Summary of Contents for International Thermal Research The WaterHeater
- Page 1 The WaterHeater™ by ITR Installation and Operating Manual Continuous Domestic Hot Water Heater and Heating System for Recreational Vehicles and Yachts...
- Page 2 Copyright © June 2005 International Thermal Research IN CANADA: IN THE UNITED STATES: 2431 Simpson Road Suite 260, 600 SE Maritime Ave. Richmond, BC, Canada V6X 2R2 Vancouver WA USA 98661 Tel: 1-800-755-1272 or 604-278-1272 Tel: 1-800-993-4402 or 360-993-4877 Fax:...
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Page 3: Table Of Contents
The WaterHeater™ by ITR Features ....1-3 Critical Factors..........1-4 Equipment, Tools and Skills ......1-5 Testing and Inspection ........1-6 Section 2, Mounting - The WaterHeater™ ....2-1 Before You Begin ......... 2-1 Identifying The WaterHeater™ by ITR Model ..2-2 Your Mounting Location......... 2-2 What NOT to Do........... - Page 4 Before You Begin .......... 7-1 Plumbing Installation........7-2 What NOT to Do ........... 7-4 Installation Procedure ........7-4 Section 8, Operating The WaterHeater™ by ITR ..8-1 Operating Instructions for The WaterHeater™ by ITR ......8-1 Turning the Power to The WaterHeater™...
- Page 5 Table of Contents Functions of the Space Heating Module (Optional) Zone Control Board..... 8-6 Maintenance ..........8-7 Protect The WaterHeater™ by ITR™ and Space Heating Module (Optional)....8-10 8.10 General Troubleshooting ......8-10 Section 9, Installing The Space Heating Module (Optional)..............9-1 Before you Begin..........
- Page 6 The WaterHeater™ by ITR – Fittings ..... 8-1 Figure 8-2 Remote Operating Panel ......8-3 Figure 8-3 The WaterHeater™ by ITR – Control Panel ..8-5 Figure 9-1 Space Heating Module Plumbing Fittings ..9-3 Figure 9-2 Space Heating Module and Hot Water Heater Hookup ......
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Page 7: Section 1, Overview
Overview Thank you for purchasing The WaterHeater™ by ITR for recreational vehicles and marine yachts. This section describes features of The WaterHeater™ by ITR and covers Some of the figures critical information you need to know before beginning the installation,... -
Page 8: Protect Your Warranty
If you discover any missing or defective parts, call ITR immediately. If you are not installing The WaterHeater™ by ITR right away, secure all components so none will be misplaced. Before installing The WaterHeater™ by ITR, read the rest of Section 1 –... -
Page 9: The Waterheater™ By Itr Features
The WaterHeater™ by ITR heats water to provide a continuous supply • Economical for all domestic hot water needs. The WaterHeater™ by ITR can also provide a single zone of space heating using the Space Heating Module (optional). See Figure 1-1. -
Page 10: Critical Factors
• Low water level switch in the tank. • Easy to install with hookups and connections easily accessible from the top and front of The WaterHeater™ by ITR. • Quiet operation and low power consumption. • Low pressure fuel system with built-in fuel pump. -
Page 11: Equipment, Tools And Skills
1/4” supply and return fuel line, approved rubber or copper. • Heater hose (to connect Space Heating Module [optional] hose fittings to interior fans). • Domestic water hose and/or tubing to connect The WaterHeater™ by ITR hose fittings to the domestic water system. International Thermal Research... -
Page 12: Testing And Inspection
After all components have been properly installed according to standard practices, RVIA or ABYC standards, and the recommendations of this Installation and Operating Manual, The WaterHeater™ by ITR should be test-operated for inspection purposes. For your convenience, you can use the pullout Inspection Check Sheet in this Manual. -
Page 13: Section 2, Mounting - The Waterheater
Section Mounting - The WaterHeater™ Before You Begin Plan the location of The WaterHeater™ by ITR and all its major components in advance to ensure the chosen locations are feasible and within the technical specifications. Consider the following factors to help you decide exactly where best to mount The WaterHeater™... -
Page 14: Identifying The Waterheater™ By Itr Model
The WaterHeater™by ITR is 14”H x 14”W x 24”D (35.6 cm x 35.6 cm x 60.9 cm). See Figure 2-1: Dimensions. The WaterHeater™ by ITR must not be installed in any compart- ! CAUTION ment with flammable gases. • The WaterHeater™ by ITR must be completely isolated from living spaces. - Page 15 WaterHeater™ by ITR for containing any unexpected leakage. NOTICE If The WaterHeater™ by ITR is going to be mounted in the engine compartment, check for adequate ventilation. When the engine is running, this area could be under a negative pressure. Make sure the air intake and exhaust hoses have no leaks and are well- fastened to the heater, muffler and thru hull fitting.
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Page 16: What Not To Do
Figure 2-1: Dimensions What NOT to Do • Don’t mount The WaterHeater™ by ITR in the rear of the coach or yacht underneath the sleeping area. The sound of The WaterHeater™ by ITR cycling on and off may disturb light sleepers. -
Page 17: Procedure
ITR: Mount The WaterHeater™ by ITR horizontally and level. Secure The WaterHeater™ by ITR in place (against the wall, floor, or a mounting platform) and eight (8) x 1/4” through bolts and 1” diameter fender washers, lock washers and nuts (See Figure 2-2: Location of Mounting Brackets.). -
Page 18: Section 3, Installing The Exhaust System
Section Installing the Exhaust System Before You Begin For efficient and safe operation of The WaterHeater™ by ITR follow all recommendations for properly installing the exhaust. Any deviations from these must be approved in advance by ITR. Although the heater’s exhaust produces very low carbon... -
Page 19: Recommendation For Installation
Make sure that the thru hull is at least 30” above the water line with a goose neck rise on the exhaust to help eliminate water from getting to The WaterHeater™ by ITR through the exhaust. If the dual exhaust air-intake thru hull is... - Page 20 • Ensure that the exhaust cannot be plugged or restricted. • The exhaust fitting on The WaterHeater™ by ITR is 1.5” O.D. and the exhaust pipe used must have a minimum of 1.5” I.D throughout its length. •...
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Page 21: What Not To Do
Securely seal the exhaust piping to The WaterHeater™ by ITR fitting using an approved exhaust clamp. Connect the exhaust piping in series with the muffler, using heavy-duty exhaust clamps. -
Page 22: Figure 3-2 The Exhaust Goose Neck Configuration
Section 3, Installing the Exhaust System Figure 3-1: Installing the Exhaust System (Down Exhaust) Figure 3-2: The Exhaust Goose Neck Configuration International Thermal Research... -
Page 23: Section 4, Installing The Fuel System
Keep gasoline and any equipment that uses gasoline away from The WaterHeater™ by ITR location. The WaterHeater™ by ITR is not rated for use in an explosive environment. Never share the fuel supply to The WaterHeater™ by ITR with any ! WARNING other fuel-burning device. Fuel System Installation Recommendation for Installation The WaterHeater™... -
Page 24: What Not To Do
A primary, UL and/or CSA approved fuel oil filter (not provided) must be installed inline in the fuel supply hose between the tank and The WaterHeater™ by ITR, in a manner that ensures easy access for maintenance. A secondary fuel filter is mounted inside The WaterHeater™... -
Page 25: Procedure
Install the inline fuel filter. The optimal location is on a compartment wall next to The WaterHeater™ by ITR, inline between the fuel tank and The WaterHeater™ by ITR. Connect the fuel line to the dedicated fitting on the main diesel fuel tank. -
Page 26: Section 5, Installing Fan Heaters - With "Space Heating Module" Only
Zone Control Board, as well as flow capacity to ensure that each fan meets system requirements. Fan System Operation ITR fans consist of a 12 VDC brushless fan and heater coil similar to a radiator. International Thermal Research... -
Page 27: Features
Figure 5-1 shows how to wire-up the aquastat in a fan. Figure 5-1: Wiring the Fan’s Aquastat • If a “passive” radiant heat system is desired (i.e. baseboard or fin and tube configurations), consult ITR for recommended installation procedures and design. The WaterHeater™ by ITR... -
Page 28: Single Zone Heating
Section 5, Installing Fan Heaters Single Zone Heating The WaterHeater™ by ITR is capable of heating a single interior zone using the optional Space Heating Module. See Section 9 – Installing the Space Heating Module. A single thermostat (positive DC compatible) can be installed to allow temperature regulation of the zone. -
Page 29: What Not To Do
What NOT to Do • Don’t install more than two (2) fans, or fan(s) that require more heat than The WaterHeater™ by ITR can produce. Your heating system will not run effectively. (If you choose to use a higher-draw fan motor, install a relay to handle the extra load;... -
Page 30: Figure 5-2 Mounting A Spacesaver Fan
(not the heater’s Control Board). See Figure 5-3: Installing a Relay for Additional Fan Amperage. To install plumbing lines to the fans, see Section 7 – Plumbing the System. Figure 5-2: Mounting a Spacesaver Fan International Thermal Research... - Page 31 Section 5, Installing Fan Heaters Figure 5-3: Installing a Relay for Additional Fan Amperage The WaterHeater™ by ITR...
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Page 32: Section 6, Wiring The Electrical System
The WaterHeater™ by ITR and its electrical Control Board are pre- wired and have been thoroughly tested together as a unit. To review the wiring system for The WaterHeater™ by ITR, refer to the schematic in this Section 6, Figure 6-1: System Wiring. -
Page 33: 120 Vac
• The WaterHeater™ by ITR is equipped with one 1500 watt 120 VAC electrical element. The connections for the electrical supply are on the top left side of The WaterHeater™ by ITR, under a cover, labeled AC power. • The power wires for the AC elements are three 14 gauge stranded copper leads that use standard AC color code (black - hot, white –... -
Page 34: Main Electronic Control Board
WaterHeater™ by ITR itself. It has no user adjustable components. Space Heating Control Board (optional) • The Space Heating Module (optional) is controlled by a separate Space Heating Control Board. See Section 9 – Installing the Space Heating Module (Optional). International Thermal Research... -
Page 35: What Not To Do
Section 6, Wiring the Electrical System What NOT to Do Never shut off The WaterHeater™ by ITR power via an inline NOTICE battery or master switch while the system is running. Never disconnect the battery when The WaterHeater™ by ITR is running, and never disconnect the battery while the inverter is charging. -
Page 36: Section 7, Plumbing The System
Section Plumbing the System Before You Begin For efficient and safe operation of The WaterHeater™ by ITR, follow all recommendations for properly installing the plumbing system. Any deviations from these must be approved in advance by ITR. The WaterHeater™ by ITR if attached to the Space Heating Module... -
Page 37: Plumbing Installation
Figure 7-1: Plumbing Fittings The plumbing installation should consider the following: • All fittings on The WaterHeater™ by ITR require two wrenches NOTICE when tightening. One wrench must be placed on the tank All fittings on the fitting and held in place to prevent this fitting from being WaterHeater™... - Page 38 The Space Heating Module contains a distribution pump and heat exchanger and is pre-wired and pre-plumbed for ease of installation. • The WaterHeater™ by ITR should be filled and flushed prior to operation to remove any foreign debris. • WaterHeater™...
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Page 39: What Not To Do
If there is any risk that solvents may contact the hose, insert it into PVC plastic tubing for protection. Installation Procedure To install and connect The WaterHeater™ by ITR and heater hose (see Section 1 – Overview, Figure 1-1: Hot Water Heater and Space Heating Module, if installed, and Section 9 –... -
Page 40: Figure 7-2 The Approved Method Of Installing Heater Hose (Consult Itr For Alternative Methods And Products)
A drain point, labeled “Drain” is provided on the front lower middle face of The WaterHeater™ by ITR and consists of a 1/2” threaded pipe with a temporary plastic cap installed. Prior to filling The WaterHeater™ by ITR with water, remove the plastic cap and install the drain valve (provided) and tighten to a leak free condition. -
Page 41: Operating Instructions For The Waterheater™ By Itr
WaterHeater™ by ITR This section describes the operation and maintenance of your new WaterHeater™ by ITR. The WaterHeater™ by ITR has the ability to support zone heating with the available add-on space heating module and Zone Control Board. The WaterHeater™ by ITR must be installed and connections made... -
Page 42: Turning The Power To The Waterheater™ By Itr On
When the burner switch is turned ON, the diesel portion of WaterHeater™ until it is filled The WaterHeater™ by ITR will turn on after ten seconds. The with water and Burner LED on the Remote Operating Panel will turn ON when all trapped air the diesel burner has been activated. -
Page 43: Activating The Cabin Fan Heaters Through The Thermostats
Section 8, Operating the WaterHeater Activating the Burner and AC Immersion Element Jointly • Turn the burner switch on the Remote Operating Panel to the ON position. Place the AC circuit breaker to the element ON. The Burner and AC Heat (green) LED’s on the Remote Operating Panel will turn ON indicating the diesel burner and AC immersion element have been selected. -
Page 44: Functions Of The Waterheater™ By Itr Control Panel
Service LED (Red) • When ON, indicates The WaterHeater™ by ITR has faulted. The specific fault can be identified by examining the WaterHeater™ Control Panel located on the WaterHeater™. There are three red and six green indicator LED’s on this panel. -
Page 45: Figure 8-3 The Waterheater™ By Itr - Control Panel
Section 8, Operating the WaterHeater Figure 8-3: The WaterHeater™ by ITR - Control Panel Power On/off Button • The Power On/Off button turns ON/OFF the power to the WaterHeater™ Control Board. The Power LED (green) turns ON when the power to the control board is ON. -
Page 46: Functions Of The Space Heating Module (Optional) Zone Control Board
Low Water LED (Red) • The Low Water level fault LED (red) turns ON when a low water level in the WaterHeater™ has been detected. Functions of the Space Heating Module (Optional) Zone Control Board The Space Heating Module (optional) Zone Control Board contains six green LED’s for power, heat available, thermostat, cabin fan,... -
Page 47: Maintenance
Section 8, Operating the WaterHeater Thermostat LED (Green) • The Thermostat LED turns ON when the thermostat in the space heating zone is calling for heat. Domestic Water Pump, Cabin Fan Pump, Cabin Fan (Green) • The Domestic Water Pump, Cabin Fan Pump and Cabin Fan LED’s turn ON when the devices are functioning. - Page 48 • The domestic water mixing valve on the WaterHeater™ should be inspected every year and replaced if necessary. See the tag attached to the valve for additional instructions (see below).
- Page 49 Section 8, Operating the WaterHeater REINSPECTION OF T & P RELIEF VALVES: WARNING: Temperature and Pressure Relief Valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced, if necessary, by a licensed plumbing contractor or qualified service technician, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.
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Page 50: Protect The Waterheater™ By Itr™ And
• Note that any domestic water in The WaterHeater™ by ITR or Space Heating Module will freeze in cold temperatures and will damage the components. The WaterHeater™ by ITR and Space Heating Module and all associated components must be completely drained of the domestic water and emptied before freezing temperatures are encountered. - Page 51 • Air in fuel line (White smoke from exhaust)? • Fuel filter (external) dirty? • Component LED’s all glowing green on The WaterHeater™ Control Panel? Burner Starts but Zone Faults • Power LED on Space Heating Module Zone Control Board glowing green? •...
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Page 52: (Optional)
Most efficient plumbing runs. • Safe and convenient access for maintenance. • Number and location of interior fans. • Location of other equipment to be installed or connected to the Space Heating Module, including Zone Box, cabin fan heaters, etc. International Thermal Research... -
Page 53: Identifying Your Space Heating
Space Heating Module must not be installed in any compartment ! CAUTION with flammable gases. • Space Heating Module must be mounted in an area that provides unrestricted access to the front panel mounted coolant The WaterHeater™ by ITR... -
Page 54: Selecting The Space Heating Module Zone Box Location
The other wrench can be used to tighten the matching half of the fitting onto it. Failure to follow this procedure will damage the Space Heating Module, WaterHeater™ and the fittings, see Figure 9-1: Space Heating Module Plumbing Fittings. International Thermal Research... -
Page 55: Figure 9-1 Space Heating Module Plumbing Fittings
Remove the plastic plug on the WaterHeater™ front panel labeled “Space Heating Module”. The hot water supply from the WaterHeater™ to the Space Heating Module is a female 1/2” NPT fitting located behind the plug. This is to be connected to the Hot Water In connection on the Space Heating Module. -
Page 56: Figure 9-2: Space Heating Module And Hot Water Heater Hookup
• The Hot Water Return connection from the Space Heating Module to the WaterHeater™ is on the front upper right face of the module and is a 1/2” NPT female fitting. This connects to the 1/2” NPT female fitting on the cold water inlet tee previously installed on the WaterHeater™. - Page 57 2” away from the tank. Remove the plastic plug on the small 12 VDC access panel on the WaterHeater™ and feed the 2 pin connector of the 12’ harness through the hole. Position the strain relief on the harness into the hole on the access panel.
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Page 58: 9.6 Electrical Connection
3% voltage drop from the power supply to the zone board. There are no direct 12 VDC power connections onto the Space Heating Module itself. International Thermal Research... -
Page 59: 9.7 Space Heating Zone Board
Space Heating Module and Zone Board Electrical Hookup, that is to be connected through a connector cord (supplied) to the connector on the leads on the clip on aquastat (previously installed on the WaterHeater™). 4 Pin Connector Cable • The Zone Board has a 4 pin connector cable that is to be connected through a connector cord (supplied) to the matching 4 pin connector cable from the Space Heating Module itself. -
Page 60: Figure 9-3 Space Heating Module And Zone
2 pin 4 pin Module White Harness 2049-10 Fuse 110 VAC Black 4 pin 2 pin Green Fuse Ground Black Water Heater Battery Clip – On Aquastat Figure 9-3: Space Heating Module and Zone Board Electrical Hookup International Thermal Research... -
Page 61: What Not To Do
9.10 INSPECTION AND TESTING After all components have been properly installed according to ABYC Industry Standards and Practices and the recommendations of this Manual, the Space Heating Module and The WaterHeater™ by ITR should be inspected using the Inspection Check Sheet this Manual. -
Page 62: Section 10, Warranty Information
Warranty Information Attention Purchaser and Installer NOTICE No warranty covers damage or failure of the heater, hot water heater, heating module, distribution module, or space heating module (collectively, “the Product”) or to the vehicle in which it is installed, due to unapproved, unauthorized, or improper installations of the Product. -
Page 63: Limited Warranty
Warranty Information International Thermal Research Limited Warranty The following warranties are in lieu of all other warranties and conditions. ITR makes no other warranties, representations, or conditions, express or implied. Expressly excluded are all implied or statutory warranties or conditions of merchantability of fitness for a particular purpose, and those arising by statute or otherwise in law or from dealing or trade usage. -
Page 64: Customer Service Calls
International Thermal Research Warranty Information • Original serial number on Product or electrical control board has been removed, altered, or is unreadable. • Product has been modified or uses non-standard parts not approved by ITR. • Product has been abused (such as by dropping it), damaged, vandalized, or has received improper maintenance. - Page 65 Warranty Information International Thermal Research Depending on your location, an authorized service person may be able to visit your coach or yacht to help troubleshoot problems and repair your Product. Such service calls are at the Owner’s expense. Regardless, you must obtain written approval from ITR or the Dealer for any warranty repair before it is undertaken.
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