not change. Range: 0 = Appliance Temperature, Activates control for use with HTP 1 – Appliance Power Modbus Board Step Modulation – Regulates burner 0 = Modbus Disabled (Default) output in 6 steps in 1 minute intervals.
  • Page 43 Control Program Reference Chart CENTRAL HEATING CURVE Factory Default Function Default Setting Programmed Setting Do Not Change 201˚ Do Not Change FUNCTION 9 Do Not Change DEFAULT RESET CURVE FUNCTION 11 5˚ 68˚ F or 150 OUTSIDE TEMPERATURE (F) Do Not Change CENTRAL HEATING CURVE Plot your Curve 0 or 1...

  • Page 44: Combustion System Test Mode

    C. Combustion System Test Mode This function is intended to simplify the gas valve adjustment if When servicing or replacing components that are in direct contact needed. Listed in the following tables are the recommended limits with appliance water, be certain that: on the appliance and Combustion Settings.

  • Page 45: 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 46 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 47: Part 13 - Maintenance

    If the burner lights during any one of these three ignition trials, Part 13 - Maintenance normal operation will resume. If the burner lights, but goes off in about 4 seconds, check the polarity of the wiring. See electrical connection section of this manual. If the burner does not light after the third ignition trial, the control In unusually dirty or dusty conditions, care must be taken to keep will enter a lockout state.

  • Page 48: Part 15 - Installation Checklist

    Part 15 - 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 16 - 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: Part 17 - Replacement Parts

    Part 17 - Replacement Parts LP-325-W 6/10/19 6/10/19 Item Replacement Description Part # COMBINATION SUPPLY/HIGH TEMP SENSOR 7450P-192 " 4 " 4 120 VOLT WIRE HARNESS (LOCATION SHOWN) 7100P-343 LOW VOLTAGE WIRING HARNESS (LOCATION SHOWN) 7100P-280 . S . 2" COUPLING (w/NUT) - AIR LINET (100/130K BTU) 7100P-114 3"...
  • Page 52 LP-325-R LP-325-R 06/19/19 06/19/19 Item Replacement Part Item Replacement Part Description Description GASKET - MOUNTING PLATE 7100P-139 COMBUSTION BLOWER 7100P-330 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 IGNITOR ELECTRODE...

  • Page 53: Limited Warranty

    COVERAGE assembly in accordance with federal, state, and local codes. A. During the first year after the date of installation, HTP warrants that 2. Maintain the appliance in accordance with the maintenance it will repair or replace, at its option, any defective or malfunctioning procedure listed in the manufacturer’s provided instructions.
  • Page 54 During the claims process a product that must be replaced will be given a 14. Failure or performance problems caused by improper sizing designation of either a) field scrap, or b) return to HTP. If the product must of the appliance, expansion device, piping, or the gas supply line,...

  • Page 55: Maintenance Notes

    Maintenance Notes LP-325 Rev. 009 Rel. 004 Date 12.2.20...

  • Page 56: Customer Installation Record Form

    Customer Installation Record Form The following form should be completed by the qualified installer / service technician 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 phr199Pioneer phr100-55Pioneer phr130-55Pioneer phr160-55 ... Show all

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