ITR POLAR HD User manual

POLAR
™
HD Heating Module
Installation and
Operating Manual
Diesel and AC Heating System

Copyright © January 2013 International Thermal Research Ltd.
POLAR™HD is a trademark of International Thermal Research Ltd.
International Thermal Research
INCANADA: INTHEUNITEDSTATES:
2431 Simpson Road 11915 NE 56th Circle, Suite B
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: [email protected]
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.

International Thermal Research iii
Table of Contents
Section 1, Overview...................................................1-1
1.1 Unpacking the Heating Module ....................... 1-2
1.2 Protect Your Warranty .................................. 1-2
1.3 POLAR™HD Heating Module Features............... 1-3
1.4 Critical Factors............................................. 1-5
1.5 Equipment, Tools and Skills........................... 1-6
1.6 Testing and Inspection.................................. 1-7
Section 2, Mounting the POLAR™HD Heating Module..2-1
2.1 Before You Begin ......................................... 2-1
2.2 Identifying 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 Location........................................ 3-1
Recommended Exhaust Outlet Locations............3-1
Recommendation for Installation ......................3-2
What NOT to Do.............................................3-4
3.3 Procedure ................................................... 3-4
Section 4, Installing the Fuel System ........................4-1
4.1 Before You Begin ......................................... 4-1
4.2 Fuel System Operation.................................. 4-1
Recommendations for Installation..................... 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

Table of Contents
iv Installation and Operating Manual for POLAR™ HD Heating Module
5.2 Fan System Operation...................................5-2
Features ....................................................... 5-2
Multiple Zone Heating ..................................... 5-3
Accessories and Components Needed................ 5-3
5.3 What NOT to Do ...........................................5-4
5.4 Mounting Locations.......................................5-4
5.5 Procedure....................................................5-5
Section 6, Wiring the Electrical System..................... 6-1
6.1 Before You Begin..........................................6-1
6.2 12 VDC .......................................................6-1
6.3 120 VAC......................................................6-2
6.4 Remote Operating Panel Cable........................6-2
6.5 Main Electronic Control Board.........................6-3
6.6 Distribution Module Zone Control Board
(Optional)....................................................6-3
6.7 What NOT to Do ...........................................6-4
Section 7, Plumbing 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 your POLAR™HD Heating Module.....8-1
8.2 Your Heating Module Model............................8-2
8.3 Operating Instructions for the
POLAR™HD Heating Module ............................8-3
8.4 Turning the Power to the
POLAR™HD Heating Module ON .......................8-4
8.5 Activating the Burner (Primary)
and AC Heat (Secondary) from the
Remote Operating Panel ................................8-5
8.6 Activating the Cabin Fan Heaters
through the Thermostats ...............................8-6
8.7 Activating the Domestic Hot Water..................8-6
8.8 Activating the Engine Heat.............................8-6
8.9 Functions of the Remote Operating Panel.........8-7
8.10 Functions of the Heating Module Control Panel..8-9

Table of Contents
International Thermal Research v
8.11 Functions of the Distribution Module (Optional)
Zone Control Panel......................................8-10
8.12 Maintenance...............................................8-11
8.13 Protecting the Heating Module and
Distribution Module (Optional) ......................8-13
8.14 General Troubleshooting ..............................8-13
Section 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........................................ 9-2
9.4 Plumbing Installation.................................... 9-3
9.5 Filling/Purging the heating loop...................... 9-7
9.6 Electrical Connection .................................... 9-8
9.7 Distribution Module Zone Control Board........... 9-9
9.8 Inspection and Testing.................................9-12
9.9 Hot water temperature adjustment................9-12
Warranty Information & Warranty Card

Table of Contents
vi Installation and Operating Manual for POLAR™ HD Heating Module
List of Figures
Figure 1-1 POLAR™HD Module ...................................1-1
Figure 1-2 POLAR™HD Heating and Distribution Module.1-5
Figure 2-1 Module Dimensions ..................................2-3
Figure 2-2 Module Mounting Brackets.........................2-5
Figure 3-1 Installing the Exhaust System
(Bottom Exhaust).....................................3-6
Figure 3-2 The Exhaust Hole Location & Mounting
Template ................................................3-6
Figure 3-7 The Exhaust Goose neck Configuration........3-7
Figure 5-1 Wiring the Fan’s Aquastat..........................5-2
Figure 5-2 Mounting a Spacesaver Fan .......................5-6
Figure 5-3 Installing a Relay for Add’l Fan Amperage....5-6
Figure 6-1 System Wiring.........................................6-3
Figure 7-1 Heating 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 Control Panel.............8-4
Figure 8-3 Remote Operating Panel............................8-7
Figure 8-4 Zone Control Panel................................ 8-11
Figure 9-1 Distribution Module ..................................9-2
Figure 9-2 Distribution Module Zone box.....................9-2
Figure 9-3 Distribution Module Fittings Location...........9-3
Figure 9-4 Domestic Hot Water System Plumbing.........9-4
Figure 9-5 Engine Heat / Pre-heat System Plumbing.....9-5
Figure 9-6 Connecting to the POLAR™HD Heating Module9-5
Figure 9-7 Connecting two Heating loops....................9-6
Figure 9-8 Initial fill up POLAR™ HD system .................9-7
Figure 9-9 Distribution Module Wiring....................... 9-10
Figure 9-10 Zone Board Wiring (No Distribution module) .9-11
Figure 9-11 Mixing valve location ..............................9-12

International Thermal Research 1-1
Overview
Thank you 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 needed.
Figure 1-1: POLAR™ HD Heating Module
Section
1

Section 1, Overview
1-2 POLAR™HD Heating Module
1.1 Unpacking the POLAR™ HD Heating
Module
When you receive the POLAR™ HD Heating Module:
1 Unpack it carefully.
2 Check each component against the shipping list to ensure that
you have everything and that all parts arrived undamaged.
3 If you discover any missing or defective parts call IT
R
immediately.
4 If you are not installing the POLAR™ HD Heating Module right
away secure all components so none will be misplaced.
5 Before installing the POLAR™ HD Heating Module read the
rest of this Installation and Operating Manual.It contains
critical information for a proper installation.
A properly installed POLAR™ HD Heating Module 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 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 POLAR™ HD
Heating Module is only guaranteed by ITR if the entire system has
been installed according to the requirements and recommendations
set out here.
This includes:
•Deviations from the instructions in this Manual.
•Changes to any piece of ITR-supplied equipment.
•Substitution of a non-ITR approved component.
No Warranty will be extended to improper installations. Use of any
unapproved materials, equipment or installation procedures will

Section 1, Overview
International Thermal Research 1-3
result in a voided warranty for the entire heating system. Any loss
of service or damage as a result of any unapproved modification is
the responsibility of the installer. ITR accepts no liability for any
damage or loss of service resulting from unapproved modifications.
1.3 POLAR™ HD Heating Module Features
The POLAR™ HD Heating Module uses a diesel burner (12 VDC)
controlled by a multi-functional electronic controller as the primary
source of heating coolant fluid (anti-freeze and water). Two 1500
Watt, 120 VAC immersion elements are used as secondary heat
sources. The POLAR™ HD Heating Module heats the coolant fluid to
provide a source of heat for all hydronic space heating needs. When
used with the Distribution Module (optional) and 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 functions.
(see Figure 1-2: POLAR™ HD Heating and Distribution Modules).
Other features of the POLAR™ HD Heating Module include:
•A high-temperature, stainless steel burner and stainless steel
jacket.
•8.2 (or 16) US gallon, welded, insulated stainless steel coolant
tank that minimizes heat loss and optimizes heat recovery.
•Low coolant level switch on the tank.
•Easy to install, completely modular and field serviceable with the
POLAR™ HD Heating Module hookups and connections easily
accessible from the front and top of the Heating Module.
•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 and smell.
• Efficient
• Clean
• Quiet
• Compact
• Safe
• Rugged
• Reliable
• Economical

Section 1, Overview
1-4 POLAR™HD Heating Module
•Fan assisted sealed combustion chamber is designed to use
outside combustion air.
•Simple, low amperage draw ignition.
•Electronically-controlled system with:
•automatic Safety Shutdown;
•manual-resettable aquastats for safety overheat protection.
•LED indicators on the Control Panel for diagnostics.
•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 for Power, Bypass,
Reset, and indicator LED’s for operational and diagnostic
information.
•Distribution Module if installed with built in distribution pumps
and heat exchanger for heating multiple zones. Heat exchanger
also allows engine pre-heating as well as using engine waste
heat. The Zone Board Controls up to five space heating zones.

Section 1, Overview
International Thermal Research 1-5
1.4 Critical Factors
THE INSTALLATION SHALL BE IN ACCORDANCE WITH THE
REGULATIONS OF AUTHORITIES HAVING JURISDICTION
The key factors to keep in mind when planning and carrying out the
installation are:
•Mounting location restrictions for the POLAR™ HD Heating
Module, optional Distribution Module , and 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 air for
combustion.
•Ability for technician to easily access and service the product,
especially fuel, plumbing, and electrical systems.
•After installation, ability to purge coolant and fuel lines and
inspect/test entire system using the ITR-supplied Inspection
Check Sheet.
Pay attention to the
notices of “Danger”
“Warning” “Caution”
and “Notice” in this
manual.

Section 1, Overview
1-6 POLAR™HD Heating Module
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 –
Overview, sub-Section 1.2, Protect Your Warranty.
You will need the following equipment and tools to install the
heating system (not supplied). This list does not include optional
equipment and accessories:
•Standard tools normally available 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 details when bends are present.).
•Exhaust collar.
•ITR-muffler with straight-through design.
•1/4” supply fuel line, approved rubber or copper.
•#10 sheet metal screws or wood screws to mount fan units
inside the occupied areas.
•Heater hose (to connect the Distribution Module (optional) hose
fittings to interior fans).
•Overflow tank to connect to the POLAR™ HD Heating Module
with clear plastic 3/8” hose; tank must be heavy-duty plastic,
with a screw-down cap, and sturdy enough to mount firmly to a
vertical surface.
•Up to five (5) thermostats (DC compatible) to allow temperature
regulation of the heating zones when connected to the
Distribution Module.

Section 1, Overview
International Thermal Research 1-7
1.6 Testing and Inspection
After all components have been properly installed according to
standard practices, industry standards, and the recommendations 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 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
1-8 POLAR™HD Heating Module

International Thermal Research 2-1
Mounting – POLAR™HD Heating
Module
2.1 Before You Begin
Plan the location of the POLAR™HD Heating Module and all its
major components in advance to ensure the chosen locations are
compatible with installation requirements and within the technical
specifications.
Consider the following factors to help you decide exactly where
best to mount the POLAR™HD Heating 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 vibration and jarring.
•Length of run from fuel source to heater.
•Most efficient plumbing runs.
•Safe and convenient access for maintenance.
•Number and location of interior fans.
•Location of other equipment to be installed or connected to
the POLAR™HD Heating Module, including the optional
Distribution Module, Zone Control Box, heat exchangers,
overflow tank, batteries, thermostats, remote panel, etc.
Section
2

Section 2, Mounting the POLAR™ HD Heating Module
2-2 POLAR™ HD Heating Module
Make sure you are familiar with Section 1 – Overview of this
Manual. If the system is not installed according to specifications
and with the correct equipment, your POLAR™HD Heating Module
may not operate properly, safety may be compromised, and your
Warranty may be voided.
2.2 Identifying Your POLAR™HD Heating
Module Model
As the owner, you must be fully aware of the controls and
operating features particular to your model of the POLAR™HD
Heating Module. This is essential for the proper functioning and
life of your POLAR™HD Heating Module as well as protecting your
warranty. Your model can be identified by locating the serial
number label on the outside case of the POLAR™HD Heating
Module. The serial number identifies 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 CH50V - POLAR™ HD Heating Module
(powder coated case)
2.3 Your Mounting Location
Your mounting location should consider the following:
•Mounting location must be able to support double the gross
weight of the POLAR™ HD Heating Module (i.e. 160 lbs. x 2 =
320lbs./73 KG x 2 = 146 KG) and must be of a non-
combustible and non absorptive surface. (Add 60 lbs to gross
weight for 16 gallon model)
•POLAR™ HD Heating Modules are 14”H x 14”W x 30” D. (35.6
cm x 35.6 cm x 76.1 cm), 8 gallon model, 16”H x 16”W x 36”D
(40.6cm x 40.6 cm x 91.4 cm) 16 gallon model, see Figure 2-1:
Module Dimensions.
•POLAR™HD Heating Modules must be installed in a
compartment which is completely isolated from the atmosphere
of living spaces.
•Combustion air must be drawn from an outside source and
cannot contain any combustible gases.
!
W
ARNING

Section 2, Mounting the POLAR™ HD Heating Module
International Thermal Research 2-3
•POLAR™ HD Heating Module must be mounted in an area that
provides unrestricted access to the front panel. Allow space for
connection to the fuel and coolant lines, as well as the power
and exhaust connections. Minimum of 6” top clearance, 0”
clearance to all other POLAR™ HD Heating Module surfaces.
Allow 1” clearance on the sides for attaching the mounting
brackets.
•Mount the unit with the front panel side facing out and
accessible. Facing out simplifies installation 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 gallon model shown)
POLAR™ HD Heating Module must not be installed or operated in
any compartment with flammable gases.
If the POLAR™ HD Heating Module is going to be mounted in the
engine compartment, check for adequate ventilation. When the
engine is running this area could be under a negative pressure.
Make sure the air-intake and exhaust hoses have no leaks and are
well fastened to the heater, muffler and any other exhaust fitting.
Assembly parts that may cause injury through accidental contact
should be protected.
! DANGER
!
W
ARNING

Section 2, Mounting the POLAR™ HD Heating Module
2-4 POLAR™ HD Heating Module
Isolate the unit in a closed compartment so that no air from the
heater will infiltrate the living areas.
•It is recommended that a catchpan be placed under the
POLAR™ HD Heating Module for containing any unexpected
leakage.
•Choose a sturdy surface in a location that won’t be unduly
affected by vibration and the jarring of rough roads or rough
seas. Use appropriate isolation 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 NOT to Do
•Don’t mount the POLAR™ HD Heating Module in any area that
is required to be low noise.
2.5 Procedure
After choosing the mounting location for the POLAR™ HD Heating
Module, mount the module horizontally and level. Secure the
POLAR™ HD Heating Module in place (against the wall, floor or a
mounting platform) using eight (8) x 1/4” through bolts and 1”
diameter fender washers, lock washers, and nuts. (See Figure 2-2:
Module Mounting Brackets.).
! DANGER

Section 2, Mounting the POLAR™ HD Heating Module
International Thermal Research 2-5
Figure 2-2: Module Mounting Brackets

Section 2, Mounting the POLAR™ HD Heating Module
2-6 POLAR™ HD Heating Module