ITR Hurricane Zephyr HW User manual

International Thermal Research
Installation and
Operating Manual
Hurricane®Zephyr™HW
Diesel Heating System for Yachts

Table of Contents
Manual Issue Date/Copyright © April 2021
International Thermal Research
IN CANADA: IN THE UNITED STATES:
2431 Simpson Road 5305 NE 121st Ave., Suite 401
Richmond, BC, Canada V6X 2R2 Vancouver, WA USA 98682
Tel: [phone] or 604-278-1272 Tel:[phone] or 360-993-
4877
Fax: [phone] Fax: [phone]
Email: [e-mail] www.itrheat.com
Website: http://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, retrieval, or transmission,
without permission in writing from International
Thermal Research
Right to Modify:
Due to our commitment for quality and ongoing
product improvement, ITR reserves the right to
modify or change without notice, any materials,
applications, equipment, accessories, and/or prices.
All measurements and weights are approximate.
Read and save these instructions for future reference

Table of Contents
International Thermal Research
Table of Contents
Technical Specifications and Standards
Dangers •Warnings •Cautions •Notices
Section 1, Overview....................................................................1-1
1.1 Unpacking the Heating System......................................... 1-2
1.2 Protect Your Warranty .................................................... 1-2
1.3 Heater Features............................................................. 1-3
1.4 Critical Factors .............................................................. 1-5
1.5 Equipment, Tools, and Skills ............................................ 1-5
1.6 Testing and Inspection.................................................... 1-6
Section 2, Mounting the Heater Unit............................................2-1
2.1 Before You Begin ........................................................... 2-1
2.2 Mounting Location.......................................................... 2-2
2.3 What NOT to 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........................... 3-1
3.3 What NOT to Do ............................................................ 3-3
3.4 Procedure..................................................................... 3-3
Section 4, Installing the Fuel System ..........................................4-1
4.1 Before You Begin ........................................................... 4-1
4.2 Fuel System Installation and recommendations .................. 4-1
4.3 What NOT to Do ............................................................ 4-2
4.4 Procedure..................................................................... 4-3
Section 5, Installing Fan Heaters ................................................5-1
5.1 Before You Begin ........................................................... 5-1
5.2 Fan System Operation .................................................... 5-2
Features....................................................................... 5-2
Multiple-Zone Heating System ......................................... 5-2
Accessories and Components Needed................................ 5-3
5.3 What NOT to Do ............................................................ 5-3
5.4 Mounting Locations ........................................................ 5-4
5.5 Procedure..................................................................... 5-4

Table of Contents
Section 6, Wiring the Electrical System....................................... 6-1
6.1 Before You Begin............................................................6-1
6.2 Hurricane® Zephyr™12 VDC........................................... 6-1
6.3 Hurricane® Zephyr™120/240 VAC (Optional) .................... 6-2
Procedure .................................................................... 6.3
6.4 Electrical Components.....................................................6-3
6.5 What NOT to DO ............................................................6-6
6.6 Procedure .....................................................................6-6
6.7 Electrical Schematic........................................................6-9
Section 7, Plumbing and filling the System ................................. 7-1
7.1 Before You Begin............................................................7-1
7.2 Heat Transfer Fluid/Plumbing Installation Procedure............. 7-2
7.3 What NOT to Do.............................................................7-4
7.4 Potable Water Plumbing Installation ..................................7-5
7.5 Engine Waste-heat and Engine pre-heat Plumbing ............... 7-6
7.6 Procedure Filling/Purging the Heating System ..................... 7-7
Section 8, Hot Water Heating and Engine Heat Management ....... 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 Zepyhr heating System......... 9-1
9.1 Features of the Hurricane Zephyr Heating System ............... 9-1
9.2 Starting the Heater.........................................................9-3
9.3 Signs of Normal Operation ............................................... 9-3
9.4 Main Control Board Operation...........................................9-4
9.5 Stopping the Heater (seasonal) ........................................ 9-4
9.6 Using the Electric Heating Elements ..................................9-5
9.7 Activating the Cabin Fans through the Thermostats ............. 9.5
9.8 Activating the Domestic Hot Water.................................... 9-5
9.9 Domestic Water temperature Adjustment...........................9-6
9.10 Stopping the Heater (Maintenance) ..................................9-7
9.11 Resetting a Fault ............................................................9-7
9.12 Electrical noise............................................................... 9-7
9.13 Maintenance..................................................................9-9
9.14 Protecting the Heating System ....................................... 9-10
Section 10, Troubleshooting..................................................... 10-1
10.1 Overview .................................................................... 10-1
10.2 Power On ................................................................... 10-1

Table of Contents
International Thermal Research
10.3 Burner On ...................................................................10-1
10.4 Service Switch Off.........................................................10-2
10.5 Remote Switch Off ........................................................10-2
10.6 Heater Cycling .............................................................10-2
10.7 Thermostats Off............................................................10-3
10.8 Voltage Low of High ......................................................10-3
10.9 Overheat ....................................................................10-4
10.10 Fuse Blown ..................................................................10-4
10.11 Fuel Pump/Solenoid ......................................................10-5
10.12 Ignitor ........................................................................10-5
10.13 Combustion Fan ...........................................................10-6
10.14 Water Pump.................................................................10-6
10.15 Flame Out ...................................................................10-6
10.16 Compressor .................................................................10-8
10.17 Bypass Mode................................................................10-8
10.18 Water Pump On............................................................10-9
10-19 Flame Sensor Module ....................................................10-9
10.20 Test Points...................................................................10-9
10.21 Reduced 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 Filter ......................................................11-2
11.5 Combustion Chamber ...................................................11-2
11.6 Checking Hoses and Tubes .............................................11-2
11.7 Electrical System ..........................................................11-3
11.8 Recommended Spare Parts ............................................11-3
11.9 Protecting Hydronic Heating Systems ...............................11-4
Section 12, Warranty and Service .............................................12-1
12.1 General Warranty .........................................................12-1
12.2 Limited Warranty..........................................................12-1
12.4 Owner’s Responsibility ...................................................12-2
12.5 Not Covered Under Warranty ..........................................12-2
12.6 Customer Service Calls .................................................12-3
12.7 Returns .......................................................................12-3
12.8 Telephone Service.........................................................12-4
Inspection Check sheet (including Test Points)
Warranty Information & Warranty Card

Table of Contents
List of Figures
Figure 1-1 Hurricane® Zephyr™HW Heating System ..................... 1-1
Figure 1-2 Hurricane® Zephyr™HW Heating System Overview........ 1-4
Figure 1-3 Hurricane® Zephyr™HW Typical seiries-Plumbed Layout.1-7
Figure 2-1 Hurricane® Zephyr™HW Dimensions ...........................2-3
Figure 2-2 Heater Mounting bracket configuration ......................... 2-4
Figure 2-3 Touchscreen Operating Panel Mounting ........................ 2-5
Figure 3-1 Hurricane Zephyr™HW Typical Exhaust configuration...... 3-4
Figure 5-1 Wiring the Fan’s Aquastat............................................ 5-2
Figure 5-2 Mounting a Spacesaver 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 Diagram V2001................................................6-9
Figure 7-1 Hurricane® Zephyr™HW Heating System Overview........ 7-3
Figure 7-2 Plumbing Zephyr™for 3 Zones (opt. summer loop)......... 7-4
Figure 7-3 Three Approved Methods of Installing Heater Hose .......... 7-5
Figure 7-4 Potable Hot Water System Plumbing ............................. 7-6
Figure 7-5 Engine Heat / Pre-heat System Plumbing.......................7-7
Figure 7-6 Filling/Purging Hurricane® Zephyr Heating System ......... 7-8
Figure 8-1 Single Loop System, three fans, optional summer loop .... 8-2
Figure 9-1 Mixing Valve Location..................................................9-6
Figure 11-1 Maintenance Schedule ............................................ 11-4

International Thermal Research 1-1
Overview
Thank you for purchasing the Hurricane® Zephyr™HW
diesel hot water heating system.
This section describes features of the Hurricane® Zephyr™HW
heater and explains what to 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.
Figure 1-1: Hurricane® Zephyr™HW Heating System
Section
1
Some of the figures
in this manual
represent a typical
installation, but
other configurations
or methods may be
acceptable. If in
doubt, contact ITR
for assistance.

Section 1, Overview
1-2 Installation Manual for Hurricane® Zephyr™HW Heating System
1.1 Unpacking the Heating System
When you receive your Hurricane® Zephyr™HW
heater:
1 Unpack it carefully.
2 Check each component against the provided parts list to
ensure that you have everything and that all parts are
undamaged.
3 If you discover any missing or defective parts, call ITR
immediately.
4 If you are not installing the heater right away, secure all
components so none will be misplaced.
5 Before installing the heater, read the rest of this
Instruction and Operation Manual. It contains
critical information for a proper installation.
It’s important to follow the installation procedures 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 Warranty
This document reflects approved installation techniques,
methods, and materials, and applies only to ITR equipment.
The heater and supplied components are only guaranteed by
ITR if the entire system has been installed according to the
requirements and recommendations set forth in this manual.
Warranty coverage will not be extended to heaters and
system components (supplied by ITR) used in an improper
installation. Use of any unapproved materials, equipment, or
installation procedures will void the warranty for the entire
heating system. ITR does not accept liability for any damage
or loss of service resulting from unapproved installations
and/or modifications.
NOTICE

Section 1, Overview
International Thermal Research 1-3
1.3 Heater Features
The Hurricane® Zephyr™HW is an advanced and efficient
hydronic heater with many advantages over older technology
of forced-air systems. The Zephyr™provides space heating
using a “heat-transfer fluid”pumped to remote mounted, fan
equipped, radiator-style heat-exchangers. The same “hot”
fluid is circulated through a highly efficient, internally
mounted, flat-plate heat-exchanger to provide a continuous
supply of domestic hot water. The heater runs on 12VDC
power, using a diesel-fired burner to maintain the
temperature of the heat transfer fluid. The Hurricane®
Zephyr™HW heater can also use waste heat from the
engine, using the internal heat exchanger. The addition of an
optional secondary water pump will also allow pre-heating of
the engine.
Other 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 stainless steel burner and water jacket
to prevent premature warping or burnout
·Internal circulation pump for heating loop and hot water
heat exchanger
·Insulated enclosure retains heat and minimizes noise
·Easy to install, field serviceable, with hookups and
connections easily accessible from the top of the heater
·Quiet operation and low power consumption
·Low-pressure fuel system with built-in fuel pump
·Fuel-efficient burner capable of burning a wide variety of
diesel-based fuels
·No smoke or smell from the exhaust
·Fan assisted; sealed combustion chamber is designed to
use outside air through a direct ventilation hook-up
·Simple, low amperage draw ignition
Return fuel line to eliminate air and prevent nuisance
shutdowns
Hurricane® Zephyr™
HW ADVANTAGES
•Efficient
•Clean
•Quiet
•Compact
•Safe
•Rugged
•Reliable
•Economical

Section 1, Overview
1-4 Installation Manual for Hurricane® Zephyr™HW Heating System
·Electronically-controlled system with:
oAutomatic safety shutdown
oManual reset overheat temperature sensor and a
thermal cutoff for overheat protection
oTactile, 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 demand, continuous domestic water heating without
the need for hot water storage
·Use of engine waste heat to provide system heating
·Engine heating (using an optional external pump)
Figure 1-2: Hurricane® Zephyr™HW Heating System Overview