ITR WindowWasher User manual

from Calcutt Boats
Installation and
Operating Manual
Diesel Fired Continuous Output
Window Cleaning Water Heater

Copyright © January 2010
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.

International Thermal Research i
Table of Contents
Section 1, Overview...................................................... 1
1.1 Unpacking the WindowWasher...................... 2
1.2 Protect Your Warranty................................. 2
1.3 The WindowWasher™ by ITR Features ........... 3
1.4 Critical Factors ........................................... 4
1.5 Equipment, Tools and Skills.......................... 4
1.6 Testing and Inspection ................................ 5
Section 2, Mounting the WindowWasher....................... 7
2.1 Before You Begin........................................ 7
2.2 Your Mounting Location ............................... 8
2.3 Procedure.................................................. 9
Section 3, Installing the Exhaust System.................... 11
3.1 Before You Begin...................................... 11
3.2 Mounting Location..................................... 11
3.3 Procedure................................................ 13
Section 4, Installing the Fuel System.......................... 15
4.1 Before You Begin...................................... 15
4.2 Fuel System Installation ............................ 15
4.3 What NOT to Do ....................................... 16
4.4 Procedure................................................ 17
Section 5, Wiring the Electrical System ...................... 19
5.1 Before You Begin...................................... 19
5.2 12 VDC ................................................... 19
5.3 Remote Operating Panel Cable.................... 20
5.4 Main Electronic Control Board..................... 20
5.5 What NOT to Do ....................................... 20
Section 6, Plumbing the System ................................. 23
6.1 Before You Begin...................................... 23
6.2 Plumbing Installation................................. 23
6.3 What NOT to Do ....................................... 25
6.4 Installation Procedure................................ 25
Section 7, Operating The WindowWasher™ ................ 27
7.1 Operating Instructions............................... 27
7.2 Turning the Power “ON”............................. 28
7.4 Functions of the Remote Panel.................... 28
7.5 Functions of Control Panel.......................... 29

Table of Contents
ii WindowWasher Installation Manual
7.6 WindowWasher Maintenance.......................31
7.7 Protect the WindowWasher™ ......................33
7.8 General Troubleshooting ............................33
Section 8, Warranty Information.................................35
List of Figures
Figure 1-1: WindowWasher Unit .....................................1
Figure 2-1: Dimensions .................................................9
Figure 2-2: Location of Mounting Brackets...................... 10
Figure 3-1: Installing the Exhaust System...................... 14
Figure 5-1: System Wiring ........................................... 20
Figure 6-1: Plumbing Fittings ....................................... 23
Figure 7-1: The WindowWasher - Fittings....................... 27
Figure 7-2: Remote Operating Panel.............................. 29
Figure 7-3: The WindowWasher - Control Panel............... 30

International Thermal Research 1
Section 1, Overview
Thank you for purchasing The WindowWasher™ by ITR for
the window cleaning trade.
This section describes features of The WindowWasher™ by
ITR and 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: WindowWasher Unit
Section
1
Some of the figures
in this manual
represent a typical
installation, but
other configurations
or methods may be
acceptable. If in
doubt, obtain
approval from
Calcutt Boats or ITR.

Section 1, Overview
2 WindowWasher Installation Manual
1.1 Unpacking the WindowWasher
When you receive The WindowWasher™ by ITR:
1 Unpack it carefully.
2 Check each component against the provided parts list to
ensure that you have everything and that all parts
arrived undamaged.
3 If you discover any missing or defective parts, call
Calcutt Boats or ITR immediately.
4 If you are not installing The WindowWasher™ by ITR
right away, secure all components so none will be
misplaced.
5 Before installing The WindowWasher™ by ITR, read
the rest of Section 1 – Overview. It contains
critical information for a proper installation.
A properly installed WindowWasher™ by ITR is essential for
several reasons:
•To ensure that you and/or your customers receive
satisfactory results.
•To ensure a trouble-free installation, a successful
inspection and testing process and ease of future
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 WindowWasher™ by ITR is only guaranteed by ITR if the
entire system has been installed according to the
requirements and recommendations set out here.
Any modification must be approved in writing by
qualified Calcutt Boats or ITR personnel, prior to the
installation.
This includes:
•Deviations from the instructions in this Manual.
•Changes to any piece of ITR-supplied equipment.
•Substitution of a non-ITR-approved component.
NOTICE

Section 1, Overview
International Thermal Research 3
No warranty will be extended to improper installations. Use
of any unapproved materials, equipment, or installation
procedures will result in a voided warranty for the entire
system. Calcutt Boats and ITR accept no liability for any
damage or loss of service resulting from unapproved
modifications.
1.3 The WindowWasher™ by ITR
Features
The WindowWasher™ by ITR uses a patented diesel burner
(12 VDC) controlled by a multi-functional electronic controller
as the primary source of heating water. The
WindowWasher™ by ITR heats water to provide a continuous
supply for window cleaning.
Other features of The WindowWasher™ by ITR include:
•A high-temperature, stainless steel burner and
stainless steel jacket.
•5.3 US gallon (20.5 L) welded stainless steel
insulated water tank that minimizes heat loss and
optimises heat recovery.
•Low water level switch in the tank.
•Easy to install with hook-ups and connections easily
accessible from the top and front of The
WindowWasher™ by ITR.
•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.
•Exhaust has minimal smoke or smell.
•Fan assisted sealed combustion chamber is designed
to use outside air.
•Simple, low amperage draw ignition.
•Electronically-controlled system with:
oAutomatic Safety Shutdown.
• Efficient
• Clean
• Quiet
• Compact
• Safe
• Rugged
• Reliable
• Economical

Section 1, Overview
4 WindowWasher Installation Manual
oManual reset aquastats for safety overheat
protection.
oLED indicators on the Control Panel for
diagnostics.
oPatented, proprietary flame sensor.
•The WindowWasher™ by ITR Remote Operating Panel
with ON/OFF switch for the diesel burner and
indicator LEDs for operational and diagnostic
information.
1.4 Critical Factors
The key factors to keep in mind when planning and carrying
out the installation are:
•Mounting location restrictions for The
WindowWasher™ by ITR exhaust outlet (to reduce
noise, vibration, heat loss, etc.)
•Length, routing, and sizing of fluid lines, fuel lines,
air flow tubing, exhaust piping and wiring.
•Unrestricted intake required to draw in outside air for
combustion.
•Ability to easily access and service the product,
especially fuel, plumbing, and electrical systems.
•After installation, requirement to purge water and
fuel lines and inspect/test entire system using the
ITR-supplied Inspection Check 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 you comply
with existing industry practices, 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
supplied) to install the heating system. This list does not
include optional equipment and accessories:
•Standard tools normally available in a well-equipped
workshop.
•Appropriate fasteners for mounting the heater unit.
Pay attention to the
notices of “Danger”
“Warning” “Caution”
and “Notice” in this
manual.

Section 1, Overview
International Thermal Research 5
•Stainless steel 1-1/2” ID exhaust piping, maximum
12’ with no bends (see Section 3 – Installing the
Exhaust System, for details when bends are present).
•Optional ITR silencer.
•1/4” supply and return fuel line, approved rubber or
copper.
•Domestic water hose and/or tubing to connect The
WindowWasher™ by ITR hose fittings to the van
water system.
1.6 Testing and Inspection
After all components have been properly installed according
to standard practices, and the recommendations of this
Installation and Operating Manual, The WindowWasher™ 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 Check Sheet is
divided into progressive sections, allowing each phase of
the inspection to be carried out systematically, and then
signed off by authorized persons.

Section 1, Overview
6 WindowWasher Installation Manual