OPERATING, INSTALLATION, AND SERVICE MANUAL FOR
Contents
1. 16 FAYLNI a EOBGNDIOVIJDNVA 2715800 3 N3HIO 804 2 01 Wv NMOHS X AV DV OD lvas ONILVSH H04 001 iNVIOVH ONIIV3H LOH f 0038 E NO G 038 OL mM te a i oad I 498 NUN 86 108 0 034 8 NN sav 7 80 55 TON po th E er 51 6 D a LINN N310NVE NO LON 4 C100 JNNM NE G38N038 YOYINI INN HITONYH YIV NO LON dl RS VIO NUR 3N l NI Q3uInO3H 4017119410 JOVHOIS VNOILIQOV 2153400 ANY 9NI1009 ONILV3H NOLIVNIBWOO ONILV3H 3 ONMOOD SNILV3H NOILVNIBIWOO IVM LOH 3 1 03 24 LP 41 REV PAGE 224005 IV3H 42001 035015 SV 833 0 NI 4109 Le 2 SIYON LOVINNYA JAVA 83 10 804 2101 Wv NMOHS XIAvnOv OONVdS 8 ONILVJH INVIGVY 80014 d001 INVIOVE 180 6 5 H231 1596 28 008 1 ANOLOVA AB Q3 ONddV 38 152. 9 RE CONNECT THE SUPPLY GAS PIPING TO THE VALVE TURN ON THE GAS TO THE VOYAGER TURN THE BLUE KNOB ON THE GAS VALVE TO THE ON POSITION 0 138v1 SNINMYM 3015 335 mes 1 6 063 REMOVE THE SMALL ROUND BRASS PLUG FROM THE GAS VALVE BY TURNING IT COUNTER CLOCKWISE WITH A PAIR OF SNAP RING OR NEEDLE NOSE PLIERS SNINNVA 3015 33S I 9 44 PILDT ADJ E 330 dU o 3 TURN THE LINE VOLTAGE BACK ON TO THE VOYAGER GAS VALVE ADJUSTMENT LET THE UNIT START TO CYCLE AND LISTED CAREFULLY TO THE IGNITION IF THE IGNITION WAS QUIET THE VALVE WILL NEED NO ADJUSTMENT IF IT WAS A LOUD IGNITION OR THERE WAS NOT IGNITION AT ALL FOLLOW THESE STEPS A IF THERE WAS NO IGNITION 1 MAKE SURE THE GAS VALVE IS IN THE ON POSITION GAS IS ON TO THE UNIT AND THE GAS VALVE WIRING HARNESS IS PLUGGED INTO THE GAS VALVE AND INTO THE CONTROL BOARD 2 TURN THE ADJUSTMENT SCREW UNDER THE BRASS CAP YOU REMOVED IN STEP 8 ABOVE TURN ONE FULL TURN CLOCKWISE WITH A SMALL FLATHEAD SCREWDRIVER A IF THE UNIT STILL DOES NOT LIGHT OFF TURN THE ADJUSTMENT SCREW TWO FULL TURNS COUNTERCLOCKWISE PAGE 38 LP 41 REV 3 1 03 B IF IGNITION W
3. Ja a tha amp t vilvm 0102 e sam 3 i 6 ov gt PP SP S3OVAOA 404 NYHOVIG ONldid ONV Q OJINVIN aSaJnAda ANVI 82 55 JOVMO S N3SVAQA PAGE 23 LP 41 REV 3 1 03 0 22 an N JHL NI M20 390038 18340 6 OL 31 5 30 02 3313V JAL NI 331 Y 39V1d vi 30 v OL 3SCH 6 0 3HL JISVIHON ISAW 0351 5 350 JIVSNJONOD 40 19 31 ONOT AGIA V EC 193408 1004 Ed 3NOG 38 LONNVO SIHI 3l 1 ASYIT iv G3HOlld 38 15 JNT 31VSN3GNOO NIYSG OL N39VAOA WOUJ 31VSN30NOO Rif INT JAVSNJONOD dWAJd YIZOVYLNIN 3ivSN3O0NOO 40 NOHVTIVISN 224 H3OVAOA MOE 1MOddNS HOIL L996 7 008 1 38 LSAW ONIMWYA SiHi WOUJ SNOLVIA3Q ANY AYCIOVA SRL AB 3 0 03119905 ONIMVYT SHL NO 035 8 YOLIVYANOJ ONITIVISNI 3 1 AG 03119165 38 CINOHS SM3IQNVH SIV HLM 5834 38 YILVM 38 4 5 5 AON3 01333 HOIH 1804405 Jdid YAOVAOA lMOddhnS Jdid G3LNNON 0072 Q3INnoM NIV ASNVHX3 NI 03 xa
4. 60 60 60 70 QTY OF 90 ELBOWS 2 gt ONU N Nl O Q Z EQUIVALENT FRICTION 1055 FOR ELBOW 5 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 EQUIVALENT FEET OF PIPE 5 AFTER THE FIRST 10 OF 3 ONLY4 EQUIVALENT TABLE EQUIVALENT FITTING DESC FEET OF PIP 4 90 3 4 45 7 4 Coupling 4 Pipe 1 1 4 Tee 0 SHOWN AS INTAKE amp EXHAUST PIPE AND FITTINGS ADDED TOGETHER MAXIMUM VENT LENGTH TOTAL FRICTION LOSS FOR ELBOWS 10 10 15 20 25 30 35 40 45 50 55 60 65 15 20 25 30 35 40 45 50 55 15 20 25 30 35 40 45 15 20 25 30 35 15 20 25 15 GRAND TOTAL VENT LENGTH FEET WITH FITTING FRICTION LOSS ADDED 22 30 35 40 45 50 55 60 65 70 75 80 85 45 50 55 60 65 70 75 80 85 55 60 65 70 75 80 85 65 70 75 80 85 75 80 85 85 PAGE 7 41 REV 3 1 03 WARNING IS EXTREMELY IMPORTANT TO FOLLOW THESE INSTRUCTIONS EXACTLY FAILURE TO FOLLOW INSTRUCTIONS EXACTLY COULD RESULT IN FIRE INJURY OR DEATH SPECIAL VENTING INSTRUCTIONS FOR 2 VENTED SSV100R amp SSV130R MODELS ONLY FOR 3 VENTED MODELS SEE PAGE 5 VENTING SSV100R AND SSV130R ONLY Inlet air supply to
5. PAGE 39 LP 41 REV 3 1 03 CONNECT THE VACUUM HOSING ACCORDING TO THE FOLLOWING DIAGRAM DR e gi ER NA 10 MANOMETER fi TO MANOMETER 2 RE CONNECT THE SUPPLY GAS PIPING TO THE VALVE 8 TURN ON THE GAS TO THE VOYAGER TURN THE BLUE KNOW ON THE GAS VALVE TO ON P elf e ET a tel 4 OW gon 4 10 REMOVE THE SMALL ROUND BRASS PLUG FROM THE GAS VALVE BY TURNING IT COUNTER CLOCKWISE WITH A SMALL PUNCH AND HAMMER 4015 335 11 TURN THE LINE VOLTAGE BACK ON TO THE VOYAGER PAGE 40 LP 41 REV 3 1 03 12 13 14 20 LET THE VOYAGER CYCLE AFTER THE VOYAGER STARTS LET IT RUN FOR 30 SECONDS THEN ADJUST THE GAS VALVE BY USING THE GAS VALVE ADJUSTMENT SCREW SO THAT MANOMETER 2 READS EXACTLY THE SAME AS MANOMETER 1 EXAMPLE IF MANOMETER 1 READS 35 AND MANOMETER 2 READS 1 YOU WOULD ADJUST THE GAS VALVE BY USING THE GAS VALVE ADJUSTMENT SCREW SO THAT THE MANOMETER 2 ALSO READS 35 n ganman AD GAS VA VE ADJUSIMEN SCREW IF THERE WAS NO IGNITION A MAKE SURE THE GAS VALVE IN THE ON POSITION GAS IS ON TO THE UNIT AND THE GAS
6. 24 25 26 27 28 29 TOWARDS WATER HEATER o1 30 SNAP THE AIR ORIFICE INTO THE END OF THE AIR INLET MANIFOLD SLIDE THE AIR INLET ADAPTER OVER THE END OF THE AIR INLET MANIFOLD UNTIL THE STOP INSIDE THE AIR INLET ADAPTER CONTACTS THE END OF THE AIR INLET MANIFOLD TIGHTEN THE TRAP ADAPTER BY HAND WITH 1 8 PIPE THREAD FACING UP RE INSTALL THE 1 8 BRASS BARB BACK INTO THE TRAP ADAPTER WITH A 7 16 DEEP SOCKET PLACE GAS ORIFICE ON TOP OF THE SPLIT UNION WITH HOLE FACING UP AS SHOWN BELOW Na ORIFICE y UNION BOTTOM RE CONNECT THE GAS VALVE TO THE AIR INLET MANIFOLD BY TURNING THE UNION COUNTER CLOCKWISE AND TIGHTENING IT WITH A 10 PIPE WRENCH RE CONNECT THE CLEAR VINYL HOSE FROM THE GAS VALVE TO THE AIR INLET ADAPTER PLUG THE BLOWER POWER WIRE INTO THE LEFT BOTTOM OF THE BLOWER WITH THE WHITE TOWARDS THE TOP RE CONNECT THE CLEAR VINYL HOSE FROM THE PRESSURE SWITCH TO THE BARB ON THE BACK LEFT OF THE BLOWER PLUG THE IGNITOR WIRING HARNESS BACK INTO THE CONTROL BOARD RE CONNECT THE BLACK WIRE TO THE FLAME RECTIFICATION PROBE BY PUSHING THE CONNECTOR OVER THE BLADE ON THE FLAME RECTIFICATION PROBE SCREW THE TWO GREEN GROUNDING WIRES TO THE TOP BACK OF THE BLOWER WITH THE GREEN GROUNDING SCREW USING A 5 16 NUT DRIVER PLUG THE GAS VALVE WIRING HARNESS BACK INTO THE GAS VALVE WITH THE BLUE WIRE TOWARDS THE BOTTOM OF THE CONNECTOR RE CONNECT THE AIR INLE
7. 4 SIDE VENTING FRONT VIEW 24 MIN PORTS TO HEATING SYSTEM BRONZE CIRCULATOR 3 TO 4 P V C REDUCING COUPLING COLD IN L pr 3 SSVH MODEL WITH CIRCULATOR SNP MIN 10 REQ D 3 ABS 4 MIN B4 REQ D 1 37 4 VERTICA EXHAUST FLOOR MOUNTED PIPE SUPPORT VENTING PAGE 22 LP 41 REV 3 1 03 NMOHS SCOEILIN NOLVTIVISNI H04 JFIESNDaSda JONVAIND SI WANVA SIHi NI 38 OJSJINACONS LONNVO AYOLOV SKI 18 7 AINO GINIVINOO NOILVAYCSN NYHG ILVSN3ONOO NIYSG ILVSN3ONOD NIVHG 3LVSNJaNOD i i e 5 UJ ka la J9 1 2 2 la Tio E ui LA 141 3AWA 23 2 av S rss
8. IMPORTANT INSTRUCTIONS FOR SSVH MODELS HOW THE SYSTEM WORKS WITH RADIANT HEAT BOTH THE VOYAGER SSV AND SSVH MODELS ARE VERY EFFICIENT AND POWERFUL WATER HEATING DEVICES THE VOYAGER SSV AND SSVH MODELS PRODUCE LARGER AMOUNTS OF HOT WATER IN A VERY SMALL COMPACT DESIGN WHEN COMPARED WITH CONVENTIONAL WATER HEATERS HEAT TRANSFER PRODUCTS HAS DESIGNED THE VOYAGER SSVH MODEL EXCLUSIVELY AS A COMBINED HOT WATER RADIANT SPACE WATER HEATER THE UNITS ARE BUILT WITH A SECONDARY HEAT EXCHANGER TO TRANSFER HEAT FROM THE STORED WATER INTO THE CIRCULATOR LOOP FOR THE FLOOR CEILING OR BASEBOARD RADIANT SYSTEM THIS SECONDARY HEAT EXCHANGER ALLOWS THE VOYAGER SSVH MODEL TO HEAT BOTH THE DOMESTIC WATER AND PROVIDE OUTPUT BY THE INSTALLATION OF A RE CIRCULA TION LINE CONNECTED FROM DOMESTIC HOT WATER OUTLET TO DOMESTIC COLD WATER INLET THE VOYAGER SSVH 130 MODEL CAN TRANSFER UP TO 110 000 BTU s IN THE SECONDARY HEAT EXCHANGER AND ALSO DELIVER 180 GALLONS OF HOT WATER IN THE FIRST HOUR OF OPERATION EVEN VOYAGER SSV MODELS MAKE GREAT RADIANT HEATERS WHEN DOMESTIC HOT WATER IS NOT NEEDED IN THE INSTALLATION ANOTHER IMPORTANT FEATURE IS THAT BOTH SSV AND SSVH MODELS HAVE THE ABILITY TO DIRECT VENT WITH A ZERO CLEARANCE TOLERANCE TO ANY COMBUSTIBLE SURFACE WHICH ENABLES THE VOYAGER TO BE INSTALLED VIRTUALLY ANYWHERE THIS TYPE OF POWER EFFICIENCY AND INSTALLATION FLEXIBILITY IN SSV AND SSVH MODEL APPLIANCES IS A VOYAGER EXCLUSIVE THAT OTHER WATER HEATER MANUFA
9. ONIMWYO SIHL 084 SNOLLVIA3O ANY 03714905 ONIMVHQ NO 35 8 ONITIVISNI 3Hi AB G3TIVISNI 38 CGINOHS SYJTONYH SHJLVIH 03 13 5 9 AONJIDIIJJ YIOVADA QFINAON 40014 19993 15 3 23 5 72 038 OL Rs 6 038 498 NATT 58 H D 1nO LOH Ni 0709 LINN M3IGNVH NO LON dl 3 1 G38 N038 YOLWINIHID ONILVJH 802 dOO INVIOVAH ONY ONILV3IH 10H 2164 00 ONIIVIH NOLUVNIBNOD 3 1 03 25 LP 41 REV PAGE COMPLETE TEAR DOWN PROCEDURE TOOLS REQUIRED 5 16 NUT DRIVER FLAT HEAD SCREWDRIVER 3 8 DEEP SOCKET 2 PHILLIPS HEAD SCREWDRIVER 7 16 DEEP SOCKET 10 PIPE WRENCH Ya DEEP SOCKET 1 4 DRIVE INCH POUND TORQUE 3 8 WRENCH WRENCH RANGE 0 200 7 16 WRENCH SNAP RING OR NEEDLE NOSE PLIERS NOTE SEE END OF THIS SECTION FOR PARTS DIAGRAMS GR oi VI DISCONNECT POWER FROM UNIT SHUT OFF GAS SUPPLY REMOVE CABINET DOOR SHUT OFF GAS VALVE BY TURNING THE BLUE KNOB ON THE GAS VALVE DISCONNECT THE AIR INLET PIPE AT THE SMALL END OF THE AIR INLET CONNECTOR
10. 000 NATURAL TO PROPANE P9A6 00 000 PROPANE TO NATURAL N10AG 00 000 NATURAL TO PROPANE P 1046 30 000 PROPANE 10 NATURAL NI 346 30 000 NATURAL TO PROPANE P1340 60 000 PROPANE TO NATURAL N16AC 60 000 NATURAL 10 PROPANE P16AG 99000 PROPANE TO NATURAL N19AG 99 000 NATURAL TO PROPANE P19AG 6 UNION CONNECTOR NPPiE 7 MAN CONTROL PC BOARD 7000 702 MUST SPECIFY MODEL amp SERIAL NUMBER WHEN ORDERING 8 DISPLAY PC BOARD 7000 664 9 PRESSURE SMICH NHC1001 PSW 0 TRANSFORMER 7000 666 1 ECO TEMPERATURE PROBE WHC1001 EGO 2 HOV IGNTOR 0206FF003 SURFAGE IGNITER 3 FLAVE RECTIFICATION PROBE PSE TF1 4 OVER TEMPERATURE SWICH T1500 5 COMBUSTION BLOWER 7000 705 16 GLASS SIGHT WINDOW 62000 GASKET SIGHT WINDOW 65060 7 AIR NH ADAPTER 8 AR INLET CONNECTOR 9 AIR INLET MANIFOLD 20 EXHAUST OUTLET CONNECTOR 21 EXHAUST ELBOW AND DRAN 7000 604 22 CONDENSATE CONNECTOR HOSE 23 1 2 BARB X 1 2 ADAPTER 1436 005 24 15 16 HOSE CLAMP 222507P 25 90 DEG STREET ELBOW 412 005 26 COMBINATION 90 DEG ELBOW 1413 005 27 CONDUIT 1 2 LOCKNUT 401 28 COMBINATION 90 DEG ELBOW 1407 005 PAGE 12 LP 41 REV 3 1 03 REPLACEMENT PARTS NOT SHOWN LOW VOLTAGE CABLE ASSEMBLY INTERCONNECT RIBBON CABLE LINE CABLE PUSH BUTTON TRANSFORMER GASKET BURNER MOUNTING FLANGE GASKET BLOWER OUTLET FLANGE GASKET AIR INLET GASKET BURNER MOUNTING FLANGE WHITE ORIFICES 710B0041 7000 665 71
11. 2 3 4 5 GPM 6 GPM 7 GPM 8 GPM SSVH90 45 20 15 9 7 5 4 3 SSVH130 45 20 16 12 10 9 7 6 SSVH199 80 00 00 15 14 13 12 10 VOYAGER FIRST DRAW CAPACITY In minutes AT 115 DEGREES F Model 2 3 4 5 GPM 6 GPM 7 8 GPM SSVH90 45 30 23 14 10 8 6 5 SSVH130 45 31 24 18 16 14 11 10 SSVH199 80 00 00 23 21 20 18 15 MODEL HEIGHT WIDTH DEPTH INPUT FIRST HR RATING SSVH90 45 42 24 32 90 000 125 U S gallons SSVH130 45 42 24 32 130 000 180 U S gallons SSVH199 80 72 24 32 199 000 300 U S gallons MODEL HEAT EXCH HEAT EXCH BTU RECOVERY VENT WEIGHT SSVH90 45 32 Sa Ft 81 000 95 3 205 Lbs SSVH130 45 32 Sa Ft 110 000 94 3 205 Lbs SSVH199 80 32 Sa Ft 140 000 94 3 255 Lbs spes ze Dn STAINLESS STEEL HIGH EFFIENCY WATER HEATER HOT OUT HOT OUT 0 CONTROL CONTROL GAS INLET SSVH MODELS 1 ONLY ELECTRICAL OPTIONAL CONNECTION HEAT EXCHANGER p sse puse Pap ave KEN En L OUTLET CONDENSATE DRAIN COLD IN DRAIN Note These overall dimensions are approximate within 1 Heat Transfer Products reserves the right to change or discontinue models without notice PAGE 43 LP 41 REV 3 1 03 VERY IMPORTANT THIS VOYAGER HAS THE NEW 1200 BOARD AND BLOWER SYSTEM THE ADDITIONAL FEATURES ARE LISTED BELOW 1 THE BOARD WILL DETECT PROPER POLARITY B
12. IS ENERGIZED POWER APPLIED TO IGNITOR 24 MONITORS INCOMING VOLTAGE FROM THE ON WHEN SECONDARY VOLTAGE IS PRESENT TRANSFORMER SECONDARY ECO MONITORS STATE OF THE ECO SWITCH ON WHEN ECO SWITCH IS IN CLOSED POSITION NORMAL POSITION PRESSURE MONITORS STATE OF THE AIR SWITCH ON WHEN THE PRESSURE SWITCH IS CLOSED SUFFICIENT COMBUSTION AIRFLOW EXISTS GAS VALVE MONITORS THE GAS VALVE OUTPUT ON WHEN OUTPUT IS ENERGIZED POWER APPLIED TO GAS VALVE WATER TEMP MONITORS WATER TEMP WITHIN TANK ON WHEN TEMP DROPS BELOW SET POINT CONTROL MONITORS INTERNAL STATE OF THE ON WHEN CONTROLLER FUNCTIONALITY IS HEALTH CONTROLLER S HARDWARE AND SOFTWARE GREEN ON MONITORS POLARITY AND GROUND CIRCUIT ON WHEN GROUND AND POLARITY ARE MAIN CONTROL BOARD VERY IMPORTANT SET UP INSTRUCTIONS IF YOU HAVE A COMBUSTION ANALYZER THE FOLLOWING RATINGS WILL BE VERY HELPFUL IN SETTING UP YOUR VOYAGER FOR NATURAL GAS CO2 READING SHOULD BE BETWEEN 9 2 8 10 2 O2 READING SHOULD BE BETWEEN 3 2 amp 4 7 CO READING SHOULD BE UNDER 10 PPM FOR PROPANE GAS CO2 READING SHOULD BE BETWEEN 10 2 8 11 2 O2 READING SHOULD BE BETWEEN 3 2 amp 4 7 CO READING SHOULD BE UNDER 10 PPM PAGE 14 LP 41 REV 3 1 03 SEE K1 H COMB BLOWER K5 IGNITER ELEMENT 24 ECO VENT PRESSURE GAS GAS SWITCH SWITCH VALVE VALVE RLY 1 RLY 2 GAS VA
13. THE FLAT SIDE OF THE FLANGE FACING DOWN 6 REPLACE THE BLOWER OUTLET FLANGE GASKET WITH A NEW GASKET BE SURE THAT BOTH SIDES OF THE GASKET ARE SPRAYED WITH PERMATEX HIGH TACK SPRAY A GASKET ADHESIVE SEALANT PART 99MA Fi PLACE BLOWER ON BURNER MOUNTING FLANGE BE SURE THAT THE SIGHT GLASS IS IN PLACE AND THE GASKET IS INSTALLED CORRECTLY AS SHOWN BELOW NOTE IF GASKET OR SIGHT WINDOW ARE DAMAGED IN ANY WAY REPLACE THEM WITH NEW ONES SIGHT GLASS G2000 GASKET 35060 8 TIGHTEN THE BLOWER BOLTS FIRST TO 50 INCH POUNDS TORQUE THEN TO 150 INCH POUNDS TORQUE IN THE FOLLOWING ORDER 20 40 9 PLACE THE IGNITOR BACK INTO THE BURNER MOUNTING FLANGE BEING VERY CAREFUL OF THE ELEMENT WHICH IS EXTREMELY FRAGILE PAGE 27 LP 41 REV 3 1 03 10 11 12 13 14 TIGHTEN THE TWO 3 8 IGNITOR NUTS TO 50 INCH POUNDS TORQUE PLACE THE FLAME RECTIFICATION PROBE BACK INTO THE BURNER MOUNTING FLANGE AND TIGHTEN THE SCREW WITH A 2 PHILLIPS HEAD SCREWDRIVER RE INSTALL THE AIR INLET GASKET TO THE RIGHT SIDE OF THE BLOWER WITH THE TWO ANGLE CUTS FACING TOWARD THE WATER HEATER RE INSTALL THE ALUMINUM AIR INLET ASSEMBLY WITH THE TWO ANGLE CUTS FACING THE WATER HEATER TIGHTEN THE FOUR 3 8 NUTS TO 5 INCH POUNDS TORQUE IN THE FOLLOWING ORDER NOTE IF THESE BOLTS ARE OVER TIGHTENED THE BLOWER WILL BE DAMAGED AND WILL HAVE TO BE REPLACED 15 16 17 18 19 20 21 22 23
14. VALVE WIRING HARNESS IS PLUGGED INTO THE GAS VALVE AND INTO THE CONTROL BOARD TURN THE ADJUSTMENT SCREW UNDER THE BRASS CAP YOU REMOVED IN STEP 8 TURN ONE FULL TURN CLOCKWISE WITH SMALL FLATHEAD SCREWDRIVER IF THE UNIT STILL DOES NOT LIGHT OFF TURN THE ADJUSTMENT SCREW TWO FULL TURNS COUNTERCLOCKWISE SHUT THE VOYAGER DOWN THEN START IT UP AGAIN LET IT RE LIGHT IF THE IGNITION WAS GOOD THE VALVE NEEDS NO FURTHER ADJUSTMENT IF THE IGNITION WAS POOR SHUT DOWN THE UNIT AND LET IT CYCLE AGAIN TURN THE GAS VALVE ADJUSTMENT SCREW SO THAT MANOMETER 2 READS 10 MORE THAT MANOMETER 1 EXAMPLE 1 READS 35 ADJUST MANOMETER 2 SO THAT IT READS 25 IF THIS DOES NOT STOP THE POOR IGNITION ADJUST THE GAS VALVE ADJUSTMENT SCREW ANOTHER 10 EXAMPLE B IF MANOMETER 1 READS 35 MANOMETER 2 SHOULD BE ADJUSTED TO NOW READ 15 PUT THE GAS VALVE ADJUSTMENT SCREW COVER BACK IN PLACE AND TIGHTEN REMOVE ALL THE CLEAR VINYL HOSES FROM THE GAS VALVE REMOVE THE BARB IN THE OUTLET PRESSURE TAP REPLACE IT WITH THE ORIGINAL PLUG AND TIGHTEN RE CONNECT THE CLEAR VINYL HOSE TO THE GAS VALVE AND TO THE TRAP ADAPTER 8 a in __ CONNECT HOSE 229 HERE 8 IT Og H e PUT THE VOYAGER DOOR BACK IN PLACE PAGE 41 LP 41 REV 3 1 03
15. ae 26 464 106 woe 179 154 134 119 108 SSV100 45R 45 100 000 EE 55 1 168 140 122 wo o SSV90 155 90 000 GPM Im 55 196 168 140 108 er 75 SSVHOO 455 90 000 GPM Recovery on rating plate is based at 94 thermal efficiency at 100 degrees Fahrenheit rise as required by A N S I SHIP FIRST HOUR VENT RECOVERY MODEL HEIGHT WIDTH WEIGHT DEPTH MODEL INPUT RATING SIZE EFFIC Yo SSV199 119R 405 Lbs SSV199 119R 199 000 SSV199 80R 235 Lbs SSV199 80R 199 000 5 5 23 1 4 MODELS ARE ONLY AVAILABLE AS R MODELS WITH 160 DEGREES F SETPOINT THIS MODEL IS ALSO AVAILABLE AS AN S MODEL WITH 180 DEGREE F MAX SETPOINT AND 3 VENT FIRST HOUR VENT RECOVERY HEAT HEAT SHIP MODEL HEIGHT WIDTH DEPTH INPUT RATING SIZE EFFIC EXCHANGER BTUEXCHANGER WEIGHT SVH199 80R 24 1 4 199 000 300 Gallons 140 000 32 sa ft 255 Lbs 9 5 3 SSVH130 45S 421 2 231 4 130 000 180 Gallons 110 000 32 sq ft 205 Lbs SSVH90 45S 42 1 2 23 1 4 90 000 125 Gallons 81 000 32 sa ft 205 Lbs SSVH MODELS HAVE OPTIONAL HEAT EXCHANGER FOR FLOOR RADIANT AND COMBINED HEAT CONNECTION SIZES ARE 1 NPT DOMESTIC INLET DOMESTIC OUTLET FOR THE 45 GALLON UNITS CONNECTION SIZES ARE 1 1 2 NPT DOMESTIC INLET DOMESTIC OUTLET FOR THE 80 amp 119 GALLON UNITS Note These overall dimensions are
16. approximate within 1 Heat Transfer Products reserves the right to change specifications or discontinue models without notice PAGE 2 41 REV 3 1 03 WARNING IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS 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 Ifyou cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier DANGER WETTE A DANGER Water temperature over 125 degrees F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See eo E rt instruction manual before setting temperature at water heater Feel water before pss quie c gt bathing showering Temperature limiting valves are available LOCATION Choose a location for your water heater centralized to the piping system along with consideration to vent pipe length As the length of vent pipe increases the firing rate of the appliance decr
17. be clean and free from burs debris ragged ends and particles of PVC For exhaust piping lower pipe on the right of the shroud for the first 7 use 3 ABS sch 40 or 3 CPVC sch 40 or 80 For concrete con struction or to meet certain fire codes exhaust piping lower pipe on right of shroud and inlet air piping top pipe on the right of the shroud must be 3 CPVC schedule 40 or 80 only to meet local fire codes The balance of the inlet and exhaust piping may be PVC schedule 40 or 80 or ABS solid only NOT FOAM CORE For residential style wooden construction exhaust piping lower pipe on right of shroud must be 3 ABS solid NON FOAM CORE or 3 CPVC schedule 40 or 80 for the first 7 only The balance of the inlet and exhaust piping may be PVC or ABS solid NON FOAM CORE or CPVC to meet local codes The only approved exhaust vent materials are ABS solid NON FOAM CORE first 84 or CPVC The balance of the exhaust piping must be ABS solid NON FOAM CORE CPVC or PVC sch 40 NON FOAM CORE ONLY Exhaust piping should be sloped back to the connection on the Voyager at least 1 4 per foot to remove additional condensate that forms within the pipe The total combined length of pipe intake piping plus exhaust piping added together including elbow allowances intake and exhaust each elbow 5 of pipe should not exceed 85 The combined vent length should not be less than a combined length of 6 plus two 90 degree elbows Choose your vent terminati
18. button to the left of REMEDY 1 Check wire and connection at burner 2 Check connectors 3 Replace flame probe 4 Turn on gas supply 5 Replace gas valve 6 Replace gas valve 7 Replace control 8 Adjust burner 9 Clean burner 10 Verify green LED on on control board is illuminated when power is applied 11 Monitor flame current see note below The flame current is monitored by pressing the the LED s during the heat cycle or when the Gas Valve LED is illuminated The 3 segment LED display will display the actual flame current The expected flame current is 4 0 to 5 1 micro amps ECO SWITCH OPEN ECO LED POSSIBLE CAUSE 1 Temp probe unplugged 1 2 Temp probe wiring damaged 3 Water in tank too hot 5 Flashing REMEDY Check connectors 2 Repair wiring Normal condition when water temp exceeds safety limit Allow water to cool or admit cold water into tank and manually reset the control Determine cause for overtemp condition PAGE 16 LP 41 REV 3 1 03 e o e 24 ECO VENT PRESSURE Ki 1 A O COMB BLOWER 9 K5 an IGNITER ELEMENT 1 GAS GAS SWITCH SWITCH VALVE VALVE RLY 1 RLY 2 GAS VALVE IS Ki CONTROL Ko ELECTRONICS K3 pM CONTROL WAT HEALTH TEMPERATURE 1 24 EGO VENT PRESSURE GAS GAS LINE SWITCH SWITCH VALVE VALVE RLY 1
19. guideline certain site conditions such as multiple roof lines pitches may require venting modifications consult factory The air inlet must be a minimum of 1 vertically above the maximum snow level or 24 which ever is greater The air inlet must also be a minimum of 10 horizontally from the roof and terminated with a tee The exhaust must be a minimum of 24 above the air inlet opening and terminated with a coupling It is very important that there are no other vents chimneys or air inlets in any direction for at least 4 Please refer to typical venting on pages 21 and 22 All venting must be properly supported as the Voyager is not intended to support any venting whatsoever All piping glue solvents cleaners fittings and components must conform to ASTM American Society for Testing and Materials and ANSI American National Standard Institute 12 It is recommended that you use one of the mentioned vent kits specifically for Voyager installations either KGAVTO501CVT 2 in KGAVTO601CVT 3 in or V1000 CLEANER CEMENT Cement for all venting must be ALL PURPOSE Cement and must conform to ASTM D 2235 D 2564 and F 493 and cleaner for the piping and fittings must conform to ASTM F 656 For joining ABS to PVC you must use transition green cement listed by NSF and IAPMO and exceeds ASTM D 3138 to make solid liquid tight joints and gas tight joints PIPE FITTINGS The first 84 7 of exhaust piping must be of 3 ABS solid o
20. run the blower for 30 seconds At this point the control will return to step 2 8 If flame is present the control will enter the heating mode where it will continue heating the tank water until the set point temperature plus 4 degrees F is reached At this point the gas valve is closed and the control enters the post purge cycle The flame can be viewed through a window on the lower right of combustion blower flange 9 The post purge cycle continues to run the combustion blower for an additional 30 seconds to purge the system of all combustion gases After this time period the blower is de energized and will coast to a stop 10 The control will now enter the idle state while continuing to monitor internal tank water temperature If the temperature drops to 4 degrees F below the set point value the control will automatically return to step 1 PAGE 10 LP 41 REV 3 1 03 STATUS INDICATORS Pages 15 16 and 17 contain seven individual diagrams which illustrate the various operating states of the appliance and their relation to the LED status indicators found on the controller These diagrams reflect normal water heater operation MAINTENANCE The control system requires no periodic maintenance under normal conditions However in unusually dirty or dusty conditions period vacuuming of the cover to maintain visibility of the display and indicators is recommended In dirty environments construction sites building constructions c
21. will result in failure to operate 3 Make sure that the cold water supply has been turned on and that the Voyager is completely filled with water Verify this by opening a hot water faucet and allowing water to flow until all air is removed and a clear water flow is present 4 Turn on electrical supply 5 The control will first display 102 then 88 8 which is the control display test and finally the actual tank temperature at the probe SET POINT ADJUSTMENT PROCEDURE The three digit LED display will illustrate actual water temperature within the tank under normal operating conditions However this display is also used to indicate the temperature set point when in the programming mode and also ignitor amp draw and flame current The controller has a temperature set point range 70 degrees F to 160 degrees F The factory set point is 118 degrees F VERY IMPORTANT NOTE POWER MUST BE APPLIED TO THE CONTROLLER PRIOR TO ANY PROGRAMMING OPERATIONS PAGE 9 41 REV 3 1 03 SET POINT ADJUSTMENT PROCEDURE CONTINUED To change or access the programmed temperature set point value utilize the red button on the display panel Momentarily depressing the button will briefly illustrate the existing set point value If the button is held down for more than one second the programming mode is entered and the set point value will begin incrementing by one degree per second When the desired set point value is reached sim ply release
22. wiring See electrical on page 4 If the burn er does not light after the third ignition trial the control will enter a lockout state This lockout state indicates that a problem exists with either the appliance the controls or the gas supply Under such circumstances a qualified service technician should be contacted immediately to properly service the appliance and correct the problem If a technician is not available depressing the red button once will remove the lockout state so additional trials for ignition can be performed Any time LOC is shown you must look for an LED out or flashing The LED that is out or flashing will assist you in diagnosing lock out condition PAGE 11 LP 41 REV 3 1 03 DIAG RAM ENTS HOT O l 2 1 2 NPE X GAS INLET NIPPLE GAS VALVE cv1000 3 GAS VALVE ELBOW PBESO 4 GAS ORIFICE UNON CGUS 5 GAS ORIFICE CONVERSION KITS 90 000 PROPANE TO NATURAL N9AG 90
23. you will need a hot water expansion tank listed for potable water use The expansion tank should be located on the cold inlet piping close to the water heater The expan sion tank must be suitable for hot potable water DOMESTIC WATER CONNECTIONS WARNING NEVER USE DIELECTRIC UNIONS OR GALVANIZED STEEL FITTINGS ON ANY DOMESTIC WATER CONNECTIONS USE ONLY COPPER OR BRASS FITTINGS TEFLON THREAD SEALANT MUST BE USED ON ALL CONNECTIONS The domestic water connections must be installed in accordance to all local and national plumbing codes or any applicable standard which prevails The inlet and outlet ports of the Voyager are 1 on 45 gallon models On the 80 and 119 gallon models the inlet and outlet ports are 1 1 2 On the cold inlet bottom left install a 1 brass tee on 45 gallon models or a 1 tee on 80 and 119 gallon models On the run of the 1 brass tee install with pipe sealant compound a 1 brass drain cock or equivalent Into the branch of the 1 or a 1 brass tee install a copper male adapter to match your copper plumbing system For convenience you may install a sweat shut off valve and a union in the cold inlet piping to ease servicing in the future If there is a back flow preventer or any type of a return valve in the system then you must install an additional tee here for a suitable potable hot water expansion tank In the hot out let top left install a suitable adapter to match the copper tubing of the pl
24. 000 702 5 1259 BOARD _ _ _ 7000 664 35 AY BOARD TO CONTROL BOARD WIRE M 17000665 5 PRESSURE SWITC I e WHC1001 PSW 6 WIRE HARNESS FROM CN6 TO GAS VALVE FLAME PROBE AND PRFSS SWITC 10B0041 ud WIRE 55 FROM CN TO LINE POWER pu 710B0048 8 WRF ARNESS FROM CN2 TO COMBLS ON BLOWER 4 TRANSFORVER _ 7000 666 _ 9 ECO TEMPERATURE PROBE WIRED TO CNS _ u g WHC1001 CO 10 PUSH BUTTON SWIICE FOR GN 10R amp FLAME CURRENT _ 7000 667 __ NOT SHOWN OVER TEMPERAIUSE SWITCH AN I PAGE 19 LP 41 REV 3 1 03 PLEASE TYPICAL VENTING VERY IMPORTANT YOU MUST USE SUPPLIED ABS PIPE FOR FIRST 84 OF EXHAUST PIPING ADDITIONAL PIPING CAN ABS OR PVC YOU MUST SUPPORT ALL PIPING THE APPLIANCE IS NOT INTENDED TO SUPPORT VENTING PIPES NOTE HE METHODS DESCRIBED ARE SUGGESTED GENERIC METHODS ONLY SPECIFIC JOB SITE OBSERVATIONS AND SIZING MAY REQUIRE ALTERNATE INSTALLATION METHODS CONSULT HE FACTORY WITH SPECIFIC JOB REQUIREMENTS FOR ADDITIONAL RECOMMENDATIONS 12 Never vent into a walkway or patio area or an alley or otherwise public area less than 7 from the ground Never install a heat saver or similar product to capture waste heat from exhaust Always have a vent location at least 1 above maximum snow level Always have vent 1 above ground level away from shrub
25. 080048 7000 667 7000 666 G5010 G5020 G5030 G5040 All of the Voyager gas fired water heaters have unique air and gas orifice sizes Special attention should be paid to these sizes when ever converting a heater from one fuel type to another or when the orifice is changed for any reason Below is a list of orifice sizes for conversions to other fuel types and the sizes the voyager was shipped with from the factory Please note that air orifices do not have to be changed when switching from one fuel type to another This information is not intended to allow field conversions by drilling ori fices This is only a guide to correct orifice sizing If orifices are drilled the result will be poor ignition a VOIDED WARRANTY severe bodily injury death and or explosion All orifices must be obtained through the factory with all necessary labels and the seri al number must be provided to the factory or warranty will be voided 199 000 BTU VOYAGERS GAS ORIFICE SIZES AIR ORIFICE 1 375 NATURAL GAS 379 PROPANE LP GAS 295 160 000 BTU VOYAGERS GAS ORIFICE SIZES AIR ORIFICE 1 375 NATURAL GAS 362 PROPANE LP GAS 295 130 000 BTU VOYAGERS GAS ORIFICE SIZES AIR ORIFICE 1 125 NATURAL GAS 280 PROPANE LP GAS 235 NATURAL GAS CONVERSION FROM PROPANE LP 285 PROPANE LP GAS CONVERSION FROM NATURAL GAS 250 100 000 BTU VOYAGERS GAS ORIFICE SIZES AIR ORIFICE 1 125 NATURAL GAS 280 PROPANE LP GAS 23
26. 5 NATURAL GAS CONVERSION FROM PROPANE LP 285 PROPANE LP GAS CONVERSION FROM NATURAL GAS 250 90 000 BTU VOYAGERS GAS ORIFICE SIZES AIR ORIFICE 1 000 NATURAL GAS 261 PROPANE LP GAS 205 NATURAL GAS CONVERSION FROM PROPANE LP 253 PROPANE LP GAS CONVERSION FROM NATURAL GAS 215 PAGE 13 LP 41 REV 3 1 03 CAUTION THERE ARE NO USER SERVICEABLE PARTS WITHIN THE CONTROL SYSTEM MAINTAIN SAFETY AND PROPER APPLI ANCE PERFORMANCE REFER ALL TROUBLE SHOOTING TO QUALIFIED SERVICE PERSONNEL TROUBLESHOOTING The appliance controller has many inherent diagnostic and fault detection routines built into its operating software and hardware These routines along with the three digit LED display and nine LED status indicators present on the display panel can greatly assist the service person in quickly pinpointing the source of problems that may occur with the appliance In certain circumstances multiple LED s may be lit or flashing to better pinpoint the problem Also there is a green LED on the main control board to indicate proper polarity and grounding The following charts diagrams and information can be used during troubleshooting procedures LED CONTROLLER FUNCTION MEANING LINE MONITORS INCOMING AC LINE VOLTAGE ON WHEN LINE VOLTAGE IS PRESENT BLOWER MONITORS THE BLOWER MOTOR OUTPUT ON WHEN OUTPUT IS ENERGIZED POWER APPLIED TO BLOWER IGNITOR MONITORS IGNITOR ELEMENT OUTPUT ON WHEN OUTPUT
27. AND PRESSURE RELIEF VALVE A temperature and pressure relief valve is installed into the marked port upper right we recommend a WATTS 100XL 4 valve or equivalent for 100 000 BTU models or below input 40XL5 valve or equivalent for 130 000 BTU models or above input meeting the requirements for relief valves for hot water heaters as per ANSI Z21 22B 1984 by a nationally recognized lab that maintains a periodic inspection of production of such listed safety device The pressure rating of the valve must not exceed the listed working pressure of this appliance and must be rated to the proper BTU hr capacity of the water heater Do not under any circumstances thread a cap or plug into the relief valve Explosion serious injury or death may result Relief valve piping must be directed to the floor or to an open drain but not connected directly There must be a 6 space between the outlet of relief valve piping and drain or floor Do not hook up to drain system directly without an air space The relief valve must be periodically checked for proper operation PAGE 3 41 REV 3 1 03 EXPANSION TANK A potable hot water expansion tank may be required to offset the water expansion as the water is heated most city plumbing sys tems the water meter has a no return or back flow device built into the system to prevent back flowing of water back into city mains Some require back flow preventers on all incoming water supplies Under these circumstances
28. AS POOR 1 LOOK AT THE COLOR OF THE FLAME WHILE THE UNIT IS RUNNING THROUGH THE SIGHT GLASS IF IT 15 GREEN OR RED IN COLOR OR THE HEATER WHISTLES ON IGNITION TURN THE ADJUSTMENT SCREW COUNTERCLOCKWISE AT 7 TURN INTERVALS UNTIL THE FLAME TURNS BLUE LIGHT BLUE IN COLOR OR THE WHISTLING AT IGNITION STOPS IF THE FLAME IS VERY WEAK OR PULSING TURN THE ADJUSTMENT SCREW CLOCKWISE UNTIL THE FLAME STEADIES 8 J a 55 8 88 Ge GAS VALVE ADJUSTMENT SCREW 2 PUT THE GAS VALVE ADJUSTMENT SCREW COVER BACK IN PLACE AND TIGHTEN 3 PUT THE VOYAGER CABINET DOOR BACK INTO PLACE PROCEDURE 2 1 REMOVE THE OUTLET PRESSURE TAP PLUG FROM THE RIGHT SIDE OF THE GAS VALVE WITH A 3 16 ALLEN WRENCH fel 2 la o R C ag 2 PUT A 1 8 NPT HOSE BARB IN PLACE OF THE OUTLET PRESSURE TAP PLUG NO SEALANT IS REQUIRED ON THIS FITTING RE CONNECT THE GAS VALVE WIRING TO THE GAS VALVE SLIDE THE GAS VALVE BACK INTO POSITION BY PUTTING THE GAS VALVE INLET PIPE THROUGH THE GAS VALVE INLET HOLE IN THE LEFT TOP OF THE VOYAGER CABINET 5 PLACE THE GAS ORIFICE BACK ON THE BOTTOM HALF OF THE UNION AND TIGHTEN THE UNION Pw 5 EN ER mi B m B BI UE Lo Bi GAS ORIFICE
29. BY LOOSENING THE HOSE CLAMP WITH A 5 16 NUT DRIVER REMOVE THE CLEAR VINYL HOSE THAT RUNS FROM THE GAS VALVE TO THE AIR INLET ADAPTER BREAK THE GAS ORIFICE UNION BY TURNING THE UNION CLOCKWISE WITH A 10 PIPE WRENCH NOTE BE SURE NOT TO LOOSE THE GAS ORIFICE HELD INSIDE THE UNION 8 9 REMOVE THE BRASS BARB FROM THE AIR INLET ADAPTER WITH A 7 16 DEEP SOCKET LOOSEN THE AIR ADAPTER AND PULL THE AIR INLET ADAPTER THROUGH THE SIDE OF THE CABINET NOTE BE SURE NOT TO LOOSE THE AIR ORIFICE SNAPPED INTO THE END OF THE ALUMINUM PIPE 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 REMOVE THE FOUR BRASS NUTS HOLDING THE ALUMINUM AIR INLET MANIFOLD TO THE BLOWER WITH A 3 8 DEEP SOCKET REMOVE THE BLOWER OUTLET FLANGE GASKET FROM THE BLOWER REMOVE THE GAS VALVE WIRING HARNESS FROM THE GAS VALVE BY PRESSING ON THE TABS ON THE TOP AND BOTTOM OF THE PLUG AND PULLING REMOVE THE TWO GREEN GROUNDING WIRES FROM THE TOP REAR OF THE BLOWER BY TAKING OUT THE GREEN GROUNDING SCREW WITH A 5 16 NUT DRIVER REMOVE THE BLACK WIRE FROM THE FLAME RECTIFICATION PROBE BY PULLING ON IT REMOVE THE IGNITOR WIRING HARNESS FROM THE CONTROL BOARD BY PRESSING ON THE TABS ON THE TOP AND BOTTOM OF THE PLUG AND PULLING REMOVE THE TWO BRASS NUTS RETAINING THE IGNITOR WITH A 3 8 DEEP SOCKET GENTLY PRY THE IGNITOR BACK ABOUT 1 16 OF AN INCH WITH A 4 FLAT HEAD SCREWDRIVER NOW PULL THE IG
30. CORE CPVC or PVC 3 NON FOAM CORE pipe and fittings for both the intake and exhaust piping On 3 piping you may go an additional 125 equivalent feet of pipe and fittings com bined total length Total equivalent would be 30 of 2 plus 125 of 3 Never use different pipe sizes for intake and exhaust The vent system must be balanced by friction loss equivalent CONDENSATE This is a condensing high efficiency appliance therefore this unit has a condensate removal system Condensate is nothing more than water vapor derived from the combustion products similar to an automobile when it is initially started This condensate does have a low PH and should be treated with a condensate filter This filter contains either lime crystals or marble crystals which will neutralize the condensate The outlet of the filter is sized for 5 8 ID Inside diameter plastic tubing It is very important that the condensate line is sloped away from and down to a suitable inside drain if the condensate outlet on the Voyager is lower than the drain you must use a condensate removal pump A condensate filter and a condensate pump kit are available from HTP It is also very important that the condensate line is not exposed to freezing temperatures or any other type of blockage Plastic tubing should be the only material used for the condensate line as steel brass copper or others will be subject to corrosion and deterioration A second vent may be neces sary to prevent
31. CTURER CAN OFFER HOW THE SYSTEM WORKS WITH HEATING COOLING BOTH SSV AND SSVH MODELS CAN WORK IN CONNECTION WITH AIR HANDLING EQUIPMENT TO PROVIDE AIR OR RADI ANT HEATING COOLING AND DOMESTIC HOT WATER THESE TYPES OF SYSTEMS PROVIDE THE ADVANTAGE OF ZONED HEATING AND COOLING WHICH PROVIDE MUCH GREATER COMFORT AND OPERATING EFFICIENCY VERSUS CONVENTIONAL SYSTEMS HOW TO INSTALL THE SYSTEM IN THIS MANUAL YOU WILL FIND SAMPLE DRAWINGS WHICH CAN PROVIDE YOU WITH IDEAS ON HOW TO LAY OUT THE SYSTEM THE USE OF A MIXING VALVE IS ALWAYS RECOMMENDED TO ACHIEVE FLEXIBILITY IN ADJUSTING TEMPERA TURE TO MEET THE SYSTEM DEMAND IS ESSENTIAL TO READ THIS INSTALLATION MANUAL TO ASSURE PROPER OPERATION OF THE VOYAGER SYSTEM AREAS IN THIS MANUAL THAT NEED SPECIAL ATTENTION ARE CONDENSATE REMOVAL VENTING OF COMBUSTION GASES AND CONNECTION OF A BRONZE CIRCULATOR BETWEEN DOMESTIC HOT WATER OUTLET DOMESTIC COLD WATER INLET NOTE IT IS VERY IMPORTANT TO FOLLOW EITHER LOCAL OR FEDERAL PLUMBING CODES WHEN INSTALLING AND OPERATING A MIXING VALVE FOR A DOMESTIC HOT WATER SYSTEM HOW TO SIZE THE COMBINATION SYSTEM FOR RADIANT HEATING IT IS IMPORTANT TO SIZE BOTH HEATING LOAD AND DOMESTIC HOT WATER LOAD IN CHOOSING WHICH VOYAGER SSVH MODEL YOU WILL NEED TO PURCHASE FOR THE JOB ON THE FOLLOWING PAGE IS A CHART WHICH REPRESENTS DESIGN OUTPUTS OF THE SECONDARY HEAT EXCHANGER IN THE VOYAGER SSVH MODEL THIS CHART OUTLINES OUT PUT CHARAC
32. D GAS ORIFICE 5 AND INSTALL THE NEW GAS ORIFICE IN THE UNION THAT CORRESPONDS TO THE UNIT MODEL NUMBER AND FUEL BEING USED SEE KIT CONTENT LIST FOR THE CORRECT ORIFICE TO BE USED DISCARD ORIFICES NOT USED i 00000 AIR WITH GLAND INSIDE INLET ADAPTER 3 FOR LABELING CHANGE THE RATING PLATE LABEL FROM THE ORIGINAL FUEL TYPE TO THE NEW FUEL TYPE BY PLACING THE NEW LABEL OVER THE EXISTING LABEL SUPER STOR By Heat Transfer Products inc File 082 5 2158 429 120 Braley Road Classified by Underwriters Laborotories East Freetown MA 02717 in accordance with American National 508 763 8071 Standards Institute ANSI Z21 10 3b 92 Direct Vent Automatic Storage Water Heater Water Heater and CAN 1 4 3 85 FOR YOUR SAFETY Do not store or use gasoline or other lammable vapors or liquids in the vicinity of this or any other appliance ODEL NO SSVI99 455A DATE 07 97 SERIAL 62100000 AA Soho T Er P E po fiy GAS TYPE 2 GAS TYPE NATURAL BTU HR 199 000 INLET PRESSURE 14 W C MAX INLET PRESSURE 14 W C INLET PRESSURE 7 W C MIN INLET PRESSURE 7 W C RECOVERY RATING 270 G P H RECOVERY RATING 270 G P H 1100 DEGREE RISE m 1100 DEGREE RI
33. ERIOD OF TIME NOW WE CAN DETERMINE WHICH VOYAGER SSVH MODEL WILL SUIT YOUR NEEDS FOR THE JOB TO DO THIS REFER TO THE DOMESTIC HOT WATER CHART IF THE DOMESTIC HOT WATER DEMANDS EXCEED THE VOYAGER SSVH S CAPACITY THEN A STORAGE RE CIRCULATION TANK CAN BE INSTALLED TO MEET THE SYSTEM HOT WATER LOAD AFTER YOU HAVE SIZED YOUR DOMESTIC LOAD AND HEATING LOAD YOU ARE NOW READY TO CHOOSE THE VOYAGER SSVH MODEL SUITABLE FOR THE JOB PAGE 42 41 REV 3 1 03 NOTE A BRONZE CIRCULATOR BETWEEN THE DOMESTIC HOT WATER OUTLET AND DOMESTIC COLD WATER INLET IS REQUIRED TO ACHIEVE RATINGS BELOW VOYAGER SSVH MODEL SIZING CHART Flow TEMPERATURE RISE DEGREES F GPM 15 20 25 30 2 15 000 20 000 25 000 30 000 3 22 500 30 000 37 500 45 000 4 30 000 40 000 50 000 60 000 5 37 500 50 000 62 500 75 000 6 45 000 60 000 75 000 90 000 7 52 500 70 000 87 500 105 000 6 60 000 80 000 100 000 N R 9 71 400 95 200 119 000 124 500 10 85 000 113 250 140 000 140 000 FOR SSVH 130 MODELS ONLY FOR SSVH 199 80 MODELS ONLY NOTE THE VOYAGER MUST BE SET 25 DEGREES F ABOVE THE SYSTEM TEMPERATURE THE ABOVE CHART IS BASED ON USING THE CIRCULATOR BETWEEN THE DOMESTIC COLD WATER INLET AND THE DOMESTIC HOT WATER OUTLET FOR SET POINT TEMPERATURES ABOVE 120 DEGREES F YOU MUST USE AN ANTI SCALD TEMPERING VALVE ON THE OUT LET TO DOMESTIC HOT WATER FIXTURES VOYAGER FIRST DRAW CAPACITY In minutes AT 140 DEGREES F Model
34. ING COUPLING OR REDUCING ELBOW VENT CHANGED FROM 3 TO 4 WITHOUT GOING REQUIRED 10 ON BOTH INTAKE AND EXHAUST VENTING NOT CLEANED AND GLUED TOGETHER FOR PRESSURE TIGHT JOINTS INTAKE AIR CONTAINING EXHAUST FROM ANOTHER VENT OR APPLIANCE GAS SUPPLY GAS PRESSURE TOO LOW NEED 7 GAS PRESSURE UP TO 14 GAS PRESSURE GAS METER TOO LOW IN CAPACITY GAS REGULATOR NOT SIZED PROPERLY TOO LOW IN CAPACITY GAS PIPE TOO SMALL 34 MINIMUM GAS SUPPLY SIZE GAS REGULATOR CLOSE TO APPLIANCE NEED 10 OF PIPE FOR EVERY 200 000 BTU S PER HOUR GAS REGULATOR WITH LONG VENT OR BLEED VENT ORIFICE REGULATOR SLOW TO RESPOND GAS METER RESTRICTION OR IN NEED OF REPAIR REPLACEMENT GAS SUPPLY PRESSURE DROPS BELOW 3 WHEN APPLIANCE FIRES ELECTRICAL APPLIANCE NOT GROUNDED ELECTRICAL POLARITY REVERSED FLAME WILL LIGHT BUT GO BACK OUT IN 4 6 SECONDS VOLTAGE TOO LOW OR TOO HIGH APPLIANCE CYCLES BUT NO IGNITION LOOK FOR GLOW FROM IGNITOR IF NOT REPLACE IGNITOR PLUMBING SSVH MODELS WITHOUT RE CIRCULATING PUMP INSTALLED amp WITHOUT WIRING IN PARALLEL WITH HEATING CIRCULATOR DIELECTRIC UNIONS INSTALLED RUSTY WATER CONDENSATE CONDENSATE LINE NOT PITCHED TO DRAIN CONDENSATE LINE NOT DRAINING DUE TO LONG RUN WITHOUT VENT CONDENSATE PUMP NOT WORKING CONDENSATE TRAP PLUGGED WITH PVC SHAVINGS BURNER EXTREMELY LOUD BANG ON IGNITION BURNER FAILED OR END CAP OFF RED BURNER DECK AS SEEN THROUGH VIEW PORT GAS VALVE NEEDS ADJUSTMENT PAGE 38 GA
35. LVE K1 CONTROL K5 ELECTRONICS K3 K4 CONTROL WATER HEALTH TEMPERATURE Note O o a 24 ECO VENT PRESSURE GAS A LINE VAC SWITCH SWITCH VALVE VALVE RLY 1 RLY 2 Ki GAS 1 VALVE COMB BLOWER He 5 IGNITER ELEMENT CONTROL HEALTH WATER TEMPERATURE NO INCOMING LINE VOLTAGE OR 24 VOLT Line LED amp 24 VAC LED Off POSSIBLE CAUSE 1 No input power 1 2 Wiring disconnected 2 3 One or more wiring 3 receptacles disconnected from control 4 LED burned out 4 5 Defective transformer aji 6 transformer wiring 6 problem The transformer is of Class internal non replaceoble fuse REMEDY Apply power check all wiring Reconnect plugs on control confirm all are fully seated Ignore or replace Display board Reploce transformer Repair transformer wiring variety and has an If blown a problem may exist with the control which is effecting the transformer In such cases it is recommended the control should be replaced os well IGNITOR LOCKOUT Ignitor Element LED Flashing POSSIBLE CAUSE 1 Broken ignitor element 2 Ignitor unplugged 3 Insufficient ignitor current draw illuminated The 3 segment LED display will display the actual ignitor current draw The expected ignitor current Note The ignitor current is monitored by pressing the blue button to the left of the warm up period or when the draw 2 5 t
36. NITOR STRAIGHT BACK BE VERY CAREFUL THAT YOU DO NOT WIGGLE THE IGNITOR AT ALL REMOVE THE FLAME RECTIFICATION PROBE BY REMOVING THE SCREW TO THE LEFT OF THE ELECTRICAL CONNECTOR WITH A 2 PHILLIPS HEAD SCREWDRIVER AND PULLING IT STRAIGHT BACK REMOVE THE CLEAR VINYL HOSE FROM THE LEFT BACK OF THE BLOWER REMOVE THE BLOWER WIRING HARNESS FROM THE LEFT BOTTOM OF THE BLOWER BY PULLING STRAIGHT OUT ON IT REMOVE THE FOUR BRASS NUT RETAINING THE BLOWER TO BURNER MOUNTING FLANGE WITH A 7 16 WRENCH PULL THE BLOWER STRAIGHT BACK BEING CAREFUL NOT TO LOSE THE SIGHT GLASS REMOVE THE BURNER BY PRYING IT AWAY FROM THE BURNER MOUNTING FLANGE AND THEN PULLING IT STRAIGHT BACK REMOVE THE OLD BURNER MOUNTING FLANGE GASKET BY REMOVING THE SIX NUTS WITH A Ye DEEP SOCKET REMOVE ALL OF THE OLD GASKET MATERIAL FROM ALL SURFACES EXCEPT FOR THE SIGHT GLASS WINDOW GASKET PAGE 26 LP 41 REV 3 1 03 ASSEMBLY 1 REPLACE THE WHITE FIBER BURNER MOUNTING FLANGE GASKET WITH A NEW GASKET PUT THE BURNER MOUNTING FLANGE BACK IN PLACE WITH THE HOLE NEXT TO THE LARGE HOLE IN THE CENTER OF THE PLATE TO THE RIGHT AND WITH THE STUDS FACING OUT 3 TIGHTEN THE SIX Ye NUTS TO 50 INCH POUNDS TORQUE AND THEN 200 INCH POUNDS TORQUE IN THE FOLLOWING ORDER 4 REPLACE THE BURNER MOUNTING FLANGE GASKET WITH A NEW GASKET BE SURE THAT BOTH SIDES OF THE GASKET ARE SPRAYED WITH PERMATEX HIGH TACK SPRAY A GASKET ADHESIVE SEALANT PART 99MA 5 RE INSERT THE BURNER WITH
37. OPERATING INSTALLATION AND SERVICE MANUAL FOR THE VOYAGER GAS FIRED WATER HEATER SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE PTE C US gama ANSI Z 21 10 3 MANUFACTURED BY HEAT TRANSFER PRODUCTS INC P O BOX 429 120 BRALEY ROAD EAST FREETOWN MA 02717 TEL 1 508 763 8071 and outside of MA 1 800 323 9651 FAX 1 508 763 3769 sales cust svc 1 508 763 3448 purchasing 1 508 763 5269 engineering technical or visit our website at WWW HTPRODUCTS COM PAGE 1 LP 41 REV 3 1 03 TO REFERENCE VOYAGER MODEL NUMBERS PLEASE USE THE FOLLOWING GUIDELINES SSV 130 45 s A LP Temperature Warranty Degrees Fahrenheit 6 yrs parts 6 yrs comm 10 yrs res Series BTU U S Temp Warr Gas Type 160 B 1 yr parts 3 yrs comm 10 yrs res Gal Deg F 6 180 SPECIFICATIONS re M TEMPERATURE RISE IN DEGREES FAHRENHEIT MODEL CAPACITY NATURAL amp LP GAS ao so e so oo wo so 120 10 180 Lan buds GPH 55 199 1198 119 198 000 6e 5 45 as sa s 27 GPH SSV SSVH199 B0R 198 000 9 7 s 4 as 53 4 27 5 GPH 198 185 5 SSV199 45S 199000 NER 25 GPH 158 ma 12 SSV160 458 45 160 000 24 2 GPH SSV130 80R 130 000 GPM GPH SSV130 119R 119 130 000 GPM GPH 109 SSV130 45R S 45 130 000 GPM 45 45 45 5 SSVH130 45S G x
38. R e ye REMOVE THIS SIDE OF UNION REMOVE THE CLEAR VINYL HOSE THAT CONNECTS BETWEEN THE GAS VALVE AND THE TRAP ADAPTER 6 a DISCONNECT HOSE FROM HERE PAGE 36 41 REV 3 1 03 7 BREAK THE UNION THAT CONNECTS THE GAS VALVE TO THE AIR INLET MANIFOLD Sen 1 2 Beene NO RD D 8 SLIDE THE GAS VALVE OUT THROUGH THE FRONT OF THE VOYAGER CABINET REMOVE THE GAS VALVE WIRING HARNESS FROM THE GAS VALVE GAS VALVE REPLACEMENT INSTALLATION NOTE IF YOU HAVE TWO MANOMETERS AVAILABLE THEN FOLLOW INSTALLATION PROCEDURE 2 IF NO MANOMETERS ARE AVAILABLE USE INSTALLATION PROCEDURE 1 PROCEDURE 1 1 RE CONNECT THE GAS VALVE WIRING HARNESS TO THE GAS VALVE 2 SLIDE THE GAS VALVE BACK INTO POSITION BY PUTTING THE GAS VALVE INLET THROUGH THE GAS VALVE INLET HOLE IN THE LEFT TOP OF THE VOYAGER CABINET 3 PLACE THE GAS ORIFICE BACK ON THE BOTTOM HALF OF THE UNION AND TIGHTEN THE UNION GAS ORIFICE 4 RE CONNECT THE CLEAR VINYL HOSE TO THE GAS VALVE AND TO THE TRAP ADAPTER CONNECT H HERE PAGE 37 41 REV 3 1 03 8
39. RLY 2 Ki GAS l VALVE Cu COMB I BLOWER 2 m sud 4 CONTROI TAKS ELECTRONICS K3 IGNITER ELEMENT NET e CONTROL HEALTH TEMPERATURE OG u e LINE Ki e 0 8 O BLOWER k KS IGNITER ELEMENT 24 ECONENT PRESSURE GAS GAS SWIICH SWITCH VALVE VALVE RLY 1 RLY 21 GAS VALVE O 3 perc 852 K ki CONTROL ELECTRONICS Mes CONTROI HEALTH TEMI PERATURE 1 Temp probe wiring open E Note CONTROL HEALTH LED Flashing POSSIBLE CAUSE This indicates that the control has failed one of REMEDY Press button on the display board to reset its internal diagnostic control if this error self tests occurs repeatedly replace the control COMBUSTION AIR BLOCKAGE LED Flashing REMEDY Pressure Switch POSSIBLE CAUSE 1 Combustion air 1 Check exhaust piping and blocked flue for obstructions 2 Blower not operating a check biower wiring 2a Repair wiring b check blower motor 2b Replace biower motor 5 Defective air switch 3 Repiace air switch TEMPERATURE PROBE FAULI Water Temp LED Flashing POSSIBLE CAUSE REMEDY Repair wiring 2 Defective probe 2 Repiace probe 3 No water in iank tank 3 Contro is recording in freezing conditions an out of bounds condition iurn on water suppiy remove tank from freezi
40. S VALVE PUFFING ON IGNITION ADJUST GAS VALVE SEE PAGE 38 LOUD POP ON IGNITION THEN RUNNING SMOOTH ADJUST GAS VALVE SEE PAGE 38 HUFF AND PUFF DURING OPERATION ADJUST GAS VALVE SEE PAGE 38 RUNNING GREAT BUT INTERMITTENTLY HUFFING OR POPPING CHECK FOR RE CIRCULATION UNDER VENTING PAGE 44 LP 41 REV 3 1 03
41. SE TANK CAPACITY 170 LITERS 45 U S GAL TANK CAPACITY 170 LITERS 45 U S GAL TEST PRESSURE 2068 KPA TEST PRESSURE 2068 KPA I WORKIN PRESSURE 1034 KPA I WORKIN PRESSURE 1034 KPA 1151200 001 115 100 001 eM FM a 2522 s OU dans kosa J Storage volume 45 U S Gallons Maximum working pressure 150 P S Test Pressure 300 P S L Electrical 60 Hz 120 Volt less than 12 amperes heaters Under no circumstances shall Heat Transfer Products Inc be held liable for any such water damage whatsoever BOTTOM PAGE 35 LP 41 REV 3 1 03 TOP ORIFICE mye 10 MW e AIR ORIFICE 5 REPLACE GAS TYPE LABEL LS2000 E OR F OVER GAS INLET PIPE THIS APPLIANCE 15 SET UP FOR NATURAL GAS i1 ONLY METHANE 1 _ THIS APPLIANCE IS SET UP FOR LP GAS ORLY PROPANE IF YOU ENCOUNTER COMBUSTION PROBLEMS REFER TO PROCEDURE 1 ON PAGE 40 GAS VALVE REPLACEMENT REMOVAL ARON c 6 SHUT OFF POWER TO THE VOYAGER REMOVE THE DOOR FROM THE VOYAGER CABINET SHUT OFF THE GAS VALVE BY TURNING THE BLUE KNOB ON THE VALVE TO THE OFF POSITION SHUT OF THE GAS SUPPLY TO THE VOYAGER BREAK THE UNION ON THE GAS LINE LOCATED BEFORE THE GAS VALVE AND REMOVE THE HALF OF THE UNION THAT IS CONNECTED TO THE GAS VALVE INLET PIPE n D 18 SPY
42. T PIPING BY LOOSENING THE SMALLER HOSE CLAMP ON THE AIR INLET CONNECTOR ALL THE WAY AND THEN SLIDING THE BOOT OVER THE END OF THE AIR INLET ADAPTER THEN TIGHTEN USING A 5 16 NUT DRIVER PAGE 28 LP 41 REV 3 1 03 PARTS ILLUSTRATIONS AIR INLET ADAPTER NI110 AIR INLET MANIFOLD A5000 PAGE 29 LP 41 REV 3 1 03 GASKET AIR INLET G5030 GAS ORIFICE UNION GGU5 PAGE 30 LP 41 REV 3 1 03 GAS ORIFICE 01000 N A AIR ORIFICE A3001 1 0 SIZE A3002 1 125 SIZE A3003 1 375 SIZE FLAME RECTIFICATION PROBE PSE TF1 PAGE 31 LP 41 REV 3 1 03 E oO o Jo GASKET BURNER MOUNTING FLANGE G5010 BURNER MOUNTING FLANGE 7000 616 PAGE 32 LP 41 REV 3 1 03 GAS VALVE GV1000 AIR INLET CONNECTOR F3000 PAGE 33 LP 41 REV 3 1 03 110V IGNITOR SURFACE IGNITER 0206FF003 GASKET BURNER MOUNTING FLANGE WHITE G5040 GASKET BLOWER OUTLET FLANGE G5020 PAGE 34 LP 41 REV 3 1 03 GAS ORIFICE CONVERSION INSTRUCTIONS 1 IF UNIT IS INSTALLED TURN OFF POWER AND GAS SUPPLY BEFORE PERFORMING ANY CONVERSIONS 2 TO CHANGE GAS ORIFICE DISCONNECT UNION 6 BETWEEN THE GAS VALVE AND AIR INLET REMOVE OL
43. TERISTICS IN TERMS OF FLOW RATE THROUGH THE SECONDARY HEAT EXCHANGER TEMPERATURE RISE AND BTU OUTPUT IT IS IMPORTANT TO CHECK WITH YOUR RADIANT SUPPLIER THE OUTPUT TEMPERATURE DESIGN TEMPERATURE RISE OR DELTA TEE AND THE TOTAL BTU OUTPUT REQUIRED FOR THE JOB A BRONZE CIRCU LATOR BETWEEN DOMESTIC HOT WATER OUTLET AND DOMESTIC COLD WATER INLET IS REQUIRED ONCE YOU HAVE DETERMINED YOUR SYSTEM OUTPUT REQUIREMENTS REFER TO VOYAGER SSVH MODEL SIZING CHART ON NEXT PAGE TO DETERMINE MODEL AND FLOW RATE REQUIRED THROUGH THE SECONDARY HEAT EXCHANGER IN ORDER TO MEET THE LOADS OF THE SYSTEM EXAMPLES ARE PROVIDED TO GUIDE THROUGH THE SELECTION PROCESS ONCE WE KNOW THAT THE SECONDARY HEAT EXCHANGER HAS BEEN SIZED CORRECTLY TO MEET THE RADIANT HEAT LOAD WE MUST NOW LOOK INTO THE HOT WATER LOAD FIRST YOU NEED TO UNDERSTAND THE DIFFERENCE BETWEEN FIRST DRAW CAPACITY AND FIRST HOUR CAPACITY FIRST DRAW CAPACITY IS ESTABLISHED AS THE TIME FRAME AT DIFFERENT OUTPUT RATES WHICH THE VOYAGER SSVH MODEL CAN DELIVER THE DESIRED TEMPERATURE BEFORE THE TANK RATE INPUT AND STORAGE ARE CONSUMED THIS USUALLY OCCURS WHEN THERE IS A LARGER DRAW OF HOT WATER IN A VERY SHORT TIME FRAME EXAMPLE HOT TUB 80 GALLON WITH A FILL RATE OF 10 MINUTES FIRST HOUR RATING IS ESTABLISHED AS A RATING SYSTEM COMPARE THE WATER HEATER S ABILITY TO RECOVER OVER ONE HOUR PERIOD THE FIRST HOUR RATING CAN BE VERY MISLEADING WHEN THE HOT WATER LOAD IS REQUIRED IN A VERY SHORT P
44. Y ILLUMINATING THE GREEN LED LIGHT LOCATED ON THE LOWER RIGHT CORNER OF THE BOARD NO LIGHT MEANS IMPROPER POLARITY 2 THE BLOWER CABLE AND THE CURRENT LIMITER HAVE BEEN ELIMINATED 3 THE LED DISPLAY 16 FIVE TIMES BRIGHTER GIVING GREATER VISIBILITY IN BRIGHT LIGHT 4 THE PUSH BUTTON IN THE FRONT OF THE CABINET ALLOWS THE USER TO READ IGNITOR DRAW IN AMPS 2 5 3 5 AND FLAME QUALITY IN MICRO AMPS 4 5 5 1 TO READ IGNITOR DRAW WAIT FOR THE LED LIGHT FOR THE IGNITOR TO COME ON THEN SIMPLY PUSH THE BUTTON IN ON THE FRONT OF THE CABINET TO READ FLAME QUALITY WAIT FOR THE GAS VALVE TO BE ACTIVATED AND THE IGNITOR LIGHT TO GO OFF THEN SIMPLY PUSH IN THE BUTTON ONCE THIS WILL TAKE PLACE IN THE NORMAL OPERATING SEQUENCE IN A HEAT CYCLE 5 THE 1200 BOARD AND BLOWER SYSTEM PARTS ARE NOT INTERCHANGEABLE WITH THE VOYAGER PARTS 1000 SYSTEM PREVIOUS TO THE 1200 SYSTEM PARTS FOR THE OLD 1000 VOYAGER SYSTEM ARE STILL AVAILABLE THROUGH OUR STANDARD DISTRIBUTION MOST COMMON VOYAGER INSTALLATION CONCERNS VENTING VENT LENGTH TOO LONG OVER 85 VENTING NOT PITCHED PROPERLY CONDENSATE BUILD UP IN VENT EXHAUST GAS RE CIRCULATION VENT TERMINALS NOT USED WRONG FITTINGS USED SIGHT PROBLEMS BUSH IN FRONT OF VENT TERMINAL INSIDE CORNER OF BUILDING FOR VENT LOCATION OVERHANG WITH VENT UNDERNEATH COMPOUND ROOF PITCH OR ABOVE ROOF FIRE WALL ADDITIONAL FITTINGS INSTALLED INTO TERMINALS VENT SIZED FROM 3 TO 4 BY USING BUSHINGS INSTEAD OF REDUC
45. are must be taken to keep the appliance door in place and drywall or saw dust away from appliance Failure to do so VOIDS WARRANTY INTERNAL WIRING For specific wiring information please refer to the diagrams on pages 18 and 19 SHUTDOWN PROCEDURE If the burner is operating lower the set point value to 70 degrees F and wait for the burner to shut off Continue to wait for the com bustion blower to stop so all latent combustion gases are purged from the system This should take a maximum of 40 to 90 seconas Disconnect the electrical supply If the burner is not operating disconnect the electrical supply VACATION PROCEDURE If there is danger of freezing change the set point to 70 degrees F DO NOT turn off electrical power If there is no danger of freezing follow the Shutdown Procedure FAILURE TO OPERATE Should the burner fail to light the control will perform two more ignition trials prior to entering a lockout state LOC Note that each subsequent ignition trial will not occur immediately After a failed ignition trial the blower must run for approximately 10 seconds to purge the system then the ignitor element must complete a 30 second warm up period Therefore a time period of approximately 40 to 90 seconds will expire between each ignition trial If the burner lights during any one of these three ignition trails normal operation will resume If the burner lights but goes off in about 4 seconds check the polarity of the
46. condensate line vacuum lock if a long horizontal run is used Also an increase to 1 tubing may be necessary See the diagram on page 24 PAGE 8 41 REV 3 1 03 SSVH MODEL PERFORMANCE AND SET UP INFORMATION The SSVH models are available in the 90 000 BTU hr 130 000 and 199 000 BTU hr firing rates The illustration on page 43 show the location of the heat exchanger and other ports For maximum output the bronze circulator provided must be attached between the hot outlet and cold inlet as shown on page 22 For complete SSVH information and sizing refer to pages 42 and 43 CONTROL DESCRIPTION The fully integrated water heater control is an all electronic fully automatic controller which will provide many years of trouble free ser vice The control requires no periodic maintenance and includes a built in microprocessor which performs a number of diagnostic tests to verify proper appliance and control operation Should an unsafe condition occur the burner will shut down and the appropriate status indicators will illuminate indicating the need for service Consisting of two printed circuit board assemblies the controller s main board is attached to inside left of the shroud while the display board is mounted to the front top of the shroud This arrangement simplifies access to the user adjustments while enhancing the visibility of the temperature display and status indicators A power step down transformer and blower pressure switch are als
47. eases You must also locate the Voyager where it will not be exposed to freez ing temperatures Additionally you will need to place the water heater so that the controls drain inlet outlet and gas valve are easily accessed This appliance must not be installed outdoors as it is certified as an indoor appliance and must be kept vertical and on a level surface Also care must be exercised when choosing the location of this appliance where leakage from the relief valve leakage from related piping or leakage from the tank or connections will not result in damage to the surrounding areas or to the lower floors of the building A water heater should always be located in a area with a floor drain or installed in a drain pan suitable for water heaters Proper clearance must be provided around the Voyager as follows Sides bottom top and back 0 zero clearance Front of the appliance needs 24 service clearance minimum This front service may be achieved by a non rated or combustible door or access panel providing the 24 service clearance is achieved when the door is opened or panel is removed Under no circum stances shall Heat Transfer Products Inc be held liable for any such water damage whatsoever This water heater must not be located near flammable liquids such as gasoline adhesives solvents paint thinners butane liquefied propane etc as the controls of this appliance could ignite those vapors causing an explosion TEMPERATURE
48. form to ASTM D 2235 D 2564 F 493 and cleaner for piping and fittings must conform to ASTM F 656 For joining ABS to PVC you must use transition green cement listed by NSF and IAPMO and exceeds ASTM D 3138 to make solid liquid tight joints and gas tight joints PIPE FITTINGS The exhaust piping and all of intake piping standard 2 PVC sch 40 conforming to ASTM D 1785 and fittings to ASTM D 2466 and ABS pipe conforming to ASTM D3965 and ASTM D2661 and fittings conforming to ASTM D2661 amp ASTM D3311 Foam core pipe may be used for the entire intake system providing it conforms to ASTM F 891 and is cemented together using above materials never use foam core pipe for the exhaust pipe VERY IMPORTANT SSV100R amp SSV130R MODELS ONLY All venting must be 2 both intake and exhaust NEVER use any piping less than 2 or different size pipe on the intake and exhaust You may use 3 or 4 venting on both intake and exhaust to lower the pressure drop to provide additional venting length It is imperative when using 3 to follow these instructions very carefully For longer venting lengths the first 10 of both the intake and exhaust piping are 2 For the intake 10 of 2 PVC or ABS or CPVC plus one 90 degree or two 45 degree elbows and for the exhaust 10 of 2 PVC NON FOAM CORE or ABS solid NON FOAM CORE or CPVC plus one 90 degree or two 45 degree elbows Then use a 2 x 3 PVC or ABS reducing coupling Then proceed with ABS solid NON FOAM
49. ifferential is required the value of the differential can be field adjusted by holding the set point button when power is applied to the control Shut off power to the control Next hold in the set point button Now reapply power to the control Using the set point button the value of the differential can be incremented or decremented as above When the proper value is reached release the button and the new differential has been stored into permanent memory OVERALL APPLIANCE AND CONTROL OPERATION A normal operating sequence is as follows 1 The control determines that the actual water temperature inside tank is 4 degrees F with the factory set 8 degree F differential below programmed temperature set point 2 The control performs selected system diagnostic checks 3 If all checks are successfully passed the combustion blower is energized for the 40 second pre purge cycle 4 During the pre purge cycle is complete power is applied to the ignitor element for the ignitor warm up period blower should continue to run 5 The ignitor warm up period will last for 30 seconds then gas valve will be opened allowing gas to enter the burner chamber 6 The ignitor will remain on for an additional 4 seconds then it will be turned off 7 After an additional 2 seconds the control will verify the presence of flame If the flame was not established the gas valve will be closed power will be removed from the ignitor element and the control will
50. is the hot lead and the white wire is the neutral lead Once all connections have been made the electrical access may be closed It is very important that the electri cal power is not turned on at this time A green LED is provided on the main control board This LED must be luminated when appliance is turned on for proper operation Failure to luminate means bad or missing ground or reverse polarity GAS CONNECTION Gas supply shall have a maximum inlet pressure of less than 14 water column 350 mm 1 2 pound pressure 3 4 kPa and mini mum of 7 water column The entire piping system gas meter and regulator must be sized properly to prevent pressure drop greater than 0 5 as stated in the National Fuel Gas Code This information is listed on the rating plate It is very important that you are connected to the type of gas as noted on the rating plate LP or liquefied petroleum or propane gas or Nat natural gas or city gas All gas connections must be approved by the local gas supplier or utility in addition to the governing authority prior to turning the gas supply on The nipple provided is 1 2 and it is mandatory that a 3 4 to 1 2 reducing bushing provided is used threaded into the branch of a 3 4 tee and a drip leg fabricated as per the national Fuel Gas Code You must ensure that the entire gas line to the connection at the Voyager is no smaller than 3 4 Once all the inspections have been performed the piping m
51. mp SGNN 38 GINOHS OO t t y 9 2 NIME 38 GINOHS ONIGVIH ZO c i X Z L OL NIJMLIJB 38 ATNOHS ONIGVIH ZOD 5 9 INVdOMd 803 OL 38 0100 5 ONIGVSY OO v NIIMIZB 38 GINOHS ONIAVIY ZO Z L 01 9 X 6 33 138 38 GINOHS ONIGVSH ZOO SVO WHTLVN 804 SNOILOMALSN AFOVAOA ENOA dn 9 5 NI 1N5d 13 38 TilM SONILYY ONIMOTIO4 3Hl 22 NO ge ASJA TM JISNBWOV v ZAVH dl NVLYOGAL MIA zCIS SNILNJA 3915 L 330913 70 038 48 NA 48 5 SEV iSnwv x3 SAVIN 3 1 03 LP 41 REV 21 PAGE BE PVC oo x MIN 10 8505 QUIVALENT 5 ABS MIN 84 REQ D REDUCED TO 5 TO UTILIZE SIDE WALL VENT TERMINAL 4 PVC MAX 125 FEET OF 4 3 P V C MIN 10 REQ D FOR COMBUSTION OPTIONAL V1000 VENT SIDE VIEW i F i M TT SE 4 TO 3 P V C amas ASI REDUCING COUPLING FLOOR MOUNTED PIPL SUPPORT SIDE VENTING 3 4 3 SIDE VIEW FLOOR MOUNTED PIPE SUPPORT 3 ABS MIN 84 REQ D 3 YO 4 REDUCING COUPLING 57
52. ng conditions 4 Water level in tank low 4 Control is recording orobe in steam an out of bounds condition Fil tank 5 Probe wiring shorted 5 Replece probe If the temperature probe housing fractures and allows into ihe sensor section of the prove 5 in effect the temperature displayed on the Display panel the ole is dispiaying highly inconsistent temperature this is an indication the temperature probe is defective due to water contamination PAGE 17 LP 41 REV 3 1 03 HOLMS 35055354 ae JJ NOI JA SVD ET HOiMS iNJAT i 8 JASOJSNV a 3 8 D E 15 ON 777 JONVYO No RES IN MOVIE NE 037 N3349 NOUDVINNOCO SUNN IN didyo YOLOMANOD CYVOH AV idSI PAGE 18 LP 41 REV 3 1 03 VIEGRATER WATER HEATER CONTRO 1200 M PARTS IDENTIFICATION TEM M DESCRIPTION 5 2 I HTP PART NJVBER 1 TRANSFORMER amp BLOWER SJ2PLY CABLE 7000 666 CONIROL BOARD I MEM 2 MUST SPECIFY MODE amp SERIAL NUMBER WHEN ORDERING 7
53. nly provided or CPVC NEVER cellular foam core pipe on exhaust piping and conform to ASTM D 3965 for ABS or ASTM F 441 for CPVC and fittings to ASTM D2661 amp D3311 for ABS and ASTM F 439 for CPVC the balance of exhaust piping and all of intake piping use standard 3 PVC sch 40 or 3 ABS schedule 40 conforming to ASTM D2665 or ABS conforming to ASTM D 3965 amp ASTM R 441 for ABS and fittings conforming to ASTM D 2665 amp D331 ABS may also be used for intake venting as long as pipe conforms to ASTM D3965 amp D2661 and fittings meet ASTM D2661 amp D3311 Foam core pipe may be used for the entire intake system providing it conforms to ASTM F 891 and is cemented together using above materials FOR LONGER VENT LENGTHS All venting must be 3 both intake and exhaust NEVER use any piping less than 3 or different size pipe on the intake and exhaust You may use 4 venting on both intake and exhaust to lower the pressure drop to provide additional venting length Itis imperative when using 4 to follow these instructions very carefully For longer venting lengths the first 10 of both the intake and exhaust piping are 3 For the intake 10 of 3 PVC plus one 90 degree or two 45 degree elbows and for the exhaust 10 of ABS solid NON FOAM CORE or CPVC plus one 90 degree or two 45 degree elbows Then use a 4 x 3 PVC or 4 x 3 ABS reducing coupling Then proceed with PVC 4 NON FOAM CORE pipe and fittings for both the intake and exhau
54. o 4 5 amps KEY Lamp ON Lamp OFF Lamp FLASHING REMEDY 1 Replace ignitor element 2 Plug in ignitor 3 Monitor ignitor current see note below LED s during the ignitor Ignitor Element LED is PAGE 15 LP 41 REV 3 1 03 IGNITER ELEMENT 60 24 ECO VENT PRESSURE GAS SWITCH SWITCH VALVE GAS VALVE RLY RLY 2 GAS VALVE K1 CONTROL KS ELECTRONICS K3 CONTROL WATER HEALTH TEMPERATURE Note K3 4 LINE COMB BLOWER IGNITER ELEMENT LI 24 ECO VENT PRESSURE GAS VALVE RLY 1 RLY 2 SWITCH SWITCH K1 CONTROL K5 ELECTRONICS K3 K4 CONTROL WATER HEALTH TEMPERATURE IGNITION LOCKOUT Gas Valve LED Flashing This condition results from a failure to establish burner ignition after three successive trials In such cases First investigate the possible cause and remedy any observations Second momentarily press the button on the display panel to reset the lockout condition Third confirm proper appliance operation POSSIBLE CAUSE 1 Burner ground wire broken or corroded Connectors unplugged Flame probe faulty Gas shut off Clogged gas valve Faulty gas valve Defective control Burner improperly adjusted Dirty burner Improper line connection 5 11 Insufficient flame current blue
55. o mounted on the inside left of the shroud The controller display functions include a high visibility three digit LED readout which is used to display the actual water temperature within the tank along with the programmed desired water temperature set point temperature Nine individual LED indicators are also mounted on the display board which are used to determine the operating status of the appliance and provide assistance when troubleshooting any problems which may occur All indicators are of the solid state variety and should last for the life of the appliance The controller has sufficient built in memory to retain the programmed temperature set point in the event input power is ever interrupted The final component of the control system includes a temperature sensing probe which is threaded into the side of the tank This probe is of unique construction in that both the temperature sensing control and safety limit functions are performed by this single device All probe components are of solid state con struction to provide extended operational life START UP PROCEDURE 1 Make sure that the Voyager has been installed to these instruction procedures along with all applicable province and local codes 2 Make sure all gas piping and connections have been verified and inspected by all applicable inspectors Turn on gas supply Insure that the gas line and the LP tank if applicable have been properly purged Failure to properly purge the gas lines
56. on locations carefully see pages 21 and 22 You must additionally make certain that exhaust gas does not re circulate back into the intake pipe You must place them in a open area and follow the following guidelines Never vent into a walkway or patio area or an alley or otherwise public area less than 7 from the ground Never vent over or under a window or over a doorway Never install a heat saver or similar product to capture waste heat from exhaust Always have vent location at least 1 above maximum snow level Always have vent 1 above ground level away from shrubs and bushes Follow local gas codes in your region or refer to National Fuel Gas Code or Can B149 Always have vent at least 3 from an inside corner of outside walls Maintain at least 4 clearance to electric gas meters and exhaust fans or inlets Very Important Inlet air must be taken from outside of building next to exhaust outlet no closer than 8 Always place screens in all openings in intake and exhaust to prevent foreign matter from entering the Voyager OO ON OOS OU PAGE 5 41 REV 3 1 03 VENTING FOR ALL 3 VENTED MODELS EXCEPT SSV100 45R AND SSV130 45R WHICH ARE 2 VENTED FOR 2 VENTED MODELS SSV100 45R AND SSV130 45R SEE MIDDLE OF PAGE 8 11 The vent intake and exhaust must be properly cleaned and glued for pressure tight joints Several methods for venting the Voyager can be found on pages 21 and 22 Use the following layout as a
57. p pipe on the right of the shroud Use 2 PVC schedule 40 or 2 ABS for all inlet air piping It is very important that you plan the location properly to eliminate long pipe runs and excessive fittings Inlet pipe size must not be reduced Do not combine the inlet air with any other inlet pipe including an inlet to an additional similar appliance The joints must be properly cleaned primed and cemented The piping must also be properly supported as per local and national standard plumbing codes It is important that the piping must be clean and free from burs debris ragged ends and particles of PVC or ABS Exhaust piping lower pipe on right of shroud must be of 2 PVC schedule 40 NON FOAM CORE or 2 ABS NON FOAM CORE 2 CPVC may also be used 3 PVC 3 ABS solid NON FOAM CORE or 3 CPVC can also be used Exhaust piping should be sloped back to the connection on the Voyager at least 1 4 per foot to remove additional condensate that forms within the pipe The total combined length of pipe including elbow allowances each elbow 5 of pipe should not exceed 85 both the intake pipe added to the exhaust pipe The combined vent length should not be less than a combined length of 6 plus two 90 degree elbows Choose your vent termination locations carefully see pages 21 and 22 You must place them in a open area and use the guidelines found on page 20 CLEANER CEMENT Cement for exhaust amp intake piping must be All Purpose Cement and con
58. s and bushes Always be at least 2 horizontally from doors or windows Always have vent at least 3 from inside corner of outside walls aintain at least 4 clearance to electric gas meters and exhaust fans or inlets VERY IMPORTANT Inlet air must be taken from outside of building next to exhaust outlet no closer than 8 Always place screens in all the intake and exhaust openings to prevent foreign matter from entering the Voyager The vent intake and exhaust must be properly cleaned and glued for pressure tight joints The vent intake and exhaust must be properly cleaned and glued for pressure tight joints Several methods for venting the Voyager can be found on pages 23 and 24 Use the following layout as a guideline certain site conditions such as multiple roof lines pitches may require venting modifications consult factory The air inlet must be a minimum of 1 vertically above the maximum snow level or 24 whichever is greater The air inlet must also be a minimum of 10 horizontally from the roof and terminated with a tee The exhaust must be minimum of 24 above the air inlet opening and terminated with a coupling It is very important that there are no other vents chimneys or air inlets in any direction for at least 4 Please refer to typical venting on pages 23 and 24 ALL VENTING MUST BE PROPERLY SUPPORTED AS THE VOYAGER IS NOT INTENDED TO SUPPORT ANY VENTING WHATSOEVER All piping glue solven
59. st piping On 4 piping you may go an additional 125 equivalent feet of pipe and fittings combined total length The 4 fittings have a friction loss allowance as follows 4 90 degree 3 and a 4 45 degree 1 The total maximum venting length can be 125 plus the first 10 of each 3 and a maximum fitting allowance of the 3 total two 90 degree or four 45 degree before increasing to 4 Total equivalent would be 30 of 3 plus 125 of 4 Never use different pipe sizes for intake and exhaust The vent system must be balanced by friction loss equivalent NOTE THE METHODS DESCRIBED ARE SUGGESTED GENERIC METHODS ONLY SPECIFIC JOB SITE OBSERVATIONS AND SIZ ING MAY REQUIRE ALTERNATE INSTALLATION METHODS CONSULT THE FACTORY WITH SPECIFIC JOB REQUIRE MENTS FOR ADDITIONAL RECOMMENDATIONS PAGE 6 LP 41 REV 3 1 03 3 VENTED MODELS EQUIVALENT FITTING FEET DESC OF PIPE 90 5 45 3 Coupling 1 1 Concentric vent kit 3 V1000 vent kit VENTING EXAMPLES NOTE FRICTION LOSS EQUIVALENCE TABLES 2 VENTED MODELS SSV100 45R SSV130 45R FITTING DESC 90 45 Tee Pipe N N N N Coupling Concentric vent kit MINIMUM VENT LENGTH TOTAL COMBINED VENT LENGTH FEET INTAKE EXHAUST 12 20 20 20 20 20 20 20 20 20 20 20 20 30 30 30 30 30 30 30 30 30 40 40 40 40 40 40 40 50 50 50 50 50
60. the button and the controller will automatically retain this value temporary memory After 30 seconds this new set point will be retained in permanent memory NOTE IF POWER IS INTERRUPTED DURING THIS 30 SECOND PERIOD THE NEW SET POINT WILL NOT BE RETAINED IN PERMA NENT MEMORY ITIS A GOOD PRACTICE TO RE CHECK THE SET POINT VALUE APPROXIMATELY 60 SECONDS AFTER A NEW VALUE HAS BEEN RE ENTERED If the button is held down long enough the set point will reach 160 degrees F and stop since this is its maximum value At this point if the desired set point has not been obtained release the button and depress it again the set point will decrement down to 70 degrees F and stop The set point value will now restart at 70 degrees F its minimum and once again increase in value for as long as the button is pressed DIFFERENTIAL ADJUSTMENT PROCEDURE To allow proper water heater operation the control has a 8 degree F window around the set point This means that the burner will be turned on when the water temperature drops to 4 degrees F below the set point and it will be turned off when the water tempera ture reaches 4 degrees F above the set point Thus if the set point is set to 120 degrees F the control will turn on the burner when the water temperature drops to 116 degrees F and will continue to heat the water until the temperature reaches 124 degrees F The differential is factory set to 8 degrees F or 4 degrees F If another d
61. ts cleaners fittings and components must conform to ASTM American Society for Testing and Materials and ANSI American National Standard Institute It is recommended that you use one of the mentioned vent kits specifically for Voyager installations either KGAVTO501CVT 2 in or 6 3 in or the V1000 PAGE 20 LP 41 REV 3 1 03 INOM4 NI LADLOSOLAVOM 14 LINJA 2 ONIINJA 4008 T1VOLLM3A v 382913 lHOddnS 3 C3IN DOA YOO 14 INOY4H ONILNSA 2008 TYLA FAN 19509915 Jdid 1 YOOTs 4015 SN 2915 JANGE GOL 8 SEV WA NIA 4 1090 930 11 D 1savex3 ANSA OIEINIONOO d D avn 1S nv X3 ae 0102 L DIVIN 0 034 8 SEV LL CORE 58 l SEK ee je 74008 JAQAY PZ 30 NAKNIXYN fv 73431 MONS QGilVdlOlLNV 1S3H9lH 3 8 32NVNV31O VOYNVO 804 81 ZE NIVLNIYW 3003 08 ve 40 tous lt gt 804 81 NIN 01 NIVLNIYA OL a
62. umbing system A thermal trap or heat trap loop may be installed here to provide additional energy savings and prevent the thermal siphoning of domestic hot water Refer to pages 23 or 24 for typical installations A domestic hot water tempering anti scald valve should be installed into hot water line to prevent the maximum outlet water temperature from exceeding 119 degrees F as per the national standard plumbing code to prevent scald injury ELECTRICAL CONNECTION The electrical connection for the Voyager is on the left side of the combustion shroud There is a 1 2 knockout location for electrical connection All electrical wiring must be performed by a qualified licensed electrician and in accordance with National Electrical Code or to the applicable local codes and standards The electrical requirements are for standard 120 volts 60 Hz 10 amp service It is rec ommended that an electrical disconnect switch be placed on a nearby wall and that the connection to the Voyager be made using 3 8 extra flex or 3 8 greenfield or equivalent This unit must be wired with 14 awg and fused for no more than 15 amps Itis of extreme importance that this unit be properly grounded Ground the water heater by connecting the green wire in the electri cal access compartment directly to the main building ground system It is very important that the building system ground is inspected by a qualified electrician prior to making this connection The black wire
63. urged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in the failure of the Voyager lighting off This problem is especially noticeable in NEW LP installa tions and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide mainte nance to their lines The gas valve is a special gas valve which has a Pressure Augmented Regulator feature as well as negative out let pressure This valve must not be replaced with a conventional valve under any circumstances Make sure valve is in the OFF position prior to turning gas supply on As an additional safety feature this valve has a left hand thread on the outlet end and a special tamper resistant electrical connector VENTING FOR ALL MODELS 3 VENTED EXCEPT SSV100 45R AND SSV130 45R WHICH ARE 2 VENTED FOR 2 VENTED MODELS SSV100 45R AND SSV130 45R SEE TOP OF PAGE 8 For inlet air supply top pipe on the right of the shroud use 3 PVC schedule 40 It is very important that you plan the location properly to eliminate long pipe runs and excessive fittings Inlet pipe size must not be reduced Do not combine the inlet air with any other inlet pipe including an inlet to an additional similar appliance The joints must be properly cleaned primed and cemented The piping must also be properly supported as per local and national standard plumbing codes It is important that the piping must
64. ust be leak test ed If the leak test requirement is a higher test pressure than the maximum inlet pressure you must isolate the Voyager from the gas line In order to do this you must disconnect the union and cap the inlet gas line In the event the gas valve is exposed to a pressure greater than 1 2 PSI 14 water column the gas valve must be replaced Never use an open flame lit match lighter to check gas connections PAGE 4 41 REV 3 1 03 GAS CONNECTION CONTINUED Failure to follow all precautions could result in fire explosion or death It is recommended that a soapy solution be used to detect leaks Bubbles will appear on pipe to indicate leak is present The gas piping must be sized for the proper flow and length of pipe to avoid pressure drop Both the gas meter and the gas regulator must be properly sized for the total gas load If you experience a pressure drop greater than 1 WC the meter or regulator or gas line is undersized or in need of service On the inlet side of the gas valve there is a 1 8 NPT plug which can be removed to attach a hose barb hose and inches of water column meter Also you can attach a meter to the incoming gas drip leg by removing the cap and installing the meter The gas pressure must remain between 7 14 during stand by and unit running heat cycle If an in line regulator is used it must be a minimum of 10 feet from the Voyager It is very important that the gas line is properly p
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