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OPERATING, INSTALLATION, AND
SERVICE MANUAL FOR THE
VOYAGER GAS FIRED WATER HEATER
SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE
member
gama
ANSI Z 21.10.3
NATIONAL COMBUSTION CO. INC.
TH
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
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Summary of Contents for Natco ANSI Z 21.10.3
- Page 1 OPERATING, INSTALLATION, AND SERVICE MANUAL FOR THE VOYAGER GAS FIRED WATER HEATER SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE member 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.
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Page 3: Temperature And Pressure Relief Valve
WARNING IF THE INFORMATIONIN THESE INSTRUCTIONS ARE NOT FOLLOWEDEXACTLY, 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;... -
Page 4: Domestic Water Connection
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. -
Page 5: Electrical Connection
CAUTION 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 Super-E is on the left side of the combustion shroud. There is a 1/2" knockout location for electrical connection. - Page 6 WARNING The gas valve is a special gas valve which has a Pressure Augmented Regulator feature, as well as negative outlet 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.
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Page 7: Pipe/ Fittings
It is recommended that you use one of the mentioned vent kits specifically for Voyager installations; either KGAVT0501CVT (2 in.), KGAVT0601CVT (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. - Page 8 FRICTION LOSS EQUIVALENCE TABLES 2" VENTED MODELS AFTER THE FIRST 10’ OF 3" 3" VENTED MODELS SSV100-45R/SSV130-45R ONLY4" EQUIVALENT TABLE EQUIVALENT EQUIVALENT EQUIVALENT FITTING FEET FEET FITTING DESC. FEET OF DESC. OF PIPE FITTING DESC. OF PIPE PIPE 3” 90 5’...
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Page 9: Control Description
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. -
Page 10: Start-Up Procedure
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. -
Page 11: Maintenance
OVERALL APPLIANCE AND CONTROL OPERATION A normal operating sequence is as follows: 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; The control performs selected system diagnostic checks; If all checks are successfully passed, the combustion blower is energized for the 40 second pre-purge cycle;... - Page 12 PAGE: 12...
- Page 13 REPLACEMENT PARTS NOT SHOWN LOW VOLTAGE CABLE ASSEMBLY (710B0041) INTERCONNECT RIBBON CABLE (7000-665) LINE CABLE (710B0048) PUSH BUTTON (7000-667) TRANSFORMER (7000-666) GASKET BURNER MOUNTING FLANGE (G5010) GASKET BLOWER OUTLET FLANGE (G5020) 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.
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Page 14: Troubleshooting
90,000 BTU SUPER-E’S- 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" 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. - Page 15 PAGE: 15...
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- Page 20 TYPICAL VENTING CAUTION YOU MUST USE SUPPLIED ABS PIPE FOR FIRST 84” OF EXHAUST PIPING. ADDITIONAL PIPING CAN BE ABS OR PVC. YOU MUST SUPPORT ALL PIPING, THE APPLIANCE IS NOT INTENDED TO SUPPORT VENTINGPIPES. PLEASE NOTE: THE METHODS DESCRIBED ARE SUGGESTED GENERIC METHODS ONLY. SPECIFIC JOB SITE OBSERVATIONS AND SIZING MAY REQUIRE ALTERNATE INSTALLATION METHODS.
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- Page 27 COMPLETE TEAR DOWN PROCEDURE TOOLS REQUIRED: 5/16" NUT DRIVER ¼" FLAT HEAD SCREWDRIVER 3/8" DEEP SOCKET #2 PHILLIPS HEAD SCREWDRIVER 7/16" DEEP SOCKET 10" PIPE WRENCH ½" DEEP SOCKET 1 ¼" DRIVE INCH POUND TORQUE 3/8" WRENCH WRENCH (RANGE 0-200) 7/16"...
- Page 28 ASSEMBLY REPLACE THE WHITE FIBER BURNER MOUNTING FLANGE GASKET WITH A NEW GASKET. PUT THE BURNER MOUNTING FLANGE BACK IN PLACE WITH THE ½" HOLE NEXT TO THE LARGE HOLE IN THE CENTER OF THE PLATE TO THE RIGHT AND WITH THE STUDS FACING OUT. TIGHTEN THE SIX ½"...
- Page 29 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.
- Page 30 PARTS ILLUSTRATIONS PAGE: 30...
- Page 31 GAS VALVE REPLACEMENT - REMOVAL SHUT OFF POWER TO THE SUPER-E. REMOVE THE DOOR FROM THE SUPER-E 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.
- Page 32 BREAK THE UNION THAT CONNECTS THE GAS VALVE TO THE AIR INLET MANIFOLD. 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.
- Page 33 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 THE "ON" POSITION. 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.
- Page 34 IF IGNITION WAS POOR: 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 AT ½ TURN INTERVALS, UNTIL THE FLAME TURNS BLUE/LIGHT BLUE IN COLOR, OR THE WHISTLING AT IGNITION STOPS.
- Page 35 CONNECT THE VACUUM HOSE ACCORDING TO THE FOLLOWING DIAGRAM: 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.
- Page 36 LET THE SUPER-E CYCLE. AFTER THE 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".
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Page 37: How To Installthesystem
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 IN A VERY SMALL COMPACT DESIGN, WHEN COMPARED WITH CONVENTIONAL WATER HEATERS. - Page 38 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.) 15,000 20,000 25,000 30,000 22,500 30,000 37,500 45,000 30,000 40,000 50,000 60,000...
- Page 39 VERY IMPORTANT!!! SUPER-E THIS HAS THE NEW 1200 BOARD AND BLOWER SYSTEM! THE ADDITIONAL FEATURES ARE LISTED BELOW: 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 POLARITY! THE BLOWER CABLE AND THE CURRENT LIMITER HAVE BEEN ELIMINATED.
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