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Pioneer PHR100-55 Instruction Manual

Pioneer water heater instruction manual
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Pioneer
INSTALLATION
START-UP
MAINTENANCE
PARTS
Pioneer Water Heater Models*
PHR100-55 / 130-55 / 160-55 / 199-55
*A suffix of "LP" denotes propane gas
This manual must be used by a qualified installer/service technician. Read all instructions in this manual
before installing. Perform steps in the given order. Failure to comply could result in substantial property
damage, severe personal injury, or death.
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held
liable for typographical errors in literature.
120 Braley Rd. P.O. Box 429
East Freetown, MA 02717-0429
www.htproducts.com

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Summary of Contents for Pioneer PHR100-55

  • Page 1 MAINTENANCE PARTS Pioneer Water Heater Models* PHR100-55 / 130-55 / 160-55 / 199-55 *A suffix of “LP” denotes propane gas This manual must be used by a qualified installer/service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to comply could result in substantial property damage, severe personal injury, or death.
  • Page 2 IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
  • Page 3 The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 4: For The Installer

    FOR THE INSTALLER This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. This appliance must be installed by qualified and licensed personnel.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PART 1 – GENERAL SAFETY INFORMATION ..................7 A. PRECAUTIONS ............................ 7 B. IMPROPER COMBUSTION ......................... 8 C. GAS ..............................8 D. WHEN SERVICING THE HEATER ...................... 8 E. WATER QUALITY ..........................8 F. WINTERIZING ............................9 PART 2 –...
  • Page 6 K. MULTIPLE HEATERS ........................22 L. PIPING DETAIL ..........................23 PART 7 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL ........... 26 A. GENERAL ............................26 B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS ..........26 C. EXHAUST AND INTAKE AIR VENT PIPE LOCATION ..............27 1.

  • Page 7: Part 1 - General Safety Information

    F. FINAL CHECKS BEFORE STARTING HEATER ................49 PART 10 – START-UP PROCEDURE ....................... 49 A. OPERATING INSTRUCTIONS ......................49 B. CASCADE SYSTEM ........................... 50 C. ADJUSTING THE SET POINT ......................50 D. STATUS MENU ..........................51 E. TEST MODE ............................52 F.

  • Page 8: Improper Combustion

    NOTE: If the heater is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman: 1. FIRE 2. DAMAGE 3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

  • Page 9: Winterizing

    F. WINTERIZING NOTE: Consider piping and installation when determining heater location. Do not place the heater in an area where it will be prone to freezing. To winterize the heater, drain the entire system. Pump two gallons of non-toxic, NSF food grade, FDA rated GRAS (Generally Recognized As Safe) propylene glycol into the tank.
  • Page 10 Bottom Water Temperature Sensor This sensor monitors return water temperature. The control module reduces or increases heater input accordingly. Temperature and Pressure Gauge Allows the user to monitor system temperature and pressure. Control The integrated control system monitors return and supply water temperature. The control system regulates the unit’s BTU output by controlling fan speed, allowing the unit to deliver only the amount of heated energy required.

  • Page 11: Optional Equipment

    The indirect sensor allows the installer to operate the heater with two temperatures: one for central heating and the other for the SuperStor Indirect Water Heater. 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 heating.

  • Page 12: Part 3 - Dimensions And Clearances

    PART 3 – DIMENSIONS AND CLEARANCES Figure 1 – LP-325-L...

  • Page 13: Part 4 - Prepare Heater Location

    CLEARANCE ACCESS Figure 2 – LP-325-M PART 4 – PREPARE HEATER LOCATION Before considering location, there are many factors to be addressed. These factors are covered in detail in this installation manual. Please read the entire manual, as it could save time and money. Piping, Venting, and Condensation Removal are just a few of the issues that need attention prior to the installation of the heater.

  • Page 14: Leveling

    If replacing an existing heater, check for and correct any existing system problems, such as: • System leaks • Heater is located in a condition that could cause the system to freeze and leak. • Incorrectly-sized expansion tank Clean and flush system when reinstalling a heater. B.

  • Page 15: Direct Vent Installation Of Exhaust And Intake

    1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE 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.

  • Page 16: Prevent Combustion Air Contamination

    Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space, which could result in severe personal injury or death. NOTE: To prevent combustion air contamination, see Table 1. F. PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the heater as described in the Venting Section.

  • Page 17: Part 5 - Prepare The Heater

    When removing an existing heater, follow the steps below. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.

  • Page 18: Part 6 - Heater Piping

    PART 6 – HEATER PIPING Plumbing of this heater should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The heater may be connected to an indirect storage tank to supply domestic hot water. HTP offers 30/45/60/80/119 gallon size indirect storage tanks in Stainless Steel or 50/80/119 in Glass Lined construction.

  • Page 19: Backflow Preventer

    C. BACKFLOW PREVENTER Use a backflow preventer specifically designed for hydronic heater installations. This valve should be installed on the cold water fill supply line per local codes (see Piping Details). D. SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE-UP WATER 1.

  • Page 20: Indirect Fired Water Heater Scalding

    F. INDIRECT FIRED WATER HEATER SCALDING This heater can deliver scalding water. Be careful APPROXIMATE TIME / whenever using hot water to avoid scalding injury. TEMPERATURE RELATIONSHIPS IN SCALDS Certain appliances, such as dishwashers and More than 5 minutes automatic clothes washers may require increased 1 ½...

  • Page 21: Fill And Purge Heating System

    5. Install a pressure reducing valve on the cold feed make-up water line, (15 PSI nominal on the system return). Check temperature and pressure gauge which should read minimum pressure of 12 PSI. 6. Install a circulator as shown in piping details (this section). Make sure the circulator is properly sized for the system and friction loss.

  • Page 22: Zoning With Zone Valves

    Anti-freeze solutions expand more than water. For example: A 50% by volume glycol solution expands 4.8% in volume during a temperature increase from 32 F to 180 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.

  • Page 23: Piping Detail

    L. PIPING DETAIL Figure 5 –Central Heating Detail – LP-325-F 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 Heater is 1-inch. 3.
  • Page 24 Figure 6 –Water Heater Detail 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 Heater is 1-inch. 3.
  • Page 25 Figure 7 – 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 Heater is 1-inch. 3.

  • Page 26: Part 7 - Venting, Combustion Air And Condensate Removal

    PART 7 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL The heater must be vented as detailed in this Venting Section. Ensure exhaust and intake piping complies with these instructions regarding vent system. Inspect finished combustion air intake and exhaust piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as with the instructions provided in this manual.

  • Page 27: Exhaust And Intake Air Vent Pipe Location

    C. EXHAUST AND INTAKE AIR VENT PIPE LOCATION 1. DETERMINE EXHAUST VENT LOCATION Both exhaust and intake air vents must exit from the same side of the building to assure correct appliance operation. a. The vent piping for this water heater is approved for zero clearance to combustible construction.

  • Page 28: Exhaust And Intake Air Vent Sizing

    Figure 8 – Venting D. EXHAUST AND INTAKE AIR VENT SIZING 1. The exhaust and intake vent size is 2" for the PH100 and PH130 and 3" for the PH160 and PH199. 2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet.

  • Page 29: Longer Vent Runs

    a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table below: FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS EQUIVALENT FEET FITTINGS OR PIPING 2” 3” 4” 90 DEGREE ELBOW* 5’ 5’ 3’ 45 DEGREE ELBOW 3’...

  • Page 30: Exhaust Vent And Intake Air Pipe Installation

    TRANSITION POINT (FT. TEL OF OVERSIZED VENT MAXIMUM TEL OF ALL VENT FROM WATER HEATER) PIPE (FT.)* PIPE (FT.) 77-1/2 117-1/2 60-1/2 110-1/2 8-1/2 88-1/2 NONE Table 6 – TEL = Total Equivalent Length *Oversized vent pipe diameter is 1” or greater than factory supplied connection.

  • Page 31: Venting Drawings

    G. VENTING DRAWINGS 1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE 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.
  • Page 32 Figure 10 NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 33 Figure 11 NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 34 Figure 12 – Roof Vent with Tee - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 35 Figure 13 NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 36 Figure 14 NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

  • Page 37: Indoor Combustion Air Installation In Confined Or Unconfined Space

    2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE This heater 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.
  • Page 38 Figure 16 NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

  • Page 39: Exhaust Vent And Intake Air Pipe Installation

    H. EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION 1. Use only solid PVC or CPVC pipe. FOAM CORE PIPING IS NOT APPROVED. 2. Remove all burrs and debris from joints and fittings. 3. All joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material.

  • Page 40: Condensate Removal System

    fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer exhaust fan. Close all fireplace dampers. 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously. 5.

  • Page 41: Part 8 - Field Wiring

    Figure 17 – 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 reduce vacuum lock in the drain line.

  • Page 42: Line Voltage Wiring For Standard Heater

    The heater is capable of directly controlling 2 pumps when in standard mode and 3 pumps when configured as a cascade master heater. When configured as a standard unit, each pump output can provide a maximum of 3 amps at 120 volts. If pumps require more than this amount of power, an external contactor or motor starter is needed.

  • Page 43: Outdoor Sensor (Optional)

    2. Mount the thermostat on an inside wall as centrally to the area being heated as possible, but away from drafts or heat producing devices such as television sets that could influence the ability of the thermostat to measure room temperature. 3.

  • Page 44: Ul353 Low Water Cut-Off Interface Kit

    H. UL353 LOW WATER CUT-OFF INTERFACE KIT (OPTIONAL) 1. If an HTP 7450P-255 UL353 Low Water Cut-Off (LWCO) Interface Kit is not used, move on to Section 2. The control box of the kit should be mounted to the left side of the heater near the low water cut-off probe, which is located near the outlet nipple of the heater.

  • Page 45: Cascade Master Pump And Sensor Wiring

    J. CASCADE MASTER PUMP AND SENSOR WIRING 1. Connect the system pump hot wire to the terminal marked 8. 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 VOLT terminal to terminal 9.

  • Page 46: Cascade Follower Pump And Sensor Wiring

    K. CASCADE FOLLOWER PUMP AND SENSOR WIRING 1. Connect the heater pump to the terminals labeled 1, 2, and 3. If you are using an indirect fired water tank connected directly to the follower heater connect the pump for it to the 4, 5, and 6 terminals.

  • Page 47: Check/Control Water Chemistry

    Do not use petroleum-based cleaning or sealing compounds in heater system. Damage to elastomer seals and gaskets in system could occur, resulting in substantial property damage. A. CHECK/CONTROL WATER CHEMISTRY Water pH between 6.0 and 8.0 1. Maintain heater water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by a water treatment company.

  • Page 48: Fill And Test Water System

    2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions. C. FILL AND TEST WATER SYSTEM 1. Fill system only after ensuring the water meets the requirements of this manual. 2.

  • Page 49: Final Checks Before Starting Heater

    F. FINAL CHECKS BEFORE STARTING HEATER 1. Read Startup Procedures within this manual for proper steps to start heater. (See Startup Report to record steps for future reference). 2. Verify heater and system are full of water and all system components are correctly set for operation. 3.

  • Page 50: Cascade System

    2. Adjust the temperature set point of the heater if desired. The factory default setting is 180 F. If changes are necessary, follow, “Adjusting the Set point”, below. 3. Set the thermostat to create a demand for heat. 4. If the appliance fails to start, refer to the Troubleshooting section in the back of this manual. B.

  • Page 51: Status Menu

    1. Press {S3} once to access |C|, Heater Temperature Set Point. To adjust the temperature of the heater, simply press in the {S3} key for three seconds until you see a flashing (C) then an alternating value of (180). This number is the factory set point of 180 To change the temperature, push either {S1} {S2}...

  • Page 52: Test Mode

    |d5| — Actual temperature from the outdoor sensor |NC|. |d6| — Actual fan speed multiplied by 10 (Example: If fan speed displayed is |410| RPM x 10 = 4100 actual fan speed) |d7| — Actual ionization current read from flame rectification probe |d8| —...

  • Page 53: Purge Air From Water System

    the highest and lowest fan speed. After 20 minutes, Test mode stops automatically. To exit Test Mode manually, press {S1} {S2} together for 1 second. COMBUSTION SETTINGS HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS NATURAL GAS PROPANE LP High high Carbon Monoxide...
  • Page 54 action for 1 minute, the display returns to normal operation. Changes are effective immediately but not directly stored until the {S4} key is pressed down for 3 seconds then the new values are stored. Listed below are the varieties of functions the installer can program. DEFAULT VALUE DESCRIPTION...
  • Page 55 Power on hours for cascade priority change over. This parameter is used to set how many power on hours will go by before the priority appliance will be rotated in the cascade system. Not applicable, must be at 0. System Pump Freeze Protection (Default – Disabled) Use this function on a cascade master to activate the system pump if the outdoor temperature drops below the set value.

  • Page 56: Part 12 - Troubleshooting

    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: The homeowner can adjust the heat curve down by adjusting the central heating temperature to a lower setting.
  • Page 57 926 CONTROL BOARD ERROR CODES CODE DESCRIPTION CORRECTIVE ACTION Outdoor sensor shorted Inspect wiring from outdoor sensor for damage or shorted connections and repair as or temperature less than - necessary. Measure resistance of outdoor sensor and compare to resistance chart. If not within range on chart, shorted or open, replace sensor.
  • Page 58 Interrupted or shorted upper (supply) temperature sensor. 1. Check the electrical connection to the appropriate temperature sensor. 2. If connection is okay, replace bad sensor. Interrupted or shorted lower (return) temperature sensor. Upper (supply) temperature 1. If water in tank is not greater than 210 F, check wiring.
  • Page 59 Figure 22...
  • Page 60 Figure 23...

  • Page 61: Part 13: Maintenance

    PART 13: MAINTENANCE Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition.

  • Page 64: Maintenance Notes

    MAINTENANCE NOTES...

  • Page 65: Htp Customer Installation Record Form

    HTP 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.

This manual is also suitable for:

Phr130-55Phr199-55Phr160-55

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