operating, installation, and service manual for the voyager
Contents
1. 24 PRESSURE GAS VAC SWI SWITCH TE GAS VALVE RLY 2 COMB BLOWER CONTROL WATER HEALTH TEMPERATURE NOTE The flame current is monitored by pressing the black button to the left of 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 24 ECO VENT PRESSURE GAS GAS VAC SWITCH VALVE VALVE RLY 1 RLY 2 CONTROL WATER HEALTH TEMPERATURE 24 ECO PRESSURE GAS Qi Swine VALVE CONTROL WATER HEALTH TEMPERATURE IGNITION LOCKOUT with Gas Valve LED Flashin 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 momentarily press the button on the display to reset the lockout condition ane confirm proper appliance operation POSSIBLE CAUSE REMEDY 1 Burner ground wire 1 Check wire and connection broken or corroded at burner Check connectors Replace flame probe Turn on gas supply Replace gas valve Connectors unplugged 2 3 4 6 Replace gas valve 7 8 9 0 Flame probe faulty Gas shut off Clogged gas valve Faulty gas valve Defective control Burner improperly adjusted Dirty burner Improper line connection 1 Replace control Adjust burner2. 31 5 30 09 dANd HIZNVHLNIN 31 5 30 02 40 NOHVTIVISN 1MOdgdnS HJIL 1696 7 008 1 HY AHOLIVJ 3HL AB G3A0BddV jg 15 SNOLVIAJO ANY 78314405 JHL NO 03578 HOLDVHLNOJ ONITWLSNI OSTIWISN 38 Q InOHS SHJlQNVH SHILVIH HILYM 03414 59 2 3 21322 HMH 830 5 TE HOD Jdid NYED UNCON H 07023 i HART 21158502 SJATYA 3HIO 804 3 01 Av NMOHS O2HVdS IIT Jj 7 lt gt NIA 96 5 Di LINN H370NYH 10N di GaWinD3 IND HITONYH MW NO LON l quA j9vMOIS ONIIV3H 4007 ONIIV3IH LOH 2163800 ONY 9 11002 ONILV3H JNILV3H E31VM 193 QuS3AOQ NOLLVNIBINOO 399005 3007 035019 SV MJOVAOA NI 0702 SHOWIN Dee HIHNLOVIANYN 3AWA LINSNOD SJATVA HSHLO 03 2101 NMOHS XINvnOv O2HVdS 110 10H 80014 ONILV3H NOILVNIBEWOO iMOddns HJIL 1696 26 008 HLY AMOLOvJ SHL AB O3A08ddV ISNA ONIMVHO SIHL WOH4 SNOLVIA3U AN
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4. 000000 3 VENTED MODELS EQUIVALENT FITTING FEET DESC OF PIPE 90 45 3 Coupling 0 0 1 21 Concentric vent kit 3 V1000 vent kit 0 VENTING EXAMPLES NOTE MINIMUM VENT LENGTH TOTAL COMBINED VENT LENGTH FEET INTAKE amp EXHAUST 12 FRICTION LOSS EQUIVALENGE TABLES QTY OF 90 NNNNNN 2 VENTED MODELS SSV100 45R SSV130 45R EQUIVALENT FEET FITTING DESC OF PIPE 90 5 45 3 Coupling 0 0 121 Concentric vent kit 2 EQUIVALENT FRICTION TOTAL LOSS FRICTION FEET LOSS FOR EACH FOR ELBOWS ELBOW ELBOWS 1 5 OB OW on O1 C1 O1O1 C1 Cl JI AFTER THE FIRST 10 OF 3 ONLY4 EQUIVALENT TABLE FITTING DESC 4 90 4 45 4 Coupling 4 Pipe 4 Tee GRAND TOTAL VENT LENGTH FEET WITH FITTING FRICTION LOSS ADDED EQUIVALENT FEET OF PIPE SHOWN AS amp EXHAUST PIPE AND FITTINGS ADDED TOGETHER MAXIMUM VENT LENGTH PAGE 8 WARNING IS EXTREMELY IMPORTANT TO FOLLOW THESE INSTRUCTIONS EXACTLY FAILURETO FOLLOW_INSTRUCTIONS EXACTLY COULD RESULTIN FIRE INJURY OR DEATH SPECIAL
5. MUST SPECIFY MODEL amp SERIAL NUMBER WHEN ORDERING 3 DISPLAY BOARD 7000 664 DISPLAY BOARD TO CONTROL BOARD WIRE 7000 665 5 PRESSURE SWITCH 7250P 150 6 WIRE HARNESS FROM CN6 GAS VALVE FLAME PROBE AND PRESS SWITCH 710B0041 7 WIRE HARNESS FROM CN1 TO LINE POWER 710B0048 8 WIRE HARNESS FROM CN2 TO COMBUSTION BLOWER amp TRANSFORMER 7000 666 9 ECO TEMPERATURE PROBE WIRED CN3 WHC1001 C0 1 PUSH BUTTON SWITCH FOR IGNITOR amp FLAME CURRENT 7000 667 11 LOW WATER CUT OFF SENSOR ASSEMBLY FOR 80 AND 119 GAL ONLY 7000P 852 NOT SHOWN 9 9 we I sO FOR 80 AND 119 D YA GAL ONLY D GROUND WIRE BLACK PAGE 19 TYPICAL VENTING CAUTION 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 VENTINGPIPES PLEASE NOTE N gt O c SN gt Nr 12 gt THE METHODS DESCRIBED SUGGESTED GENERIC METHODS ONLY SPECIFIC JOB SITE OBSERVATIONS AND SIZING MAY REQUIRE ALTERNATE INSTALLATION METHODS REFER TO FIG PG 21 FOR FURTHER DETAILS Never vent into walkway or patio area or any alley or otherwise public area less than 7 from the ground never install a heat saver or similar product to capture waste heat fr
6. Reset manual reset check for blocked flue condition test over temp switch for continuity after reseting 4 Over temp switch open 4 PAGE 16 SWITCH SWITCH 24 PRESSURE GAS VAC VALVE RLY IGNITER ELEMENT CONTROL WATER HEALTH TEMPERATURE e 9 ni 24 ECO VENT PRESSURE GAS GAS VAC SWITCH SWITCH VALVE VALVE RLY 1 RLY 2 IGNITER ELEMENT CONTROL WATER HEALTH TEMPERATURE 24 ECO VENT PRESSURE GAS VAC SWITCH SWITCH de IGNITER ELEMENT CONTROL WATER HEALTH TEMPERATURE Note CONTROL HEALTH LED Flashing POSSIBLE CAUSE This indicates that the control has failed one of its internal diagnostic self tests REMEDY Press button on the display board to reset control if this error occurs repeatedly replace the control COMBUSTION AIR BLOCKAGE Pressure Switch LED Flashing POSSIBLE CAUSE 1 Combustion air blocked 2 Blower not operating a check blower wiring b check blower motor 3 Defective air switch 4 One of the gas valve wires may be disconnected during ignition sequence 5 Poly hose between the blower and air pressure switch is blocked or disconnected REMEDY 1 Check exhaust piping and fresh air intake for obstructions 2a Repair wiring 2b Replace blower motor 3 Replace air switch 4 Check wires to Gas valve Reseat wires into wire harness Remove or correct blockage connect hose to blower or air pressure switch T
7. WHICHEVER 15 GREATER HOT OUI 4 PORTS HEATING SYSTEM 27 10 4 REDUCING COUPLING MIN 10 REO D 3 ABS MIN 84 REQ D COLD IN SSVH MODEL WITH CIRCULATOR INSTALLED EXHAUST COLD FLOOR MOUNTED PIPE SUPPORT 3 4 VERTICAL ROOF VENTING FRONT VIEW ak km PAGE 23 NMOHS SCO IJA NOLVTIVISN GI43INNOIN SN31B80Sd 303 JTEISNOdS3IH 9754 38 LONNVO AYOLIVS 341 AINO JONYOIND 804 SI IWONVA SHE NI GSNIVLNOD ATUYSNIONOD L T Le ci i as 17 2 4 If ac JAWA a anre 82 55 LOH n N31vM 0102 i LNG gt gt LOH 303 WVHOVIO ONIdid ANY 3SN3A3M ANWL 3OVSO S PAGE 24 25 PAGE JNO NIVHO 201 AnnovA 35N03M ATMIdObe OL HJZNMYHLNIN 31 5 30 02 3314 331 V 32v1d ONY Q i 30 ANANA OL 3508 31VSN3UNOO ISVIHON ISNA 0357 5 ISOH 3ivSN3UNOO 40 H19N31 SNOT AHIA BO 3NOO 3B 10 2 SIH 3 Nivad AJM3dONd 01 1203 B3d 15911 iV GaH2lld 157 31 5 20 02 MEO OL Or HJOVADA MOHS H3OVADA 31WSN30NO2
8. ONATCO SUPER Erriciency OPERATING INSTALLATION AND SERVICE MANUAL FOR THE VOYAGER GAS FIRED WATER HEATER SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE GAS FIRED member LISTED gama ANSI Z 21 10 3 NATIONAL COMBUSTION CO INC 104 11 180 STREET JAMAICA NY 11433 TEL 1 718 291 8400 and 1 888 OK NATCO FAX 1 718 291 6870 sales cust svc or visit our website at www nationalcombustion com 2006 2005 2004 National Combustion Co Inc PAGE 1 LP 41 REV 1 1 06 PAGE 2 WARNING IF THE INFORMATIONIN THESE INSTRUCTIONS ARE NOT FOLLOWEDEXACTLY FIREOR 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 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 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 performed by qualified installer service agency or the gas supplier DANGER Water temperature over 125 degrees cause severe burns instantly 6 0 or death from scalds Children disabled and elderly at highest risk 62 i eom of being
9. va O CONTROL COLD IN O CONDENSATE NOTE THESE OVERALL DIMENSIONS ARE APPROXIMATE WITHIN 1 HEAT TRANSFER PRODUCTS RESERVES THE RIGHT TO CHANGE OR DISCONTINUE MODELS WITHOUT NOTICE Note These overall dimensions are approximate within 1 Heat Transfer Products reserves the right to change or discontinue models without notice PAGE 38 VERY IMPORTANT THIS SUPER E HAS THE NEW 1200 BOARD AND BLOWER SYSTEM THE ADDITIONAL FEATURES ARE LISTED BELOW a THE BOARD WILL DETECT PROPER POLARITY BY ILLUMINATING THE GREEN LED LIGHT LOCATED ON THE LOWER RIGHT CORNER OF THE BOARD NO LIGHT MEANS IMPROPER POLARIT Y 2 THE BLOWER CABLE AND THE CURRENT LIMITER HAVE BEEN ELIMINATED 9 THE LED DISPLAY IS FIVE TIMES BRIGHTER GIVING GREATER VISIBILITY IN BRIGHT LIGHT 4 THE BLACK 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 BLACK 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 BLACK BUTTON ONCE THIS WILL TAKE PLACE IN THE NORMAL OPERATING SEQUENCE IN A HEAT CYCLE 3 THE 1200 BOARD AND BLOWER SYSTEM PARTS ARE NOT INTERCHANGEABLE WITH THE VOYAGER PARTS 1000 SYSTEM PREVIOUS TO THE 1200 SYSTEM PARTS FOR THE O
10. MONITORS THE GAS VALVE OUTPUT MONITORS WATER TEMP WITHIN TANK MONITORS INTERNAL STATE OF THE CONTROLLER S HARDWARE AND SOFTWARE MONITORS POLARITY AND GROUND CIRCUIT VERY IMPORTANT SET UP INSTRUCTIONS MEANING ON WHEN LINE VOLTAGE IS PRESENT ON WHEN OUTPUT IS ENERGIZED POWER APPLIED TO BLOWER ON WHEN OUTPUT IS ENERGIZED POWER APPLIED TO IGNITOR ON WHEN SECONDARY VOLTAGE IS PRESENT ON WHEN ECO SWITCH AND LOW WATER CUT OFF IS IN CLOSED POSITION NORMAL POSITION ON WHEN THE PRESSURE SWITCH IS CLOSED SUFFICIENT COMBUSTION AIRFLOW EXISTS ON WHEN OUTPUT IS ENERGIZED POWER APPLIED TO GAS VALVE ON WHEN TEMP DROPS BELOW SET POINT ON WHEN CONTROLLER FUNCTIONALITY IS O K ON WHEN GROUND AND POLARITY ARE O K IF YOU HAVE A COMBUSTION ANALYZER THE FOLLOWING RATINGS WILL BE VERY HELPFUL IN SETTING UP YOUR SUPER E FOR NATURAL GAS FOR PROPANE GAS CO2 READING SHOULD BE BETWEEN 9 75 4 10 72 O2 READING SHOULD BE BETWEEN 72 amp 4 72 CO READING SHOULD BE UNDER 10 PPM CO2 READING SHOULD BE BETWEEN 10 4 11 72 O2 READING SHOULD BE BETWEEN 72 amp 4 72 CO READING SHOULD BE UNDER 10 PPM PAGE 14 NO INCOMING LINE VOLTAGE 24 VOLT Line LED amp 24 VAC LED Off O amp ECO VENT PRESSURE GAS POSSIBLE CAUSE REMEDY RLY 1 1 No input power 1 Apply power COMB BLOWER IGNITER ELEMENT CONTROL WATER HEALTH TEMPERATURE 24 ECO VENT PRESSURE GAS VAC SW
11. m 7 8 TIGHTEN THE BLOWER BOLTS FIRST TO 50 INCH POUNDS TORQUE THEN 150 INCH POUNDS TORQUE THE FOLLOWING ORDER S PLACE THE IGNITOR BACK INTO THE BURNER MOUNTING FLANGE BEING VERY CAREFUL OF THE ELEMENT WHICH IS EXTREMELY FRAGILE PAGE 28 10 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 12 RE INSTALL THE AIR INLET GASKET TO THE RIGHT SIDE OF THE BLOWER WITH THE TWO ANGLE CUTS FACING TOWARD THE WATER HEATER 19 RE INSTALL THE ALUMINUM AIR INLET ASSEMBLY WITH THE TWO ANGLE CUTS FACING THE WATER 14 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 SA j TOWARDS WATER gt HEATER 15 SNAP THE AIR ORIFICE INTO THE END THE AIR INLET MANIFOLD 16 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 18 RE INSTALL THE 1 8 BRASS BARB BACK INTO THE TRAP ADAPTER WITH 7 16 DEEP SOCKET 19 PLACE GAS ORIFICE ON TOP OF THE SPLIT UNION WITH THOLE FACING UP AS SHOWN BELOW GAS ORIF
12. make sure that the cold water supply is turned on and the water heater is completely filled with water Verify this by opening a hot water faucet allowing the water to flow until all the air is removed and clear water is present Turn the elec tric supply back on and manually reset the control STEP 2 If the ECO Vent Switch LED light is still flashing after step 1 check the low water cut off switch for possible damage Remedy Low water cut off switch damage Make sure the low water cut off is operating correctly by checking the voltage with an electric meter You should see 24 volts AC across the red and black lead of the connector from the wire harness If the electric meter reads 24 volts indicating there is power to the switch the next step is to put a jumper across the two green leads of the connector If the ECO Vent Switch LED illuminates and the water temperature LED is on then the low water cut off switch needs to be replaced WARNING DO NOT ALLOW THE WATER HEATERTO OPERATE WITH THE JUMPER IN PLACE PERMANENT DAMAGE TO THEHEATEXCHANGER COULD RESULTAND WARRANTYVWILL BE VOID STEP 3 If the ECO Vent Switch LED light is still flashing check the low water cut off wire harness for possible damage or disconnected Remedy Low water cut off wire harness damage or disconnected Make sure that all the wire connections are connected properly reference the water heater control diagrams in the Installation Manual on page 18 and 19 make
13. 2 IF NO MANOMETERS ARE AVAILABLE USE INSTALLATION PROCEDURE 1 PROCEDURE 1 2 RE CONNECT THE GAS VALVE WIRING HARNESS TO THE GAS VALVE 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 SUPER E CABINET PLACE THE GAS ORIFICE BACK ON THE BOTTOM HALF OF THE UNION AND TIGHTEN THE UNION i 1 a P RE CONNECT THE CLEAR VINYL HOSE TO THE GAS VALVE AND TO THE TRAP ADAPTER L F rn aM ASO e c Y WD DANN e PAGE 32 5 THE SUPPLY GAS PIPING TO THE VALVE 6 TURN ON THE GAS TO THE SUPER E 7 TURN THE BLUE KNOB ON THE GAS VALVE TO THE ON POSITION 8 Segel 0 ON I Nm RE 1 NO Egg gt 3 5 Q SES 9 r sel TP uk P FA Quee Pf GJE lin ON V p A 55 AD 8 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 9 TURN THE LINE VOLTAGE BACK ON TO THE SUPER E GAS VALVE ADJUSTMENT LET THE UNIT START CYCLE AND LISTED CAREFULLY TO THE IGNITION IF THE IGNITION WAS QUIET THE VALVE WILL NEED NO ADJUSTMENT
14. GASKET G5010 ALUMINUM AIR ORIFICE AIR INLET ASSEMBLY 7000 435 1 00 BURNER MOUNTING FLANGE ASSEMBLY A5000 7000 751 1 125 7000 820 7000 752 1 375 AIR INLET CONNECTOR GAS BLOWER OUTLET FLANGE OUTER BURNER MOUNTING FLANGE 7000 380 F3000 2 3 COUPLING F3001 2 2 COUPLING 7000 427 30 GAS VALVE REPLACEMENT REMOVAL 1 SHUT OFF POWER TO THE SUPER E 2 REMOVE THE DOOR FROM THE SUPER E CABINET 3 SHUT OFF THE GAS VALVE BY TURNING THE BLUE KNOB ON THE VALVE TO THE OFF POSITION 4 SHUT OF THE GAS SUPPLY TO THE VOYAGER 5 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 ffe A SY i 1 3 HEN EN 115 JNION 6 REMOVE THE C TRAP ADAPTER IMPORTANT IT IS IMPORTANT TO NOTE FOR MAINTENANCE PURPOSES THE THREAD ON THE END OF THIS GAS VALVE AND NIPPLE IS A LEFT HANDED THREAD DISCONNECT HOSE PAGE 31 8 NE gt hi 7 ry LI 9 ER AY Q ey 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
15. LEL NANNA Wed 91 X 2 1 NISMG gt GE tl OL NIIMLGB OL H30NN GA 2 1 NIIMES OL 3 X Z 6 NIME 2 COE MA _____ MIA 1NON4 ON INJA 008 WOLE3A E 39 3 luOdgns dde STON SOOT TATT MINS CL J2NYMY 312 vOVNWS HOU WI 01 WIN 6d 38 GINOHS ONIOV3M O2 38 GINOHS ONICWAY 60 3H 671046 SNIOV3H 202 SVD zNWVdOMHd 403 39 01 5 ONIOVIH CI 3B 5 ONIGVSY cO GINOHS 9SNIQv3H 209 SVO TVYTIVN MJOMVAOA HIOA 9 13 NI 103973 38 TM 38 SONILWH ONIMOTIOd JHL HSZATYNY NOLSNENOI v 3l SNOLINGISNL 35 IAVLYOdAL AGIA e 408 ON INSA 2015 6 JANG HOIU NA E Sey at 1 1421050 ANGA BRINGONDS E 2615 SNILNSA 3015 jHBOcans Jdid HOOT4 Et Eid 22 REDUCED TO 3 UTILIZE SIDE WALL VENT TERMINAL 4 125 EQUIVALENT FEET OF 4 3 MIN 10 REQ D 4 TO 3 P V C REDUCING COUPLING FLOOR MOUNTED 3 ABS PIPE SUPPORT MIN 84 REQ D 537 0 4 REDUCING COUPLING FLOOR MOUNTED PIPL SUPPORT SIDE VENTING 3 4 3 SIDE VIEW 3 4 SIDE VENTING FRONT VIEW 2 Bie el sw
16. ORIFICE 1 000 GAS ORIFICE SIZES NATURAL GAS CONVERSION FROM PROPANE LP PROPANE LP GAS CONVERSION FROM NATURAL GAS NATURAL GAS 261 PROPANE LP GAS 205 293 215 CAUTION THERE ARE NO USER SERVICEABLE PARTS WITHIN THE CONTROL SYSTEM TO MAINTAIN SAFETY AND PROPER APPLI ANCE PERFORMANCE REFER ALL TROUBLE SHOOTING TO QUALIFIED SERVICE PERSONNEL TROUBLE SHOOTING 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 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 LINE BLOWER IGNITOR 24V ECO PRESSURE GAS VALVE WATER TEMP CONTROL HEALTH GREEN ON MAIN CONTROL BOARD CONTROLLER FUNCTION MONITORS INCOMING AC LINE VOLTAGE MONITORS THE BLOWER MOTOR OUTPUT MONITORS IGNITOR ELEMENT OUTPUT MONITORS INCOMING VOLTAGE FROM THE TRANSFORMER SECONDARY MONITORS STATE OF THE ECO SWITCH AND LOW WATER CUT OFF MONITORS STATE OF THE AIR SWITCH
17. PULL THE BLOWER STRAIGHT BACK BEING CAREFUL NOT TO LOSE THE SIGHT GLASS REMOVE THE BURNER BY PRYING IT AWAY FROM THE OUTER BURNER MOUNTING FLANGE AND THEN PULLING IT STRAIGHT BACK REMOVE THE OLD BURNER MOUNTING FLANGE GASKET BY REMOVING THE SIX NUTS WITH A DEEP SOCKET REMOVE ALL OF THE OLD GASKET MATERIAL FROM ALL SURFACES EXCEPT FOR THE SIGHT GLASS WINDOW GASKET PAGE 27 ASSEMBLY REPLACE THE WHITE FIBER BURNER MOUNTING FLANGE GASKET WITH A NEW GASKET 2 PUT THE BURNER MOUNTING FLANGE BACK IN PLACE WITH THE 7 HOLE NEXT TO THE LARGE HOLE IN THE CENTER OF THE PLATE TO THE RIGHT AND WITH THE STUDS FACING OUT TIGHTEN THE SIX 2 NUTS 50 INCH POUNDS TORQUE AND THEN 200 INCH POUNDS TORQUE IN THE FOLLOWING ORDER 4 REPLACE THE BURNER MOUNTING FLANGE GASKET WITH NEW GASKET BE SURE THAT BOTH SIDES OF THE GASKET ARE SPRAYED WITH PERMATEX HIGH STACK SPRAY A GASKET ADHESIVE SEALANT PART 99 S RE INSERT THE BBURNER WITH 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 99 PLACE BLOWER BURNER MOUNTING FLANGE BE SURE THAT THE SIGHT GLASS IS IN PLACE AND THE GASKET IS INSTALLED CORRECTLY AS SHOWN BELOW IF GASKET OR SIGHT WINDOW ARE DAMAGED IN ANY WAY REPLACE THEM WITH NEW ONES SIGHT GLASS 52000 f GASKET 05060 d
18. Vent and Extensions in Plastic 2 3 and 4 Pipe Schedule 40 or 80 1 Non Foam Core PVC Pipe 2 Non Foam Core CPVC Pipe 3 Non Foam Core ABS Pipe Vent Piping must conform to following Non Core Pipe Polyvinyl Chloride to ASTM D 1785 or D 1784 Class 12454 B Formerly designated Type 1 Grade 1 2 CPVC Chlorinated Polyvinyl Chloride Class 23447 B Formerly designated Type IV Grade 1 conforming to ASTM D 1784 3 ABS Acrylonitrile Butadiene Styrene Class 3 2 2 2 2 conforming to ASTM D3965 PIPE FITTINGS The first 84 7 of exhaust piping must be of 3 ABS solid only provided or CPVC NEVER cellular foam core pipe on exhaust piping and conform to ASTM D 3965 for ABS or ASTM F 441 for CPVG and fittings to ASTM D2661 amp D3311 for ABS and ASTM F 439 for the balance of exhaust piping 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
19. a combined length of 6 plus two 90 degree elbows Choose your vent termination locations carefully see pages 22 and 23 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 NOTE Per requirement of the ANSI Z21 10 3 2004 1 CSA 4 3 2004 a thorough review and compliance to Fig 3 A pg 21 in this manual Is required WARNING 1 Never vent into a walkway or patio area or an alley or otherwise public area less than 7 from the ground 2 Never vent over or under a window or over a doorway 3 Never install a heat saver or similar product to capture waste heat from exhaust 4 Always have vent location at least 1 above maximum snow level 5 Always have vent 1 above ground level away from shrubs and bushes 6 Follow local gas codes in your region or refer to National Fuel Gas Code or Can B149 7 Always have vent at least 3 from an inside corner of outside walls 8 Maintain clearance to electric gas meters and exhaust fans or inlets See Fig 3A pg 21 for clearances 9 Very Important Inlet air must be taken from outside of building next to exhaust outlet no closer than 8 10 Always place screens in all openings in intake and exhaust to prevent foreign matter from entering the Voyager 11 The vent intake and exhaust must be properly cleaned and glued for pressure tight joints Several methods for
20. 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 seconds 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 wiring See electrical connection section on page 4 If the burner does not light after the third ignition trial the control will enter a lockout state This lockout state indicates that problem exists with either the appliance the controls or the gas supply Under such circumstances a qualified service technician should be contacte
21. 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 Super E is lower than the drain you must use a condensate removal pump A condensate filter and a condensate pump kit are available from NATCO 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 necessary to prevent 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 25 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 back page shows 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 the back of this manual CONTROLDESCRIPTION The fully integrated water heater control is an all electronic with a fully automatic controller that will provide many years of trouble free service The co
22. current The controller has a temperature set point range 70 degrees F to 160 degrees F The factory set point is 118 degrees F 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 im of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available VERY IMPORTANT NOTE POWER MUST BE APPLIED TO THE CONTROLLER PRIOR TO ANY PROGRAMMING OPERATIONS 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 the button and the controller will automatically retain this value in 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 15 A GOOD PRACTICE TO RE CHECK THE SET POINT VALUE APPROXIMATELY 60 SECONDS AFTER NEW VALUE HAS BEEN RE ENTERED If the button is held dow
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24. 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 no 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 plumbing 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 22 to 26 for typical installations NEW LOW WATER CUT OFF NORMAL OPERATION A low water cut off switch has been added to the Super E to stop the possibility of dry firing the water heater and damaging the internal heat exchanger The low water cut off switch will be activated when the water heater is completely filled and the LED light becomes illuminated on the ECO Vent Switch located on the front of the water heater FAULT CONDITIONS STEP 1 Check for low water condition in tank If the water heater is not completely filled the low water switch will not activate the water heater During a low water fault the control board three digit LED display will show LOC and the ECO Vent Switch LED light will begin to flash It could take as long as 5 minutes before the water heater will physically lock out during the water heater operation Remedy Low water condition in tank Turn off the electric supply
25. must place them in a open area and use the guidelines found on page 20 VERY IMPORTANT SSV100R amp SSV130R MODELS ONLY All venting must be 2 both 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 impera tive when using 3 to follow these instructions very carefully For longer venting lengths the first 10 of both the intake and exhaust pip ing are 2 For the intake 10 of 2 PVC or ABS or CPVC plus 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 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 CORE CPVC or PVC 3 NON FOAM CORE pipe and fit tings for both the intake and exhaust piping On 3 piping you may go an additional 125 equivalent feet of pipe and fittings combined total length Total equivalent would be 30 of 2 plus 125 of 3 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
26. opened or panel is removed Under no circum stances shall National Combustion Co 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 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 EXPANSION TANK A
27. potable hot water expansion tank may be required to offset the water expansion as the water is heated In 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 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 CAUTION The expansion tank must be suitable for hot potable water PAGE 3 DOMESTIC WATER CONNECTION CAUTION 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 ALLCONNECTIONS 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 Super E are 1 on 45 gallon models On the 80 and 119 gallon models the inlet and outlet ports are 1 72 On the cold inlet bottom left install 1 brass tee on 45 gallon models 1 7 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 72 brass tee install a copper male adapter to match your copper plumbing system For convenience you
28. 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 90 degree or two 45 degree elbows Then use 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 exhaust 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 A WARNING 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 7
29. 0 17 AIR INLET ADAPTER 18 AIR INLET CONNECTOR 19 AR INLET MANIFOLD 20 EXHAUST OUTLET CONNECTOR 21 EXHAUST ELBOW AND DRAIN 7000 604 22 CONDENSATE CONNECTOR HOSE 23 1 77 BARB X 1 2 M ADAPTER 9500 0027 24 15 16 HOSE CLAMP 7000 828 25 CONDUIT 1 2 LOCKNUT 6000 0006 26 COMBINATION 90 DEG ELBOW 2500 0019 27 LOW WATER CUT OFF 7000 852 on 80 and 119 Gallon Only PAGE 12 REPLACEMENT PARTS NOT SHOWN LOW VOLTAGE CABLE ASSEMBLY 71080041 INTERCONNECT RIBBON CABLE 7000 665 LINE CABLE 710B0048 PUSH BUTTON 7000 667 TRANSFORMER 7000 666 GASKET BURNER MOUNTING FLANGE 65010 GASKET BLOWER OUTLET FLANGE 65020 GASKET AIR INLET G5030 GASKET BURNER MOUNTING FLANGE WHITE 7000 815 ORIFICES 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 WARNING If orifices are drilled the result will be poor ignition explosion severe bodily injury or death All orifices mu
30. ALLATION 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 SUPER E TO BE INSTALLED VIRTUALLY ANYWHERE THIS OF POWER EFFICIENCY AND INSTALLATION FLEXIBILITY IN SSV AND SSVH MODEL APPLIANCES IS A SUPER E EXCLUSIVE THAT NO OTHER WATER HEATER MANUFACTURER CAN OFFER HOW THESYSTEM WORKS WITHHEATING 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 INSTALLTHESYSTEM IN THIS MANUAL YOU WILL FIND SAMPLE DRAWINGS WHICH CAN PROVIDE YOU WITH IDEAS ON HOW TO LAY OUT THE SYSTEM THE USE OF 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 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 SYS
31. CREW 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 iem uz _ E PUT THE SUPER E CABINET DOOR BACK IN PLACE PAGE 36 IMPORTANT INSTRUCTIONS FOR SSVH MODELS HOW THESYSTEM WORKS WITHRADIANTHEAT BOTH THE SUPER E SSV AND SSVH MODELS ARE VERY EFFICIENT AND POWERFUL WATER HEATING DEVICES THE SUPER E SSV AND SSVH MODELS PRODUCE LARGER AMOUNTS OF HOT WATER VERY SMALL COMPACT DESIGN WHEN COMPARED WITH CONVENTIONAL WATER HEATERS HEAT TRANSFER PRODUCTS HAS DESIGNED THE SUPER E SSVH MODEL EXCLUSIVELY AS 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 SUPER E SSVH MODEL TO HEAT BOTH THE DOMESTIC WATER AND PROVIDE OUTPUT BY THE INSTALLATION OF RE CIRCULA TION LINE CONNECTED FROM DOMESTIC HOT WATER OUTLET TO DOMESTIC COLD WATER INLET THE SUPER E SSVH 130 MODEL CAN TRANSFER UP 110 000 BTU s IN THE SECONDARY HEAT EXCHANGER AND ALSO DELIVER 180 GALLONS OF HOT WATER IN THE FIRST HOUR OF OPERATION EVEN SUPER E SSV MODELS MAKE GREAT RADIANT HEATERS WHEN DOMESTIC HOT WATER IS NOT NEEDED IN THE INST
32. Clean burner Verify green LED on on control board is illuminated when power is applied Monitor flame current see note below IGNITION LOCKOUT Gas Valve LED Flashing and Control Health LED Flashing gt 11 Insufficient flame current 11 This condition results from failure to establish burner ignition after three successive trials In such cases First investigate the possible cause and remedy any observations _ momentarily press the button on the display to reset the lockout condition hird confirm proper appliance operation POSSIBLE CAUSE 1 Gas Valve wire connector has either the blue or yellow wire pushed out of the connector This is observed at either the start up or if either wire comes loose during igniter heat up sequence REMEDY 1 Look into the front end of the gas valve wire harness connector to determine which wire has been pushed back Push that wire back into the connector You hear click Reconnect the connector to the gas valve and retry ECO SWITCH OPEN ECO LED Flashing POSSIBLE CAUSE REMEDY Temp probe unplugged 1 Check connectors Temp probe wiring 2 Repair wiring damaged Water in tank too hot 3 Normal condition when water temp exceeds safety limit 198 opens 160 closes Allow water into the tank or admit cold water into tank and manually reset the control Determine cause for overtemp condition
33. E 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 2 GPM 3 GPM 4 GPM 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 GPM 3 GPM 4 GPM 5 6 7 8 90 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 95 205 Lbs SSVH130 45 32 Sq Ft 110 000 94 3 205 Lbs SSVH199 80 32 Sq Ft 140 000 94 3 255 Lbs L LOW WATER CUT OFF oui VOYAGER DIMENSIONS 45 GAL 119 GAL sms sen RT HOT OUT DIS 0 5 0 48 35 174 66 174 CONTROL 5 812 22 25 1 4 1 4 23 1 4 1 4 27 1 4 ELECTRICAL i 29 3 4 ve CONNECTION 35 1 4 EXCHANGER N EXHAUST CONDENSATE
34. E SUPER E 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 c M L IF THERE WAS NO IGNITION A MAKE SURE THE GAS VALVE 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 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 COUNTER CLOCKWISE 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 MANOMETER 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 IF MANOMETER 1 READS 35 MANOMETER 2 SHOULD BE ADJUSTED TO NOW READ 15 PUT THE GAS VALVE ADJUSTMENT S
35. EMPERATURE PROBE FAULT Water Temp LED Flashing POSSIBLE CAUSE 1 Temp probe wiring open 2 Defective probe 5 No water in tank tank in freezing conditions 4 Water level in tank low probe in steam 9 Probe wiring shorted REMEDY 1 Repair wiring 2 Replace probe 3 Control is recording an out of bounds condition Turn on water supply remove tank from freezing conditions 4 Control is recording an out of bounds condition Fill tank Replace probe If the temperature probe housing fractures and allows water into the sensor section of the probe this may effect the temperature displayed on the Display panel If the display is displaying highly inconsistant temperature readings this is an indication the temperature probe is defective due to water contamination PAGE 17 AINO 611 08 804 340 109 MOT OL m SEER 3JNV 14 HOLIMS IYNSSIHd JAVA 3 Mis m E a HOLIMS Buc DN ae es x 5 HH ps re X 1 2 4 j8OMd 093 2 Nogaly F3MNIVYIANIL ae YOLONANOO 9 DE 5 TIT O 33 9 AV IdSIG WVYOVIC NOILOANNOO SEIN PENN PAGE 18 INTEGRATED WATER HEATER CONTROL 1200 BOARD SYSTEM REPLACEMENT PARTS IDENTIFICATION CONTROL BOAR 7000 702
36. GAS VALVE WITH A 3 16 ALLEN WRENCH ex 1 EE il 8 md 0 R i EE TNR 6 3 d P a 1 8 HOSE BARB IN PLACE OF THE OUTLET PRESSURE TAP PLUG NO SEALANT IS REQUIRED ON THIS FITTING 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 PLACE THE GAS ORIFICE BACK ON THE BOTTOM HALF OF THE UNION AND TIGHTEN THE UNION ME EN 3 1 0 TE 3 J iL LIL pui IF Ki Tree FL AH i d E gy PAGE 34 6 ro 10 11 CONNECT THE VACUUM HOSE ACCORDING TO THE FOLLOWING DIAGRAM D 5 IO MANOMETER aet TO MANOMETER 2 RE CONNECT THE SUPPLY GAS PIPING TO THE VALVE TURN ON THE GAS TO THE SUPER E TURN THE BLUE KNOB ON THE GAS VALVE TO ON REMOVE THE SMALL ROUND BRASS PLUG FROM THE GAS VALVE BY TURNING IT COUNTER CLOCKWISE WITH A SMALL PUNCH AND HAMMER TURN THE LINE VOLTAGE BACK ON TO THE SUPER E PAGE 35 12 5 14 15 16 18 20 LET THE SUPER E CYCLE AFTER TH
37. ICE gt TT TT UNION BOTTOM 20 RE CONNECT THE GAS VALVE TO THE AIR INLET MANIFOLD BY TURNING THE UNION COUNTER CLOCKWISE AND TIGHTENING IT WITH A 10 PIPE WRENCH 21 THE CLEAR VINYL HOSE FROM THE GAS VALVE TO THE AIR INLET ADAPTER 22 PLUG THE BLOWER POWER WIRE INTO THE LEFT BOTTOM OF THE BLOWER WITH THE WHITE TOWARDS THE 29 RE CONNECT THE CLEAR VINYL HOSE FROM THE PRESSURE SWITCH TO THE BARB ON THE BACK LEFT OF THE BLOWER 24 PLUG THE IGNITOR WIRING HARNESS BACK INTO THE CONTROL BOARD 295 THE BLACK WIRE TO THE FLAME RECTIFICATION PROBE BY PUSHING THE CONNECTOR OVER THE BLADE ON THE FLAME RECTIFICATION PROBE 20 SCREW THE TWO GREEN GROUNDING WIRES TO THE TOP BACK OF THE BLOWER WITH THE GREEN GROUNDING SCREW USING A 5 16 NUT DRIVER 27 PLUG THE GAS VALVE WIRING HARNESS BACK INTO THE GAS VALVE WITH THE BLUE WIRE TOWARDS THE BOTTOM OF THE CONNECTOR 28 THE AIR INLET PIPING BY LOOSENING THE SMALLER HOSE CLAMP ON THE AIR INLET 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 29 PARTS ILLUSTRATIONS GAS VALVE GV1000 110V SURFACE IGNITOR om 0206FF003 FLAME RECTIFICATION PROBE 5 1 ZN GAS ORIFICE 5500 0009 GAS ORIFICE UNION 9500 0028 TRAP ADAPTER 9500 0025 AIR INLET ASSEMBLY GASKET G5030 BURNER MOUNTING FLANGE
38. IF IT WAS ALOUD IGNITION OR THERE WAS NOT IGNITION AT ALL FOLLOW THESE STEPS 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 THIS WILL INCREASE THE GAS VOLUME IN THE COMBUSTION PROCESS A IF THE UNIT STILL DOES NOT LIGHT OFF TURN THE ADJUSTMENT SCREW TWO FULL TURNS COUNTERCLOCKWISE PAGE 33 2 3 B IF IGNITION WAS POOR 1 LOOK AT THE COLOR OF THE FLAME WHILE THE UNIT IS RUNNING THROUGH THE SIGHT GLASS IF IT IS GREEN OR RED IN COLOR OR THE HEATER WHISTLES ON IGNITION TURN THE ADJUSTMENT SCREW COUNTERCLOCKWISE 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 fae ET Fane EEL lid 15 2 LJ GE X v FS v r 1 F HT rmi ia DS re NL d e ba z SCRE W PUT THE GAS VALVE ADJUSTMENT SCREW COVER BACK IN PLACE AND TIGHTEN PUT THE VOYAGER CABINET DOOR BACK INTO PLACE PROCEDURE 2 1 REMOVE THE OUTLET PRESSURE TAP PLUG FROM THE RIGHT SIDE OF THE
39. ITCH SWITCH kver 2 Wiring disconnected 3 One or more wiring receptacles disconnected from control 4 LED burned out 5 Defective transformer 6 transformer wiring problem 2 3 Repair transformer check all wiring Reconnect plugs on control confirm all are fully seated Ignore or replace Display board Replace transformer wiring Note The transformer is of Class variety and has an internal non replaceable fuse If blown a problem may exist with the control which is affecting the transformer In such cases it is recommended the control should be replaced as well POSSIBLE CAUSE 1 Broken ignitor element 2 Ignitor unplugged 3 Insufficient ignitor current draw IGNITOR LOCKOUT Ignitor Element LED Flashing REMEDY 1 Replace ignitor element 2 Plug in ignitor 3 Monitor ignitor current see note below IGNITER ELEMENT CONTROL WATER HEALTH TEMPERATURE Note The ignitor current is monitored by pressing the black button to the left of the LED s during the ignitor warm up period or when the Ignitor Element LED is illuminated The 3 segment LED display will display the actual ignitor current draw The expected ignitor current draw 2 5 to 4 5 amps NOTE THE TRANSFORMER HAS AN INTERNAL NON REPLACEABLE FUSE THE CONTROL HAS A REPLACEABLE 3 AMP FUSE LINKED TO THE TRANSFORMER SHORT KEY LED lights ON LED lights OFF O LED lights flashing 6 PAGE 15
40. LD 1000 VOYAGER SYSTEM ARE STILL AVAILABLE THROUGH OUR STANDARD DISTRIBUTION MOST COMMON SUPER E 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 REDUCING 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 MINIMUM GAS SUPPLY SIZE GAS REGULATOR TOO 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 37 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 N
41. LLY 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 TO 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 PERIOD OF TIME NOW WE CAN DETERMINE WHICH SUPER E 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 SUPER E 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 SUPER E SSVH MODEL SUITABLE FOR THE JOB PAGE 37 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 T 52 500 70 000 87 500 105 000 8 60 000 80 000 100 000 N R 9 71 400 95 200 119 000 124 500 10 85 000 113 25077 140 000 140 000 FOR SSVH 130 MODELS ONLY FOR SSVH 199 80 MODELS ONLY NOTE THE SUPER E MUST BE SET 25 DEGREES F ABOVE THE SYSTEM TEMPERATUR
42. O 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 32 GAS VALVE PUFFING ON IGNITION ADJUST GAS VALVE SEE PAGE 32 LOUD POP ON IGNITION THEN RUNNING SMOOTH ADJUST GAS VALVE SEE PAGE 32 HUFF AND PUFF DURING OPERATION ADJUST GAS VALVE SEE PAGE 32 RUNNING GREAT BUT INTERMITTENTLY HUFFING OR POPPING CHECK FOR RE CIRCULATION UNDER VENTING 2006 2005 2004 National Combustion Co Inc PAGE 39 PAGE 40
43. SE THE AIR ORIFICE SNAPPED INTO THE END OF THE ALUMINUM PIPE 10 12 13 14 15 16 17 18 19 20 27 23 24 25 REMOVE THE FOUR BRASS NUTS HOLDING THE ALUMINUM AIR INLET ASSEMBLY 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 74 FLAT HEAD SCREWDRIVER NOW PULL THE IGNITOR 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 REMOVE THE FOUR BRASS NUT RETAINING THE BLOWER TO THE OUTER BURNER MOUNTING FLANGE WITH 7 16 WRENCH
44. TEM HOW TO SIZE THECOMBINATIONSYSTEM FOR RADIANTHEATING IT IS IMPORTANT TO SIZE BOTH HEATING LOAD AND DOMESTIC HOT WATER LOAD IN CHOOSING WHICH SUPER E 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 SUPER E SSVH MODEL THIS CHART OUTLINES OUT PUT CHARACTERISTICS IN TERMS OF FLOW RATE THROUGH THE SECONDARY HEAT EXCHANGER TEMPERATURE RISE AND BTU OUTPUT IT IS IMPORTANT TO CHECK WITH YOUR RADIANT SUPPLIER ON 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 SUPER E 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 SUPER E SSVH MODEL CAN DELIVER THE DESIRED TEMPERATURE BEFORE THE TANK RATE INPUT AND STORAGE ARE CONSUMED THIS USUA
45. 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 top 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 22 and 23 You
46. Y 037142405 9 JHI NO 035 8 HOLDVHINDJ SNITIVISNI AB O3TIWISNI 38 OTNOKHS S3310NVH alv S33lviH HALVA 934 599 49435343 MOS 3er HE LINN HJIQNVH NO LON l INM NI 038N038 SOIVIDOMNIS M03 4001 INVIOVH 1 LOH JIIS3AOG 5 DNILV3K NOLLVNIBINOO PAGE 26 COMPLETE DOWN PROCEDURE TOOLS REQUIRED 5 16 NUT DRIVER Ya FLAT HEAD SCREWDRIVER 3 8 DEEP SOCKET 2 PHILLIPS HEAD SCREWDRIVER 7 16 DEEP SOCKET 10 PIPE WRENCH 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 Qu cun 22 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 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 LOSE 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 INLET ADAPTER AND PULL THE AIR INLET ADAPTER THROUGH THE SIDE OF THE CABINET NOTE BE SURE NOT TO LO
47. ange 9 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 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 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 ic vacuuming of the cover to maintain visibility of the display and indicators is recommended In dirty environments construction sites building constructions care must be taken to keep the appliance door in place and drywall or saw dust away from appliance CAUTION In unusually dirty or dusty conditions care must be taken to keep appliance door in place 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 and wait for the
48. d 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 COMPONENTS DIAGRAM 1 2 NPT X 6 GAS INLET NIPPLE 2 GAS VALVE HTPPAM203 3 GAS VALVE ELBOW P1002 4 GAS ORIFICE UNION 9500 0028 5 GAS ORIFICE 5500 0009 9 GAS CONVERSION KITS 90 000 PROPANE NATURAL NYAG 90 000 NATURAL PROPANE P9A6 100 000 PROPANE NATURAL NTOAC 100 000 NATURAL TO PROPANE P10A6 130 000 PROPANE NATURAL NTSAG 190 000 NATURAL PROPANE P1 SAG 160 000 PROPANE NATURAL NTOAG 160 000 NATURAL PROPANE P16AG 199 000 PROPANE NATURAL NT9AG 199 000 NATURAL TO PROPANE P19AG UNION CONNECTOR NIPPLE MAIN CONTROL PC BOARD WHC1001 CNT 2 OR CNT 3 MUST SPECIFY MODEL amp SERIAL NUMBER WHEN ORDERING 8 DISPLAY PC BOARD WHC1001 DSP 9 PRESSURE SWITCH WHC1001 PSW 10 TRANSFORMER WHC1001 XMR 11 ECO TEMPERATURE PROBE WHC1001 ECO 1 12 110V SURFACE IGNITOR 0206 7003 13 FLAME RECTIFICATION PROBE PSE TF1 14 OVER TEMPERATURE SWITCH VS210 15 COMBUSTION BLOWER HTPBDC120 SPECIFY BTU OF YOUR UNIT WHEN ORDERING 16 GLASS SIGHT WINDOW 62000 GASKET SIGHT WINDOW 0506
49. em includes 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 sure that the Super E 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 will result in failure to operate 3 Make sure that the cold water supply has been turned on and that the Super E 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 Turn on electrical supply The control will first display 102 then 88 8 which is the control display test and finally the actual tank temperature at the probe B 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
50. ional standard plumbing codes It is important that the piping must be clean and free from burrs 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 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
51. is very important that the building system ground is inspected by a qualified electrician prior to making this connection The black wire 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 electrical 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 a 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 A WARNING It is very important that you are connected to the type of gas as noted on the rating plate You must ensure that the entire gas line to the connection at the Super E is no smaller than 3 4 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 Failure to follow all precautions below could result in fire explosion or death 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 uti
52. lity in addition to the governing authority prior to turning the gas supply on The nipple provided is 1 2 and it is manda tory 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 Once all the inspections have been performed the piping must be leak tested 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 DANGER Never use an open flame lit match lighter to check gas connections This could result in serious injury or death It is recommended that a soapy solution be used to detect leaks Bubbles will appear on pipe to indicate a 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 under sized 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 and 14 during stand by and unit running hea
53. n long enough the set point will reach 160 degrees 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 differential 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
54. ntrol 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 simpli fies 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 also 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 PAGE 9 used to determine the operating status of the appliance and provide assistance when troubleshooting any problems which 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 syst
55. om exhaust Always have vent location at least 1 above maximum snow level Always have vent 1 above ground level away from shrubs and bushes Always be at least 2 horizontally from doors or windows 36 for Canadian installations Refer to Fig pg 21 Always have vent at least 3 from inside corner of outside walls Maintain at least 4 clearance to electric bas 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 Super E can be found on pages 22 and 23 Use the following layout as 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 of 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 lea
56. scalded See instruction manual before setting temperature c water heater Feel water before bathing or showering Temperature ca limiting valves are available LOCATION Choose 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 decreases 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 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 water heater should always be located in area with floor drain or installed in drain pan suitable for water heaters Proper clearance must be provided around the Voyager as follows Sides bottom top and back are 0 Zero clearance Front of the appliance needs 24 service clearance minimum This front service may be achieved by non rated or combustible door or access panel providing the 24 service clearance is achieved when the door is
57. st 4 Please refer to typical venting on pages 22 and 23 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 It is recommended that you use one of the mentioned vent kits specifically for Super E installations either KGAVT0501CVT 2 in or KGAVTO601CVT 3 in or the V1000 CLEARANCE SHALL BE IN ACCORDANCE WITH LOCAL INSTALLATION CODES AND TH REQUIREMENTS OF THE GAS SUPPLIER PAGE 20 5 700 7 ISNV 494 94 Y SIU Y 14 110 02 2 UONDSS Bugsa anjer PAJE pu aq eys jo euo 6r L8 vSO 10 VdAN 176227 ISNY ut jou SSJUEJESD 104 a UYjESUSq sapis og jo uo si 10 Auo f sBunjamp ujoq serues pue ajGurs uaamjaq 4 9 JUIA JJ 1 JU3A 921195 2 5 jquiasse Jojejnbas Jayaul _ 3233 atg
58. st be obtained through the factory with all necessary labels and the serial number must be provided to the factory OR WARRANTY WILL BE VOIDED SUPER E GAS CONVERSION INSTRUCTIONS FOR CONVERSION OF THE VOYAGER TO PROPANE OR NATURAL GAS YOU MUST ORDER A CONVERSION KIT FROM THE FACTORY BELOW IS A LIST OF THE DIFFERENT MODEL NUMBERS YOU WILL NEED TO REFERENCE WHEN ORDERING YOUR KIT PLEASE CALL THE FACTORY AT 1 800 323 9651 CUSTOMER SERVICE TO PLACE YOUR ORDER 90 000 PROPANE TO NATURAL N9AG 90 000 NATURAL TO PROPANE P9A6 100 000 PROPANE TO NATURAL N10AG 100 000 NATURAL TO PROPANE P10AG 130 000 PROPANE TO NATURAL N13AG 130 000 NATURAL TO PROPANE P13AG 160 000 PROPANE TO NATURAL N16AG 160 000 NATURAL TO PROPANE P16AG 199 000 PROPANE TO NATURAL N19AG 199 000 BTU SUPER E S GAS ORIFICE SIZES AIR ORIFICE 1 375 NATURAL GAS 379 PROPANE LP GAS 295 160 000 BTU SUPER E S GAS ORIFICE SIZES AIR ORIFICE 1 375 NATURAL GAS 362 PROPANE LP GAS 2959 130 000 BTU SUPER E S GAS ORIFICE SIZES AIR ORIFICE 1 125 NATURAL GAS 280 PROPANE LP GAS 235 NATURAL GAS CONVERSION FROM PROPANE LP 2809 PROPANE LP GAS CONVERSION FROM NATURAL GAS 250 100 000 BTU SUPER E S 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 PAGE 13 90 000 BTU SUPER E S AIR
59. stored into permanent memory PAGE 10 OVERALL APPLIANCE AND CONTROL OPERATION normal operating sequence 15 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 d 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 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 Atthis point the gas valve is closed and the control enters the post purge cycle The flame can be viewed through window on the lower right of combustion blower fl
60. sure that the wire harness is not damaged If the wire harness is damaged replace the wiring harness Part Number 7000 857 After completing steps 1 through 3 and the ECO Vent Switch LED light is still flashing it will be required to trouble shoot the ECO switch see page 16 in the Installation Manual PAGE 4 CAUTION 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 as per the national standard plumbing code to prevent scald injury ELECTRICAL CONNECTION The electrical connection for the Super E 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 WARNING It is of extreme importance that this unit be properly grounded Ground the water heater by connecting the green wire in the electrical access compartment directly to the main building ground system
61. t 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 purged by the gas sup plier 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 installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines PAGE 5 WARNING The gas valve is special gas valve which has Pressure Augmented Regulator feature as well as negative outlet pressure This valve must not be replaced with 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 VENT PIPE MATERIALS REQUIRED 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 nat
62. venting the Voyager can be found on pages 22 and 23 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 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 All venting must be prop erly supported as the SUPER E 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 PAGE 6 12 It is recommended that you use one of the mentioned vent kits specifically for Voyager installations either KGAVT0501CVT 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 APPROVED VENTING MATERIALS Exhaust
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