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Section 8, Operating the Heating Module

International Thermal Research

8-15

•

Air in fuel line (white smoke from exhaust or popping
sound from exhaust)?

•

Fuel filter (external) 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 LED pairings all glowing green on the
Distribution Module Zone Control Panel?

•

If any of the cabin fan or loop LED’s are RED, then that
component has blown a fuse.

Содержание POLAR HD

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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