Pioneer PHR100-55 User manual

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

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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
•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 fire department. Installation and service must be
provided by a qualified installer, service agency, or the gas supplier.

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The following defined terms are used throughout this manual to bring attention to the presence of
hazards of various risk levels or to important product information.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
FOREWORD
This manual is intended to be used in conjunction with other literature provided with the heater. This
includes all related control information. It is important that this manual, all other documents included with
this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be
reviewed in their entirety before beginning any work.
Installation should be made in accordance with the regulations of the local code authorities and utility
companies which pertain to this type of heating equipment.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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FOR THE INSTALLER
This appliance must be installed by qualified and licensed personnel. The installer should be guided by
the instructions furnished with the heater, and with local codes and utility company requirements. In the
absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.
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.
In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale
Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian
Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.
Code for the installation of Heat Producing Appliances (latest version), from American Insurance
Association, 85 John Street, New York, NY 11038.
The latest version of the National Electrical Code
, NFPA No. 70.
This product is 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. Damage or failure of this product (or the system in which it is installed)
due to unauthorized use IS NOT COVERED BY WARRANTY.
This manual must only be used by a qualified heating installer/service technician. Read all instructions in
this manual before installing. Perform steps in the order given. Failure to comply could result in severe
personal injury, death or substantial property damage.

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TABLE OF CONTENTS
PART 1 – GENERAL SAFETY INFORMATION..........................................................................................7
A. PRECAUTIONS....................................................................................................................................7
B. IMPROPER COMBUSTION.................................................................................................................8
C. GAS......................................................................................................................................................8
D. WHEN SERVICING THE HEATER......................................................................................................8
E. WATER QUALITY ................................................................................................................................8
F. WINTERIZING ......................................................................................................................................9
PART 2 – BEFORE YOU START ................................................................................................................9
A. WHAT’S IN THE BOX...........................................................................................................................9
B. HOW THE HEATER OPERATES ........................................................................................................9
C. OPTIONAL EQUIPMENT...................................................................................................................11
PART 3 – DIMENSIONS AND CLEARANCES..........................................................................................12
PART 4 – PREPARE HEATER LOCATION ..............................................................................................13
A. BEFORE LOCATING THE HEATER..................................................................................................13
B. LEVELING ..........................................................................................................................................14
C. CLEARANCES FOR SERVICE ACCESS..........................................................................................14
D. RESIDENTIAL GARAGE INSTALLATION.........................................................................................14
E. EXHAUST VENT AND INTAKE AIR VENT........................................................................................14
1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE.......................................................15
2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE.........15
F. PREVENT COMBUSTION AIR CONTAMINATION...........................................................................16
G. REMOVING A HEATER FROM A COMMON VENT SYSTEM.........................................................16
PART 5 – PREPARE THE HEATER..........................................................................................................17
PART 6 – HEATER PIPING .......................................................................................................................18
A. GENERAL PIPING INFORMATION...................................................................................................18
B. RELIEF VALVE...................................................................................................................................18
C. BACKFLOW PREVENTER ................................................................................................................19
D. SYSTEM WATER PIPING METHODS ..............................................................................................19
E. CIRCULATOR PUMPS.......................................................................................................................19
F. INDIRECT FIRED WATER HEATER SCALDING..............................................................................20
G. HYDRONIC PIPING - CIRCULATORS, ZONE VALVES AND MULTIPLE HEATERS.....................20
H. FILL AND PURGE HEATING SYSTEM.............................................................................................21
I. ZONING WITH ZONE VALVES...........................................................................................................22
J. ZONING WITH CIRCULATORS .........................................................................................................22

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K. MULTIPLE HEATERS........................................................................................................................22
L. PIPING DETAIL ..................................................................................................................................23
PART 7 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL...........................................26
A. GENERAL...........................................................................................................................................26
B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS.............................................26
C. EXHAUST AND INTAKE AIR VENT PIPE LOCATION .....................................................................27
1. DETERMINE EXHAUST VENT LOCATION...................................................................................27
2. DETERMINE AIR INTAKE VENT LOCATION................................................................................27
D. EXHAUST AND INTAKE AIR VENT SIZING.....................................................................................28
E. LONGER VENT RUNS.......................................................................................................................29
F. EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION...............................................................30
G. VENTING DRAWINGS.......................................................................................................................31
1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE.......................................................31
2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE.........37
H. EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION..............................................................39
I. REMOVING AN EXISTING WATER HEATER....................................................................................39
J. CONDENSATE REMOVAL SYSTEM.................................................................................................40
PART 8 – FIELD WIRING...........................................................................................................................41
A. INSTALLATION MUST COMPLY WITH: ...........................................................................................41
B. FIELD WIRING...................................................................................................................................41
C. LINE VOLTAGE WIRING FOR STANDARD HEATER......................................................................42
D. THERMOSTAT...................................................................................................................................42
E. OUTDOOR SENSOR (OPTIONAL) ...................................................................................................43
F. INDIRECT SENSOR (OPTIONAL).....................................................................................................43
G. 0-10 VOLT BUILDING CONTROL SIGNAL (OPTIONAL).................................................................43
H. UL353 LOW WATER CUT-OFF INTERFACE KIT (OPTIONAL........................................................44
I. WIRING OF CASCADE SYSTEM COMMUNICATION BUS...............................................................44
J. CASCADE MASTER PUMP AND SENSOR WIRING........................................................................45
K. CASCADE FOLLOWER PUMP AND SENSOR WIRING ..................................................................46
PART 9 – START-UP PREPARATION......................................................................................................46
A. CHECK/CONTROL WATER CHEMISTRY........................................................................................47
B. FREEZE PROTECTION (WHEN USED) ...........................................................................................47
C. FILL AND TEST WATER SYSTEM....................................................................................................48
D. PURGE AIR FROM WATER SYSTEM..............................................................................................48
E. CHECK THERMOSTAT CIRCUIT(S).................................................................................................48

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F. FINAL CHECKS BEFORE STARTING HEATER...............................................................................49
PART 10 – START-UP PROCEDURE.......................................................................................................49
A. OPERATING INSTRUCTIONS ..........................................................................................................49
B. CASCADE SYSTEM...........................................................................................................................50
C. ADJUSTING THE SET POINT...........................................................................................................50
D. STATUS MENU..................................................................................................................................51
E. TEST MODE.......................................................................................................................................52
F. PURGE AIR FROM WATER SYSTEM...............................................................................................53
PART 11 – PROGRAMMING THE HEATER.............................................................................................53
A. PROGRAM ACCESS .........................................................................................................................53
B. PROGRAM SYSTEM SETTINGS ......................................................................................................53
PART 12 – TROUBLESHOOTING.............................................................................................................56
A. HEATER ERROR CODE....................................................................................................................56
B. HEATER ERROR ...............................................................................................................................56
C. HEATER FAULT.................................................................................................................................56
PART 13: MAINTENANCE.........................................................................................................................61
MAINTENANCE NOTES ............................................................................................................................64
HTP CUSTOMER INSTALLATION RECORD FORM........................................................................65
PART 1 – GENERAL SAFETY INFORMATION
A. PRECAUTIONS
This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides
and back. Front must have room for service, 24” recommended. (A combustible door or removable panel
is acceptable front clearance.) This appliance has been approved for closet installation. Do not install this
appliance directly on carpeting. For installation on combustible flooring. Category IV vent systems only.
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. Refer to user’s
information manual for your reference. Have this heater serviced/inspected by a qualified service
technician annually.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL
PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

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NOTE: If the heater is exposed to the following, do not operate until all corrective steps have been made
by a qualified serviceman:
1. FIRE
2. DAMAGE
3. WATER
Any claims for damage or shortage in shipment must be filed immediately against the transportation
company by the consignee.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified
service technician. Replace any part of the control unit that has been under water.
Be sure to disconnect electrical power before opening heater cabinet. Failure to do so could result in an
electrical shock that could result in serious injury or death.
B. IMPROPER COMBUSTION
NOTE:
Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe
operation.
C. GAS
Should overheating or gas supply fail to shut off, do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location external to the appliance.
D. WHEN SERVICING THE HEATER
•To avoid electric shock, disconnect electrical supply before performing maintenance.
•To avoid severe burns, allow heater to cool.
E. WATER QUALITY
•Do not use petroleum-based cleaning or sealing compounds in a heater system. Gaskets and
seals in the system may be damaged. This can result in substantial property damage.
•Do not use “homemade cures” or “heater patent medicines”. Substantial property damage,
damage to heater, and/or serious personal injury may result.
•Continual fresh make-up water will reduce heater life. Mineral buildup reduces heat transfer,
overheats the heat exchanger, and causes failure. Addition of oxygen by make-up water can
cause internal corrosion in system components. Leaks in the heater or piping must be repaired at
once.
•If you have an old system with cast iron radiators, thoroughly flush the system (without heater
connected) to remove sediment. Sediment can reduce the efficiency of the heater and, in extreme
cases, cause damage to the internal heat exchanger.
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 injury or death.

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F. WINTERIZING
NOTE: Consider piping and installation when determining heater location. Do not place the heater in an
area where it will be prone to freezing.
To winterize the heater, drain the entire system. Pump two gallons of non-toxic, NSF food grade, FDA
rated GRAS (Generally Recognized As Safe) propylene glycol into the tank. Consult the glycol
manufacturer for specific instructions on concentration percentage as well as freeze and burst protection
methods. Check the concentration of antifreeze to assure protection is adequate to protect the bottom of
the heater from freezing.
PART 2 – BEFORE YOU START
A. WHAT’S IN THE BOX
Also included with the heater:
•Pressure and Temperature Gauge
•30 psi Temperature and Pressure Relief Valve
•Intake PVC Tee with Screens
•Exhaust PVC Coupling with Screens
•Installation Manual
•Warranty
•Outdoor Sensor (Part # 7250P-319)
B. HOW THE HEATER OPERATES
Condensing Technology maximizes efficiency by measuring the needs of your heating system through
the use of sensors and a control unit. The heater uses data gathered by these sensors to intelligently
deliver highly efficient hydronic heating.
Heat Exchanger
The highly efficient combustion heat exchanger flows exhaust gas through the primary section into the
secondary heat exchanger section, where the coldest water on the bottom of the tank extracts the last
residual amount of energy.
Modulating Combustion System
Modulation during central heating operation is based on the supply temperature. The set point used for
the control depends upon the programmed central heating curve. The slope of the heating curve can be
changed by the heater installer. The control monitors the system, regulating burner output during
operation to match system demand, effectively increasing efficiency and providing substantial fuel
savings.
Gas Valve
The gas valve senses suction from the blower, allowing gas to flow only if combustion air is flowing.
Swirl Plate System
The Swirl Plate on the gas valve controls air and gas flow into the burner, assuring better mixing for
improved combustion.
Combination Top High Temperature Sensor
This sensor monitors supply temperature. The control module adjusts heater firing rate, correcting supply
temperature.

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Bottom Water Temperature Sensor
This sensor monitors return water temperature. The control module reduces or increases heater input
accordingly.
Temperature and Pressure Gauge
Allows the user to monitor system temperature and pressure.
Control
The integrated control system monitors return and supply water temperature. The control system
regulates the unit’s BTU output by controlling fan speed, allowing the unit to deliver only the amount of
heated energy required.
Burner
Constructed with metal fiber and stainless steel, the burner uses pre-mixed air and gas, providing a wide
range of firing rates.
Electrical Field Connections with Terminal Strips
The cabinet allows easy access to the line voltage and low voltage terminal strips, which are clearly
marked to facilitate wiring to the heater.
Condensate Drain Connection
This is a condensing high efficiency appliance, and therefore has a condensate removal system.
Condensate is nothing more than water vapor derived from combustion products. The condensate is
similar to that of an automobile when it is initially started.
It is very important that the condensate line slopes away from the heater, down to a suitable drain. If the
condensate outlet is lower than the drain, you must use a condensate removal pump (kit 554200,
available from HTP).
A condensate filter, if required by local authorities, can be made up of lime crystals, marble or phosphate
chips, and will neutralize the condensate. This can be purchased from HTP (7450P-212) and installed in
the field.
It is also very important that the condensate line is not exposed to freezing temperatures or any other
type of blockage. Plastic pipe must be the only material used for condensate line. Steel, brass, copper, or
other materials will be subject to corrosion or deterioration.
A second vent may be necessary to prevent a condensate line vacuum lock in a long, horizontal line.
Also, an increase in pipe size may be necessary to drain properly. Support of the condensation line may
be needed to avoid blockage of flow.
Spark Ignition
The burner flame ignites by applying high voltage to the system spark electrode. This causes a spark
from electrode to ground.
Outdoor Sensor
The outdoor sensor allows the installer to make the heater even more efficient by basing temperature
delivered to the central heating circuits on outdoor temperature. (See Optional Equipment, Section C).
(Optional) Indirect Tank Sensor – Indirect Priority
To control the temperature of low temperature heating circuits when using an indirect fired water heater, a
thermostatic mixing valve is required. Failure to install a thermostatic mixing valve could result in property
damage.