Hurricane SCH25 Programming manual

Version 1.0
from Calcutt Boats
Service and
Troubleshooting
Manual
Diesel Hot Water Heating System
for Boats and Recreational Vehicles

Copyright © October 2013
MANUFACTURED BY: SOLE EUROPEAN DISTRIBUTORS:
International Thermal Research Calcutt Boats Ltd.
2431 Simpson Road, Tomlow Road, Stockton,
Richmond, BC, Canada, V6X 2R2 Southam, CV47 8HX, UK
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
Email: [email protected] Email: [email protected]
Website: www.itrheat.com Website: www.dieselheating.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
transmission, without permission in writing from International Thermal
Research and/or Calcutt Boats Ltd.
Disclaimer:
Due to our commitment for quality and ongoing product improvement, ITR &
Calcutt Boats reserve the right to modify or change without notice, any
materials, applications, equipment, accessories, and/or prices. All
measurements and weights are approximate.

Table of Contents
General Information ........................................................................ 1
TOOLS........................................................................................ 1
MAXIMUM TORQUE VALUES ........................................................... 1
1. Operation of the Hurricane SCH25 ............................................... 3
1.1. Component Views................................................................ 4
1.2. Burner............................................................................... 6
2. Control Board ........................................................................... 9
3. Troubleshooting .......................................................................13
3.1. Overview ..........................................................................13
3.2. Power On (Green) ..............................................................13
3.3. Burner On .........................................................................13
3.4. V- Service Switch Off .........................................................13
3.5. 9- Remote Switch Off.........................................................13
3.6. <- Heater Cycling (Normal Operation)...................................14
3.7. T- Thermostats Off (Normal Operation).................................14
3.8. 0- Voltage Low or High.......................................................15
3.9. 1- Overheat.......................................................................15
3.10. 2- Fuse Blown................................................................16
3.11. 3- Fuel Pump/Solenoid ....................................................16
3.12. 4- Ignitor ......................................................................16
3.13. 5- Combustion Fan..........................................................17
3.14. 6- Water Pump...............................................................17
3.15. 7- Flame Out..................................................................18
3.16. 8- Compressor ...............................................................19
3.17. )- Bypass Mode..............................................................19
3.18. Water Pump On (Green)...................................................20
3.19. Test Points .....................................................................20
3.20. LCD Readout Remote Panel ..............................................21
3.21. Flame Sensor Module.......................................................21
3.22. Reduced Output ..............................................................22
3.23. Smokey, Smelly Exhaust..................................................22
4. Step-by-step Troubleshooting ..............................................23
4.1. Flame Out.........................................................................23
4.2. Voltage.............................................................................29
5. Servicing the Hurricane SCH25.............................................31
5.1. Indications Service Is Required ............................................31
5.2. Cleaning the Combustion Chamber .......................................32
5.3. Parts Replacements............................................................33
5.3.1. Fuel Solenoid...............................................................33

5.3.2. Igniter........................................................................34
5.3.3. Fuel Nozzle..................................................................35
5.3.4. Flame Sensor...............................................................36
Appendices....................................................................................37
Appendix 1 - Technical Bulletins ....................................................37

Page 1
General Information
TOOLS
The tools in this list should be considered the minimum required for
performance of routine maintenance, servicing and minor repair work.
•Spanner sizes 11/32, 9/16, 5/8, 7/8, 15/16, 1 3/8
•Socket sizes ¼, 5/16, 7/16, 11/32
•Adjustable crescent spanner
•Phillips head screwdriver No. 2
•Flat head screwdriver
•Pliers – vice grip
•Pliers – needle nose
•Multimeter
MAXIMUM TORQUE VALUES
The fasteners used to assemble this heater are all US thread size. Most
threaded fasteners should be tightened to a specific torque value. Over
tightening the fastener can weaken it and cause it to break, while under
tightening can cause it to eventually come loose. Below is a table with
the specific torque values for each type of bolt/screw used in this heater.
Be sure to follow the recommendations closely.
Table 1: Fastener Torque values
U.S. Thread Size Ft-lbs In-lbs Nm
#8 2 24 3
#10 3 36 4.5
¼-20 6 to 9 72 to 108 9 to 12
3/8-16 22 to 32 264 to 384 30 to 43

Page 2

Page 3
1. Operation of the Hurricane SCH25
The Hurricane SCH25 has a single source of heat; a 25,000 BTU burner.
EXHAUST
HOT WATER
OUT
AIR INTAKE
COLD WATER
IN
FLAME
OBSERVATION
WINDOW
HOURMETER
FUEL INLET
FUEL RETURN
CABLE TO
CONTROL BOX
NEGATIVE TO
BATTERY
SERVICE
SWITCH
DIAGNOSTIC
CODE
WINDOW
CONTROL BOX REMOTE SWITCH
LCD DISPLAY
WARNING
BUZZER
RESET
BUTTON

Page 4
1.1. Component Views
COMPRESSO
R
FUEL PUMP
COMBUSTION FAN
FUEL REGULATO
R
HOURMETE
R
THERMAL CUTOFF
IGNITE
R
FUEL BLOCK
FLAME SENSO
R
HOURMETE
R
FUEL SOLENOID
BURNER &
COUNTERFLOW
TUBE
FUEL
BLEED/RETURN
VALVE

Page 5
BURNER &
COUNTERFLOW
TUBE
COMBUSTION
CHAMBER
NOZZLE

Page 6
1.2. Burner
The burner consists of the following components:
1. Fuel inlet
2. Fuel Pump
3. Fuel return/bleed
4. Fuel filter
5. Fuel regulator
6. Fuel solenoid
7. Flame sensor
8. Nozzle block
9. Nozzle
10. Igniter
11. Combustion fan
12. Thermal cutoff
13. Compressor
14. Air filter
When the heater is turned on (service switch on and remote switch on)
and there is a call for heat from either the room thermostat and/or the
cylinder thermostat, it will go through the following ignition sequence:
1
2
3
4
56
89
11
13
14
7
10
12
Figure 1: Burner schematic