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Section 9, Installing the Distribution Module

9-12

The POLAR™HD Heating Module

Figure 9-10: Zone Board Wiring (No DM12)

9.8 Inspection and Testing

After all components have been properly installed according to
any applicable industry standards, the Distribution Module and

POLAR™HD Heating Module should be inspected using the
Inspection Check Sheet in this Manual. The Inspection
Check Sheet is divided into relevant sections allowing each
phase of the Inspection to be carried out systematically, and
then signed off by authorized personnel.

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Summary of Contents for POLAR HD

Page 1: ...POLAR HD Heating Module Installation and Operating Manual Diesel and AC Heating System...

Page 2: ...105 Email info 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 photocop...

Page 3: ...ntifying Your POLAR HD Heating Module 2 2 2 3 Your Mounting Location 2 2 2 4 What NOT to Do 2 4 2 5 Procedure 2 4 Section 3 Installing the Exhaust System 3 1 3 1 Before You Begin 3 1 3 2 Mounting Loca...

Page 4: ...bing the System 7 1 7 1 Before You Begin 7 1 7 2 Plumbing Installation 7 1 7 3 What NOT to Do 7 4 7 4 Installation Procedure 7 4 Section 8 Operating the POLAR HD Heating Module 8 1 8 1 Features of you...

Page 5: ...n 9 Installing Distribution Module DM 12 optional 9 1 9 1 Installing your Distribution Module optional 9 1 9 2 Selecting the Module Location 9 1 9 3 Selecting the Distribution Module Zone Box Location...

Page 6: ...ating Module 7 3 Figure 7 2 Three Approved Methods of Installing Heater Hose consult ITR for alternative methods and products 7 5 Figure 8 1 POLAR HD Heating Module 8 3 Figure 8 2 Heating Module Main...

Page 7: ...u for purchasing the POLAR HD Heating Module This section covers critical information you need to know before beginning the installation including how to protect your Warranty and tools and equipment...

Page 8: ...dule is essential for several reasons To ensure that you and or your customers receive satisfactory results and enjoy a warm comfortable environment To ensure a trouble free installation a successful...

Page 9: ...nd its integral distribution pumps the POLAR HD Heating Module has the ability to circulate the coolant fluid to all space heating areas The POLAR HD also incorporates engine heat and preheat function...

Page 10: ...ics Patented proprietary flame sensor Heating Module Remote Operating Panel with ON OFF switch for the diesel burner AC elements and engine heat if installed Heating Module Control Panel with buttons...

Page 11: ...d 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 vent required to draw in 100 outside...

Page 12: ...in a well equipped shop Approved fasteners for mounting the heater unit Steel or stainless steel 2 ID exhaust system piping maximum 12 with no bends See Section 3 Installing the Exhaust System for de...

Page 13: ...commendations of this Installation and Operating Manual The POLAR HD Heating Module should be test operated for inspection purposes For your convenience you can use the pullout Inspection Check Sheet...

Page 14: ...Section 1 Overview 1 8 POLAR HD Heating Module...

Page 15: ...ing Module POLAR HD Heating Module weight when full 160 lbs 8 gallon model 220 lbs 16 gallon model Ventilation requirements Exhaust outlet location and maximum acceptable length Potential for vibratio...

Page 16: ...ntifies the model type through the first series of letters and numbers The types of POLAR HD Heating Module models are 8 gallon model CH50M POLAR HD Heating Module powder coated case 16 gallon model C...

Page 17: ...stallation and maintenance POLAR HD Heating Module must be mounted horizontal and level using eight 1 4 through bolts and 1 diameter fender washers lock washers and nuts Figure 2 1 Module Dimensions 8...

Page 18: ...olation mounts for mounting the heater if required Ensure that the exhaust tubing can be properly and safely routed to the outside The maximum exhaust run for the system is 12 see chapter 3 2 4 What N...

Page 19: ...Section 2 Mounting the POLAR HD Heating Module International Thermal Research 2 5 Figure 2 2 Module Mounting Brackets...

Page 20: ...Section 2 Mounting the POLAR HD Heating Module 2 6 POLAR HD Heating Module...

Page 21: ...that no air from the unit 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...

Page 22: ...s off the side of the vehicle not directly underneath the coach or under an opening window vent or slide out Recommendations for Installation The following applies You may use sweep bends but each 90...

Page 23: ...imum of every 3 of its installed length The exhaust and POLAR HD Heating Module connection point must use appropriate clamps and sealing compound to ensure that the connections are tight and leak free...

Page 24: ...present Don t use any mufflers not supplied or approved by ITR Don t over tighten exhaust clamps or you may crush the POLAR HD Heating Module s exhaust outlet pipe 3 3 Procedure Figure 3 1 Installing...

Page 25: ...a suitable location to mount the air intake adapter Drill a 2 hole through the side wall minimum maximum 2 wall thickness Insert the adapter and use 3 screws to mount against side wall Use a 32 gear...

Page 26: ...Section 3 Installing the Exhaust System 3 6 The POLAR HD Heating Module Figure 3 1 Installing the Exhaust System Bottom Exhaust Figure 3 2 The Exhaust Hole Location Mounting Template 8 gallon model...

Page 27: ...odule is not rated for use in an explosive environment Never share the fuel supply to the POLAR HD Heating Module with any other fuel burning device 4 2 Fuel System Installation The fuel pump in the P...

Page 28: ...g and kinking during normal operation All fuel line connection points and hoses must use suitable clamps and or sealant and must be checked for leaks on the initial installation and also periodically...

Page 29: ...stem installation 1 Install the inline fuel filter The optimal location is on a compartment wall next to the POLAR HD Heating Module inline between the fuel tank and the POLAR HD Heating Module 2 Conn...

Page 30: ...Section 4 Installing the Fuel System 4 4 POLAR HD Heating Module...

Page 31: ...They have a built in aquastat optional which turns on the fan when the water running through it reaches 120 F 49 C The Defrost Heater provides up to 20 000 BTU h and uses a three speed fan 200 275 450...

Page 32: ...ach fan unit Features ITR heater fans can be supplied with a built in aquastat which prevents fan operation until the system has reached minimum operating temperature The aquastat can be deleted to me...

Page 33: ...Outlet Vents covers that are installed flush with the wall to vent heat for the installed heater unit Fan Guards to protect the fan blades from damage recommended for fans installed in storage areas...

Page 34: ...ions of your fans Locate the fans to evenly heat the zone Provision must be made to protect water lines from freezing Install fan at floor level or very near floor level in order to optimize circulati...

Page 35: ...se up to the Zone Control Board in Section 9 Installing the Distribution Module 4 The zone control board can control up to 5 zones The cabin fan 1 lead orange can supply up to a maximum of 10 Amps The...

Page 36: ...Section 5 Installing Fan Heaters 5 6 POLAR HD Heating Module Figure 5 2 Mounting a Spacesaver Fan Figure 5 3 Installing a Relay for Additional Fan Amperage...

Page 37: ...rdance with all applicable standards 6 2 12 VDC The following apply to the 12 VDC connections for the POLAR HD Heating Module There is one paired set of 12 VDC electrical connections on the top right...

Page 38: ...ment side of the POLAR HD Heating Module The secondary set of wires is connected to the other AC element If only one AC circuit breaker is available you must connect to the primary wire set only Once...

Page 39: ...System International Thermal Research 6 3 Figure 6 1 System wiring 6 5 Main Electronic Control Board The main electronic Control Board is mounted onboard the POLAR HD Heating Module itself It has no u...

Page 40: ...onnect the battery when the POLAR HD Heating Module is running and never disconnect the battery while the inverter is charging Do not wire the POLAR HD Heating Module through a disconnect that is used...

Page 41: ...ration you must Minimize heat loss from the Heating Module and hoses Follow the flow directions for the fluids in the Heating Module Figure 9 3 Plumbing for Five Zones Using the Distribution Module in...

Page 42: ...hread sealant Hose and or tubing used to connect to the POLAR HD Heating Module or Distribution Module input and output connections must be heavy duty heater hose minimum 3 4 I D or 5 8 PEX All fittin...

Page 43: ...cation of inadequate flow is when the POLAR HD Heating Module is running and up to normal operating temperature the difference between the inlet and outlet coolant temperature to the POLAR HD Heating...

Page 44: ...o contact with solvents which may cause it to soften and swell If there is any risk that solvents may contact the hose insert it into PVC plastic tubing for protection 7 4 Installation Procedure To in...

Page 45: ...Heating Module with the appropriate glycol water anti freeze solution and bleed all trapped air Use the filling manifold to properly add the appropriate glycol water mixture and properly purge the sys...

Page 46: ...Section 7 Plumbing the System 7 6 The POLAR HD Heating Module...

Page 47: ...ronic space heating needs When used with the Distribution Module and its integral distribution pumps the POLAR HD Heating Module has the ability to circulate the coolant fluid to all space heating are...

Page 48: ...ting Module Control Panel with buttons for Power Bypass Reset and indicator LED s for operational and diagnostic information Available with the Optional Distribution Module Three distribution pumps on...

Page 49: ...eating Module 16 Gallon 8 3 Operating Instructions for the POLAR HD Heating Module The POLAR HD Heating Module must be installed and connections made in accordance with the recommendations in the Inst...

Page 50: ...ON power LED will turn ON to turn the DC electrical power to the main control board and module ON and is required to be left ON during any period where heat is requested When the POLAR HD Heating Modu...

Page 51: ...turned OFF or the temperature range is again achieved If the burner switch on the remote panel is turned OFF the burner stops and the POLAR HD Heating Module enters a two minute cool down stage prior...

Page 52: ...cabin fan has a built in aquastat that prevents the cabin fan from blowing cold air Once the room temperature has reached the temperature called for by the thermostat the cabin fan will turn off 8 7...

Page 53: ...Heating Start the vehicle engine and let it come up to the normal operating temperature Turn the burner switch on the Remote Operating Panel to the ON position The POLAR HD Heating Module will come up...

Page 54: ...urce CH50 and DM8 used in Tandem The triple position AC element switch controls the activation of a single 120 VAC immersion element only dual 120 VAC immersion elements jointly or both elements off T...

Page 55: ...AR HD Heating Module Control Panel for further details Zone Fault LED Red Functional with Distribution Module Equipped Models Only When ON indicates the space heating zone s has faulted The specific f...

Page 56: ...OLAR HD Heating Module is in Bypass mode AC Heat LED Green The AC Heat LED Green turns ON when a single or dual AC immersion element s have been activated Compressor Fuel Pump Combustion Fan Igniter G...

Page 57: ...istribution Module Zone Control Panel Figure 8 4 Zone Control Panel contains seven green LED s for Power Zone 1 2 3 4 and 5 Thermostat s and Domestic Water It also contains nine matched pairings of re...

Page 58: ...ing normally The red LED turns ON if a fuse has been blown 8 12 Maintenance Customer Monthly Maintenance Check the following and correct as required Coolant hoses and fittings for leaks and integrity...

Page 59: ...ecessary To access the combustion tube the front panel of the POLAR HD must be removed along with the burner box cover The fuel block must then be removed from its mounting position Finally the burner...

Page 60: ...le is designed not to allow operation if either are incorrect indicated by lit Voltage LED or Low Water LED on the POLAR HD Heating Module Control Panel Burner Does Not Start Up POLAR HD Heating Modul...

Page 61: ...xternal dirty Restrict the fuel return line with needle valve or pinch off completely Burner Starts but Zone Faults Power LED on Distribution Module Zone Control Panel glowing green Component matched...

Page 62: ...Section 8 Operating the Heating Module 8 16 The POLAR HD Heating Module...

Page 63: ...diction Proper workmanship is essential to the proper function and life of your module as well as protecting your warranty 9 2 Selecting the Module Location The installation should consider the follow...

Page 64: ...le must be mounted in the position as shown against a wall or on the floor Figure 9 1 Distribution Module DM12 9 3 Selecting the Distribution Module Zone Box Location Mount the Distribution Module Zon...

Page 65: ...ribution Module is connected to the Distribution Module Zone Control Board through the electrical connections located at the bottom of the Zone Control Board box The distance apart is dictated by the...

Page 66: ...le The Cold water supply can be connected using a NPT fitting The maximum water supply pressure to the module is 150 PSI 10 bar The Hot water Outlet temperature is regulated by an internal mixing valv...

Page 67: ...ule at the engine heat inlet The engine heat outlet returns the coolant back to the engine supply When the pre heat function is installed an additional pump is connected between the engine heat outlet...

Page 68: ...r is connected to the cold coolant return inlet on the POLAR HD Heating Module It is recommended to use minimal ID hose for this connection See Figure 9 6 Connecting to the POLAR HD heating module Fig...

Page 69: ...ing the heating system The Distribution module contains two valves with NPT connections to be used for filling the heating loop To initially fill up and bleed the air out of the system do the followin...

Page 70: ...coolant as the air is being bleed from the system 5 Turn on the pump activation switch located on top of the zone box this will activate the pumps inside the distribution module and fill up both heati...

Page 71: ...le Zone Control Board itself A 25 amp fuse or breaker must be included inline from the power source to the positive connection on the zone board The primary power wire gauge must be sized to permit no...

Page 72: ...ry ground The cabin fan 1 leads orange can supply up to a maximum of 10 Amps The other cabin fan leads 2 5 can supply up to a maximum of 5 Amps each The total current draw is not to exceed 18 Amps for...

Page 73: ...9 Installing the Distribution Module International Thermal Research 9 11 Figure 9 9 Distribution Module Wiring If the zone board is being used without the distribution module use the following wiring...

Page 74: ...been properly installed according to any applicable industry standards the Distribution Module and POLAR HD Heating Module should be inspected using the Inspection Check Sheet in this Manual The Insp...

Page 75: ...er can be removed by removing the 6 Philips head screws The mixing valve adjustment knob is shown in the figure below Figure 9 11 Mixing valve location The parts inside the module are HOT when in oper...

Page 76: ...Section 9 Installing the Distribution Module 9 14 The POLAR HD Heating Module...

Page 77: ...arranty repairs in the future Limited Warranty The following warranties are in lieu of all other warranties and conditions ITR makes no other warranties representations or conditions express or implie...

Page 78: ...Product was originally purchased about a warrantable failure and to obtain prior written approval for warranty repair Original serial number on Product or electrical control board has been removed alt...

Page 79: ...on an authorized service person may be able to visit your coach or yacht to help troubleshoot problems and repair your Product Such service calls are at the Owner s expense Regardless you must obtain...

Page 80: ...s given only in good faith as an accommodation to the customer Such information should not be relied upon without an independent verification of its applicability to the customer s particular situatio...

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