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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.  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.

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 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.

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 utility 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 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.  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.

Содержание ANSI Z 21.10.3

Страница 1: ... 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 OPERATING INSTALLATION AND SERVICE MANUAL FOR THE VOYAGER GAS FIRED WATER HEATER SUPER HIGH EFFICIENCY GAS FIRED WATER HEATING COMBINATION APPLIANCE ...

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Страница 3: ...s 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 ...

Страница 4: ...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 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 i...

Страница 5: ... 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 s...

Страница 6: ... 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 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 foll...

Страница 7: ... 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 FORLONGER 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...

Страница 8: ...5 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...

Страница 9: ...iency 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...

Страница 10: ... are available VERY IMPORTANT NOTE POWER MUST BE APPLIED TO THE CONTROLLER PRIOR TO ANY PROGRAMMING OPERATIONS SET POINTADJUSTMENT 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...

Страница 11: ...onditions 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 INTERNAL WIRING For specific wiring information please refer to the diagrams on pages 18 and 19 SHUTDOWN PROCEDURE If the burn...

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Страница 13: ...his 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 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 SUPER E GAS CONVERSION INSTRUCTIONS FOR CONVERSION OF THE VOYAGER TO PROPANE OR NATURAL GAS ...

Страница 14: ...iance 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 MONI...

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Страница 20: ...ds for venting the Super E 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 of 24 whichever is greater The air inlet must also be a minimum of 10 horizontally from the roof and terminated wi...

Страница 21: ...PAGE 21 Figure 3 A Direct Vent Terminal Clearances per ANSI Z21 10 3 2004 CSA 4 3 2004 ...

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Страница 27: ...THE GAS VALVE BY PRESSING ON THE TABS ON THE TOP AND BOTTOM OF THE PLUG AND PULLING 13 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 14 REMOVE THE BLACK WIRE FROM THE FLAME RECTIFICATION PROBE BY PULLING ON IT 15 REMOVE THE IGNITOR WIRING HARNESS FROM THE CONTROL BOARD BY PRESSING ON THE TABS ON THE TOP AND BOTTO...

Страница 28: ... 200 INCH POUNDS TORQUE IN THE FOLLOWING ORDER 4 REPLACE THE BURNER MOUNTING FLANGE GASKET WITH A NEW GASKET BE SURE THAT BOTH SIDES OF THE GASKET ARE SPRAYED WITH PERMATEX HIGH STACK SPRAY A GASKET ADHESIVE SEALANT PART 99MA 5 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 SPR...

Страница 29: ...IRE TOWARDS THE BOTTOM OF THE CONNECTOR 28 RE CONNECT THE AIR INLET PIPING BY LOOSENING THE SMALLER HOSE CLAMP ON THE AIR INLET CONNECTOR ALL THE WAY AND THEN SLIDING THE BOOT OVER THE END OF THE AIR INLET ADAPTER THEN TIGHTEN USING A 5 16 NUT DRIVER 15 SNAP THE AIR ORIFICE INTO THE END OF THE AIR INLET MANIFOLD 16 SLIDE THE AIR INLET ADAPTER OVER THE END OF THE AIR INLET MANIFOLD UNTIL THE STOP I...

Страница 30: ...PAGE 30 PARTS ILLUSTRATIONS ...

Страница 31: ... 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 ...

Страница 32: ...VAILABLE THEN FOLLOW INSTALLATION PROCEDURE 2 IF NO MANOMETERS ARE AVAILABLE USE INSTALLATION PROCEDURE 1 PROCEDURE 1 1 RE CONNECT THE GAS VALVE WIRING HARNESS TO THE GAS VALVE 2 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 3 PLACE THE GAS ORIFICE BACK ON THE BOTTOM HALF OF THE UNION AND TIGHTEN THE UN...

Страница 33: ...GGED 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 8 REMOVE THE SMALL ROUND BRASS PLUG FROM THE GAS VALV...

Страница 34: ...THE OUTLET PRESSURE TAP PLUG FROM THE RIGHT SIDE OF THE GAS VALVE WITH A 3 16 ALLEN WRENCH 2 PUT THE GAS VALVE ADJUSTMENT SCREW COVER BACK IN PLACE AND TIGHTEN 3 PUT THE VOYAGER CABINET DOOR BACK INTO PLACE 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 S...

Страница 35: ...ND BRASS PLUG FROM THE GAS VALVE BY TURNING IT COUNTER CLOCKWISE WITH A SMALL PUNCH AND HAMMER 7 RE CONNECT THE SUPPLY GAS PIPING TO THE VALVE 8 TURN ON THE GAS TO THE SUPER E 9 TURN THE BLUE KNOB ON THE GAS VALVE TO ON 6 CONNECT THE VACUUM HOSE ACCORDING TO THE FOLLOWING DIAGRAM ...

Страница 36: ...DS 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 15 PUT THE GAS VALVE ADJUSTMENT SCREW COVER BACK IN PLACE AND TIGHTEN 16 REMOVE ALL THE CLEAR VINYL HOSES FROM THE GAS VALVE 17 REMOVE TH...

Страница 37: ... AND CONNECTION OF A 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 SYSTEM HOW TO SIZETHECOMBINATIONSYSTEM FORRADIANTHEATING IT IS IMPORTANT TO SIZE BOTH HEATING LOAD AND DOMESTIC HOT WATER LOAD IN CHOOSING WHICH SUPER E SSV...

Страница 38: ... 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...

Страница 39: ... 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 PROPE...

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