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Voyager SSV199-119R Operating, Installation And Service Manual

Gas fired water heater
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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
gama
ANSI Z 21.10.3
MANUFACTURED BY:
Visit our website at: WWW.HTPRODUCTS.COM
© 2008, 2006, 2005, 2004 Heat Transfer Products, Inc.
PAGE: 1
LP-41 REV: 9/26/08

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Summary of Contents for Voyager SSV199-119R

  • 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 gama ANSI Z 21.10.3 MANUFACTURED BY: Visit our website at: WWW.HTPRODUCTS.COM © 2008, 2006, 2005, 2004 Heat Transfer Products, Inc.
  • Page 2 TO REFERENCE VOYAGER MODEL NUMBERS, PLEASE USE THE FOLLOWING GUIDELINES: - 45 Temperature Warranty (Degrees Fahrenheit) A = 6 yrs. parts; 6 yrs. comm.; 10 yrs. res. Series U.S. Temp. Warr. Gas Type R = 160 B = 1 yr. parts; 3 yrs. comm.; 10 yrs. res.
  • Page 3 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 decreases. You must also locate the Voyager where it will not be exposed to freez- ing temperatures.
  • Page 4 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 ½".
  • Page 5 The gas pressure must remain between 7" and 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 purged by the gas sup- plier or utility.
  • Page 6 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 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.
  • Page 7 WARNING You must not connect vent connectors serving other appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. Follow the venting instructions below carefully. Failure to do so may result in severe personal injury, death, or substantial property damage. Install the water heater venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes.
  • 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’...
  • Page 9 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.

  • Page 10: Overall Appliance And Control Operation

    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.

  • Page 11: Shutdown Procedure

    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 F.
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  • Page 13 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.

  • Page 14: Natural Gas

    MAIN CONTROL BOARD WARNING YOU MUST USE A COMBUSTION ANALYZER WHEN SETTING UP THE VOYAGER. ONLY AN HTP APPROVED CONVERSION KIT SHOULD BE USED WHEN DOING A GAS CONVERSION. COMBUSTION SETTINGS HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS...
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  • Page 20 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 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’...
  • Page 21 Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot. There should be no more than 2 vents and 2 intakes then a space of 36” to the next set of vents.
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  • Page 26 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 27 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 28 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 29 PARTS ILLUSTRATIONS PAGE: 29...
  • Page 30 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 31 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 32 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. 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.
  • Page 33 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.
  • Page 34 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 VOYAGER. PAGE: 34...
  • Page 35 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.
  • Page 36 ONCE. THIS WILL TAKE PLACE IN THE NORMAL OPERATING SEQUENCE IN A HEAT CYCLE. 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.
  • Page 37 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 38 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
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  • Page 40 © 2008, 2006, 2005, 2004 Heat Transfer Products, Inc. PAGE: 40...

This manual is also suitable for:

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