ITR Hurricane Zephyr HW, Installation And Operating Manual

Page 1: ...International Thermal Research Installation and Operating Manual Hurricane Zephyr HW Diesel Heating System for Yachts...

Page 2: ...com All rights reserved No part of this manual may be reproduced or transmitted in any form by any means electronic or mechanical including photocopying and recording information storage retrieval or...

Page 3: ...o Do 2 4 2 4 Procedure 2 4 2 5 Remote Operating Touch Screen Panel Mounting Procedure 2 5 Section 3 Installing the Exhaust System 3 1 3 1 Before You Begin 3 1 3 2 Mounting Location and recommendations...

Page 4: ...gement 8 1 8 1 Before You Begin 8 1 8 2 Domestic Hot Water System 8 1 8 3 Engine Waste Heat Function 8 2 procedure 8 3 8 4 Engine Pre Heat Function 8 3 procedure 8 4 Section 9 Operating the Hurricane...

Page 5: ...ed Output 10 10 10 22 Smokey Smelly Exhaust 10 10 10 23 A Silent Killer 10 11 Section 11 Maintenance 11 1 11 1 The First Few Weeks 11 1 11 2 Adding Coolant 11 1 11 3 Nozzle 11 2 11 4 Fuel Lines and Fi...

Page 6: ...Fan 5 5 Figure 5 3 Installing a Relay for Additional Fan Amperage 5 5 Figure 6 1 Sample Wiring Diagram for Electrical Elements 6 3 Figure 6 2 Wiring for a Fan Speed Switch 6 8 Figure 6 3 Wiring Diagra...

Page 7: ...do when you first receive your heater It also covers critical information you need to know before beginning the installation including how to protect your warranty and tools and equipment needed Figur...

Page 8: ...ocedures in this manual to ensure maximum performance of the heater and that you and or your customers enjoy a warm comfortable environment and plenty of hot water when needed 1 2 Protect Your Warrant...

Page 9: ...features of the heating system include 1500 Watt 120 VAC North America electric element for a supplemental and backup heating source when the vehicle is connected to a power source High temperature st...

Page 10: ...ion o Tactile Touch screen control panel for operating control and diagnostics with audible alarm Heating control for up to four separate space heating zones each with its own optional thermostat On d...

Page 11: ...heck Sheet 1 5 Equipment Tools and Skills As the user and or installer you must be qualified and authorized to do the installation which requires mechanical aptitude and electrical knowledge Make sure...

Page 12: ...s depending on the number of zones for temperature regulation of each zone up to 4 A self priming pump for filling the system with heat transfer fluid after installation Cabin fans or passive radiator...

Page 13: ...Section 1 Overview International Thermal Research 1 7 Figure 1 3 Hurricane Zephyr HW Typical Series Plumbed Layout...

Page 14: ...Section 1 Overview 1 8 Installation Manual for Hurricane Zephyr HW Heating System...

Page 15: ...st outlet location and maximum acceptable length including all 90 degree bends Refer to section 3 2 Potential for vibration and jarring Fuel storage location Most efficient plumbing runs Safe and conv...

Page 16: ...9 and the air intake silencer part 10455 Securely clamp and seal all air inlet hose connections Ensure the supply of combustion air to the appliance is not obstructed or cut off The heater must be mou...

Page 17: ...tment so that no exhaust from the heater will infiltrate the living areas Choose a sturdy surface in a location that won t be unduly affected by vibration and the jarring of rough roads Mount the unit...

Page 18: ...panels or creates interference with the top mounted connections 2 4 Procedure After choosing the mounting location for the heater unit 1 Mount the unit horizontally 2 Secure the heater in place again...

Page 19: ...el Mounting Procedure The Remote Operating Panel is mounted inside the Yacht in an easy to access location An opening for the remote panel must be cut in the wall or mounting panel The Remote Operatin...

Page 20: ...Section 2 Mounting the Heater Unit 2 6 Installation Manual for Hurricane Zephyr HW Heating...

Page 21: ...Heater exhaust can reach high temperatures never install exhaust parts close to combustible materials or through a combustible wall or ceiling without fireproof protection Heater exhaust must be direc...

Page 22: ...dation for Installation You may use sweep bends but each 90 bend is equivalent to two feet of exhaust piping For example if you use two 90 bends you must deduct two feet per bend from the maximum allo...

Page 23: ...there are any leaks in the exhaust system Periodically check exhaust fittings clamp connections exhaust tube pipe for leaks and integrity also check the integrity of exhaust insulation if installed 3...

Page 24: ...2 ID part 8019 to the air intake fitting on top of the heater The other end of the air intake hose can be installed on the dual through hull or near an air intake vent in the yacht 7Use 32 gear clamps...

Page 25: ...HW is not rated for use in an explosive environment Never share the fuel supply line to the Hurricane Zephyr HW with any other fuel burning device 4 2 Fuel System Installation The fuel pump in the Hur...

Page 26: ...must be checked for leaks upon initial installation and periodically as part of normal maintenance A primary UL and or CSA approved 10 micron fuel oil filter not provided must be installed in the fue...

Page 27: ...artment wall next to the Hurricane Zephyr HW inline between the fuel tank and the heater 2 Connect the fuel supply line to a dedicated pick up fitting on the main diesel fuel tank 3 Inspect the supply...

Page 28: ...Section 4 Installing the Fuel System 4 4 Installation Manual for Hurricane Zephyr HW Heating System...

Page 29: ...floor as possible It is recommended that an individual temperature sensor aquastat be installed on the fans to prevent the fan from blowing cold air while the heat transfer fluid is being heated by t...

Page 30: ...res ITR heating fans can be supplied with an aquastat which prevents the fan from operating and blowing cold air when the system heat transfer fluid is below 120 F 49 C Figure 5 1 shows how to wire up...

Page 31: ...he fan blades Screws 10 sheet metal screws or wood screws to mount the fan units See Figure 5 2 Mounting a Spacesaver Fan Two Speed Fan Switches to enable low and high speed settings from inside the b...

Page 32: ...or bulkhead away from windows and heating fans 5 5 Procedure After choosing the appropriate mounting location and configuration 1 Mount the fan using 10 sheet metal screws or wood screws see Figure 5...

Page 33: ...Section 5 Installing Fan Heaters International Thermal Research 5 5 Figure 5 2 Mounting a Low Profile Cabin Fan Figure 5 3 Installing a Relay for Additional Fan Amperage...

Page 34: ...Section 5 Installing Fan Heaters 5 6 Installation Manual for Hurricane Zephyr HW Heating System...

Page 35: ...rdance with CSA Standard C22 1 Canadian Electrical Code Part l or the National Electric Code ANSI NFPA 70 6 2 Hurricane Zephyr 12 VDC The following applies to the 12VDC power supplied to the Hurricane...

Page 36: ...hyr 120 240 VAC The Hurricane Zephyr HW is equipped with one 1500 Watt 120 VAC North America or one 1500 Watt 240 VAC Europe electric immersion element The connections for the electrical supply are on...

Page 37: ...ating pump will turn on and circulate the heated coolant when there is a call for heat thermostats or domestic water 3 The circulating pump will continue to operate until there is no longer a call for...

Page 38: ...rmostats up to four Additional 4 zone board available for larger applications o Fan heaters o Fan speed switches between F1 F4 and the fans o Internal Circulation pump 12 vdc o Domestic water aquastat...

Page 39: ...ing element supplying adequate heat to the system The operating circuitry of the burner in the heater itself is non functional In the ON position all operations and features of the heater and control...

Page 40: ...ng the normal system controls after it has completed its purge When running in bypass mode never leave the heater unattended 6 6 Procedure Consult the following table for required wire gauges and leng...

Page 41: ...ive terminal of the battery or to an adjacent chassis ground location 6 Wire the thermostats for the fan heaters to the terminals in the control board using 18 gauge wire minimum and a single 8 fork c...

Page 42: ...Section 6 Wiring the Electrical System 6 8 Installation Manual for Hurricane Zephyr HW Heating System Figure 6 2 Wiring for a Fan Speed Switch...

Page 43: ...Section 6 Wiring the Electrical System International Thermal Research 6 9...

Page 44: ...table water occurs due to a leak in the heat exchanger which can be caused if the fresh water in the system is allowed to freeze For efficient Hurricane Zephyr Heating System operation Minimize heat l...

Page 45: ...e 3 4 ID heating loop return hose to the 3 4 brass hose barb connection labeled Heat Loop Return Ensure proper direction of flow 3 All connections must be clamped constant tension spring clamps are re...

Page 46: ...s adequate through the Hurricane Zephyr Heating System The flow rate through the space heating loop should be at least 2 5 GPM A large temperature difference between each subsequent fan in the space h...

Page 47: ...ump is one of the most critical parts of the system Never let the pump run dry or damage will occur to the rotor This is not covered under warranty Don t use low quality heater hose Don t let the hose...

Page 48: ...s such are made with a crimped Pex to Pex connection The maximum water supply pressure to the heater is 150 PSI 10 bar The Hot water outlet temperature is regulated by an internal mixing valve factory...

Page 49: ...pace heating and hot water The Engine Heat Supply Return connections are located on the back of Hurricane Zephyr and can be made using 1 2 MPT x 1 2 hose barb or 1 2 MPT x 3 4 hose barb fittings If th...

Page 50: ...for Filling Purging the Hurricane Zephyr Heating System 1 Do not operate the Hurricane Zephyr until the entire circulation system has been filled with the proper heat transfer fluid solution and all t...

Page 51: ...off filling pump and place the pump circulation jumper on the control board circuit board onto both pins The Hurricane Zephyr internal pump will run and circulate fluid through the entire system The f...

Page 52: ...Figure 6 4 wiring schematic in Section 6 Wiring the Electrical System 8 2 Domestic Hot Water System The components needed for installation and operation of the domestic hot water system include Heat...

Page 53: ...e and to use waste heat produced by the engine While running a liquid cooled engine produces a large amount of heat some of this heat can be captured by the Hurricane Zephyr and used to heat water and...

Page 54: ...ill operate normally 3 The circulating pump will continue to operate until the engine aquastat has cooled down or all thermostats or domestic water aquastat are satisfied A manual switch can be wired...

Page 55: ...ol board that connects to the boat s power source beside the battery connection see Figure 6 4 in Section 6 Wiring the Electrical System The switch circuit should include a 5 amp fuse on the power sid...

Page 56: ...ce heating areas The Hurricane Zephyr provides domestic hot water using an integral heat exchanger which also makes use of engine waste An optional engine preheat feature is provided using an addition...

Page 57: ...optimizes heat recovery Quiet operation Low pressure fuel system with built in fuel pump Fuel efficient burner capable of burning a wide variety of diesel based fuels CSA UL certified for diesel 1 and...

Page 58: ...on the side of the electronic control box 9 3 Signs of Normal Operation When the heater is operating normally When the service switch on the side of the control box is switched ON and the ON button i...

Page 59: ...s operating normally you must check the safety functions of the main board To ensure these functions work properly place a short piece of hose or a tube over the sintered bronze compressor inlet filte...

Page 60: ...re controlling the activation of the heating element When the tank reaches a certain temperature the heating element will automatically shut off The 1500 watt heating element provides about 5000 BTU a...

Page 61: ...ns of incoming supply water and maintain the temperature at which it is set However in some cases the temperature of the incoming water and the flow rate demand of multiple faucets may limit the abili...

Page 62: ...ostic code Note Component faults can only be reset using the service switch 9 12 Electrical Noise Noise is an unwanted electrical signal which produces undesirable effects in the electronic circuits o...

Page 63: ...ning parallel or in close vicinity to each other This is especially true when the wires from several different circuits are bundled together in order to make the system wiring appear neat Electrostati...

Page 64: ...by a trained service technician Only personnel familiar with the equipment and its operation should perform the service tune up It is recommended that a certified dealer be contacted for this service...

Page 65: ...hyr from temperature extremes and any dusty dirty corrosive environment Protect the Hurricane Zephyr from cold temperatures and corrosion by using a proper mixture of anti freeze and water Use only a...

Page 66: ...npoint the fault Once the fault has been corrected it can be reset by switching the service or remote switch OFF then ON again The diagnostic codes are described below 10 2 Power On Green The POWER ON...

Page 67: ...ol board will purge the system with the combustion fan and circulating pump for two minutes If the remote switch is put in the ON position the control board will resume operation and a small red LED w...

Page 68: ...e heater will resume normal operation If the heater fails to resume operations check the thermostat and their connections 10 8 0 Voltage Low or High The battery or power supply voltage is below 11Vdc...

Page 69: ...e service or remote switch OFF then ON again If the fault does not reset check for a faulty aquastat and proper ground If diagnostic code 1 lights up and the heater is not in an overheat condition che...

Page 70: ...the service switch OFF then ON again The remote panel switch does not reset short circuit faults 10 12 4 Igniter The igniter is open or shorted The burner will shut down The diagnostic code 4 will be...

Page 71: ...t fault 10 14 6 Water Pump The water pump is shorted The burner will shut down The diagnostic code 6 will be displayed The buzzer will sound for 10 seconds The control board will purge with the combus...

Page 72: ...section 10 3 If the external fuel filter is dirty it could create restriction in the fuel line and cause flame faults Inspect and replace as necessary A flame fault can also be caused by starvation o...

Page 73: ...pump for two minutes In order to restart the burner check the air compressor Then reset the fault by switching the service switch OFF then ON again The remote panel switch does not reset a short circ...

Page 74: ...module flashing and the board still shuts down diagnostic code 7 Flame Out the board may be defective 10 20 Test Points The test points on the electrical control board allow for testing and troublesho...

Page 75: ...ed TP10 Voltage Fault The voltage will be 0 volts if there is no voltage fault and between 4 8 and 5 volts when there is a voltage fault TP11 Remote Switch The voltage will be 0 volts when the remote...

Page 76: ...heater from outdoors This is the recommended procedure no matter where the heater is installed When combustion air is drawn from an unventilated heated space the heater flame will become increasingly...

Page 77: ...on Hurricane hydronic heating systems should never produce smoke or a detectable odor If this occurs the heater requires service Section 2 1 All components including frames fuel filters solenoid valve...

Page 78: ...d to verify the proper operation of all components 11 2 Adding Heat Transfer Fluid Antifreeze Once the system has been filled with water and purged of all air during the installation procedure you nee...

Page 79: ...problems such as clogging will result in a poor flame small and blue Carefully disassemble Hold nozzle vertically and turn stem counter clockwise Clean distributor orifice and air slots of any debris...

Page 80: ...are getting 12 volts from the battery Check for corrosion of wires 11 8 Recommended Spare Parts Like any piece of machinery your Hurricane Zephyr HW heater will need servicing from time to time A sugg...

Page 81: ...AIR COMPRESSOR FUEL PUMP COMBUSTION FAN MOTOR SEASONALLY INSPECT FOR LEAKS CORROSION WEAR Figure 11 1 Maintenance Schedule 11 9 Protecting Hydronic Heating Systems The advantage of closed hydronic he...

Page 82: ...ter than 7 and less than 10 5 The key to preventing corrosion is to make sure that the heating system is free of leaks and there is no need to replace it with fresh oxygen rich boiler fill water Corro...

Page 83: ...Section 11 Maintenance 11 6 Installation Manual for Hurricane Zephyr HW Heating System...

Page 84: ...will be a valuable reference if you need warranty repairs in the future Limited Warranty The following warranties are in lieu of all other warranties and conditions ITR makes no other warranties repre...

Page 85: ...he Product was originally purchased about a warrantable failure and to obtain prior written approval for warranty repair Original serial number on Product or electrical control board has been removed...

Page 86: ...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 All r...

Page 87: ...t be relied upon without an independent verification of its applicability to the customer s particular situation For customer service or other information contact IN CANADA IN THE UNITED STATES 2431 S...

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Page 89: ...Warranty Information International Thermal Research Page 6 International Thermal Research...