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Voyager SSV199-119R Operating Manual

Gas fired water heater
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See also: Operating, Installation and Service Manual
OPERATING, INSTALLATION, AND
VOYAGER GAS FIRED WATER HEATER
SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE
MANUFACTURED BY:
SERVICE MANUAL FOR THE
HEAT TRANSFER PRODUCTS, INC.
P.O. BOX 429, 120 BRALEY ROAD
EAST FREETOWN, MA 02717
TEL.: 1-508-763-8071 and (outside of MA) 1-800-323-9651
FAX: 1-508-763-3769 (sales, cust. svc.)
1-508-763-3448 (purchasing)
1-508-763-5269 (engineering, technical)
......or visit our website at: WWW.HTPRODUCTS.COM
member
gama
gama
ANSI Z 21.10.3
PAGE: 1
LP-41 REV: 3/1/03

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  • 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: HEAT TRANSFER PRODUCTS, INC. P.O. BOX 429, 120 BRALEY ROAD EAST FREETOWN, MA 02717 TEL.: 1-508-763-8071 and (outside of MA) 1-800-323-9651...

  • Page 2: Specifications

    TO REFERENCE VOYAGER MODEL NUMBERS, PLEASE USE THE FOLLOWING GUIDELINES: - 45 Temperature Warranty A = 6 yrs. parts; 6 yrs. comm.; 10 yrs. res. (Degrees Fahrenheit) Series BTU U.S. Temp. Warr. Gas Type B = 1 yr. parts; 3 yrs. comm.; 10 yrs. res.

  • Page 3: What To Do If You Smell Gas

    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: Expansion Tank

    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.

  • Page 6: Pipe / Fittings

    The vent intake and exhaust must be properly cleaned and glued, for pressure tight joints. Several methods for venting the Voyager can be found on pages 21 and 22. Use the following layout as a guideline; certain site conditions such as multiple roof lines/pitches may require venting modifications-consult factory.
  • Page 7 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 8 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 9: Control Description

    Make sure that the cold water supply has been turned on and that the Voyager is completely filled with water. Verify this by opening a hot water faucet, and allowing water to flow until all air is removed and a clear water flow is present;...

  • Page 10: Overall Appliance And Control Operation

    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.

  • Page 11: Maintenance

    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.
  • Page 12 PAGE: 12 LP-41 REV: 3/1/03...
  • 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: Troubleshooting

    BOARD VERY IMPORTANT SET-UP INSTRUCTIONS! IF YOU HAVE A COMBUSTION ANALYZER, THE FOLLOWING RATINGS WILL BE VERY HELPFUL IN SETTING UP YOUR VOYAGER: FOR NATURAL GAS - CO2 READING SHOULD BE BETWEEN 9 ½% & 10 ½% O2 READING SHOULD BE BETWEEN 3 ½% & 4 ½%...
  • Page 15 PAGE: 15 LP-41 REV: 3/1/03...
  • Page 16 PAGE: 16 LP-41 REV: 3/1/03...
  • Page 17 PAGE: 17 LP-41 REV: 3/1/03...
  • Page 18 PAGE: 18 LP-41 REV: 3/1/03...
  • Page 19 PAGE: 19 LP-41 REV: 3/1/03...
  • Page 20 TYPICAL VENTING PAGE: 20 LP-41 REV: 3/1/03...
  • Page 21 PAGE: 21 LP-41 REV: 3/1/03...
  • Page 22 PAGE: 22 LP-41 REV: 3/1/03...
  • Page 23 PAGE: 23 LP-41 REV: 3/1/03...
  • Page 24 PAGE: 24 LP-41 REV: 3/1/03...
  • Page 25 PAGE: 25 LP-41 REV: 3/1/03...
  • 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

    PARTS ILLUSTRATIONS AIR INLET ADAPTER NI110 AIR INLET MANIFOLD A5000 PAGE: 29 LP-41 REV: 3/1/03...
  • Page 30 GASKET AIR INLET G5030 GAS ORIFICE UNION GGU5 PAGE: 30 LP-41 REV: 3/1/03...

  • Page 31: Gas Orifice

    GAS ORIFICE 01000 AIR ORIFICE A3001 = 1.0 SIZE; A3002 = 1.125 SIZE; A3003 = 1.375 SIZE FLAME RECTIFICATION PROBE PSE-TF1 PAGE: 31 LP-41 REV: 3/1/03...
  • Page 32 GASKET BURNER MOUNTING FLANGE G5010 BURNER MOUNTING FLANGE 7000-616 PAGE: 32 LP-41 REV: 3/1/03...
  • Page 33 GAS VALVE GV1000 AIR INLET CONNECTOR F3000 PAGE: 33 LP-41 REV: 3/1/03...
  • Page 34 110V IGNITOR - SURFACE IGNITER 0206FF003 GASKET BURNER MOUNTING FLANGE WHITE G5040 GASKET BLOWER OUTLET FLANGE G5020 PAGE: 34 LP-41 REV: 3/1/03...
  • Page 35 GAS ORIFICE CONVERSION INSTRUCTIONS IF UNIT IS INSTALLED, TURN OFF POWER AND GAS SUPPLY BEFORE PERFORMING ANY CONVERSIONS. TO CHANGE GAS ORIFICE, DISCONNECT UNION (#6) BETWEEN THE GAS VALVE AND AIR INLET; REMOVE OLD GAS ORIFICE (#5), AND INSTALL THE NEW GAS ORIFICE IN THE UNION THAT CORRESPONDS TO THE UNIT MODEL NUMBER AND FUEL BEING USED.
  • Page 36 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 37 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 38 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 39 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 40 TURN THE BLUE KNOW 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: 40 LP-41 REV: 3/1/03...
  • Page 41 TURN THE ADJUSTMENT SCREW TWO FULL TURNS COUNTERCLOCKWISE. SHUT THE VOYAGER DOWN, THEN START IT UP AGAIN; LET IT RE-LIGHT. IF THE IGNITION WAS GOOD, THE VALVE NEEDS NO FURTHER ADJUSTMENT. IF THE IGNITION WAS POOR, SHUT DOWN THE UNIT AND LET IT CYCLE AGAIN.
  • Page 42 HOW TO SIZE THE COMBINATION SYSTEM FOR RADIANT HEATING IT IS IMPORTANT TO SIZE BOTH HEATING LOAD AND DOMESTIC HOT WATER LOAD, IN CHOOSING WHICH VOYAGER SSVH MODEL YOU WILL NEED TO PURCHASE FOR THE JOB. ON THE FOLLOWING PAGE IS A CHART WHICH REPRESENTS DESIGN OUTPUTS OF THE SECONDARY HEAT EXCHANGER IN THE VOYAGER SSVH MODEL.
  • Page 43 **FOR SSVH-199-80 MODELS ONLY! NOTE: THE VOYAGER MUST BE SET 25 DEGREES F. ABOVE THE SYSTEM TEMPERATURE. THE ABOVE CHART IS BASED ON USING THE CIRCULATOR BETWEEN THE DOMESTIC COLD WATER INLET AND THE DOMESTIC HOT WATER OUTLET. FOR SET POINT TEMPERATURES ABOVE 120 DEGREES F., YOU MUST USE AN ANTI-SCALD TEMPERING VALVE ON THE OUT- LET TO DOMESTIC HOT WATER FIXTURES.

  • Page 44: Very Important

    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.

This manual is also suitable for:

Ssv199-45sSsvr199-80rSsv160-45sSsv130-119rSsv13-80rSsv130-45r ... Show all

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