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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

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Summary of Contents for 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: ...www itrheat 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 r...

Page 3: ...The WaterHeater by ITR Model 2 2 2 3 Your Mounting Location 2 2 2 4 What NOT to Do 2 4 2 5 Procedure 2 5 Section 3 Installing the Exhaust System 3 1 3 1 Before You Begin 3 1 3 2 Mounting Location 3 1...

Page 4: ...ard 6 3 6 6 Space Heating Control Board optional 6 3 6 7 What NOT to Do 6 4 Section 7 Plumbing the System 7 1 7 1 Before You Begin 7 1 7 2 Plumbing Installation 7 2 7 3 What NOT to Do 7 4 7 4 Installa...

Page 5: ...he Space Heating Module Optional 9 1 9 1 Before you Begin 9 1 9 2 Identifying Your Space Heating Optional Model 9 2 9 3 Your Mounting Location 9 2 9 4 Selecting the Space Heating Module Zone Box Locat...

Page 6: ...3 Installing a Relay for Add l Fan Amperage 5 6 Figure 6 1 System Wiring 6 3 Figure 7 1 Plumbing Fittings 7 2 Figure 7 2 The Approved Method of Installing Heater Hose Consult ITR for Alternative Meth...

Page 7: ...d to know before beginning the installation including how to protect your warranty and tools and equipment eeded n Some of the figures in this manual represent a typical installation but other configu...

Page 8: ...ture maintenance To protect your Warranty 1 2 Protect Your Warranty This document reflects approved installation techniques methods and materials and applies only to ITR equipment The WaterHeater by I...

Page 9: ...ource of heating water A single 1500 watt 120 VAC immersion element is used as a secondary heat source 240 VAC also available The WaterHeater by ITR heats water to provide a continuous supply for all...

Page 10: ...ed sealed combustion chamber is designed to use outside air Simple low amperage draw ignition Electronically controlled system with o Automatic Safety Shutdown o Manual reset aquastats for safety over...

Page 11: ...ractices using the highest and most recent standards and codes Good workmanship is essential Please refer back to Section 1 2 Protect Your Warranty You will need the following equipment and tools not...

Page 12: ...allation 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 The Inspection C...

Page 13: ...tential for vibration and jarring Fuel storage location Most efficient plumbing runs Safe and convenient access for maintenance Number and location of interior fans Location of other equipment to be i...

Page 14: ...unting location must be able to support double the gross weight of The WaterHeater by ITR i e 150 lbs x 2 300 lbs 68 KG x 2 136 KG and must be of a non combustible surface The WaterHeater by ITR is 14...

Page 15: ...e and exhaust hoses have no leaks and are well fastened to the heater muffler and thru hull fitting Assembly parts that may cause injury through accidental contact should be protected Isolate the unit...

Page 16: ...ure 2 1 Dimensions 2 4 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 distu...

Page 17: ...orizontally and level 2 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 Fig...

Page 18: ...t will infiltrate the living areas Never place any exhaust parts close to combustible material or through a combustible wall or ceiling without fireproof protection The exhaust can reach high temperat...

Page 19: ...e is placed between 10 o clock and 2 o clock and also goose necked to avoid water ingestion see Figure 3 2 There needs to be a 1 8 air gap around the exhaust thru hull The standard thru hull is 3 in d...

Page 20: ...and leak free The WaterHeater by ITR exhaust outlet pipe and the exhaust pipe itself must not be distorted or damaged during this process When The WaterHeater by ITR is running the connection points a...

Page 21: ...he WaterHeater by ITR fitting using an approved exhaust clamp 3 Connect the exhaust piping in series with the muffler using heavy duty exhaust clamps If you use vibration isolation mounts they must be...

Page 22: ...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 3 5...

Page 23: ...om 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 other fuel burning device WARN...

Page 24: ...connection points and hoses must use suitable clamps and or sealant and must be checked for leaks on the initial installation and also periodically as part of normal maintenance A primary UL and or C...

Page 25: ...aged during normal operation 4 4 Procedure To complete the fuel system installation 1 Install the inline fuel filter The optimal location is on a compartment wall next to The WaterHeater by ITR inline...

Page 26: ...running through it reaches 120 F 49 C The Defrost Heater provides up to 28 000 BTU h and uses a three speed fan 200 275 450 cfm 40 55 100 watts Note A limited number of fan heaters can be used with Th...

Page 27: ...ch prevents fan operation until the system has reached minimum operating temperature The aquastat can be deleted to meet particular installation requirements but it is recommended that all systems be...

Page 28: ...Guards to protect the fan blades from damage recommended for fans installed in storage areas or other accessible areas where something could contact the fans Screws 10 sheet metal screws or wood scre...

Page 29: ...t floor level or very near floor level in order to optimize circulation Allow a minimum 16 square inch 100 cm sq opening in the fan heaters mounting compartment to allow sufficient intake of air ITR s...

Page 30: ...ou will wire these up to the Zone Control Board see Section 9 Installing the Space Heating Module Optional 4 If the fan s require s more than 8 amps install a separate relay to power the fans This rel...

Page 31: ...Section 5 Installing Fan Heaters Figure 5 3 Installing a Relay for Additional Fan Amperage 5 6 The WaterHeater by ITR...

Page 32: ...or the National Electric Code Section 6 WARNING 6 2 12 VDC The following apply to the 12 VDC connections to the The WaterHeater by ITR There is one paired set of 12 VDC electrical connections on the t...

Page 33: ...AC electrical connectors and terminals Once the connection is completed the wires are to be inserted back into their compartment and the cover secured Do not operate the electric elements until water...

Page 34: ...rol Board is mounted on board The WaterHeater by ITR itself It has no user adjustable components 6 6 Space Heating Control Board optional The Space Heating Module optional is controlled by a separate...

Page 35: ...ater by ITR is running and never disconnect the battery while the inverter is charging NOTICE Doing either will severely damage The WaterHeater by ITR because it fails to automatically purge the combu...

Page 36: ...tion you must Minimize the heat loss from the hoses and eliminate air from the system Follow the flow directions for the fluids in The WaterHeater by ITR Section 1 Overview Figure 1 1 Hot Water Heater...

Page 37: ...water heater to the Space Heating Module if installed see Section 9 Installing the Space Heating Module All fittings hose and or tubing involving the domestic water must be approved for use with domes...

Page 38: ...lief hose This valve drains through the drain relief hose located at an opening on the left front lower face of the WaterHeater and is labeled Temp Pressure Relief Valve Do not block or plug the valve...

Page 39: ...eled Cold Water Inlet and the hot water output is labeled Hot Water Outlet Ensure proper direction of flow 2 Two male 1 2 NPT PEX tube fittings not supplied must be fit into the supply and return fitt...

Page 40: ...led 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 Use two wrenches Use a food safe Teflon tape for...

Page 41: ...as 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 in accordance with the recomm...

Page 42: ...e Remote Operating Panel will turn ON when the diesel burner has been activated The burner will continue to operate until the water in The WaterHeater by ITR reaches the set operating temperature rang...

Page 43: ...the Space Heating Module and calling for heat will cause the cabin fan controlled by that thermostat to commence running The ITR cabin fan heater has a built in aquastat that prevents the cabin fan f...

Page 44: ...erHeater 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 R...

Page 45: ...n turns ON when the power to the control board is ON Bypass Button The Bypass button is for authorized service personnel only Reset Button The Reset button when pressed resets the WaterHeater Control...

Page 46: ...Voltage fault LED red turns ON when a voltage fault has been detected Low Water LED Red The Low Water level fault LED red turns ON when a low water level in the WaterHeater has been detected 8 7 Funct...

Page 47: ...d integrity Exhaust and air intake checked for no obstructions Fuel lines fittings for leaks and integrity External fuel filter for clogging Annual Factory Maintenance Perform the following Factory Se...

Page 48: ...handwheel was set to number ______ Any change in the setting to a higher number may raise the discharge temperature to an unsafe temperature which may lead to scalds The temperature and pressure safet...

Page 49: ...nstalled to allow complete drainage of both the valve and the discharge line No reducing coupling or other restriction shall be installed in the discharge line The discharge line must pitch downward f...

Page 50: ...cturer s instructions for the type of anti freeze and mixture recommended for your application Note that any domestic water in The WaterHeater by ITR or Space Heating Module will freeze in cold temper...

Page 51: ...l supply present and adequate Air intake or exhaust not blocked or obstructed Air in fuel line White smoke from exhaust Fuel filter external dirty Component LED s all glowing green on The WaterHeater...

Page 52: ...echnical specifications Consider the following factors to help you decide exactly where best to mount the Space Heating Module Space Heating Module weight when full Potential for vibration and jarring...

Page 53: ...The serial number identifies the model type through the first series of letters and numbers The type of Space Heating Module model is SHM Space Heating Module 9 3 Your Mounting Location Your mounting...

Page 54: ...lay LED s on the board itself The module is connected to the space heating zone board through the electrical connections located at the bottom of the control board box and the distance apart is dictat...

Page 55: ...e disabled and the WaterHeater tank drained before the valve is removed and the cold water inlet tee installed Use two wrenches Reinstall the drain valve into the axial side of the newly installed tee...

Page 56: ...female 1 2 NPT fitting located on the upper left face of the module A male 1 2 NPT x 3 4 hose barb not supplied 3 4 I D heavy duty rubber hose and good quality hose clamps are recommended for connecti...

Page 57: ...e placed on the copper hot water drain pipe located inside the WaterHeater Remove the front face plate of the heater and locate the 1 2 copper hot water pipe on the tank Clip the aquastat onto the bar...

Page 58: ...ectrical Connection All field wiring is to be in accordance with CSA Standard C22 1 Canadian Electrical Code Part l the National Electric Code or local regulations CAUTION 12 VDC Primary DC power to t...

Page 59: ...nnector 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 Cabin Fan...

Page 60: ...Cabin Fan Pump Cabin Fan Power Cabin Fan Thermostat Cabin Fan Yellow Cabin Ground Yellow Black Water Heater Remote 4 pin 4 pin Thermostat Return Pink Thermostat Out Red Water Heater 2 pin 2 pin AC Box...

Page 61: ...hrough bolts and 1 diameter fender washers lock washers and nuts 9 10 INSPECTION AND TESTING After all components have been properly installed according to ABYC Industry Standards and Practices and th...

Page 62: ...warranty Before mailing make photocopies of the completed Warranty Card for your records It will be a valuable reference if you need warranty repairs in the future General Warranty ITR warrants all wa...

Page 63: ...pon warranty contract or negligence ITR s maximum liability shall not in any case exceed the contract price for the Products claimed to be defective No one is authorized to increase alter or enlarge I...

Page 64: ...n brushes Product malfunctions due to improper installation of parts or Products including but not limited to malfunctions causing inadequacies in air fuel or coolant flow voltage problems due to impr...

Page 65: ...serial number of the Product on the outside of the shipping container and ship prepaid and insured 4 Provide written details of the problems date of installation proof of purchase and a return address...

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