iMASS IWH-1.5 Instantaneous Water Heater User Manual

iMASS IWH-1.5 Instantaneous Water Heater

Specifications

IWH-1.5 (10 kW)

• Gas pressure propane (mbar): 27.5
• Nominal max. input in kW (propane): 13.65
• Maximum consumption (g/h): Universal LPG
• Minimum input in kW: 5
• Efficiency (%): Not specified
• Maximum water pressure (bar): Not specified
• Minimum water pressure (bar): Not specified
• Minimum starting water flow (l/min): Not specified
• Shut down water flow (l/min): Not specified
• Power supply voltage VDC: Not specified
• Maximum current consumption (A): Not specified

IWH-1.5-13.5 (13.5 kW)

• Gas pressure propane (mbar): 27.5
• Nominal max. input in kW (propane): 13.65
• Maximum consumption (g/h): Universal LPG
• Minimum input in kW: 5
• Efficiency (%): Not specified
• Maximum water pressure (bar): Not specified
• Minimum water pressure (bar): Not specified
• Minimum starting water flow (l/min): Not specified
• Shut down water flow (l/min): Not specified
• Power supply voltage VDC: Not specified
• Maximum current consumption (A): Not specified

Description
The IWH-1.5 and IWH-1.5-13.5 are instantaneous water heaters designed without a storage tank, utilizing a finned copper, highly efficient heat exchanger. The heaters feature a four-blade burner controlled by a patented modulation valve with low electrical consumption and a maximum modulation rate of 1:4.

Frequently Asked Questions (FAQ)

• Q: How do I adjust the temperature setting on the water heater?
  A: To adjust the temperature setting, use the remote control provided with the unit. Follow the instructions in the user manual to set your desired water temperature.

• Q: What should I do if I encounter error codes on the display?
  A: If you see error codes on the display, refer to the Trouble Shooting Guide in the user manual to identify the issue and follow the recommended steps for troubleshooting.

IMASS GmbH Flaringer Berg 9 84416 Taufkirchen Germany

• SERVICE MANUAL Model
• IWH-1.5 and IWH-1.5-13.5 (Australian Version) Instantaneous Water heater

Specifications IWH-1.5 (10 kW)

• Gas pressure propane (mbar) 27.5
• Nominal max. input in kW (propane) 10.7
• Maximum consumption (g/h) 765
• Minimum input in kW 3.3
• Efficiency (%) >90
• Maximum water pressure (bar) 5.0
• Minimum water pressure (bar) 0.5
• Minimum starting water flow (l/min) 1.5
• Shut down water flow (l/min) 1.3
• Selectable water temperature (°C) 35 ….. 60
• Temperature rise at 3.3 l/min (°C) 37.7
• Precondition for a stable min. temperature of 35°C water inlet temp. 15°C at 2.7l/min
• Power supply voltage VDC 10.5 ….. 15.0
• Maximum current consumption (A) 0.44

Specifications IWH-1.5-13.5 (13.5 kW)

• Gas pressure propane (mbar) 27.5
• Nominal max. input in kW (propane) 13.65
• Maximum consumption (g/h)
• Minimum input in kW 5.0
• Efficiency (%) >90
• Maximum water pressure (bar) 5.0
• Minimum water pressure (bar) 0.5
• Minimum starting water flow (l/min) 1.5
• Shut down water flow (l/min) 1.3
• Selectable water temperature (°C) 35 ….. 60
• Temperature rise at 5 l/min (°C) 37.0
• Precondition for a stable min. temperature of 35°C water inlet temp. 15°C at 2.7l/min
• Power supply voltage VDC 10.5 ….. 15.0
• Maximum current consumption (A) 1.5

Gas Consumption & Configuration Data

| Supply Pressure| Test Point| Injector Nozzle| NGC
---|---|---|---|---
Universal LPG| | Pressure (kPa)| 4 x Ø 1.06 mm| 49.14 MJ/h

Description

• The 2 water heaters are designed without storage tank and use a finned copper, highly efficient, heat exchanger.
• The four-blade burner is controlled by a unique patented modulation valve, which has a very low electrical consumption.
• The maximum modulation rate is 1:4.
• For a very high operational reliability and high thermal efficiency, even under extreme weather conditions, the water heater is equipped with an exhaust blower and a highly efficient brushless DC motor. Ball bearings and no carbon brushes guarantee a quite operation and a very long lifetime.
• The water flow rate is detected by a precise flow rate meter with high resolution.
• The hot water temperature can be selected in 1°C steps from 35 to 60°C.
• The µ-processor of the electronic control is continuously comparing the cold-water temperature, the hot water outlet temperature and the current water flow rate.
• With the combination of these 3 data, the control drives the modulation valve and tries to reach the selected temperature in the shortest possible time without overheating.
• Also with using these 3 values, the control is continuously calculating the burner power and is limiting the power with the modulation valve to 10.7 kW (13.65 kW), even if the gas pressure in the RV is through a defect of the pressure regulator up to 60 mbar.
• The airflow is detected by a differential air pressure switch in the exhaust blower.
• Every value, which is out of the programmed limits, will cause immediately an interruption of the gas flow, or the unit will even not start without correct data.
• At the upper end of the heat exchanger, a safety temperature switch will switch of the device in case of overheating, caused may be through a defect sensor.
• The flame detection is using the ionization principle.
• In case of a high water pressure from the water line, the IWH-1.5 is protected via an overpressure valve with 5.5 bar.
• The electronic control is equipped with an unique failure diagnostic software and a special service mode.
• With the remote control, the water heater can be switched off completely or it remains in standby mode. In this mode, the display is switched off after one minute in order to save energy and to have no disturbing illumination during night time.
• Also selectable on the remote control is the max. outlet temperature of the hot water.
• Also on the display is shown a possible error code in case of a failure. With the input of a code, the service technician can recall data in the service mode.
• The IWH-1.5-13.5 version is equipped with an additional DC-DC converter, which increases the DC input range and makes it even more stable for critical weather condition like strong wind.

Recommended Test Equipment

1. Multimeter for voltage and current (DC)
2. Gas pressure meter digital (recommended) or analog
3. Water flow meter
4. Thermometer with external sensor up to 150°C
5. Optional a rev meter and a combustion analyzer

Remote Control

1. Selectable functions:

2. ON/OFF switch

3. Gas pressure mode

4. Parameters of water heater

5. Functions:
   Operation indicator – green LED

6. Functions:

7. Temperature setting

8. Adjustment gas pressure mode

9. Selection of inner parameters

Temperature Setting Range

Preset temperature: last selected temperature (also after disconnecting 12V power)

• Temperature range: 35° …… 65°C
  • from 35 … 50°C: 1°C per keystroke
  • from 50 … 65°C: 5°C per keystroke

Position of components

• front view
• right side

• left side
• rear view

Schematics and Diagrams

Ladder Diagram – IWH-1.5

Wiring Diagram IWH-1.5 Wiring diagram IWH-1.5-13.5

Trouble Shooting Guide

Notice :
Before starting the trouble-shooting steps suggested below verify that:

• There is power connected to the water heater
• Green ON LED is lighting
• Wiring is not damaged in any way
• All connectors are plugged in
• Water flowing through the unit when you open a hot water faucet
• LPG gas is connected and the gas tank (bottle) is not empty
• exhaust outlet is not blocked through dirt or anything else

First steps

1. No light at the remote control – burner doesn’t start
   Check the 12 V of the power supply.
   Check the fuse (2 AT) in the power cord, which is inside the heater close to the control.

2. Green LED of the remote control is burning – burner doesn’t start
   Check the water flow.
   If the water flow is low, look also for dirt in the inlet filter of the cold water inlet If there is enough water:

3. Demount the water flow sensor and/or check the sensor cable

4. Replace the control

5. Water is flowing, you hear the igniter, no flame

6. Check the gas pressure at the gas inlet

7. Try to ignite at least 5 times – maybe there is air in the gas line because of a change of the gas bottle

8. Measure the gas pressure at the pressure test point of the nozzle block
   It should be for start between 15 and 23 mBar

Error Codes (display) and Troubleshooting

• Gas supply system : source of supply
• Electrical power supply ： source of supply, power cord / cable, safety fuse
• Ignition system ： igniter
• Control System : ionization cable

E2| Continuously operating for 60 minutes| In normal condition ： overtime operation
E4| Detected signal while turning on the water| Control system : control unit
E5| Defect hot water sensor, but water heater still operating| Detection system ： hot water temperature sensor
E6| Hot water sensor short-circuited or the hot water temperature has reached 85 ℃.| Detection system ： hot water temperature sensor Through pulsing water supply at low flow rate (membrane pumps), the burner could switch continuously switch and and off, without starting the temperature regulation
E7| Continuously flame out for 15 times| Gas supply system ： source of supply
---|---|---
E8| Safety (temperature) switch defect| Detection system ： safety temperature switch
E9| Ventilator, air pressure switch (APS), air flow blocked or operating voltage too low failure|

• check the supply voltage
• Is the ventilator running smooth, or do you hear any scratching noise ?
• c heck for dirt or water in the flow sensor (exhaust pipe) and in the 2 transparent wires to the pressure switch

EA| Cold water sensor defect| Detection system ： cold water temperature sensor
EB| CPU or circuit broken| Control system: control unit
EE| Arithmetic-logic calculation abnormal| Control system: control unit
ON| ON/OFF Switch|
| |
| |

• If all steps above doesn’t solve the problem, you should check first all the wiring and plugs. Especially the plugs in the ECU must be plugged in properly.
• As final and last step you could change the ECU. But if see a correct display and you can make a reset, a defect ECU is very unlikely.
• NOTE: For a RESET, you must disconnect the el. power for at least 2 min.

Typical failures – mostly caused through operating errors

Failure E9: This is the air pressure switch (APS) and therefore the airflow
Possible reasons:

1. exhaust pipe blocked with dirt or something similar
2. the 2 small silicone tubes from the air flow sensor to the air pressure switch (APS) have a problem (or reversed)
3. air inlet blocked
4. supply voltage too low (measure and increase to 12-13 VDC)
5. blower motor doesn’t work, or blower wheel is loose
6. APS defect or the electrical connection (2 wires)
7. Fuse (2A slow) in the DC power line (ground wire) blown

Failure E6: Defect temperature sensor or overheating

• E6 is for shorted hot water sensor or hot water over 85°.
• Please check, if the display shows the current outlet water temperature and the temperature rises to 85°C.

Possible reasons:

• 85° can be normally only be reached, if somebody is “playing” with a real low water flow (up and down) or the water flow is “pulsing”. So best would be to use a higher water flow (<5l/min) to see, if it is caused through overheating (in normal operation not happening).
• If this doesn’t happen, check with a multimeter, if the sensor is short-circuited (sensor plugged off)

Failure E7: Problem with flame detection
The control detects an inconstant ionisation signal for 15 times during one operation period.

Possible reasons:

1. gas pressure and gas type. Low supply gas pressure can cause the error
2. check ground wire (at the burner) if connected correctly.
3. ionization electrode and wire harness – loose connection, etc. can cause the failure
4. check the gas input pressure and the burner pressure under high water flow condition. Input should be at 27 kPa, at the nozzle block of the burner should be around 23 kPa.
5. check gas inlet filter for dirt

Hidden function mode (service mode)

To enter laboratory/maintenance mode

1. Power on, water heater standby.
2. Adjust the temperature to 47°C
3. Press and hold “ON/OFF KEY” (green) for > 3 sec.
4. Adjust the temperature to 39°C
5. Press and hold “ON/OFF KEY” (green) for > 3 sec – the unit is now in maintenance /lab. mode.

• Between each step a delay (without pressing button) for > 5 sec. is not allowed, otherwise you must start over again from step 1.
• With every push on the green button, you move one code position forwards (backwards not possible). The not described codes are only for production. Just go ahead by pressing the green button.
• With each keystroke, in the display appears first the code number and afterwards the measured value.
• To stop the service mode, remove for 2 min the 12V supply.

• Remark 5 Seven segment display; ex. 53 stands for 5.3L, 86 stands for 8.6L.
• Remark 6 Seven segment display; ex. if you see 45 and flashing 2, it stands for 45.2℃.
• Remark 7 Hexadecimal, seven segment display; ex. 16 stands for 22℃, 1A stands for 26℃.
• Remark 8 Seven segment display; ex. A4 stands for 10.4L, B4 stands for 11.4L.

Special mounting hints

1. Gas connection line
2. The gas connection line is fixed inside the housing to the gas valve with a cap nut and a counter nut.
3. For the installation insert the outer connection (from inside) through the hole at the backside of the outer housing.
4. Connect the cap nut quite loose to the gas valve – just a smart fixation for mounting. Now place the 2 screws for fixing the flange to the backside of the housing.
5. Remove the cap nut again and place between the thread of the valve and the flange of the copper line the gasket. Be sure, that all components are aligned. Maybe you have to bend the copper pipe a little.
6. Fix the cap nut with “sensibility” (around 10 Nm).
7. Hold now the cap nut with an open-end wrench in position, and fix the counter cap counterclockwise to the cap nut.
8. For additional safety, you can use in a addition a screw locking glue.
9. After fixing test the connection for leaks with soap water or leak detector spray.
10. Water flow sensor
11. For removing the sensor, just pull the 2 clamps, which are shown on the photo below.
12. For mounting again, be sure, that the pipes are completely inserted in the sensor, before fixing the clamps.

Who to Contact
For service and spares, please contact your selling agent:

• Camec Pty Ltd
  • Head Office – Victoria
  • 47-63 Remington Drive Dandenong South, Vic 3175 Australia
  • Phone: (03) 9799 6455
  • Fax: (03) 9799 6466
  • Email: [email protected]
• New South Wales Branch
  • Units 2 & 3
  • No. 1 Koonya Circuit
  • Caringbah NSW 2229, Australia
  • Phone: (02) 9525 2588
• Queensland Branch
  • Bldg 3 Archerfield Industrial Park
  • Cnr Kerry & Beaudesert Road
  • Archerfield, Qld 4108
  • Phone: (07) 3710 9000
  • Fax: (07) 3710 9011
• Western Australia Branch
  • 190 Welshpool Road
  • Welshpool WA 6106, Australia
  • Phone: (08) 9351 0044
• New Zealand Branch
  • 44 Montgomerie Road
  • Mangere Auckland NZ
  • Phone: (64) 9257 2419

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