Voyager SSV130-119R, SSV199-45S, SSV13-80R, SSV130-45R, SSV100-45R Operating Manual
...
PAGE: 1 LP-41 REV: 3/1/03
member
gamagama
OPERATING, INSTALLATION, AND
SERVICE MANUAL FOR THE
VOYAGER GAS FIRED WATER HEATER
SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE
ANSI Z 21.10.3
MANUFACTURED BY: HEAT TRANSFER PRODUCTS, INC.
P.O. BOX 429, 120 BRALEY ROAD
EAST FREETOWN, MA 02717
TEL.: 1-508-763-8071 and (outside of MA) 1-800-323-9651
FAX: 1-508-763-3769 (sales, cust. svc.)
1-508-763-3448 (purchasing)
1-508-763-5269 (engineering, technical)
......or visit our website at: WWW.HTPRODUCTS.COM
PAGE: 2 LP-41 REV: 3/1/03
SPECIFICATIONS
Recovery on rating plate is based at 94% thermal efficiency at 100 degrees Fahrenheit rise, as required by A.N.S.I.
THESE MODELS ARE ONLY AVAILABLE AS "R" MODELS WITH 160 DEGREES F. MAX. SETPOINT
*THIS MODEL IS ALSO AVAILABLE AS AN "S" MODEL WITH 180 DEGREE F. MAX. SETPOINT AND 3" VENT
TO REFERENCE VOYAGER MODEL NUMBERS, PLEASE
USE THE FOLLOWING GUIDELINES:
SSVH MODELS HAVE OPTIONAL HEAT EXCHANGER FOR FLOOR RADIANT AND COMBINED HEAT
CONNECTION SIZES ARE 1" NPT DOMESTIC INLET, DOMESTIC OUTLET FOR THE 45 GALLON UNITS.
CONNECTION SIZES ARE 1 1/2" NPT DOMESTIC INLET, DOMESTIC OUTLET FOR THE 80 & 119 GALLON UNITS.
Note: These overall dimensions are approximate within +/– 1".
Heat Transfer Products reserves the right to change specifications or discontinue models without notice.
SSV 130 -45 S A LP
Series BTU U.S. Temp. Warr. Gas Type
Gal. (Deg. F.)
Temperature
(Degrees Fahrenheit)
R = 160
S = 180
Warranty
A = 6 yrs. parts; 6 yrs. comm.; 10 yrs. res.
B = 1 yr. parts; 3 yrs. comm.; 10 yrs. res.
GALLON INPUT BTU/HR. TEMPERATURE RISE IN DEGREES FAHRENHEIT
MODEL CAPACITY NATURAL & LP GAS 40 50 60 70 80 90 100 110 120 130 140
GPH 545 436 363 311 272 242 218 198 181 167 155
SSV199-119R
SSV & SSVH199-80R
SSV199-45S
SSV160-45S
SSV130-80R
SSV130-119R
SSV130-45R/S
SSVH130-45S
SSV100-45R
SSV90-45S
SSVH90-45S
119 199,000 GPM 97654.543.53.332.72.5
GPH 545 436 363 311 272 242 218 198 181 167 155
80 199,000 GPM 97654.543.53.332.72.5
GPH 545 436 363 311 272 242 218 198 181 167 155
45 199,000 GPM 97654.543.53.332.72.5
GPH 436 349 290 249 218 193 174 158 145 134 124
45 160,000 GPM 7 5.8 4.8 4 3.6 3.2 2.9 2.6 2.4 2.2 2
GPH 354 283 236 202 177 157 141 128 118 109 101
80 130,000 GPM 5.9 4.7 3.9 3.9 2.9 2.6 2.3 2.1 1.9 1.8 1.6
GPH 354 283 236 202 177 157 141 128 118 109 101
119 130,000 GPM 5.9 4.7 3.9 3.9 2.9 2.6 2.3 2.1 1.9 1.8 1.6
GPH 354 283 236 202 177 157 141 128 118 109 101
45 130,000 GPM 5.9 4.7 3.9 3.9 2.9 2.6 2.3 2.1 1.9 1.8 1.6
GPH 354 283 236 202 177 157 141 128 118 109 101
45 130,000 GPM 5.9 4.7 3.9 3.9 2.9 2.6 2.3 2.1 1.9 1.8 1.6
GPH 269 215 179 154 134 119 108 98 89 82 77
45 100,000 GPM 4.4 3.5 2.9 2.5 2.2 1.9 1.7 1.5 1.4 1.3 1.2
GPH 245 196 163 140 122 109 98 89 81 75 70
45 90,000 GPM 4 3.2 2.7 2.3 2 1.8 1.6 1.4 1.3 1.2 1.1
GPH 245 196 163 140 122 109 98 89 81 75 70
45 90,000 GPM 4 3.2 2.7 2.3 2 1.8 1.6 1.4 1.3 1.2 1.1
SHIP.
MODEL HEIGHT WIDTH WEIGHT DEPTH
SSV199-119R
SSV199-80R
SSV199-45S
SSV160-45S
SSV130-119R
SSV130-80R
SSV130-45R*
SSV100-45R
SSV90-45S
74"
72"
42 1/2"
42 1/2"
74"
72"
42 1/2"
42 1/2"
42 1/2"
27 1/4"
23 1/4" 235 Lbs. 32"
23 1/4" 175 Lbs. 32"
23 1/4" 175 Lbs. 32"
27 1/4"
23 1/4" 230 Lbs. 32"
23 1/4" 175 Lbs. 32"
23 1/4" 175 Lbs. 32"
23 1/4" 175 Lbs. 32"
405 Lbs. 36"
400 Lbs. 36"
MODEL INPUT RATING SIZE EFFIC. %
SSV199-119R
SSV199-80R
SSV199-45S
SSV160-45S
SSV130-119R
SSV130-80R
SSV130-45R*
SSV100-45R
SSV90-45S
199,000 335 3" 94%
199,000 300 3" 94%
199,000 270 3" 94%
160,000 220 3" 94%
130,000 250 2" 94%
130,000 220 2" 94%
130,000 180 S-3"/R-2" 94%
100,000 138 2" 95%
90,000 125 3" 95%
FIRST HOUR VENT RECOVERY
FIRST HOUR VENT RECOVERY HEAT HEAT SHIP.
MODEL HEIGHT WIDTH DEPTH INPUT RATING SIZE EFFIC. % EXCHANGER BTU EXCHANGER WEIGHT
SSVH199-80R 32" 199,000 300 Gallons 3" 94% 140,000 32 sq. ft. 255 Lbs.
SSVH130-45S 23 1/4" 32" 130,000 180 Gallons 3" 94% 110,000 32 sq. ft. 205 Lbs.
72"
42 1/2"
SSVH90-45S 32" 90,000 125 Gallons 3" 95% 81,000 32 sq. ft. 205 Lbs.
24 1/4"
23 1/4"42 1/2"
PAGE: 3 LP-41 REV: 3/1/03
WARNING:
IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY
RESULT; CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance;
WHAT TO DO IF YOU SMELL GAS:
- Do not try to light any appliance;
- Do not touch any electrical switch; do not use any phone in your building;
- Immediately call your gas supplier from a neighbor's phone;
- Follow the gas supplier's instructions;
- If you cannot reach your gas supplier; call the fire department;
- Installation and service must be performed by a qualified installer; service agency or the gas supplier.
DANGER:
Water temperature over 125 degrees F. can cause severe burns instantly, or death from
scalds. Children, disabled, and elderly are at highest risk of being scalded. See
instruction manual before setting temperature at water heater. Feel water before
bathing or showering! Temperature limiting valves are available.
LOCATION
Choose a location for your water heater centralized to the piping system, along with consideration to vent pipe length. As the length of
vent pipe increases the firing rate of the appliance decreases. You must also locate the Voyager where it will not be exposed to freezing temperatures. Additionally, you will need to place the water heater so that the controls, drain, inlet/outlet, and gas valve are easily
accessed. This appliance must not be installed outdoors, as it is certified as an indoor appliance, and must be kept vertical and on a
level surface. Also, care must be exercised when choosing the location of this appliance; where leakage from the relief valve, leakage
from related piping, or leakage from the tank or connections, will not result in damage to the surrounding areas or to the lower floors of
the building. A water heater should always be located in a area with a floor drain or installed in a drain pan suitable for water
heaters. Proper clearance must be provided around the Voyager as follows: Sides, bottom, top, and back are 0" (zero clearance).
Front of the appliance needs 24" service clearance minimum. This front service may be achieved by a non-rated or combustible door
or access panel; providing the 24" service clearance is achieved when the door is opened or panel is removed. Under no circum-
stances, shall Heat Transfer Products Inc. be held liable for any such water damage whatsoever. This water heater must not
be located near flammable liquids such as gasoline, adhesives, solvents, paint thinners, butane, liquefied propane, etc.; as
the controls of this appliance could ignite those vapors, causing an explosion.
TEMPERATURE AND PRESSURE RELIEF VALVE
A temperature and pressure relief valve is installed into the marked port (upper right), we recommend a WATTS 100XL-4 valve or
equivalent for 100,000 BTU models or below input, 40XL5 valve or equivalent for 130,000 BTU models or above input, meeting the
requirements for relief valves for hot water heaters as per ANSI Z21.22B-1984 by a nationally recognized lab that maintains a periodic
inspection of production of such listed safety device. The pressure rating of the valve must not exceed the listed working pressure of
this appliance, and must be rated to the proper BTU/hr capacity of the water heater. Do not, under any circumstances, thread a cap
or plug into the relief valve! Explosion, serious injury or death may result! Relief valve piping must be directed to the floor or to
an open drain, but not connected directly. There must be a 6" space between the outlet of relief valve piping and drain or floor. Do not
hook up to drain system directly without an air space. The relief valve must be periodically checked for proper operation.
PAGE: 4 LP-41 REV: 3/1/03
EXPANSION TANK
A potable hot water expansion tank may be required to offset the water expansion as the water is heated. In most city plumbing systems, 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. The expan-
sion tank must be suitable for hot potable water.
DOMESTIC WATER CONNECTIONS
WARNING!!
NEVER USE DIELECTRIC UNIONS OR GALVANIZED STEEL FITTINGS ON ANY DOMESTIC WATER CONNECTIONS.
USE ONLY COPPER OR BRASS FITTINGS. TEFLON THREAD SEALANT MUST BE USED ON ALL CONNECTIONS.
The domestic water connections must be installed in accordance to all local and national plumbing codes, or any applicable standard
which prevails. The inlet and outlet ports of the Voyager are 1" on 45 gallon models. On the 80 and 119 gallon models, the inlet and
outlet ports are 1 ½". On the cold inlet, (bottom left), install a 1" brass tee on 45 gallon models, or a 1 ½" 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 ½" brass tee, install a copper male adapter to match your copper plumbing system. For convenience, you may install a sweat
shut off valve and a union in the cold inlet piping to ease servicing in the future. If there is a back flow preventer, or any type of a 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 outlet, (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 23 or 24
for typical installations. A domestic hot water tempering/anti-scald valve should be installed into hot water line to prevent the maximum
outlet water temperature from exceeding 119 degrees F. as per the national standard plumbing code, to prevent scald injury.
ELECTRICAL CONNECTION
The electrical connection for the Voyager is on the left side of the combustion shroud. There is a 1/2" knockout location for electrical
connection. All electrical wiring must be performed by a qualified licensed electrician, and in accordance with National Electrical Code,
or to the applicable local codes and standards. The electrical requirements are for standard 120 volts, 60 Hz 10 amp service. It is recommended 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.
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. It 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 electri
-
cal power is not turned on at this time
! A green LED is provided on the main control board. This LED must be luminated
when appliance is turned on for proper operation. Failure to luminate means bad or missing ground or reverse polarity.
GAS CONNECTION
Gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), 1/2 pound pressure (3.4 kPa), and a minimum of 7" water column. The entire piping system, gas meter, and regulator must be sized properly to prevent pressure drop greater
than 0.5" as stated in the National Fuel Gas Code. This information is listed on the rating plate. It is very important that you are
connected to the type of gas as noted on the rating plate. "LP" or liquefied petroleum, or propane gas; or "Nat" natural gas or city
gas. All gas connections must be approved by the local gas supplier, or utility in addition to the governing authority, prior to turning the
gas supply on. The nipple provided is 1/2", and it is mandatory that a 3/4" to 1/2" reducing bushing (provided) is used, threaded into
the branch of a 3/4" tee, and a drip leg fabricated, as per the national Fuel Gas Code. You must ensure that the entire gas line to
the connection at the Voyager is no smaller than 3/4". Once all the inspections have been performed, the piping 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. In the event the gas valve is exposed to a pressure
greater than 1/2 PSI, 14" water column, the gas valve must be replaced. Never use an open flame (lit match, lighter) to check gas
connections.
PAGE: 5 LP-41 REV: 3/1/03
GAS CONNECTION (CONTINUED)
Failure to follow all precautions could result in fire, explosion or death! It is recommended that a soapy solution be used to
detect leaks. Bubbles will appear on pipe to indicate 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 undersized or in need of service. On the inlet side of the gas
valve, there is a 1/8" NPT plug, which can be removed to attach a hose barb, hose, and inches of water column meter. Also, you can
attach a meter to the incoming gas drip leg, by removing the cap and installing the meter. The gas pressure must remain between 7"
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 supplier or utility. Failure to properly purge the lines or
improper line sizing, will result in the failure of the Voyager lighting off. This problem is especially noticeable in NEW LP installa-
tions, and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines. 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.
VENTING
FOR ALL MODELS 3" VENTED EXCEPT
SSV100-45R AND SSV130-45R (WHICH ARE 2" VENTED)
(FOR 2" VENTED MODELS SSV100-45R AND SSV130-45R, SEE TOP OF PAGE 8)
For inlet air supply, top pipe on the right of the shroud, use 3" PVC schedule 40. It is very important that you plan the location properly,
to eliminate long pipe runs and excessive fittings. Inlet pipe size must not be reduced. Do not combine the inlet air with any other inlet
pipe including an inlet to an additional similar appliance. The joints must be properly cleaned, primed, and cemented. The piping must
also be properly supported as per local and national standard plumbing codes. It is important that the piping must be clean and free
from burs, debris, ragged ends, and particles of PVC.
For exhaust piping, lower pipe on the right of the shroud, for the first 7’, use 3” ABS sch 40 or 3”CPVC sch 40 or 80. For concrete construction or to meet certain fire codes, exhaust piping - lower pipe on right of shroud, and inlet air piping - top pipe on the right of the
shroud, must be 3" CPVC schedule 40 or 80, (only to meet local fire codes). The balance of the inlet and exhaust piping may be PVC
schedule 40 or 80, or ABS solid only, NOT FOAM CORE. For residential style wooden construction exhaust piping, lower pipe on right
of shroud, must be 3" ABS solid (NON FOAM CORE) or 3" CPVC schedule 40 or 80 for the first 7’ only. The balance of the inlet and
exhaust piping may be PVC or ABS solid NON FOAM CORE or CPVC to meet local codes.
The only approved exhaust vent materials are ABS solid NON FOAM CORE; first 84" or CPVC. The balance of the exhaust piping
must be ABS solid NON FOAM CORE, CPVC or PVC sch 40 NON FOAM CORE ONLY. Exhaust piping should be sloped back to the
connection on the Voyager, at least 1/4" per foot to remove additional condensate that forms within the pipe. The total combined
length of pipe (intake piping plus exhaust piping added together) including elbow allowances intake and exhaust (each elbow = 5' of
pipe) should not exceed 85'. The combined vent length should not be less than a combined length of 6' plus two 90 degree elbows.
Choose your vent termination locations carefully; see pages 21 and 22
. You must additionally make certain that exhaust gas does not
re-circulate back into the intake pipe. You must place them in a open area, and follow the following guidelines.
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 at least 4' clearance to electric, gas meters, and exhaust fans or inlets;
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.
PAGE: 6 LP-41 REV: 3/1/03
VENTING
FOR ALL 3" VENTED MODELS EXCEPT SSV100-45R AND SSV130-45R (WHICH ARE 2” VENTED)
(FOR 2" VENTED MODELS SSV100-45R AND SSV130-45R, SEE MIDDLE OF PAGE 8)
11) The vent intake and exhaust must be properly cleaned and glued, for pressure tight joints. Several methods for venting the
Voyager can be found on pages 21 and 22
. Use the following layout as a guideline; certain site conditions such as multiple
roof lines/pitches may require venting modifications-consult factory. The air inlet must be a minimum of 1' vertically above the
maximum snow level or 24" which ever is greater. The air inlet must also be a minimum of 10' horizontally from the roof, and
terminated with a tee. The exhaust must be a minimum of 24" above the air inlet opening, and terminated with a coupling. It
is very important that there are no other vents, chimneys, or air inlets in any direction for at least 4'. Please refer to typical
venting on pages 21 and 22
. All venting must be properly supported, as the Voyager is not intended to support any
venting whatsoever. All piping, glue, solvents, cleaners, fittings, and components, must conform to ASTM (American
Society for Testing and Materials), and ANSI (American National Standard Institute).
12) It is recommended that you use one of the mentioned vent kits specifically for Voyager installations; either 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. For joining ABS to PVC, you must use transition green cement listed by NSF and
IAPMO and exceeds ASTM D-3138 to make solid liquid tight joints and gas tight joints.
PIPE / FITTINGS
The first 84" (7’) of exhaust piping, must be of 3" ABS solid 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 CPVC, and fittings to ASTM D2661 & D3311 for ABS and ASTM F-
439 for CPVC, the balance of exhaust piping, and all of intake piping, use standard 3" PVC sch. 40 or 3" ABS schedule 40, conforming
to ASTM D2665, or ABS conforming to ASTM D-3965 & ASTM R-441 for ABS; and fittings conforming to ASTM D-2665 & D331. ABS
may also be used for intake venting as long as pipe conforms to ASTM D3965 & D2661 and fittings meet ASTM D2661 & D3311.
Foam core pipe may be used for the entire intake system providing it conforms to ASTM F-891, and is cemented together using above
materials.
FOR LONGER VENT LENGTHS
All venting must be 3", both intake and exhaust, NEVER use any piping less than 3", or different size pipe on the intake and
exhaust. You may use 4" venting on both intake and exhaust, to lower the pressure drop, to provide additional venting length. It is
imperative when using 4", to follow these instructions very carefully. For longer venting lengths, the first 10' of both the
intake and exhaust piping are 3". For the intake 10' of 3" PVC plus one 90 degree or two 45 degree elbows and for the
exhaust 10' of ABS solid NON FOAM CORE, or CPVC plus one 90 degree or two 45 degree elbows. Then use a 4" x 3" PVC or
4" x 3" ABS reducing coupling. Then proceed with PVC 4" NON FOAM CORE pipe and fittings for both the intake and 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". 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 SIZING MAY REQUIRE ALTERNATE INSTALLATION METHODS. CONSULT THE FACTORY WITH SPECIFIC JOB REQUIREMENTS FOR ADDITIONAL RECOMMENDATIONS.
PAGE: 7 LP-41 REV: 3/1/03
FITTING
DESC.
EQUIVALENT
FEET
OF PIPE FITTING DESC.
EQUIVALENT
FEET
OF PIPE
FITTING DESC.
EQUIVALENT
FEET OF
PIPE
3” 90 5’ 2” 90 5’ 4” 90 3’
3” 45 3’ 2” 45 3’ 4” 45 1’
3” Coupling 0’ 2” Coupling 0’ 4” Coupling 0’
3” Tee 0’ 2” Tee 0’ 4” Pipe 1’ = 1’
3” Pipe 1’ = 1’ 2” Pipe 1’ = 1’ 4” Tee 0’
3” Concentric vent kit 3’ 2” Concentric vent kit 3’
3” V1000 vent kit 0’
VENTING EXAMPLES (NOTE: SHOWN AS INTAKE & EXHAUST PIPE AND FITTINGS ADDED TOGETHER)
* = MINIMUM VENT LENGTH ** = MAXIMUM VENT LENGTH
TOTAL
COMBINED
VENT LENGTH
(FEET)
INTAKE &
EXHAUST
QTY.
OF 90
°°
ELBOWS
EQUIVALENT
FRICTION
LOSS
(FEET)
FOR EACH
ELBOW
TOTAL
FRICTION
LOSS
FOR
ELBOWS
GRAND TOTAL
VENT LENGTH
(FEET)
WITH FITTING
FRICTION
LOSS ADDED
*12 2 5 10 22
20 2 5 10 30
20 3 5 15 35
20 4 5 20 40
20 5 5 25 45
20 6 5 30 50
20 7 5 35 55
20 8 5 40 60
20 9 5 45 65
20 10 5 50 70
20 11 5 55 75
20 12 5 60 80
20** 13 5 65 85**
30 3 5 15 45
30 4 5 20 50
30 5 5 25 55
30 6 5 30 60
30 7 5 35 65
30 8 5 40 70
30 9 5 45 75
30 10 5 50 80
30** 11 5 55 85**
40 3 5 15 55
40 4 5 20 60
40 5 5 25 65
40 6 5 30 70
40 7 5 35 75
40 8 5 40 80
40** 9 5 45 85**
50 3 5 15 65
50 4 5 20 70
50 5 5 25 75
50 6 5 30 80
50** 7 5 35 85**
60 3 5 15 75
60 4 5 20 80
60** 5 5 25 85
70** 3 5 15 85
FRICTION LOSS EQUIVALENCE TABLES
2" VENTED MODELS AFTER THE FIRST 10’ OF 3"
3" VENTED MODELS SSV100-45R/SSV130-45R ONLY4" EQUIVALENT TABLE
PAGE: 8 LP-41 REV: 3/1/03
WARNING:
IT IS EXTREMELY IMPORTANT TO FOLLOW THESE INSTRUCTIONS EXACTLY. FAILURE TO FOLLOW INSTRUCTIONS
EXACTLY COULD RESULT IN FIRE, INJURY OR DEATH.
SPECIAL VENTING INSTRUCTIONS FOR 2" VENTED SSV100R, & 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 21 and 22
. You must place them in a open area, and use the guidelines found on page 20.
CLEANER / CEMENT
Cement for exhaust & intake piping, must be All Purpose Cement, and conform to ASTM D-2235, D-2564, F-493 and cleaner for piping
and fittings must conform to ASTM F-656. For joining ABS to PVC, you must use transition green cement listed by NSF and IAPMO
and exceeds ASTM D-3138 to make solid liquid tight joints and gas tight joints.
PIPE / FITTINGS
The exhaust piping, and all of intake piping, standard 2" PVC sch. 40, conforming to ASTM D-1785, and fittings to ASTM D-2466, and
ABS pipe conforming to ASTM D3965 and ASTM D2661 and fittings conforming to ASTM D2661 & ASTM D3311. Foam core pipe
may be used for the entire intake system providing it conforms to ASTM F-891, and is cemented together using above materials, never
use foam core pipe for the exhaust pipe!
VERY IMPORTANT
SSV100R & SSV130R MODELS ONLY!
All venting must be 2", both intake and exhaust, NEVER use any piping less than 2", or different size pipe on the intake and
exhaust. You may use 3" or 4" venting on both intake and exhaust, to lower the pressure drop, to provide additional venting length. It
is imperative when using 3" to follow these instructions very carefully. For longer venting lengths, the first 10' of both the intake and
exhaust piping are 2". For the intake 10' of 2" PVC or ABS or CPVC, plus one 90 degree or two 45 degree elbows and for the exhaust
10' of 2" PVC NON FOAM CORE or ABS solid NON FOAM CORE or CPVC, plus one 90 degree or two 45 degree elbows. Then use a
2" x 3" PVC or ABS reducing coupling. Then proceed with ABS solid NON FOAM CORE, CPVC, or PVC 3" NON FOAM CORE pipe
and fittings for both the intake and exhaust piping. On 3" piping you may go an additional 125 equivalent feet of pipe and fittings, combined total length. Total equivalent would be 30' of 2" plus 125' of 3". Never use different pipe sizes for intake and exhaust. The vent
system must be balanced by friction loss equivalent.
CONDENSATE
This is a condensing high efficiency appliance, therefore this unit has a condensate removal system. Condensate is nothing more than
water vapor, derived from the combustion products, similar to an automobile when it is initially started. This condensate does have a
low PH and should be treated with a condensate filter. This filter contains either lime crystals or marble crystals, which will neutralize
the condensate. The outlet of the filter is sized for 5/8" ID (Inside diameter) plastic tubing. It is very important that the condensate line
is sloped away from and down to a suitable inside drain, if the condensate outlet on the Voyager is lower than the drain, you must use
a condensate removal pump. A condensate filter and a condensate pump kit are available from HTP. It is also very important that the
condensate line is not exposed to freezing temperatures, or any other type of blockage. Plastic tubing should be the only material used
for the condensate line; as steel, brass, copper, or others will be subject to corrosion and deterioration. A second vent may be 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 24
).
PAGE: 9 LP-41 REV: 3/1/03
SSVH MODEL PERFORMANCE AND SET-UP INFORMATION
The SSVH models are available in the 90,000 BTU/hr, 130,000, and 199,000 BTU/hr. firing rates. The illustration on page 43 show the
location of the heat exchanger and other ports. For maximum output, the bronze circulator provided must be attached between the hot
outlet and cold inlet as shown on page 22
. For complete SSVH information and sizing, refer to pages 42 and 43.
CONTROL DESCRIPTION
The fully integrated water heater control is an all electronic, fully automatic controller which will provide many years of trouble free service. The control requires no periodic maintenance and includes a built-in microprocessor which performs a number of diagnostic tests
to verify proper appliance and control operation. Should an unsafe condition occur, the burner will shut down and the appropriate status
indicators will illuminate indicating the need for service. Consisting of two printed circuit board assemblies, the controller's main board
is attached to inside left of the shroud while the display board is mounted to the front top of the shroud. This arrangement simplifies
access to the user adjustments while enhancing the visibility of the temperature display and status indicators. A power step-down
transformer and blower pressure switch are 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
used to determine the operating status of the appliance and provide assistance when troubleshooting any problems which may occur.
All indicators are of the solid state variety and should last for the life of the appliance. The controller has sufficient built-in memory to
retain the programmed temperature set point in the event input power is ever interrupted. The final component of the control system
includes a temperature sensing probe which is threaded into the side of the tank. This probe is of unique construction in that both the
temperature sensing/control and safety limit functions are performed by this single device. All probe components are of solid state construction to provide extended operational life.
START UP PROCEDURE
1. Make sure that the Voyager has been installed to these instruction procedures; along with all applicable province and local
codes;
2. Make sure all gas piping and connections have been verified and inspected by all applicable inspectors. Turn on gas supply.
Insure that the gas line and the LP tank, if applicable, have been properly purged. Failure to properly purge the gas lines will
result in failure to operate;
3. Make sure that the cold water supply has been turned on and that the Voyager is completely filled with water. Verify this by
opening a hot water faucet, and allowing water to flow until all air is removed and a clear water flow is present;
4. Turn on electrical supply;
5. The control will first display "102", then "88.8", which is the control display test; and finally the actual tank temperature at the
probe.
SET POINT ADJUSTMENT PROCEDURE
The three digit LED display will illustrate actual water temperature within the tank under normal operating conditions. However, this
display is also used to indicate the temperature set point when in the programming mode; and also ignitor amp draw and flame current.
The controller has a temperature set point range 70 degrees F. to 160 degrees F. The factory set point is 118 degrees F.
VERY IMPORTANT NOTE
:
POWER MUST BE APPLIED TO THE CONTROLLER PRIOR TO ANY PROGRAMMING OPERATIONS.
PAGE: 10 LP-41 REV: 3/1/03
SET POINT ADJUSTMENT PROCEDURE (CONTINUED)
To change or access the programmed temperature set point value, utilize the red button on the display panel. Momentarily depressing
the button will briefly illustrate the existing set point value. If the button is held down for more than one second, the programming mode
is entered and the set point value will begin incrementing by one degree per second. When the desired set point value is reached, simply 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 PERMANENT MEMORY. IT IS A GOOD PRACTICE TO RE-CHECK THE SET POINT VALUE APPROXIMATELY 60 SECONDS AFTER A
NEW VALUE HAS BEEN RE-ENTERED.
If the button is held down long enough, the set point will reach 160 degrees F. and stop, since this is its maximum value. At this point,
if the desired set point has not been obtained, release the button and depress it again, the set point will decrement down to 70 degrees
F. and stop. The set point value will now restart at 70 degrees F. (its minimum) and once again increase in value for as long as the
button is pressed.
DIFFERENTIAL ADJUSTMENT PROCEDURE
To allow proper water heater operation, the control has a 8 degree F. "window" around the set point. This means that the burner will
be turned on when the water temperature drops to 4 degrees F. below the set point, and it will be turned off when the water temperature 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 stored into permanent memory.
OVERALL APPLIANCE AND CONTROL OPERATION
A normal operating sequence is as follows:
1. The control determines that the actual water temperature inside tank is 4 degrees F., with the factory set 8 degree F.
differential, below programmed temperature set point;
2. The control performs selected system diagnostic checks;
3. If all checks are successfully passed, the combustion blower is energized for the 40 second pre-purge cycle;
4. During the pre-purge cycle is complete, power is applied to the ignitor element for the ignitor warm-up period (blower should
continue to run);
5. The ignitor warm-up period will last for 30 seconds, then gas valve will be opened, allowing gas to enter the burner chamber;
6. The ignitor will remain on for an additional 4 seconds, then it will be turned off;
7. After an additional 2 seconds, the control will verify the presence of flame. If the flame was not established, the gas valve will
be closed, power will be removed from the ignitor element, and the control will run the blower for 30 seconds. At this point,
the control will return to step 2;
8. If flame is present, the control will enter the heating mode where it will continue heating the tank water until the set point
temperature plus 4 degrees F. is reached. At this point, the gas valve is closed and the control enters the post-purge cycle.
The flame can be viewed through a window on the lower right of combustion blower flange;
9. The post-purge cycle continues to run the combustion blower for an additional 30 seconds to purge the system of all
combustion gases. After this time period, the blower is de-energized and will coast to a stop;
10. The control will now enter the idle state while continuing to monitor internal tank water temperature. If the temperature drops
to 4 degrees F. below the set point value, the control will automatically return to step 1.
PAGE: 11 LP-41 REV: 3/1/03
STATUS INDICATORS
Pages 15, 16, and 17 contain seven individual diagrams which illustrate the various operating states of the appliance and their relation
to the LED status indicators found on the controller. These diagrams reflect normal water heater operation.
MAINTENANCE
The control system requires no periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic 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. Failure
to do so VOIDS WARRANTY!
INTERNAL WIRING
For specific wiring information, please refer to the diagrams on pages 18 and 19
.
SHUTDOWN PROCEDURE
If the burner is operating, lower the set point value to 70 degrees F. and wait for the burner to shut off. Continue to wait for the combustion 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 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 a problem exists with
either the appliance, the controls, or the gas supply. Under such circumstances, a qualified service technician should be contacted
immediately to properly service the appliance and correct the problem. If a technician is not available, depressing the red button once
will remove the lockout state so additional trials for ignition can be performed. Any time “LOC” is shown, you must look for an LED
out, or flashing. The LED that is out or flashing will assist you in diagnosing lock out condition.
PAGE: 12 LP-41 REV: 3/1/03
PAGE: 13 LP-41 REV: 3/1/03
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 (G5040)
ORIFICES
All of the Voyager gas fired water heaters have unique air and gas orifice sizes. Special attention should be paid to these sizes whenever 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 orifices. This is only a guide to correct orifice sizing. If orifices are drilled the result will be poor ignition, a VOIDED WARRANTY,
severe bodily injury, death and/or explosion. All orifices must be obtained through the factory with all necessary labels and the serial number must be provided to the factory or warranty will be voided.
199,000 BTU VOYAGERS- GAS ORIFICE SIZES-
AIR ORIFICE = 1.375" NATURAL GAS = .379" PROPANE/LP GAS = .295"
160,000 BTU VOYAGERS- GAS ORIFICE SIZES-
AIR ORIFICE = 1.375" NATURAL GAS = .362" PROPANE/LP GAS = .295"
130,000 BTU VOYAGERS- GAS ORIFICE SIZES-
AIR ORIFICE = 1.125" NATURAL GAS = .280" PROPANE/LP GAS = .235"
NATURAL GAS CONVERSION FROM PROPANE/LP = .285"
PROPANE/LP GAS CONVERSION FROM NATURAL GAS = .250"
100,000 BTU VOYAGERS- GAS ORIFICE SIZES-
AIR ORIFICE = 1.125" NATURAL GAS = .280" PROPANE/LP GAS = .235"
NATURAL GAS CONVERSION FROM PROPANE/LP = .285"
PROPANE/LP GAS CONVERSION FROM NATURAL GAS = .250"
90,000 BTU VOYAGERS- GAS ORIFICE SIZES-
AIR ORIFICE = 1.000" NATURAL GAS = .261" PROPANE/LP GAS = .205"
NATURAL GAS CONVERSION FROM PROPANE/LP = .253"
PROPANE/LP GAS CONVERSION FROM NATURAL GAS = .215"
PAGE: 14 LP-41 REV: 3/1/03
CAUTION:
THERE ARE NO USER SERVICEABLE PARTS WITHIN THE CONTROL SYSTEM. TO MAINTAIN SAFETY AND PROPER APPLIANCE PERFORMANCE, REFER ALL TROUBLE-SHOOTING TO QUALIFIED SERVICE PERSONNEL.
TROUBLESHOOTING
The appliance controller has many inherent diagnostic and fault detection routines built into its operating software and hardware.
These routines, along with the three digit LED display and nine LED status indicators present on the display panel, can greatly assist
the service person in quickly pinpointing the source of problems that may occur with the appliance. In certain circumstances, multiple
LED's may be lit or flashing to better pinpoint the problem. Also, there is a green LED on the main control board to indicate proper
polarity and grounding. The following charts, diagrams, and information can be used during
troubleshooting procedures:
LED
CONTROLLER FUNCTION MEANING
LINE MONITORS INCOMING AC LINE VOLTAGE “ON” WHEN LINE VOLTAGE IS PRESENT
BLOWER MONITORS THE BLOWER MOTOR OUTPUT “ON” WHEN OUTPUT IS ENERGIZED
(POWER APPLIED TO BLOWER)
IGNITOR MONITORS IGNITOR ELEMENT OUTPUT “ON” WHEN OUTPUT IS ENERGIZED
(POWER APPLIED TO IGNITOR)
24V MONITORS INCOMING VOLTAGE FROM THE “ON” WHEN SECONDARY VOLTAGE IS PRESENT
TRANSFORMER SECONDARY
ECO MONITORS STATE OF THE ECO SWITCH “ON” WHEN ECO SWITCH IS IN CLOSED POSITION
(NORMAL POSITION)
PRESSURE MONITORS STATE OF THE AIR SWITCH “ON” WHEN THE PRESSURE SWITCH IS CLOSED
(SUFFICIENT COMBUSTION AIRFLOW EXISTS)
GAS VALVE MONITORS THE GAS VALVE OUTPUT “ON” WHEN OUTPUT IS ENERGIZED
(POWER APPLIED TO GAS VALVE)
WATER TEMP. MONITORS WATER TEMP. WITHIN TANK “ON” WHEN TEMP. DROPS BELOW SET POINT
CONTROL MONITORS INTERNAL STATE OF THE “ON” WHEN CONTROLLER FUNCTIONALITY IS O.K.
HEALTH CONTROLLER’S HARDWARE AND SOFTWARE
GREEN ON MONITORS POLARITY AND GROUND CIRCUIT “ON” WHEN GROUND AND POLARITY ARE O.K.
MAIN CONTROL
BOARD
VERY IMPORTANT SET-UP INSTRUCTIONS!
IF YOU HAVE A COMBUSTION ANALYZER, THE FOLLOWING RATINGS WILL BE VERY HELPFUL IN SETTING UP
YOUR VOYAGER:
FOR NATURAL GAS - CO2 READING SHOULD BE BETWEEN 9 ½% & 10 ½%
O2 READING SHOULD BE BETWEEN 3 ½% & 4 ½%
CO READING SHOULD BE UNDER 10 PPM
FOR PROPANE GAS - CO2 READING SHOULD BE BETWEEN 10 ½% & 11 ½%
O2 READING SHOULD BE BETWEEN 3 ½% & 4 ½%
CO READING SHOULD BE UNDER 10 PPM
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