HTP Pioneer Installation And Startup Manual
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HTP Pioneer Installation And Startup Manual

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Pioneer Appliance Models*
PHR100-55 / 130-55 / 160-55 / 199-55
*A suffix of "LP" denotes propane gas
This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions in this manual
before installing. Perform steps in the order given. Failure to comply will 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.
**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.
120 Braley Rd. P.O. Box 429
Versa-Flame
Versa-Flame** Combination Appliance Models*
PHR130-55C / 160-55C / 199-55C
East Freetown, MA 02717-04
Pioneer
INSTALLATION
START-UP
MAINTENANCE
PARTS
www.htproducts.com
LP- 325 REV. 3.3.15

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  • Page 1 Perform steps in the order given. Failure to comply will 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.
  • 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. WHAT TO DO IF YOU SMELL GAS ...

  • Page 3: For The Installer

    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 installer/service technician. Read and understand all instructions in this manual before installing.

  • Page 4: Table Of Contents

    The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death.
  • Page 5 1. WIRING WITH ZONE VALVES ..................................50 2. WIRING WITH ZONE CIRCULATOR PUMPS ..............................50 K. WIRING OF CASCADE SYSTEM COMMUNICATION BUS (PIONEER ONLY) ..............51 L. CASCADE MASTER PUMP AND SENSOR WIRING (PIONEER ONLY) ................51 M. CASCADE FOLLOWER PUMP AND SENSOR WIRING (PIONEER ONLY) ................51 PART 7 –...

  • Page 6: Part 1 - General Safety Information

    D. FREEZE PROTECTION (WHEN USED) ..........................56 E. FILL AND TEST WATER SYSTEM ............................57 F. PURGE AIR FROM THE HYDRONIC SYSTEM (PIONEER AND VERSA-FLAME) ..............57 G. PURGE AIR FROM DHW SYSTEM (VERSA-FLAME) ......................57 H. CHECK THERMOSTAT CIRCUIT(S) ............................57 I.

  • Page 7: Improper Combustion

    INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given. USER – This manual is for use only by a qualified heating installer/service technician. Have this appliance serviced/inspected by a qualified service technician annually. FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS APPLIANCE SERVICED/INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

  • Page 8: Appliance System

     Thoroughly flush the system (without appliance connected) to remove sediment. The appliance can be damaged by build-up or corrosion due to sediment. HTP recommends a suction strainer in all systems.  Do not use petroleum-based cleaning or sealing compounds in the system.

  • Page 9: Versa-Flame Dhw Heat Pack Water Quality

    Clean system to remove sediment 1. You must thoroughly flush the system (without the appliance connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment. 2. For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.) 3.

  • Page 10: Part 2 - Before You Start

    Check the concentration of antifreeze to assure protection is adequate to protect the bottom of the appliance from freezing. NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT covered by warranty. PART 2 – BEFORE YOU START A.

  • Page 11: Optional Equipment

    NOTE: This application requires two separate circulators. (See Optional Equipment, Section C). VERSA-FLAME DHW MODULE The Versa-Flame combines all of the capabilities of the Pioneer with an integrated domestic hot water (DHW) module built into the appliance. Features include: Brazed Plate Heat Exchanger When the system calls for DHW, hot heat transfer fluid is drawn from the top of the appliance through the brazed plate heat exchanger.

  • Page 12: Part 3 - Prepare Appliance Location

     Vision 2 Temperature Mixing Control (Part # 7250P-322) These additional options may be purchased through your HTP distributor. NOTE: When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system efficiency.

  • Page 13: Leveling

    4. Gas control system components must be protected from dripping water during operation and service. 5. If the appliance is to replace an existing appliance, check for and correct any existing system problems, such as:  System leaks  Location that could cause the system and appliance to freeze and leak. ...

  • Page 14: Exhaust Vent And Intake Pipe

     Mount the bottom of the appliance a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are well off the floor.  Locate or protect the appliance so it cannot be damaged by a moving vehicle. E.

  • Page 15: Prevent Combustion Air Contamination

    Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty, and may result in severe personal injury or death. Failure to provide an adequate fresh combustion air can cause poisonous flue gases to enter living space, which could result in severe personal injury or death.
  • Page 16 dryers and any appliances not connected to the common venting system. Turn on any exhaust 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.
  • Page 17 Figure 3 – Dimensions LP- 325 REV. 3.3.15...

  • Page 18: Part 4 - Piping

    Plumbing of this appliance should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The appliance 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 appliance 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: Hydronic Piping - Circulators, Zone Valves And Multiple Appliances

    APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS More than 5 minutes 1 ½ to 2 minutes About 30 seconds About 10 seconds Less than 5 seconds Less than 3 seconds About 1 ½ seconds About 1 second Table 2 G. HYDRONIC PIPING - CIRCULATORS, ZONE VALVES AND MULTIPLE APPLIANCES This appliance is designed to function in a closed loop 15 PSI System.

  • Page 21: Zoning With Zone Valves

    For installation that incorporates standing iron radiation and systems 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.

  • Page 22: Central Heating Piping Detail

    L. CENTRAL HEATING PIPING DETAIL Figure 4 –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 Appliance is 1-inch. 3.
  • Page 23 8. 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. *THIS INSTALLATION IS SUITABLE FOR PIONEER HEATING APPLIANCES ONLY. LP- 325 REV. 3.3.15...

  • Page 24: Piping Into The Dhw Pack On The Versa-Flame

    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 25: Mixing Valve Installation

    the user from scalding temperature. To properly install and set up the mixing valve, follow the pre-installation steps in this manual and the enclosed instructions included with the mixing valve. E. MIXING VALVE INSTALLATION The mixing valve provided with this appliance must be installed on the hot water outlet connection to reduce the risk of scalding. This mixing valve only reduces the risk of scalding injury.
  • Page 26 Inline fittings, pipe work, layout and sizing must be taken into consideration. In installations where the valve is supplied with unbalanced hot cold pressures greater than a 2 to 1 ratio, please call HTP Technical Support Department. Installation of the Mixing Valve 1.

  • Page 27: Versa-Flame Dhw Performance

    NOTE: See the instruction sheet included with the mixing valve to adjust the maximum temperature of the mixing valve greater than Hotter water increases the risk of scald injury. Scalding may occur within 5 seconds at a setting of 140 F (60 C).
  • Page 28 Figure 9 – DHW Pack Performance on 199K BTU Models LP- 325 REV. 3.3.15...

  • Page 29: Dhw Piping With The Versa-Flame

    P. DHW PIPING WITH THE VERSA-FLAME Figure 10 – Versa-Flame Standard Installation NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F. 3.
  • Page 30 Figure 11 – Versa-Flame with Re-Circulating Line NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F. 3.

  • Page 31: Part 5 - Venting, Combustion Air And Condensate Removal

    Figure 12 – Versa-Flame with Storage Tank NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F. 3.

  • Page 32: General

    When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the appliance vent connection, and at the termination when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

  • Page 33: Requirements For Installation In Canada

    DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue products into the living space. Use only the approved pipe and fitting materials, and primer and cement specifically designed for the material used, as listed in Table 4.

  • Page 34: Exhaust Vent And Intake Pipe Location

    D. EXHAUST VENT AND INTAKE PIPE LOCATION Figure 13 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 13 NOTES: A.

  • Page 35: Exhaust Vent And Intake Pipe Sizing

    The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the appliance could result in property damage, severe personal injury, or death.

  • Page 36: Exhaust Vent And Intake Pipe Installation

    FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS EQUIVALENT FEET FITTINGS OR PIPING 2” 3” 4” 5’ 5’ 3’ 90 DEGREE ELBOW* 3’ 3’ 1’ 45 DEGREE ELBOW 0’ 0’ 0’ COUPLING 0’ 0’ 0’ AIR INLET TEE 1’ 1’ 1’ STRAIGHT PIPE 3’...

  • Page 37: Venting Drawings

    15. A screened straight coupling is provided with the appliance for use as an outside exhaust termination. 16. A screened inlet air tee is provided with the appliance to be used as an outside intake termination. Table 8 lists optional intake air/exhaust vent terminations available from HTP. DESCRIPTION STOCK CODE 2”...
  • Page 38 Figure 14 – Two Pipe Roof and Sidewall Venting with Included Equipment (Tee and Coupling) - 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 must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate.
  • Page 39 Figure 15 – Venting with Optional Kits (NOT INCLUDED WITH THE APPLIANCE) 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 must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate.
  • Page 40 Figure 16 – 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 must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate.

  • Page 41: Venting Through An Existing System

    Figure 17 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B.
  • Page 42 CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits.

  • Page 43: Indoor Combustion Air Installation In Confined Or Unconfined Space

    3. 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 space has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the appliance input.
  • Page 44 Figure 20 LP- 325 REV. 3.3.15...

  • Page 45: Condensate Removal System

    If the appliance condensate outlet is lower than the drain, you must use a condensate removal pump (kit 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 46: Part 6 - Field Wiring

    PART 6 – FIELD WIRING To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death.
  • Page 47 Figure 22 – Internal Wiring Diagram LP- 325 REV. 3.3.15...

  • Page 48: Field Wiring

    B. FIELD WIRING All connections made to the appliance in the field are done on the field connection board located in the cabinet on the top left area of the unit. Multiple knockout locations are available to route field wires into and out of the cabinet.

  • Page 49: Outdoor Sensor (Optional)

    1. If an indirect water tank is not used in the installation, move on to Section G. 2. The appliance will operate an indirect fired water tank with either a thermostat type aquastat installed in the indirect tank or an HTP 7250P-325 tank sensor.

  • Page 50: Versa-Flame Wiring For Dhw Priority With Zone Valves Or Circulators

    J. VERSA-FLAME WIRING FOR DHW PRIORITY WITH ZONE VALVES OR CIRCULATORS For proper installation of the appliance with zone relay panels, follow the wiring instructions in Subsections 1 and 2 below. It is critical that the installation is followed for proper DHW Priority. 1.

  • Page 51: Wiring Of Cascade System Communication Bus (Pioneer Only)

    Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends that the maximum length of communication bus cables not exceed 200 feet.

  • Page 52: Part 7 - Gas Connections

    NOTE: In a cascade system the alarm output of the appliance addressed as #1 will also be active if the master appliance has a lockout condition. The alarm output of appliances addressed as 2-7 will only activate an alarm if a lockout condition occurs on that specific appliance.

  • Page 53: Gas Piping

    It is very important that you are connected to the type of gas as noted on the rating plate: "LP" for liquefied petroleum, propane gas, or "Nat" for natural or city gas. All gas connections must be approved by the local gas supplier or utility, in addition to the governing authority, prior to turning the gas supply on.

  • Page 54: Gas Valve

    Figure 29 – Gas Valve LP-179-P 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 LP gas will result in extremely dangerous burner operation, leading to fire, explosion, severe injury or death.

  • Page 55: Check For Gas Leaks

    DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. The appliance MUST BE replaced if it has been submerged. 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.

  • Page 56: Freeze Protection (When Used)

    Water Hardness Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in the water. The concentration of these salts is expressed in mg/L, ppm or grains per gallon, as a measure of relative hardness of water. Grains per gallon is the common reference measurement used in the U.S.

  • Page 57: Fill And Test Water System

    5. The system may have residual substances that could affect water chemistry. After the system has been filled and leak tested, verify water pH and chlorine concentrations are acceptable. F. PURGE AIR FROM THE HYDRONIC SYSTEM (PIONEER AND VERSA-FLAME) IMPORTANT! While commissioning the system, the air vent on top of the appliance must remain fully open to allow the appliance to properly fill.

  • Page 58: Part 9 - Start-Up Procedure

    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, physical damage or sagging. Verify exhaust vent and intake piping are intact and correctly installed per Venting section and local code.

  • Page 59: Adjusting The Set Point

    (Decrease Value) or {S2} (Increase Value). Ranges 5° F to 30° F. 3. NOTE: Only in use if using an indirect storage tank with a PIONEER (*NOT IN USE ON VERSA-FLAME). Press {S3} a third time and you will see the Indirect Temperature Set Point |de| and an alternating value of 119. Range 95 – 180. To adjust, press either...

  • Page 60: Status Menu

    |d1| — Actual temperature from top sensor |d2| — Actual temperature from bottom sensor |d3| — PIONEER: Actual tank temperature if an indirect sensor is used. *VERSA-FLAME: Displays the state of DHW demand – 1 if flow switch is active (closed) 0 if flow switch is not active (open) |d4| —...

  • Page 61: Combustion System Test Mode

    Listed below are the varieties of functions the installer can program. DEFAULT VALUE DESCRIPTION FUNCTION |de| PIONEER ONLY: Maximum set point for indirect water appliance temperature (NOTE: Does not apply if used with mechanical control) - Range: 95 F to 185 LP- 325 REV. 3.3.15...
  • Page 62 PIONEER ONLY: Change differential in indirect water appliance - Range: 1 F to 18 Changes the indirect circulator post purge time once the sensor is satisfied. 0 min. (NOTE: Post purge time should be set no greater than 5 minutes.) - Range: 0 to 10 minutes...
  • Page 63 Table 13 * The Differential on the Tank Min. Set Point is a fixed 7 F on Versa-Flame Models. The Differential Set Point on Pioneer Models is variable based on the |dh| setting (also used for indirect differential). Central Heating Curve Function Central heating demand is detected when the room thermostat closes.

  • Page 64: Part 11 - Shutdown

    PART 11 – SHUTDOWN A. SHUTDOWN PROCEDURE If the burner is not operating, disconnect the electrical supply. If the burner is operating, lower the set point value to 70 F and wait for the burner to shut off. Continue to wait for the combustion blower to stop, so all latent combustion gases are purged from the system.
  • Page 65 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 66 1. Watch the igniter through the observation window provided. No flame detected – Appliance 2. If there is no spark, check the spark electrode for the proper ¼” gap. will make three attempts at 3. Remove any corrosion from the spark electrode and flame rectifier probe. ignition before the control goes 4.
  • Page 67 Figure 30 – Pioneer and Versa-Flame LP- 325 REV. 3.3.15...
  • Page 68 Figure 31 – Pioneer and Versa-Flame LP- 325 REV. 3.3.15...

  • Page 69: Part 13 - Maintenance

    Figure 32 – DHW Module - *Versa-Flame ONLY PART 13 – MAINTENANCE In unusually dirty or dusty conditions, care must be taken to keep appliance cabinet door in place at all times. Failure to do so VOIDS WARRANTY! Allowing the appliance to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in appliance failure, property damage, personal injury, or death.
  • Page 70 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING YEAR YEAR YEAR YEAR* Near appliance piping Check appliance and system piping for any sign of leakage; make sure they are properly supported. Vent Check condition of all vent pipes and joints. Check for any obstructions at exhaust and intake termination points.
  • Page 71 LP- 325 REV. 3.3.15...
  • Page 72 LP- 325 REV. 3.3.15...

  • Page 73: Maintenance Notes

    MAINTENANCE NOTES _______________________________________________________________________ ___________________________________________________________________________________ LP- 325 REV. 3.3.15...

  • Page 74: 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.

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