Htp Pioneer phr100 Installation manual

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 qualied 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

LP-325 Rev. 009 Rel. 004 Date 12.2.20

WARNING: If the information in these instructions is not followed exactly, a re or explosion may result causing property damage, personal

injury or death.

• Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• 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 re department.

• Installation and service must be provided by a qualied installer, service agency or the gas supplier.

Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this

manual. Installation and service must be performed by a qualied installer, service agency, or gas supplier.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

The following dened 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 serious personal injury or death.

WARNING indicates a potentially hazardous situation which, if not

avoided, could result in personal injury or death.

CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in moderate or minor personal injury.

CAUTION used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, may result

in property damage.

NOTICE is used to address practices not related to personal injury.

Foreword

This manual is intended to be used in conjunction with other

literature provided with the appliance. This includes all related

control information. It is important that this manual, all other

documents included in this system, and additional publications

including the National Fuel Gas Code - ANSI Z223.1 (latest versions),

be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of

the Authority Having Jurisdiction, local code authorities, and utility

companies which pertain to this type of water heating equipment.

For the Installer

This appliance must be installed by qualied 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 Comply With:

Local, state, provincial, and national codes, laws, regulations, and

ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1, from

American Gas Association Laboratories, 8501 East Pleasant Valley

Road, Cleveland, OH 44131.

The latest version of the National Electrical Code, NFPA No. 70.

In Canada - The latest versions of the Natural Gas and Propane

Installation Code, CSA B149.1, and the Canadian Electrical Code, C22.1,

from CSA Group, 178 Rexdale Blvd, Toronto, Ontario, Canada M9W 1R3.

NOTE: The gas manifold and controls met safe lighting and other

performance criteria when undergoing tests specied in ANSI Z21.10.3

- latest edition.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal, state,

local government, or individual such as a re chief, re marshal, chief

of a re prevention bureau, labor department or health department,

building ocial or electrical inspector, or others having statutory

authority. In some circumstances, the property owner or his/her agent

assumes the role, and at government installations, the commanding

ocer or departmental ocial may be the AHJ.

NOTE: HTP reserves the right to modify product technical specications

and components without prior notice.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

K. Cascade Follower Pump and Sensor Wiring 33

L. Internal Wiring Diagram 34

Part 8 - Gas Connections 35

A. Gas Pipe Sizing Tables 36

1. Gas Pipe Sizing 36

2. Natural Gas Pipe Sizing 36

3. LP (Liquid Propane) Gas Pipe Sizing 36

B. Gas Connection Requirements 36

C. Additional Precaution for Excess Flow Valve (EFV) 36

D. Gas Valve 37

E. Checking Gas Pressure at the Appliance for Proper Operation

Part 9 - Start-Up Preparation 38

A. Check / Control Water Chemistry 38

B. Check for Gas Leaks 38

C. Freeze Protection (When Used) 38

D. System Water Fill and Test 39

E. Purge Air from the Hydronic System 39

F. Check Thermostat Circuit(s) 39

G. Condensate Removal 39

H. Final Checks Before Starting Appliance 39

Part 10 - Start-Up Procedure 40

A. Operating Instructions 40

B. Cascade System 40

C. Adjusting the Setpoint 40

D. Status Menu 41

E. Purge Air from System 41

Part 11 - Start-Up Procedures for the Installer 41

A. Program Access 41

B. Program System Settings 41

C. Combustion System Test Mode 44

Part 12 - Troubleshooting 44

A. Error and Fault Codes 44

B. Appliance Error 44

C. Appliance Fault 44

D. Displayed Error and Fault Codes 45

Part 13 - Maintenance 47

Part 14 - Shutdown 47

A. Shutdown Procedure 47

B. Vacation Procedure 47

C. Failure to Operate 47

D. Important Notice 47

Part 15 - Installation Checklist 48

Part 16 - Maintenance Report 49

Part 17 - Replacement Parts 51

Limited Warranty 53

Maintenance Notes 55

Customer Installation Record Form 56

Table of Contents

Part 1 - General Safety Information 4

A. Operation and Installation Warnings 5

B. Improper Combustion 6

C. Gas 6

D. When Servicing the Appliance 6

E. Appliance System 6

F. Water Chemistry Requirements 6

G. Freeze Protection and Winterizing 7

H. Scalding 7

I. High Elevation Installations 7

Part 2 - Before You Start 8

A. What’s in the Box 8

B. How the Appliance Operates 8

C. Optional Equipment 8

Part 3 - Prepare the Appliance 9

A. Locating the Appliance 9

B. Leveling 9

C. Clearances for Service Access 9

D. Residential Garage and Closet Installations 10

E. Exhaust Vent and Intake Pipe 11

1. Direct Vent of Exhaust and Intake 11

2. Power Venting, Indoor Combustion Air in Conned or Unconned Space

F. Carbon Monoxide Detectors 11

G. Prevent Combustion Air Contamination 12

H. Removing an Appliance from a Common Vent System 12

I. Technical Specications 13

Part 4 - Piping 14

A. General Plumbing Information 14

B. Backow 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 Appliances 16

J. Indirect Water Heater Scalding 16

K. Fill and Purge Heating System 17

L. Central Heating Applications 18

Part 5 - Venting 20

A. General 20

B. Approved Materials for Exhaust Vent and Intake Pipe 21

C. Additional Requirements for Installation in Canada 21

D. Exhaust Vent and Intake Pipe Location 22

E. Exhaust Vent and Intake Pipe Sizing 23

F. Longer Vent Runs 23

G. Exhaust Vent and Intake Pipe Installation 23

H. Applications 24

1. Direct Vent Installation of Exhaust and Intake 24

2. Venting Through an Existing System 27

3. Power Venting, Indoor Combustion Air in Conned or Unconned Space

Part 6 - Condensate Removal 30

Part 7 - Wiring 31

A. Field Wiring 31

B. Line Voltage Wiring for Standard Appliance 31

C. Thermostat 31

D. Outdoor Sensor (Optional) 32

E. Indirect Sensor (Optional) 32

F. Optional 0-10 Volt Building Control Signal 32

G. UL353 Low Water Cut-O Kit (Optional) 32

H. Wiring of an Appliance Alarm (Optional) 32

I. Wiring of the Cascade System Communication Bus 32

J. Cascade Master Pump and Sensor Wiring 33

Part 1 - General Safety Information

This appliance is approved for indoor installations only and is

not intended for use as a pool heater. Clearance to combustible

materials: 0” top, bottom, sides, and back. Appliance must have

room for service: 24” front, 24” top, and 5” left side are minimum

recommended service clearances. (A combustible door or removable

panel is acceptable front clearance.) This appliance has been

approved for closet installation and installation on combustible

ooring. Do not install directly on carpeting. Install the appliance

in a location where temperature and pressure relief valve discharge

or a leak will not result in damage to the surrounding area. If such a

location is not available, install an auxiliary catch pan.

This appliance is rated Category IV (pressurized vent, likely to form

condensate in the vent) and requires a special vent system designed

for pressurized venting. Use only Category IV vent systems.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

Installer - Read all instructions in this manual before installing.

Perform steps in the given order.

User - This manual is for use only by a qualied heating installer

/ service technician. Have this appliance serviced / inspected

annually by a qualied installer / service technician.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE

CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE

PERSONAL INJURY, OR DEATH.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN

SUBMERGED IN WATER. Immediately call a qualied installer /

service technician. The appliance MUST BE replaced if it has been

submerged. Attempting to operate a appliance that has been

submerged could create numerous harmful conditions, such as a

potential gas leakage causing a re 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: Appliance damage due to ood or submersion is considered

an Act of God, and IS NOT covered under product warranty.

NOTE: Obey all local codes. Obtain all applicable permits before

installing the appliance.

NOTE: Install all system components and piping in such a manner

that does not reduce the performance of any re rated assembly.

DO NOT alter or modify the appliance or appliance controls. Altering

any HTP appliance with parts not manufactured by HTP WILL

INSTANTLY VOID the appliance warranty and could result in property

damage, personal injury, or death.

The hydronic supply and return connections of this product 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, personal injury, or

death. Damage or failure of this product (or the system in which it is

installed) due to unauthorized use IS NOT COVERED BY WARRANTY.

A. Operation and Installation Warnings

To avoid serious injury or death, read, understand, and follow all of

the precautions listed here.

DANGER

Vapors from ammable liquids will explode and cause a re,

resulting in personal injury or death. The appliance has a burner

that can come on at any time and ignite vapors. DO NOT use or

store ammable liquids around the appliance.

Improper venting can cause a build-up of carbon monoxide.

Breathing carbon monoxide can result in brain damage or death.

DO NOT operate the appliance unless it is properly vented to the

outside and has an adequate fresh air supply for safe operation.

Inspect the exterior exhaust gas outlet port and fresh air inlet port

on a regular basis to ensure they are functioning properly.

Failure to follow these instructions will result in property damage,

severe personal injury, or death.

Adjusting the “low re oset” or the “main ow restrictor” in small

increments can result in a signicant increase in CO concentration.

To avoid serious injury or death, DO NOT make any adjustments

to the gas valve without monitoring the exhaust gases with a fully

functional and calibrated combustion analyzer.

A concentration of carbon monoxide as small as .04% (400 parts

per million) in the air can be fatal. When making high re or low

re adjustments, CO levels must be monitored using a calibrated

combustion analyzer such 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 qualied 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.

The manufacturer cannot anticipate every circumstance that might

involve a potential hazard. Each installation has its own specialized

characteristics, requirements, and possible hazards. Therefore, all

possible incidents are not included in these warnings. Proper and

safe installation, operation, and service are the responsibility of

the qualied service technician.

Proper care of the appliance is the user’s responsibility. Ensure

the user carefully reads and understands the User’s Information

Manual before operating the appliance.

Make sure the user knows the location of the gas shut-o valve

and how to operate it. Immediately close the gas shut-o valve

if the appliance is subjected to re, overheating, ood, physical

damage, or any other damaging condition that might aect the

operation of the unit. Have the appliance checked by a qualied

service technician before resuming operation.

Do not power up the unit unless the gas and water supply valves are

fully opened. Make sure the fresh air intake port and exhaust gas port

are open and functional.

No one but a qualied service technician should attempt to install,

service, or repair this appliance. There are no serviceable parts which

can be changed by the user / owner.

User / Owner: Contact the original qualied service technician if

the appliance needs repair / maintenance. If the original technician

is unavailable, ask your gas supplier for a list of qualied service

providers.

DO NOT store or place newspapers, laundry, or other combustible

items near the appliance or the exterior exhaust gas outlet and/or

fresh air inlet port.

The owner should inspect the system monthly for damage, water

stains, signs of rust, corrosion, and exhaust vent and air intake

blockage. If inspection of the unit shows signs of damage, the

appliance should be shut o until the problem is repaired by a

qualied technician.

After installation, all appliance safety devices should be tested.

The appliance is certied for indoor installations only. The appliance

consists of gas ignition system components which must be

protected from water (dripping, spraying, etc.) during operation and

service. Carefully consider installation location and the placement of

critical components (circulators, condensate neutralizers, etc.) before

installing the appliance.

DO NOT allow children to operate this appliance. DO NOT use this

appliance if it does not appear to be operating correctly. A qualied

service technician should service and inspect the appliance annually.

WARNING

Do not use this appliance for anything other than its intended

purpose (as described in this manual). Doing so could result in

property damage and WILL VOID product warranty.

High heat sources (sources generating heat 100oF / 37oC or greater,

such as stove pipes, space heaters, etc.) may damage plastic

components of the appliance as well as plastic vent pipe materials.

Such damages ARE NOT covered by warranty. It is recommended to

keep a minimum clearance of 8”from high heat sources. Observe heat

source manufacturer instructions, as well as local, state, provincial,

and national codes, laws, regulations and ordinances when installing

this appliance and related components near high heat sources.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

B. Improper Combustion

Do not obstruct the ow of combustion and ventilating air. Adequate

air is necessary for safe operation. Failure to keep the exhaust vent

and combustion air intake clear of ice, snow, or other debris could

result in property damage, serious personal injury, or death.

C. Gas

Should overheating or gas supply fail to shut o, turn o the manual

gas control valve to the appliance.

D. When Servicing the Appliance

• To avoid electric shock, disconnect electrical supply before

performing maintenance.

• To avoid severe burns, allow appliance and associated

equipment to cool before servicing.

• Do not use petroleum-based cleaning or sealing compounds

in appliance system. Gaskets and seals in the system may be

damaged, possibly resulting in substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”.

Substantial property damage, damage to appliance, and/or

serious personal injury may result.

• Always verify proper operation after servicing the appliance.

NOTE: When inquiring about service or troubleshooting, reference the

model and serial numbers from the appliance rating label.

E. Appliance System

• Thoroughly ush the system (without the appliance connected)

to remove sediment. The high-eciency heat exchanger can

be damaged by build-up or corrosion due to sediment. The

manufacturer recommends a suction strainer in this type of

system.

• Do not use petroleum-based cleaning or sealing compounds

in appliance system. Gaskets and seals in the system may be

damaged, possibly resulting in substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”.

Substantial property damage, damage to the appliance, and/

or serious personal injury may result.

• Continual fresh make-up water will reduce appliance life.

Mineral buildup in the heat exchanger reduces heat transfer,

overheats the heat exchanger, and causes failure. Addition of

oxygen from make-up water can cause internal corrosion in

system components. Leaks in the appliance or piping must be

repaired at once.

Be sure to disconnect electrical power before opening appliance

cabinet or performing service. Label all wires while performing

service to ensure proper re-wiring of the appliance. Wiring errors

can cause improper or dangerous operation. Failure to do so could

result in electrical shock, improper appliance or system operation,

property damage, serious personal injury, or death.

NOTICE

This appliance provides an overheat shutdown limit. In the event

the appliance water temperature exceeds the setpoint of the control

limit, the cuto will trip and the appliance will shut down. Certain

local codes require additional temperature limits. In addition, certain

types of systems may operate at temperatures below the minimum

setpoint of the limit provided with the appliance. Contact the

manufacturer for additional overheat controls.

NOTE: DO NOT add cold make up 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 aect eciency and

cause severe damage to the appliance and associated equipment.

Water quality must be professionally analyzed to determine whether

it is necessary to treat the water. Various solutions are available to

adjust water quality. Adverse water quality will aect the reliability

of the system. In addition, operating temperatures above 135oF will

accelerate the build-up of lime scale and possibly shorten appliance

service life. Failure of an appliance due to lime scale build-up, low

pH, or other chemical imbalance IS NOT covered by the warranty.

The water must be potable, free of corrosive chemicals, sand, dirt,

and other contaminates. It is up to the installer to ensure the water

does not contain corrosive chemicals or elements that can damage

the heat exchanger. Potable water is dened as drinkable water

supplied from utility or well water in compliance with EPA secondary

maximum contaminant levels (40 CFR Part 143.3). If the water contains

contaminants higher than outlined by the EPA, water treatment is

recommended and additional, more frequent maintenance may be

required.

If you suspect that your water is contaminated in any way, discontinue

use of the appliance and contact an authorized qualied installer /

service technician or licensed professional.

• Water pH between 6.5 and 8.5

• pH levels below 6.5 can cause an increase in the rate of

corrosion. pH of 8.5 or higher can potentially cause lime

scale build-up

• Maintain water pH between 6.5 and 8.5. Check with litmus

paper or have it chemically analyzed by a local water

treatment company.

• If the pH is not between 6.5 and 8.5, consult a local water

treatment company for solutions.

• Hardness less than 7 grains (120 mg/L) (Water

temperatures of 140oF and greater)

• Hardness levels above the required amounts can lead to

lime scale build-up throughout the system. Water below 5

grains/gallon (85 mg/L) may be over softened.

• Consult local water treatment companies for unusually

hard water areas (above the required amounts) or for other

treatment solutions if water is being over softened (below 5

grains/gallon [85 mg/L]).

• Chloride concentration less than 100 ppm (mg/L)

• Do not ll appliance or operate with water containing

chlorides in excess of 100 ppm (mg/L).

• Using chlorinated fresh water should be acceptable as levels

are typically less than 5 ppm (mg/L).

• Do not connect the appliance to directly heat swimming

pool or spa water.

• Total Dissolved Solids (TDS) less than 500 ppm (mg/L)

• Total dissolved solids are minerals, salts, metals, and charged

particles that are dissolved in water.

• The greater the amounts of TDS present, the higher the

corrosion potential due to increased conductivity in the

water.

• If using softened water to ll the appliance, it is still possible

to have high TDS. This water can be corrosive. Consult local

water treatment companies for other treatment solutions

to reduce this eect.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

G. Freeze Protection and Winterizing

*NOTE: To promote appliance service life, it is strongly

recommended to follow the maintenance procedures in this

manual.

NOTE: Loops Serving Indirect Water Heaters (IWHs)

Glycol used in IWH loops should be food grade propylene glycol,

FDA rated as “generally recognized as safe” (GRAS). If using a glycol /

potable water mix, the water chemistry must meet the requirements

in this manual. The glycol content of the liquid must not exceed 50%,

unless the manufacturer species a dierent ratio. Glycol should be

checked periodically to prevent it from becoming acidic. Please refer

to guidelines provided by the glycol manufacturer regarding glycol

maintenance.

NOTE: Glycol not recognized as GRAS may only be used in closed

loop CH applications.

NOTE: HTP DOES NOT WARRANT THE APPLIANCE AGAINST FREEZE-

RELATED DAMAGE.

To winterize the appliance, 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. Consult the

glycol manufacturer for specic instructions on concentration

percentage as well as freeze and burst protection methods. Check

the concentration 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 ARE NOT

covered by warranty.

WARNING

NEVER use any toxic chemical, including automotive, standard

glycol antifreeze, or ethylene glycol made for hydronic (non-

potable) systems. These chemicals can attack gaskets and seals in

water systems, are poisonous if consumed, and can cause personal

injury or death.

CAUTION

Consider piping and installation when determining appliance

location. Damages resulting from incorrect installation or from use

of products not approved by the manufacturer ARE NOT covered by

warranty. Failure of the appliance due to freeze related damage IS

NOT covered by product warranty.

H. Scalding

Appliances Serving Indirect

Water Heaters

This appliance can deliver

scalding water to the

indirect water heater. Be

careful whenever using

hot water to avoid scalding

injury. Certain appliances

such as dishwashers and

automatic clothes washers

may require 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 conformance. Failure

to install a temperature limiting or mixing valve and follow these

instructions could result in property damage, severe personal injury,

or death due to scalds.

Approximate Time / Temperature Relationships in Scalds

120oF More than 5 minutes

125oF 1 1/2 to 2 minutes

130oF About 30 seconds

135oF About 10 seconds

140oF Less than 5 seconds

145oF Less than 3 seconds

150oF About 1 1/2 seconds

155oF About 1 second

Table 1 - Approximate Time / Temperature Relationships in Scalds

I. High Elevation Installations

WARNING

Combustion - At elevations above 2000 ft, the combustion of the

appliance must be checked with a calibrated combustion analyzer to

ensure safe and reliable operation. It is the Installer’s responsibility

to check and adjust the combustion in accordance with this

manual. Failure to follow these instructions may result in property

damage, serious personal injury, or death.

This appliance is designed to operate at its maximum listed capacity

in installations located at 0 - 2000 ft above Sea Level. Since the density

of air decreases as elevation increases, maximum specied capacity

should be de-rated for elevations above 2000 ft (610 m) in accordance

with the table below.

Elevations 2001 ft

(610 m)

3000 ft

(914 m)

4000 ft

(1219 m)

4500 ft

(1372 m)

5000 ft

(1524 m)

In Canada1,

de-rate by: 10% 10% 10% 10% may vary

In USA2,

de-rate by: - 12% 16% 18% 20%

NOTES:

1Canada: Elevations between 2000 - 4500 ft (610 - 1372 m), de-rate by 10%.

Consult local authorities for de-rating for elevations above 4500 ft (1372 m).

2USA: If elevation is above 2000 ft (610 m), de-rate capacity by 4% for every

1000 ft (305 m).

Table 2 - De-Rate % for High Elevations

To protect against injury, install a mixing valve in the water system.

This valve will reduce point of use discharge temperatures by mixing

cold and hot water in branch supply lines. Such valves are available

from your local plumbing supplier.

Table 1 details the relationship of water temperature and time with

regard to scald injury and may be used as a guide in determining the

safest water temperature for your applications.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

Part 2 - Before You Start

B. How the Appliance Operates

Condensing Technology maximizes eciency by measuring the needs

of your heating system through the use of sensors and a control unit.

The appliance uses data gathered by these sensors to intelligently

deliver highly ecient hydronic heating.

Heat Exchanger

Exhaust gas ows through the primary section of the highly ecient

combustion heat exchanger into the secondary heat exchanger

section, where the coldest water on the bottom of the tank extracts

the last residual amount of heat energy from the gas.

Modulating Combustion System

The combustion system modulates the output of the burner during

operation to match system demand and achieve the control set point

while in operation. The set point can change by internal or external

signals to enhance the overall performance of the system.

Gas Valve

The gas valve senses suction from the blower, allowing gas to ow only

if combustion air is owing.

Swirl Plate System

The swirl plate on the gas valve controls air and gas ow into the

burner, assuring better mixing for improved combustion.

Combination Top High Temperature Sensor

The control module adjusts appliance ring rate based on the supply

temperature monitored by this sensor.

Bottom Water Temperature Sensor

The control module reduces or increases appliance input according to

the return water temperature measured by this sensor.

Temperature and Pressure Gauge

Allows the user to monitor system temperature and pressure.

Control

The integrated control system monitors return and supply water

temperature and regulates the unit’s BTU output by controlling fan

speed, delivering only the amount of heated energy required.

Burner

The metal ber and high grade stainless steel burner uses pre-mixed

air and gas to provide a wide range of ring rates.

Electrical Field Connections with Terminal Strips

The cabinet allows easy access to the clearly marked line voltage and

low voltage terminal strips to facilitate wiring to the appliance.

Condensate Drain Connection

This is a condensing high eciency appliance with a condensate

removal system. Condensate is nothing more than water vapor derived

from combustion products, similar to that of an automobile when it

is initially started. It is very important that the condensate line slopes

away from the appliance and down to a suitable inside drain.

Components included with the appliance:

• Intake PVC Tee with Screens

• Exhaust PVC Coupling with Screens

• 30 PSI Temperature and Pressure Relief Valve

• Installation Manual and Warranty

• User’s Information Manual

• Pressure and Temperature Gauge

• Outdoor Sensor (Part # 7250P-319)

A. What’s in the Box

Remove the appliance and accessories from 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 red water appliance, a thermostatic

mixing valve is required. Failure to install a thermostatic mixing

valve could result in property damage, severe personal injury, or

death.

The indirect sensor allows the installer to operate the appliance

to satisfy two temperatures: one for central heating and the other

for a domestic hot water heater. This allows the user to increase

water temperature supplied to the appliance to recover faster by

prioritizing ow at a higher rate than may be needed for central

heating. NOTE: This application requires two separate circulators.

C. Optional Equipment

Optional equipment available from HTP (and Part #):

• 3” Stainless Steel Vent Termination Kit (V1000)

• 4” Stainless Steel Vent Termination Kit (V2000)

• 2” PVC Concentric Vent Kit (KGAVT0501CVT)

• 3” PVC Concentric Vent Kit (KGAVT0601CVT)

• 3” Polypro Vent Kit (8400P-001)

• 3” Polypro Pipe

(33’ length # 8400P-002, 49.5’ length # 8400P-003)

• System Sensor (7250P-324)

• Indirect Tank Sensor (7250P-325)

• Alarm System (7350P-602) to monitor any failure

• Outdoor Sensor (7250P-319)

• PC Connection Kit (7250P-320)

• Condensate Neutralizer (7450P-212)

• UL 353 Compliant Low Water Cut-O Interface Kit with

Manual Reset (7350P-601)

NOTE: When using an optional system sensor, pipe insulation

must be wrapped around it to improve temperature measurement

accuracy and increase overall system eciency.

If the appliance condensate outlet is lower than the drain, use a

condensate removal pump (Part # 554200, available from HTP). In

addition, local authorities may require a condensate neutralizer to

neutralize the condensate. Condensate neutralizers are made up

of lime crystals, marble, or phosphate chips. Neutralizers can be

installed in the eld by the installer and purchased from HTP (7450P-

212).

It is also very important not to expose the condensate line to freezing

temperatures or any type of blockage. Plastic tubing must be the only

material used for the condensate line. Steel, brass, copper, or other

materials will be subject to corrosion or deterioration. A second vent

may be necessary to prevent condensate line vacuum lock on a long

horizontal run. Also, an increase in pipe size may be necessary to

allow condensate to drain properly. Support of the condensate line

may be necessary to avoid blockage of the condensate ow.

Spark Ignition

The burner ame ignites by applying high voltage to the system

spark electrode. This causes a spark from electrode to ground.

Outdoor Sensor

When equipped, the outdoor sensor monitors outdoor temperature

and adjusts the set point to provide greater eciency.

(Optional) Indirect Tank Sensor – Indirect Priority

UNCRATING THE APPLIANCE - Any claims for damage or shortage

in shipment must be led immediately against the transportation

company by the consignee.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

Part 3 - Prepare the Appliance

COLD WEATHER HANDLING - If the appliance has been stored in

a very cold location (BELOW 0oF) before installation, handle with

care until the components come to room temperature. Failure to

do so could result in damage to the appliance.

Carefully consider installation when determining appliance

location. Please read the entire manual before attempting

installation. Failure to properly take factors such as appliance

venting, piping, condensate removal, and wiring into account

before installation could result in wasted time, money, and

possible property damage and personal injury.

This appliance is certied for indoor use only. DO NOT INSTALL

OUTDOORS. Outdoor installations ARE NOT covered by warranty.

Failure to install the appliance indoors could result in property

damage, severe personal injury, or death.

A. Locating the Appliance

Incorrect ambient conditions can lead to damage to the heating

system and put safe operation at risk. Ensure that the installation

location adheres to the information included in this manual. Failure

to do so could result in property damage, serious personal injury,

or death. Failure of an appliance or components due to incorrect

operating conditions IS NOT covered by product warranty.

This appliance must be installed upright in the vertical position as

described in this manual. DO NOT attempt to install this appliance

in any other orientation. Doing so will result in improper appliance

operation and property damage, and could result in serious

personal injury or death.

1. Installation Area (Mechanical Room) Operating Conditions

• Ensure ambient temperatures are higher than 32oF / 0oC and

lower than 104oF / 40oC

• Prevent the air from becoming contaminated by the

products, places, and conditions listed in this manual

• Avoid continuously high levels of humidity

• Never close existing ventilation openings

• Ensure a minimum 1” clearance around hot water and

exhaust vent pipes

• NOTE: To prevent condensing in the fan, it is recommended

to avoid prolonged exposure to temperatures below 45oF

This appliance has a condensate disposal system that may freeze

if exposed to sustained temperatures below 32oF. 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, or death.

The service life of the appliance’s exposed metallic surfaces,

such as the casing, as well as internal surfaces, such as the heat

exchanger, are directly inuenced by proximity to damp and salty

marine environments. In such areas higher concentration levels of

chlorides from sea spray coupled with relative humidity can lead

to degradation of appliance components. In these environments,

appliances must not be installed using direct vent systems

which draw outdoor air for combustion. Such appliances must

be installed using room air for combustion. Indoor air will have a

much lower relative humidity, and hence potential corrosion will

be minimized.

Failure of the appliance or components due to incorrect operating

conditions IS NOT covered by product warranty.

2. Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

3. Check area around appliance. Remove any combustible materials,

gasoline, and other ammable liquids.

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

• Incorrectly sized expansion tank

Always take future maintenance into consideration when locating

the appliance. If the appliance is located in an installation location

with limited clearances, it may be necessary to remove the appliance

from the space to perform maintenance. Failure to consider

maintenance when determining installation location could result in

property damage.

CAUTION

6. Clean and ush system when reinstalling an appliance.

B. Leveling

In order for the condensate to properly ow out of the collection

system, the area where you locate the appliance must be level.

Location must also fully support the weight of the lled appliance.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

24" MIN.

CLEARANCE

5" MIN.

0" MIN .

CLEARANCE

24" MIN.

0" MIN .

TOP VIEW

FRONT VIEW

CLEARANCE

LP-325-M

04/05/11

PLUS 2" MINIMUM

DIAMETER OF WATER HEATER

06/28/10

LP-179-W

TO OPEN DRAIN

LINE SHOULD BE AT

LEAST 3/4" ID AND

PITCHED FOR PROPER

DRAINAGE.

MAXIMUM 2"

Figure 1 - Recommended Service Clearances and Drain Pan Dimensions

NOTE: If you do not provide the minimum clearances shown in Figure

1 it might not be possible to service the appliance without removing

it from the space.

NOTE: A combustible door or removable panel is acceptable front

clearance.

All appliances eventually leak. Locate the tank where any leakage

from the relief valve, related piping, tank, or connections will not

result in damage to surrounding areas or lower oors of the building.

Any drain back tank should be installed in such a manner that if it

should leak the resulting ow of water will not cause damage to the

area in which it is installed. National Plumbing codes require a drain

pan for any appliance installation.This drain pan should be sized with

a maximum depth of 2”, and a minimum diameter 2”greater than the

diameter of the appliance. The drain pan should empty into an open

drain line. This drain line should be 3/4” ID minimum, piped to an

open drain. Leakage damages ARE NOT covered by warranty. Failure

to install a drain pan is the sole responsibility of the owner and/or

installer. Reference UPC 2000 (Uniform Plumbing Code) Section 510

- Protection from Damage or IPC 200 (International Plumbing code)

Section 504 - Safety Devices. Leakage damages ARE NOT covered by

warranty.

In addition, water leak detection devices and automatic water

shuto valves are readily available at plumbing supply houses. IT IS

HIGHLY RECOMMENDED BYTHE MANUFACTURER TO INSTALL WATER

LEAK DETECTION DEVICES AND AUTOMATIC SHUTOFF VALVES IN

ANY DRAIN BACK TANK INSTALLATION WHERE A LEAKAGE OF WATER

COULD RESULT IN PROPERTY DAMAGES.

WARNING

Appliance Area Ventilation Air Openings - Closet Installations

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 ft3or

greater, ventilation of the appliance area/room is not required.

Each ventilation air opening must meet the minimum requirements

of 1 in2per 1000 BTU/hr., but not less than 100 in2. The lower ven-

tilation opening must be located within 6 in. of the oor, 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 ttings

SHALL NOT BE USED within the closet or alcove. Only approved

CPVC, Polypropylene, or Stainless Steel vent pipe and ttings may

be used. See Table 6 for a list of approved materials. Under all

circumstances proper ventilation must be provided.

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 appliance venting section,

this manual, for descriptions of conned and unconned spaces.

Do not install the appliance in an attic.

The

appliance

cover must

be securely fastened to prevent the

appliance

from drawing air

from the

appliance

room. This is particularly important if the

appliance

is in a room with other appliances. Failure to comply with

the above warnings could result in substantial property damage,

severe personal injury, or death.

Alcove Installations

Alcove installations have the same minimum dimensions as closet

installations, except the installation must be completely open to the

room at a distance no greater than 18 in. (457 mm) from the front

of the appliance and the room must be at least three (3) times the

size of the alcove. Provided these conditions are met, the appliance

requires no extra ventilation air openings to the space. If these con-

ditions are not met, follow the requirements for Closet Installations.

Precautions

If the appliance is located in a residential garage, per ANSI Z223.1:

• Install the appliance burner and ignition devices a minimum

of 18” above the oor of the garage. This will ensure the

burner and ignition devices are well o the oor.

• When raising the appliance ensure the entire bottom and

fully lled weight of the appliance are fully supported.

• Locate or protect the appliance so it cannot be damaged by

a moving vehicle.

D. Residential Garage and Closet Installations

Check with your local Authority Having Jurisdiction for

requirements when installing the appliance in a garage or closet.

Please read the entire manual before attempting installation.

Failure to properly take factors such as venting, piping, condensate

removal, and wiring into account before installation could result in

wasted time, money, and possible property damage and personal

injury.

C. Clearances for Service Access

LP-325 Rev. 009 Rel. 004 Date 12.2.20

E. Exhaust Vent and Intake Pipe

The appliance is rated ANSI Z21.10.3 Category IV (pressurized vent,

likely to form condensate in the vent) and requires a special vent

system designed for pressurized venting.

NOTE: The venting options described here (and further detailed

in the Venting section, this manual) are the lone venting options

approved for this appliance. Failure to vent the appliance in

accordance with the provided venting instructions will void the

warranty.

Failure to vent the appliance properly will result in serious personal

injury or death.

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.

Vents must be properly supported. Appliance exhaust and intake

connections are not designed to carry heavy weight. Vent support

brackets must be within 1’ of the appliance and the balance at 4’

intervals. Appliance must be readily accessible for visual inspection

for rst 3’ from the appliance. Failure to properly support vents

could result in property damage, severe personal injury, or death.

The exhaust discharged by this appliance may be very hot. Avoid

touching or other direct contact with the exhaust gases of the vent

termination assembly. Doing so could result in severe personal

injury or death.

1. Direct Vent 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 outdoors. There are three basic direct vent options

detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.

Unbalanced Venting.

Be sure to locate the appliance such that the exhaust vent and intake

piping can be routed through the building and properly terminated.

Dierent vent terminals can be used to simplify and eliminate

multiple penetrations in the building structure (see Optional

Equipment in Venting Section). The exhaust vent and intake piping

lengths, routing, and termination methods must all comply with the

methods and limits given in the Venting Section, this manual.

When installing a combustion air intake from outdoors, care must

be taken to utilize uncontaminated combustion air. To prevent

combustion air contamination, see Table 3.

2. Power Venting, Indoor Combustion Air in Conned or

Unconned 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 3.

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 sucient combustion air based on the appliance input.

Never obstruct the supply of combustion air to the appliance. If the

appliance is installed in areas where indoor air is contaminated (see

Table 3) it is imperative that the appliance be installed as direct vent

so that all combustion air is taken directly from the outdoors into the

appliance intake connection.

Unconned space is space with volume greater than 50 cubic feet

per 1,000 BTU/hr (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.

Conned 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 appliances installed in that space. Rooms connected

directly to this space through openings not furnished with doors are

considered part of the space.

Whendrawingcombustionairfrominsidea conventionallyconstructed

building to a conned space, such space should be provided with two

permanent openings: one located 6” (15 cm) below the space ceiling,

the other 6”(15cm) above the space oor. Each opening should have a

free area of one square inch per 1,000 BTU/hr (22cm2/kW) of the total

input of all appliances in the space, but not less than 100 square inches

(645cm2).

If the conned space is within a building of tight construction, air for

combustion must be obtained from the outdoors as outlined in the

Venting section of this manual.

When drawing combustion air from the outside into the mechanical

room, care must be taken to provide adequate freeze protection.

Failure to provide an adequate supply of fresh combustion air can

cause poisonous ue gases to enter the living space, resulting

in severe personal injury or death. To prevent combustion air

contamination, see Table 3.

In the Commonwealth of Massachusetts and As Required by State

and Local Codes:

Installation of Carbon Monoxide Detectors: At the time of installation

or replacement of the vented gas fueled appliance, the installing

plumber or gas tter shall observe that a hard wired carbon monoxide

detector with an alarm and battery back-up is installed on the oor

level where the gas appliance is installed, unless the appliance is

located in a detached, uninhabitable structure separate from the

dwelling, building, or structure used in whole or in part for residential

purposes.

In addition, the installing plumber or gas tter shall observe that a hard

wired carbon monoxide detector with an alarm and battery back-up is

installed on each additional level of the dwelling, building, or structure

served by the vented gas appliance. It shall be the responsibility of the

property owner to secure the service of qualied licensed professionals

for the installation of hard wired carbon monoxide detectors.

a. In the event that the vented gas fueled appliance is installed in a

crawl space or attic, the hard wired carbon monoxide detector with

alarm and battery back-up shall be installed on the next adjacent

oor level.

b. In the event that these requirements cannot be met at the time of

completion of installation, the owner shall have a period of thirty (30)

days to comply with the above requirements; provided, however,

that during said thirty (30) day period, a battery operated carbon

monoxide detector with an alarm shall be installed.

F. Carbon Monoxide Detectors

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.

Approved Carbon Monoxide Detectors: Each carbon monoxide

detector as required in accordance with the above provisions shall

comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certied.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

G. Prevent Combustion Air Contamination

Install intake air piping for the appliance as described in the Venting

Section, this manual. Do not terminate exhaust in locations that can

allow contamination of intake air.

Ensure that the intake air will not contain any of the contaminants

in Table 3. Contaminated air will damage the appliance, resulting

in possible substantial property damage, severe personal injury, or

death. For example, do not pipe intake air near a swimming pool or

laundry facilities. These areas always contain contaminants.

Products to Avoid Areas Likely to Have

Contaminants

Spray cans containing

uorocarbons

Dry cleaning / laundry areas

and establishments

Permanent wave solutions Swimming pools

Chlorinated waxes / cleaners Metal fabrication plants

Chlorine-based swimming pool

chemicals Beauty shops

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water

softening Photo processing plants

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric or Muriatic acid Furniture renishing areas and

establishments

Cements and glues New building construction

Antistatic fabric softeners used in

clothes dryers Remodeling areas

Chlorine-type bleaches, laundry

detergents, and cleaning solvents Garages and workshops

Adhesives used to fasten building

products

Table 3 - Products and Areas Likely to Have Contaminants

NOTE: DAMAGE TO THE APPLIANCE CAUSED BY EXPOSURE TO

CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to

the limited warranty for complete terms and conditions.)

H. Removing an Appliance from a Common Vent System

Failure to follow all instructions can result in ue 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 ue 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 venting system.

2. Visually inspect the venting system for proper size and horizontal

pitch to determine if there is blockage, leakage, corrosion, or other

deciencies that could cause an unsafe condition.

3. If practical, close all building doors, windows, and doors between

the space in which the appliance remains connected to the common

venting system and other spaces in the building. Turn on clothes

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 replace dampers.

4. Place in operation the appliance being inspected. Follow the

lighting instructions. Adjust the thermostat so the appliance will

operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of

main burner operation. Use the ame of a match or candle or smoke

from a cigarette.

6. After it has been determined that each appliance remaining

connected to the common venting system properly vents when

tested as outlined, return doors, windows, exhaust fans, replace

dampers, and any other gas burning appliances to their previous

condition of use.

7. Any improper operation of the common venting system should

be corrected to conform to the National Fuel Gas Code, ANSI Z223.1.

When resizing any portion of the common venting system, the

system should approach the minimum size as determined using the

appropriate tables in Appendix G of ANSI Z223.1.

Figure 2 - CO Warning Label

LP-325 Rev. 009 Rel. 004 Date 12.2.20

I. Technical Specications

Table 4 - Technical Specications

NOTES:

1Listed Input Ratings are at minimum vent lengths at an altitude of 0 - 2000 ft. Numbers will be lower with longer venting and/or altitudes greater

than 2000 ft.

2Ratings based on standard test procedures prescribed by the US Department of Energy.

3The Pioneer requires a special venting system. Use only the vent materials and methods detailed in these installation instructions.

Model PHR100-55 PHR130-55 PHR160-55 PHR199-55

Installation Indoor, Floor Model, Fully Condensing

Minimum / Maximum Input (Btu/Hr)135,000 / 100,000 35,000 / 130,000 40,000 / 160,000 40,000 / 199,000

Thermal Eciency295% 94% 95% 95%

Flue System Category IV, Sealed Combustion Direct Vent, Power Vent

Min Combined Vent Run 16 feet

Max Combined Vent Run 2” (85 feet), 3” (125 feet) 3” (200 feet), 4” (200 feet)

Approved Exhaust Vent Materials3PVC, 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 Rectication

Burner System Premixed Fuel Modulation / Stainless Steel Metal Fiber Burner

Gas Valve System Air Ratio Valve

Dimensions

W23”

H56”

D34”

Water Content (Gallons) 55

DHW Indirect Setpoint Temperature Range 95 - 185oF (32 - 185oF with Outdoor Reset Curve)

Max Water Pressure (PSI) 30

Control Panel / Main Controller LCD Display with LED Indicators / 926 SIT Control

Connection Sizes

Supply/Return 1 1/4” NPT (Female)

Gas Inlet 3/4” NPT

Drain 1” NPT

Materials

Cabinet Black ABS

Heat Exchanger Cupronickel Primary with 800H Stainless Steel and Cupronickel Secondary Tubing

Tank 304L Stainless Steel

Safety Devices

Flame Rectier Probe, Temperature Sensor, Low Water Cut O Probe, Combination Supply /

ECO Sensor, Freeze Protection, Condensate Trap, Flue High Temp Thermostat, Blocked Vent

Pressure Switch

LP-325 Rev. 009 Rel. 004 Date 12.2.20

Figure 3 - Appliance Dimensions - NOTE: All Dimensions Are Approximate

Part 4 - Piping

Failure to follow the instructions in this section WILL VOID the

warranty and may result in property damage, severe personal injury,

or death.

Dielectric unions or galvanized steel ttings must not be used in a

system with this appliance. Doing so WILL VOID the warranty. Use

only copper, brass, or stainless steel ttings. Teon thread sealant

must be used on all connections.

Plumbing of this appliance should only be done by a qualied,

licensed plumber in accordance with all local plumbing codes. The

appliance may be connected to an indirect water heater to supply

domestic hot water. HTP oers indirect water heaters in a wide range

of gallon sizes in either stainless steel or glass lined construction.

A. General Plumbing Information

Use two wrenches when tightening water piping at appliance. Use

one wrench to prevent the appliance return or supply line from

turning. Failure to prevent piping connections from turning could

cause damage to appliance components.

The building piping system 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 Plumbing Code

of Canada, and the Uniform Plumbing Code limit heat transfer uid

pressure to less than the minimum working pressure of the potable

water system up to 30 PSI maximum. In addition, the heat transfer

uid must be water or another non-toxic uid having a toxicity of

Class 1, as listed in Clinical Toxicology of Commercial Products,

5th Edition. Failure to follow this warning could result in property

damage, severe personal injury, or death.

Do not apply a torch within 12”of the appliance. If sweat connections

are used, sweat tubing to the adapter before tting adapter to the

water connections on the appliance. Damages due to improper

installation practices ARE NOT covered by warranty.

The water connections must be installed in accordance with all local

and national plumbing codes, or any applicable standard which

prevails.

• Pipe material must be suitable to meet local codes and industry

standards.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

This appliance is designed to function in a closed loop 15 PSI System. A

factory installed low water cut o will ensure that you have adequate

water in the system. We have also included a T&P gauge which allows

the user to monitor system pressure and outlet temperature from the

appliance.

Install the appliance so the gas ignition system components are

protected from water (dripping, spraying, etc.) allowing clearance for

basic service of circulator replacement, valves and other parts. Observe

minimum 1” clearance around all hot water pipes not protected by

non-combustible materials.

On an appliance installed above radiation level, some states and local

codes require a low water cut o device at the time of installation. If the

appliance supplies hot water to heating coils in air handler units, ow

control valves or other devices must be installed to prevent gravity

circulation of appliance water in the coils during the cooling cycle.

Chilled water medium must be piped in parallel with the appliance.

Basic steps are listed below which will guide you through the

installation of the appliance.

1. Connect the system return marked“Return”.

2. Connect the system supply marked“Supply”.

3. Install purge and balance valve or shut o valve and drain on system

return to purge air out of each zone.

4. Install a back ow preventer on the cold feed make-up water line.

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.

7. Install an expansion tank on the system supply. Consult manufacturer

instructions for specic information relating to expansion tank

installation. Size the expansion tank for the required system volume

and capacity.

8. Install supply air vent to remove air when commissioning the

appliance.

9. The safety relief valve is supplied with the appliance, and must be

installed on the top ¾” NPT tting marked “T&P”. Pipe the discharge of

the safety relief valve to prevent injury in the event of pressure relief.

Discharge 6”above the drain. Provide piping that is the same size as the

safety relief valve outlet. Never block the outlet of safety relief valve.

• The pipe must be cleaned and without blemish before any

connections are made.

• Isolation (shut-o valves) should be used to ease future servicing.

• All piping should be insulated.

It is recommended to install a shut-o valve and a union in the return

and supply piping to ease future servicing. If there is a backow

preventer or any type of a no return valve in the system, install an

additional tee here suitable for an expansion tank.

NOTE: The addition of a high temperature limiting device is

important if the appliance is to be connected to a domestic hot

water system.

B. Backow Preventer

Use a backow preventer specically designed for hydronic

installations. This valve should be installed on the cold water ll

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

appliance and system water volume and temperature.The appliance

volume is 55 gallons.

2. The expansion tank must be located as shown in Applications, this

manual, or following recognized design methods. See expansion

tank manufacturer’s instructions for details.

3. Connect the expansion tank on the suction side of the circulator.

Always install the system ll connection at the same point as the

expansion tank connection to the system.

4. Most chilled water systems are piped using a closed type

expansion tank.

Diaphragm (or Bladder) Expansion Tank

Always install an automatic air vent on top of the air separator to

remove residual air from the system.

CAUTION

Undersized expansion tanks cause system water to be lost from

the relief valve, causing make-up water to be added. Eventual

appliance failure can result due to excessive make-up water

addition. SUCH FAILURE IS NOT COVERED BY WARRANTY.

Expansion tanks must be sized according to total system volume.

This includes all length of pipe, all xtures, appliances, etc. Failure

to properly size for system expansion could result in wasted time,

money, possible property damage, serious injury, or death.

WARNING

DO NOT install automatic air vents on closed type expansion tank

systems. Air must remain in the system and return to the tank to

provide an air cushion. An automatic air vent would cause air to

leave the system, resulting in improper operation of the expansion

tank.

D. Piping the Appliance

CAUTION

The appliance should not be operated as a potable hot water

heater. The appliance should not be used as a direct hot water

heating device.

Use at least the MINIMUM pipe size for all appliance loop piping.

This is to avoid the possibility of inadequate ow through the

appliance. Using less than the required minimum pipe size and

piping could result in system problems, property damage, and

premature appliance failure. Such problems ARE NOT covered by

product warranty.

E. Circulator Pumps

DO NOT install automatic air vents on closed type expansion tank

systems. Air must remain in the system and return to the tank to

provide an air cushion. An automatic air vent would cause air to leave

the system, resulting in improper operation of the expansion tank.

Sizing Space Heat System Piping

1. See piping details in this manual. Special attention must be paid

when connecting an indirect storage tank, as temperature delivered

to low temperature circuits may be higher than desired. The use of

thermostatic mixing valves is required to protect these circuits.

To control the temperature of low temperature heating circuits when

using an indirect red water heater, a thermostatic mixing valve is

required. Failure to install a thermostatic mixing valve when using

an indirect red water heater could result in damage the heating

circuits. Such damage IS NOT covered by warranty.

2. Size the piping and components in the space heating system using

recognized design methods.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

Overheated water and high pressures can cause water tank

explosion. A properly sized temperature and pressure relief valve

must be installed in the opening provided on the appliance. Failure

to install a properly sized temperature and pressure relief valve could

result in explosion and property damage, serious injury, or death.

F. Relief Valve

Install supplied temperature and pressure relief valve. Connect

discharge piping to a safe disposal location, following the guidelines

on the next page. Replacement relief valves are available. See parts list.

Do not thread a cap or plug into the relief valve or relief valve line

under any circumstances! Explosion and property damage, serious

injury, or death may result.

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and

run to a safe place of disposal. Terminate the discharge line

in a manner that will prevent possibility of severe burns or

property damage should the relief valve discharge.

• Discharge line must be as short as possible and the same

size as the valve discharge connection throughout its entire

length.

• Discharge line must pitch downward from the valve and

terminate at least 6” above the oor drain, making discharge

clearly visible.

• The discharge line shall terminate plain, not threaded, with a

material serviceable for temperatures of 375oF or greater.

• Do not pipe discharge to any location where freezing could

occur.

• No valve may be installed between the relief valve and

appliance or in the discharge line. Do not plug or place any

obstruction in the discharge line.

• Test the operation of the relief valve after lling and

pressurizing the system by lifting the lever. Make sure the

valve discharges freely. If the valve fails to operate correctly,

immediately replace with a new properly rated relief valve.

• Test T&P valve at least once annually to ensure the waterway

is clear. If valve does not operate, turn the appliance “o” and

call a plumber immediately.

• Take care whenever operating relief valve to avoid scalding

injury or property damage.

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT

IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY

OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY,

OR DEATH.

RE-INSPECTION OF T&P RELIEF VALVES: T&P valves should be

inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if

necessary, by a licensed plumbing contractor or qualied installer /

service technician to ensure that the product has not been aected

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

conditions can only be detected if the valve and its components are

physically removed and inspected. Do not attempt to conduct an

inspection on your own. Contact your plumbing contractor for a

re-inspection to assure continued safety.

FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED COULD

RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILD-UP

WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS PERSONAL

INJURY, OR DEATH.

J. Indirect Water Heater Scalding

This appliance can deliver

scalding water. Be careful

whenever using hot

water to avoid scalding

injury. Certain appliances

such as dishwashers

and automatic clothes

washers may require

increased water

temperatures. By setting

the thermostat on this

appliance to obtain

the increased water

temperature required

by these appliances you

may create the potential

for scald injury.

To protect against

injury, install the mixing

valve included with this

appliance. This valve

will reduce point of use

discharge temperatures

by mixing cold and hot

water in the branch

supply lines.

The table below details the relationship of water temperature and

time with regard to scald injury and may be used as a guide in

determining the safest water temperature for your applications.

I. Multiple Appliances

1. All piping shown is reverse return to assure balanced ow through

the connected appliances.

2. Connect DHW piping to indirect storage water appliance as

shown.

G. Zoning with Zone Valves

1. Connect appliance to system as shown in the Applications

diagrams. Properly size circulators for friction loss of zone valves and

piping for proper operation.

2. Connect DHW (domestic hot water) piping to indirect storage

water appliance as shown.

H. Zoning with Circulators

1. Connect appliance to system as shown in the Applications

diagrams. Properly size each zone circulator for friction loss of each

zone for proper operation.

2. Install a separate circulator for each zone.

3. Connect DHW piping to indirect storage water appliance as

shown.

Approximate Time / Temperature Relationships in Scalds

120oF More than 5 minutes

125oF 1 1/2 to 2 minutes

130oF About 30 seconds

135oF About 10 seconds

140oF Less than 5 seconds

145oF Less than 3 seconds

150oF About 1 1/2 seconds

155oF About 1 second

LP-325 Rev. 009 Rel. 004 Date 12.2.20

ASSE 1017 or ASSE 1070 temperature limiting or mixing valves do

not eliminate the risk of scalding.

To avoid scalding:

• Set the appliance set point temperature as low as possible.

• Feel water before bathing or showering.

• If thermostatic valves are required, use devices specically

designed for such purpose. Install these devices in

accordance with instructions provided by the manufacturer.

Failure to install a temperature limiting or mixing valve and

follow these instructions could result in property damage, severe

personal injury, or death due to scalds.

K. Fill and Purge Heating System

• Attach the hose to either balance or purge hose connector

or drain valve and run hose to nearest drain.

• Close the other side of the balance and purge valve or the

shut o valve after the drain.

• Open rst zone balance and purge or drain valve to let water

ow out the hose. If zone valves are used, open the valves

one at a time manually. (NOTE: You should check valve

manufacturer instruction prior to opening valves manually,

so as not to damage any valves.)

• Manually operate ll valve regulator. When water runs out

of the hose, while it’s connected to the balance and purge

valve or drain you will see a steady stream of water (without

bubbles). Close balance and purge valve or drain to stop the

water from owing. Disconnect the hose and connect it to

next zone to be purged.

• Repeat this procedure for additional zones (one at a time).

The appliance must be full of water and the system fully purged

BEFORE powering the appliance. Applying power to the appliance

when it is not full of water will damage the heat exchanger, and

could result in property damage, serious personal injury, or death.

Such damages ARE NOT covered by appliance warranty.

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

ows 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 the ll valve is in automatic

position and each zone balance and purge or shut o is in an open

position and zone valves are set for automatic operation.

Use only inhibited propylene glycol solutions which are FDA

RATED AS GRAS and specically formulated for hydronic systems.

Ethylene glycol is toxic and can attack gaskets and seals used in

hydronic systems. Failure to follow the instructions in this section

WILL VOID the warranty and may result in property damage,

severe personal injury, or death.

Glycol in hydronic applications includes inhibitors that prevent it from

attacking metallic system components. Make certain that system uid

is checked for the correct glycol concentration and inhibitor level.

The glycol solution should be tested at least once a year, or as

recommended by the glycol manufacturer.

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 to 180oF, 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.

A 50% glycol mixture results in a BTU output loss of 30% with a 50%

increase in head against the system circulator.

Itishighlyrecommendedthatyoucarefullyfollowglycolmanufacturer

recommended concentrations, expansion requirements, and

maintenance recommendations (pH additive break down, inhibitor

reduction, etc.) You must carefully gure the additional friction loss

in the system as well as the reduction in heat transfer coecients.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

L. Central Heating Applications

ZONE CIRCULATORS

with IFC

(TYP)

EXPANSION TANK

PRESSURE

REDUCING

VALVE

BACKFLOW

PREVENTER

DRAIN

SUPPLY

RETURN

TEMPERATURE AND PRESSURE

GAUGE (TYP)

AIR VENT

LP-325-F

07-27-10

CENTRAL HEATING

MAKE-UP

WATER

TO SYSTEM

BALL VALVE

(TYP)

NOTE: RECOMMENDED

DRAIN FOR CLEANING

EXISTING SYSTEMS

ALTERNATE LOWER RETURN

CONFIGURATION

T&P VALVE

RETURN

BALL

EXPANSION

TANK

BACKFLOW

VALVE

CENTRAL HEATING AND AN

PRESSURE

DRAIN

INDIRECT WATER HEATER

(TYP.)

VALVE

CIRCULATOR

W/ IFC

TO SYSTEM

(TYP.)

ZONE VALVE

GAUGE

PRESSURE

AND

DRAIN (TYP)

GAUGE

MAKE UP

RETURN

CIRCULATOR

WATER

PREVENTER

REDUCING

W/IFC TEMP.

PRESSURE

MIXING

VALVE

HOT WATER

OUTLET

LP-325-E1

08/08/11

TEMPERATURE AND

PRESSURE RELIEF VALVE

COLD WATER

INLET

BALL VALVE

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. The minimum pipe size for

connecting the appliance is 1.25-

inch

4. Circulators are shown with

isolation anges and integral check

valves. The alternative is standard

anges with full port ball valves

and a separate ow check valve.

Purge valves can be used with the

circulator anges 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 12 diameters

of straight pipe upstream of all

circulators.

7. Winterization: When winterizing,

put a drain valve on both the supply

and return between the union and

the shut-o connection.

8. If a backow preventer or no

return valve is installed, a thermal

expansion tank is required on

the cold water inlet between the Figure 4 - Central Heating

Figure 5 - Appliance with Indirect Water Heater

water heating

appliance and

the backow

preventer.

LP-325 Rev. 009 Rel. 004 Date 12.2.20

GAUGE (TYP.)

GAUGE

MAKE UP

WATER

TANK

PREVENTER

ZONE CIRCULATORS

RETURN

EXPANSION

REDUCING

SYSTEMS

PRESSURE

BACKFLOW

(TYP.)

with IFC

AIR ELIMINATOR

T&P VALVE (TYP.)

TEMP. AND PRESSURE

VALVE

NOTE: RECOMMENDED DRAIN

FOR CLEANING EXISTING

DRAIN (TYP.)

LP-325- N

02/08/11

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. The minimum pipe size for connecting the appliance is 1.25-inch

4. Circulators are shown with isolation anges and integral check valves. The alternative is standard anges with full port ball valves and a

separate ow check valve. Purge valves can be used with the circulator anges 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 12 diameters of straight pipe upstream of all circulators.

7. Winterization: When winterizing, put a drain valve on both the supply and return between the union and the shut-o connection.

8. If a backow 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 backow preventer.

Figure 6 - Cascaded System

LP-325 Rev. 009 Rel. 004 Date 12.2.20

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 nished 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. Failure to properly install the

vent system will result in severe personal injury or death.

A. General

This appliance is certied as a “Category IV” appliance and requires a

special venting system. The vent system will operate with a positive

pressure in the pipe. Exhaust gases must be piped directly outdoors

using the vent materials and rules outlined in these instructions. Do

not connect vent connectors serving appliances vented by natural

draft into any portion of mechanical draft systems operating under

positive pressure. Follow the venting instructions carefully. Failure

to do so will result in substantial property damage, severe personal

injury, or death.

1. Installation should be made in accordance with the regulations of

the Authority Having Jurisdiction, local code authorities, and utility

companies which pertain to this type of water heating equipment.

2. Install the venting system in accordance with these instructions and

with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149,

and / or applicable provisions of local building codes.

3. This appliance must be vented with materials, components, and

systems listed and approved for Category IV appliances.

NOTE: To avoid contamination often contained in indoor air, it is best

to pipe all intake combustion air directly to the outdoors.

NOTE: Care must be taken to prevent condensate freezing in the

exhaust vent pipe system. See local, state, provincial, and national

codes for best practices to prevent condensate freezing in the exhaust

vent pipe system.

Exhaust and intake are to be piped separately. This appliance

cannot share a common exhaust or intake with multiple appliances.

Failure to follow these instructions will result in substantial property

damage, severe personal injury, or death.

Improper seating of vent pipe gaskets can cause eventual gasket

failure and exhaust gas leakage. Ensure the exhaust vent pipe is

properly beveled and seated before insertion into the ue adapter.

Failure to do so could result in property damage, severe personal

injury, or death.

Due to the extreme ammability 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

appliance. Failure to follow these instructions will result in

substantial property damage, severe personal injury, or death. It is

the installers’ responsibility to understand the hazards associated

with explosive solvents and take the necessary precautions to

avoid these risks.

Exhaust vent adaptors are not designed as load-bearing devices,

and must not be used to support exhaust vent piping. All vent pipes

must be properly connected, supported, and the exhaust vent must

be pitched a minimum of 1/4”per foot back to the appliance to allow

drainage of condensate. Failure to properly support vent piping

and follow the information in this statement could result in product

damage, severe personal injury, or death.

• Only Stainless Steel exhaust vent pipe material may be

insulated.

• DO NOT insulate the rst three (3)

linear feet of the exhaust vent run.

• DO NOT insulate PVC, CPVC, or

Polypropylene exhaust vent pipe

material. Doing so will cause

increased vent wall temperatures,

which could result in vent pipe

failure.

• CPVC, Polypropylene, or Stainless

Steel pipe material MUST be used

if the rst three (3) linear feet

of the exhaust vent run passes

through an enclosed space greater than 6” in length, such as a

wall or ceiling.*

• If CPVC is used to meet these requirements, the balance may be

installed with approved PVC pipe.

• If Polypropylene or Stainless Steel is used to meet these

requirements, the balance of the vent run MUST be installed

with the same material.

• Failure to comply with these requirements could result in

property damage, severe personal injury, or death.

*This rule applies when the exhaust vent passes through the enclosed

space into another interior space, i.e. through a oor or wall from the

mechanical room into another room. This rule DOES NOT apply when

the exhaust vent passes through the enclosed space immediately to the

exterior of the building.

Exhaust LP-179-JJ

11/30/17

Length

Greater than

Six (6) Inches

Enclosed

Space

Within First Three (3) Linear Feet of

Appliance Exhaust Vent Adapter

It is required to insert the provided exhaust and intake screens into

the vent terminations to prevent blockage caused by debris or birds.

Failure to keep terminations clear could result in property damage,

severe personal injury, or death.

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