Aqua-Hot 200 Series User manual

INSTALLATION MANUAL
200SERIES
200P, 250P and 250D

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Table of Contents
Aqua-Hot 200 Series Installation Manual
Cautions and Introductions.................................................. 2
Aqua-Hot Hydronic Heating System
Safety Precautions and Instructions ............................ 3
Heating System Features.............................................. 6
250D Components ........................................................ 7
200P/250P Components ............................................. 8
Aqua-Hot Installation
Installing the Aqua-Hot.................................................. 9
Aqua-Hot Measurement Diagrams .............................10
Mounting Brackets ......................................................11
Installing the Expansion Bottle ...................................12
Hydronic Heating System
Heat Exchanger Floor Plan..........................................13
Heat Exchanger Installation Requirements ...............14
Mounting the Heat Exchangers ..................................15
Location, Clearances and Boost Pump ......................16
Wiring the Heat Exchangers........................................17
Wiring for OEM RV-C or Multiplex ...............................17
Plumbing the Hydronic Heating System .....................18
Domestic Water System
Requirements and Plumbing ......................................20
Switch Panel
Switch Panel Location, Mounting ...............................21
250D Switch Panel Rear View ....................................22
200P/250P Switch Panel Rear View .........................23
Fuel System
Propane Fuel Specifications .......................................24
Diesel Fuel Specifications...........................................25
Exhaust System
Exhaust System Requirements...................................27
Installing the Exhaust System.....................................27
Wiring Specifications
Wiring Harness Pin-Out ..............................................30
Connecting the 200P and 250P to DC Power ...........31
Connecting the 250D to DC Power.............................32
Connecting the 250P or 250D to AC Power ..............33
Purging the System
Purging the Hydronic Heating System ........................34
Initial Start Up
Activating the Aqua-Hot...............................................35
Appendices
Appendix A: 250P Wiring Schematic.......................... 36
Appendix B: 200P Wiring Schematic ......................... 37
Appendix C: 250D Wiring Diagram............................. 38
Appendix D: Measuring Antifreeze Concentration..... 39
Parts and Accessories ..................................................... 40
Warranty.......................................................................... 47

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Introduction and Cautions
About the Aqua-Hot 200 Series
The Aqua-Hot 200P, 250P, and 250D are hydronic (water
based) heating systems that provide interior heat and tank-
less, continuous hot water in one small, easy to install pack-
age.
The heating system provides moist, quiet, comfortable
interior heat. The Aqua-Hot is equipped with one thermostati-
cally controlled temperature zone.
The tank-less hot water system produces 90 gallons per
hour (1.5 GPM) of continuous hot water.
These TribridHot™ systems use one or a combination of
heat sources to heat FDA-approved “Generally Recognized As
Safe” (henceforth referred to as “GRAS”) propylene glycol
based antifreeze solution in the Aqua-Hot’s boiler tank.
The 200P uses a 12V DC powered propane burner to
heat the system and does not have an electric element. The
propane burner is to be used for any and all heating or hot
water needs.
The 250P and 250D employ a 12V DC burner (propane
and diesel, respectively) as the primary heating source. The
burner should be used for continuous hot water, and heating
in cold conditions. In addition to a burner, the 250P and
250D models also employ a 120V AC 1000W electric heating
element as a supplemental heating source. Once the tank
has reached temperature by way of the 12V DC burner, the
electric element may be engaged to provide light-duty hot
water and heating needs, and serves to maintain tank tem-
perature during periods which the heater is not in use. For
continuous hot water and heat in cold conditions, the burner
must be active.
Should additional assistance be needed, please contact
the Product Application Department at [phone],
Monday through Friday, 7a.m. to 4p.m. Mountain Standard
Time.
Caution Notes
As you read this information, take particular note of the NO-
TICE, CAUTION, WARNING, and DANGER symbols when they
appear. This information is important for safe and efficient
use of the Aqua-Hot equipment.
NOTICE signals a situation where potential damage to the
equipment could occur.
CAUTION signals a situation where potential harm or risk of
minor or moderate injury could occur if instructions are not
followed.
WARNING signals a hazardous situation where potential
harm, risk of serious injury or death could result if you do not
follow instructions.
DANGER signals a situation where immediate risk of serious
injury or death will result if you do not follow instructions.
NOTE: This manual will also use notes sections similar to
this one to draw attention to features and practices which
should be observed.

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Safety and Precautions
The Aqua-Hot Heating System
Read and understand all instructions before installing this
unit.
• Read this owner’s manual before installing or using the
Aqua-Hot system to reduce the risk of injury to persons or
damage to equipment.
• The product identity label contains specifications of the
unit, to what standard it has been tested, and important
safety notices.
• The Aqua-Hot must be installed in a compartment that is
closed off from living quarters and accessible only from
the outdoors.
• Propylene glycol based antifreeze “Generally Recognized
As Safe” (GRAS) by the FDA must be utilized for antifreeze
and water heating solution.
• An interlock switch prevents the Aqua-Hot heater from
operating when the cover is not installed in the correct
position.
• Should any additional assistance be needed, please con-
tact the Technical Support Department at +1 (800) 685-
4298 or [phone].
• Do not store or use gasoline or other flammable vapors or
liquids in the vicinity of this or any other appliance
• Disconnect electric wiring to the Aqua-Hot system before
welding or plasma cutting the RV or home to avoid dam-
age to equipment
• Air pressure to the tank must NOT exceed 20PSI or it will
cause damage
• The Aqua-Hot exhaust is HOT and must be kept away from
heat sensitive material
• Use caution when working on or near the propane gas
system
• DO NOT connect the 12V DC power to the Aqua-Hot if the
RV or home requires welding
• At maximum operating temperatures, the coolant will be
very hot and scalding hot vapor or coolant may result in
serious burns or injury
• DO NOT activate the burner until the antifreeze and water
heating solution has been added to the boiler tank to
avoid serious damage to the heater
WHAT TO DO IF YOU SMELL GAS
• Evacuate all persons from the vehicle
• Shut off the gas supply at the gas container or source
• Do not touch any electrical switch or use any phone or
radio in the vehicle
• Do not start the engine or electric generator (if equipped)
• Contact the nearest gas supplier or qualified service tech-
nician for repairs
• If you cannot contact the nearest gas supplier or qualified
service technician, contact the nearest fire department
• Do not turn on the gas supply until the gas leak or leaks (if
relevant) have been repaired
• Installation and service must be performed by a qualified
installer, service agency or gas supplier
The Aqua-Hot’s exhaust is HOT!
• Do NOT park in areas where dry conditions exist (i.e.
grassy, dry fields)
• Do NOT operate the burner inside an enclosed building
• The heater must be switched OFF when refueling
If the information in these instructions are not followed ex-
actly, a fire or explosion may result causing property dam-
age, personal injury, or death.

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200P Safety & Precautions

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©Aqua-Hot® 200 Series Installation Manual Rev. E
250P Safety and Precautions

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System Features
Burner
Heat Input (Propane)........................... 60,000 BTU/hr ± 10%
Heat Input (Diesel) .............................. 66,000 BTU/hr ± 10%
Fuel Consumption (Propane)........................... 0.66 gallon/hr
Fuel Consumption (Diesel)............................... 0.40 gallon/hr
Electric Heating Element (250P/250D only)
Power Consumption .....................................................1000W
Voltage ........................................................................120V AC
Maximum DC Power Consumption
Power Consumption (Propane)........................................ 42W
Power Consumption (Diesel) ......................................... 108W
Voltage ..........................................................................12V DC
Zone Heat Circulation
Pumps ..................................................................................... 1
Power Consumption ......................................................... 21W
Voltage ..........................................................................12V DC
Heating Zones
Maximum ................................................................................ 1
Domestic Water Heating
Continuous Supply ...........................................1.5 gallon/min
Specifications
Dimensions...............................17.2”H x 12.46”W x 22.44”L
Dry Weight .....................................................................84 lbs.
Wet Weight ..................................................................104 lbs.
All vehicle installations must comply with the requirements
listed in the Recreational Vehicle Industry Association’s (RVIA)
ANSI/NFPA 1192 Handbook for Recreational Vehicle Stand-
ards. To receive a copy of this handbook and other pertinent
RVIA Standards, write to:
Recreational Vehicle Industry Association
1896 Preston White Dr
PO Box 2999, Reston, VA 22090-0999
Or contact them by phone at [phone], or online at
www.rvia.org, or www.nfpa.org
NOTE: The product label is
attached to the side of
the Aqua-Hot and pro-
vides a ready reference to
specifications, test stand-
ards and important safety
notices.
Figure 1
Figure 2

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250D Components
1. Domestic Cold Water Inlet
2. Domestic Hot Water Outlet
3. Diesel Fuel Connections
4. 12V DC Harness Junction
5. Expansion Tank Connection
6. Heating Zone Outlet Port
7. Heating Zone Return Port
8. 120V AC Connection
9. Interlock Switch
10.3-Way Valve
11.Diesel Burner Assembly
12.Boiler Tank
13.Tempering Valve
14.Diesel Burner Controller
15.Zone Circulation Pump
16.Drain Valve
17.Access Cover Screw
1 2 3 4 5 6 7 8
17
9
10
11
13
14
16
15
12
Figure 3

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200P & 250P Components
1. Domestic Cold Water Inlet
2. Hot Water Outlet
3. Propane Inlet Ball Valve
4. 12V DC Harness Junction
5. Expansion Tank Connection
6. Heating Zone Outlet Port
7. Heating Zone Return Port
8. 120V AC Electrical Relay Box (250P Only)
9. Propane Burner Assembly
10.Tempering Valve
11.Boiler Tank
12.3-Way Valve
13.Propane Burner Controller
14.Interlock Switch
15.Drain Valve
16.Zone Circulation Pump
17.Access Cover Screw
51 2 3 4 86 7
16
15
14
13
12
11
10
9
17
Figure 4

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Aqua-Hot Installation
Installing the Aqua-Hot
The Aqua-Hot must be installed in a compartment
that is completely closed off from living quarters and accessi-
ble only from the outdoors.
1. Reference the following illustrations for mounting infor-
mation
2. Cut out the required mounting flange opening. Reference
figure 6 on the next page.
3. Install the flange located on the bottom of the Aqua-Hot
into the cutout opening. Reference figure 8 and figure 9
4. Take the angle brackets and included 1/4-20 bolts and
washers. Install the angle brackets into the nuts located
on the flanges.
- Front view Aqua-Hot dimensions reference figure 5.
- Floor cut-out information reference figure 6, page 10
- I.D. Label noting the clearance requirement for the
front of the heater reference page 6.
- Reference the I.D. label on page 6 for service access
clearance
NOTE: Inspect the area beneath the mounting location to en-
sure that no structural members will interfere with the cut-out
for the mounting flange.
Verify that a support structure of adequate strength has been
constructed for the Aqua-Hot.
17.2”
15.2”
2.94” 1.97”7.55”
Figure 5

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Aqua–Hot Installation
Figure 6
Minimum clearance on all
sides is 2”
22.44”
12.625”
7.675”
2”
12.57”
2”
NOTE: The mounting flange of the Aqua-Hot is not centered
on the body of the heater. Reference figure 6 for correct di-
mensions to construct the surface on which the Aqua-Hot will
be mounted.
Additional cross-members are required if the existing struc-
ture is unable to support 104 lbs.
Figure 7
Cross-member
Supports

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Aqua-Hot Installation
NOTE: Angle mounting bracket must be flush to
the underside of the coach floor and flush to the
heater flange. Tighten bolts to roughly 76 in-lbs.
Heater Flange
Mounting Bracket
1/4-20 Bolt and
lock washer
Mounting Brackets on both
sides, front and rear
1/4-20 Bolt and
Lock Washer
Coach bay floor
Seat the Aqua-Hot in the flange
cut out
Figure 8
Figure 9

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Aqua–Hot Installation
Installation of the Expansion Bottle
1. Select a mounting location that allows for easy access
and clear visibility whenever the storage bay containing
the expansion bottle is open
2. Mount the expansion tank as illustrated in figure 10.
3. Connect and clamp the overflow tubing from the expan-
sion tank to the Aqua-Hot’s expansion tank connection.
Reference figure 10.
4. Drill a hole in the bay floor and cut a piece of overflow
tubing (included with unit) of adequate length so that it
can be connected to the top of the expansion tank and
extend through the bay floor. The expansion hose should
vent to the exterior of the Aqua-Hot bay.
5. Locate the wire leads exiting the expansion bottle.
6. Connect these wires to wire #10, #15, and #16 on the
Aqua-Hot wiring harness. Note that wires #10 and #15
will co-terminate in a single yellow jacketed connector as
shown below.
7. Once complete, secure these wire leads to minimize risk
of accidental damage.
The Aqua-Hot tank and heating loop operates at 0.0 psi
(zero pressure system). Air pressure applied to the tank
MUST NOT exceed 20 psi. Excess pressure will result in in-
ternal damage.
NOTE: Avoid any dips and bends in the overflow tubing from
the Aqua-Hot to the expansion tank as air can become
trapped in these dips and bends. This will prevent the ex-
pansion of the heating solution from properly depositing in
the expansion tank.
Tension Clamps
Lower fitting of the expansion bot-
tle must not extend below this line.
Hole in the coach bay floor
for overflow
Figure 10
Expansion Hose
Fluid Level Sensor Wiring Connections

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Heat Exchanger Floor Plan
NOTE: For the best performance, the
first heat exchanger should be
placed where heat loss is the great-
est. The first heat exchanger will al-
ways output the largest volume of
heat as compared to subsequent
exchangers.
NOTE: The fifth heat exchanger
should be placed in the bathroom,
as it is typically the smallest area
and therefore requires the least
amount of heat volume to maintain
temperature.
Heat Exchanger 1
Heat Exchanger 2
Heat Exchanger 3
Heat Exchanger 5
Heat Exchanger 4
Cab
Living Area
Aqua-Hot Unit
Bathroom
Bedroom

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Installation Requirements
Installation Requirements
Sufficient ventilation must be supplied to each interior
heat exchanger. Installing heat exchangers without sufficient
ventilation will severely impact the performance of the heat
exchanger. An air inlet of approximately the same size as the
air outlet is recommended for this application.
Air supplied to the heat exchangers MUST be supplied
from the living areas. It is never acceptable for the supply air
to a heat exchanger to be drawn from the bay area.
Horizontal and vertical mounting options shown above
Figure 11
Figure 12

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Heat Exchanger Mounting
Mounting the Heat Exchangers
1. Cut out a 2.5”H x 10”W opening for each heat exchanger
outlet and cold-air return register.
2. Mount each heat exchanger permanently into place. Ref-
erence figure 13 and figure 16 (next page.)
3. Install the hot-air outlet and cold-air return registers. Ref-
erence figure 13 below.
Please note that a return-air register may not be re-
quired, however, adequate return air must nonetheless be
provided to the heat exchanger or you may experience dimin-
ished performance of the heat exchanger unit. The total cross-
sectional area of the cold-air inlet must be at least equal to
the cross-sectional area of the hot-air outlet to ensure optimal
performance.
If the toe-kick areas are inadequate to house a heat
exchanger for regular installation, a plenum assembly may be
used on the heat exchanger, which can be used with a smaller
vent as seen in figure 14. The plenum allows only the desired
outlets to be opened by removing the metal insert on the vent.
1 2 3 4 5
1. Hot air vent
2. Air ducting hose
3. Plenum
4. Cozy heat exchanger
5. Toe kick board
Figure 13
Figure 14

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Locations and Clearances
Heat Exchanger Locations and Clearances
Place the heat exchangers so that even heat distribu-
tion will be felt throughout the interior of the coach. Reference
page 13.
Place the heat exchangers where they will be accessi-
ble for potential maintenance. If used for bay heating, central-
ize and position a heat exchanger in the fresh water storage
tank plumbing bay. To achieve best results, place the heat
exchanger as close to the floor of the plumbing bay as possi-
ble. Reference figure 11, figure 13, and figure 15 and for
mounting location information. Reference figure 16 for clear-
ance information.
Boost Pump
If desired, a 6th Cozy Heat Exchanger may be added
to the heating loop within your coach. Please note, however,
that an additional boost pump is required to provide adequate
fluid pressure to allow the 6th heat exchanger to operate as
intended.
NOTE: For single slide-out configurations, it is usually sim-
plest to place a heat exchanger on the opposite side of the
coach pointing towards the slide-out.
Figure 15
Figure 16

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©Aqua-Hot® 200 Series Installation Manual Rev. E
Wiring the Heat Exchanger
Wiring the Heat Exchangers
1. Wire all heat exchangers in a parallel circuit inside the
coach (i.e. all heat exchangers share a common power
wire and a common ground wire.) Reference Figure 18 on
page 17.
2. Run the power wire from the last heat exchanger back to
the eight-pin connector and plug it into pin #7.
3. Run the ground wire from the last heat exchanger back
into the 8-pin connector and plug it into pin #8.
4. With the remaining heat exchangers, tap the power from
each exchanger into the previously connected power wire
that is running back to the 8-pin connector.
5. Repeat the above with the ground wire.
6. Reference figure 18.
Wiring for OEM RV-C or Multiplex Control
Systems
When choosing a zone control for the heat exchang-
ers, the following guidelines must be adhered to, or the Aqua-
Hot will not function correctly in any mode of operation.
• Pin 6 must be supplied with +12V DC to provide power to
the coolant circulation pump
• Pin 7 must be integrated into the OEM control of the zone
• Pin 7 will be +12V DC when there is a call for interior heat.
This +12V DC current will drop when the Aqua- Hot senses
domestic water flow
Diesel Harness Plug
Figure 17
Propane Harness Plug
Wire-insertion view shown
12V DC Power (Pin 7)
Ground (Pin 8)
Figure 18

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Heat Exchanger Installation
Plumbing the Hydronic Heating System
When plumbing the heat exchangers that will be used
to heat the coach, the guidelines listed below are written as to
support the operation of heat exchangers. Failing to adhere to
these installation principles can hinder the operation of heat
exchangers installed within the coach.
• All plumbing lines should be laid as flat as possible, and
any extreme rises in height should be avoided to eliminate
any potential air traps
• Use 5/8” I.D. (inside diameter) plumbing lines (SAW J20
type hose) for both heating loops. Use wide-sweeping el-
bows or “bend supports” whenever the plumbing lines
may be susceptible to kinking (90° bends.)
• When exceeding 5 heat exchangers, a boost pump must
be installed in the coolant line to provide adequate pres-
sure to ensure that coolant is distributed throughout the
heating loop
• Plumbing lines should be run in areas where there is no
reasonable possibility that they can be pinched off, or
damaged under normal operating conditions
• Secure all lines where necessary and apply protective
shielding in areas where chafing may occur
• Rubber coated/closed-type clamps are recommended
when securing the plumbing lines
• Inlet and outlet plumbing lines can be installed with a
straight fitting or an elbow fitting
Instructions
 Layout the plumbing lines for all heat exchangers
 Label each line and designate as an inlet or an outlet line
 Connect and clamp the outlet line from the heater to the
lowest port (inlet port)
 Connect and clamp a line from the first heat exchanger’s
highest port, and connect the other end to the next heat
exchanger’s lowest point
 Connect each additional heat exchanger in the same ar-
rangement (in through the bottom, out through the top.)
 Connect and clamp the inlet line from the heater to the
highest port on the last heat exchanger to complete the
heating loop.
Figure 19
Outlet Inlet Mounting
Tabs
(Both sides)
Figure 20