Aqua-Hot 450-DE Series User manual

INSTALLATION MANUAL
© 2008 Aqua-Hot Heating Systems Inc.

© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
General Information
Introduction ........................................................................................................................................................... 1
Danger, Warning, Caution, and Note Boxes..................................................................................................... 1
Aqua-Hot Hydronic Heating System
Technical Information.......................................................................................................................................... 2
Section 1: Aqua-Hot Installation
Installing the Mounting Tray and the Aqua-Hot.............................................................................................. 5
Installing the Expansion Tank............................................................................................................................. 9
Section 2: Hydronic Heating System
Location and Clearances .................................................................................................................................... 10
Mounting Requirements..................................................................................................................................... 10
Mounting the Heat Exchangers ........................................................................................................................11
Wiring the Heat Exchangers.............................................................................................................................. 13
Plumbing Requirements ..................................................................................................................................... 14
Plumbing the Hydronic Heating System ......................................................................................................... 15
Section 3: Thermostats
Fresh Water Tank Thermostat Location ......................................................................................................... 17
Fresh Water Tank Thermostat Mounting........................................................................................................ 17
Fresh Water Tank Thermostat Wiring ............................................................................................................. 17
Room Thermostat Location.............................................................................................................................. 18
Room Thermostat Mounting ............................................................................................................................ 18
Room Thermostat Wiring.................................................................................................................................. 18
Section 4: Domestic Water System
Domestic Water System Requirements............................................................................................................ 19
Domestic Water System Plumbing ................................................................................................................... 19
Section 5: Switch Panel
Switch Panel Location ........................................................................................................................................ 21
Switch Panel Mounting....................................................................................................................................... 21
Switch Panel Wiring ............................................................................................................................................ 22
Table of Contents

© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Table of Contents
Section 6: Fuel System
Fuel System Location .........................................................................................................................................23
Fuel System Requirements................................................................................................................................. 23
Fuel System Installation ..................................................................................................................................... 24
Section 7: Engine Preheat and Motoraide System
Engine Preheat System Location...................................................................................................................... 26
Engine Preheat System Plumbing Requirements ........................................................................................... 26
Engine Preheat System Plumbing Installation................................................................................................ 26
Section 8: Exhaust System
Exhaust System Requirements .......................................................................................................................... 29
Installing the Exhaust System ........................................................................................................................... 30
Section 9: Electronic Controller Wiring
Electronic Controller Wiring............................................................................................................................. 31
Wiring Harness Connection .............................................................................................................................. 32
Connecting the 12 Volt-DC Power .................................................................................................................. 33
Section 10: Purging the Systems
Purging the Hydronic Heating System............................................................................................................. 34
Purging the System by Grounding Zone Pumps ........................................................................................... 35
Purging the Domestic Water System................................................................................................................ 36
Section 11: Initial Start-Up
Activating the Aqua-Hot.................................................................................................................................... 36
Appendices:
Appendix A: Wiring Diagram ........................................................................................................................A-1
Appendix B: Wire Gauge Information.........................................................................................................B-1
Appendix C: Electronic Controller Features ...............................................................................................C-1
Appendix D: Antifreeze Types...................................................................................................................... D-1
Appendix E: Antifreeze Mixture Water Quality Recommendations........................................................E-1
Appendix F: Antifreeze Terms and Mixture Ratio ..................................................................................... F-1

© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
General Information
Introduction to the Aqua-Hot 450 DE/DM:
This Installation Manual is designed to aid in the instal-
lation process of the Aqua-Hot 450 Hydronic Heating
System by a trained and experienced installer. The
Aqua-Hot features a 12 Volt-DC powered diesel-burner
and a 120 Volt-AC, 1650 Watt electric heating element.
These two heating sources are used in conjunction with
an FDA-approved “GRAS” (Generally Recognized
As Safe) propylene glycol based boiler antifreeze and
water heating solution in order to provide a continuous
supply of domestic hot water, interior/fresh water tank
heating, independent interior zone heating, and engine
preheating, applicable for the 450-DE model only. Be
sure to reference Figures 1 through 6 for a complete
component overview.
Both the Aqua-Hot 450-DE and 450-DM heaters
include a motoraide feature, which uses the circulation
of the motorhome’s engine to transport the antifreeze
and water heating solution from the Aqua-Hot’s boiler
tank to the motorhome’s warm engine and back to the
boiler tank. Through this process, the boiler tank is
kept heated, which reduces the time required to bring
the tank to operating temperature for interior heat and
continuous domestic hot water.
The Aqua-Hot 450-DE also includes an engine
preheat feature, which provides an easy engine startup
whenever cool weather conditions are present. Engine
preheating occurs when the motorhome’s cold engine
coolant is circulated through the Aqua-Hot’s engine
loop where it gains warmth to transfer to the engine
while circulating.
Please note that all Danger, Warning, Caution, and
Note boxes, appearing as needed throughout this
manual, must be reviewed and adhered to during the in-
stallation procedure in order to avoid potential hazards,
which could result in injury, death, product damage, or
property damage.
Should additional assistance be needed, please
contact the Product Application Department at
1-800-685-4298, Monday through Friday, between the
hours of 8:00 AM and 5:00 PM Mountain Standard
Time.
Danger, Warning, Caution, and Note Boxes:
Danger, Warning, Caution, and Note boxes appear
throughout this manual as a means of alerting the
installer to important information.
In d I c a t e s t h a t p e r s o n a l I n j u r y I s l I k e l y o r I m m I n e n t .
Indicates that serious damage to the heater will
occur and personal injury is possible as well.
Indicates that damage to the heater is possible.
NOTE: Indicates information that requires special
attention by the installer.
— Page 1 —

© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual — Page 2 —
Aqua-Hot Hydronic Heating System
Diesel-Burner, Heat Input (Firing Rate)...............................45,000 BTU/hr
Diesel-Burner, Fuel Consumption (Continuous Operation)................0.40 gal/hr
Heater, Voltage/Maximum Power Consumption . . . . . . . . . . . . . . . . . . . . . . . .12 Volt-DC/60 watts
Electric Heating Element specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Volt-AC/1650 watts
Zone Heat Circulation Pump specications............................(2) 12 Volt-DC/21 watts each
Number of Heating Zones .........................................maximum of 5, plus Engine Preheat
Domestic Water Heating Capacity...................................continuous/on-demand
Dimensions....................................................12”Hx18.5”Wx30”L
Dry Weight.....................................................approximately 127 lbs.
WetWeight....................................................approximately184lbs.
Figure 1

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© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Aqua-Hot Hydronic Heating System
Wiring Harness
& Harness Port
VAC Access
Panel
Zone 2
Circulation
Pump
Zone 1
Circulation
Pump
Diesel-Burner
Interlock
Switch
Heating Zone 2
Outlet Port
Heating Zone
1 Outlet Port
Diesel-Burner
Controller
Diesel
Fuel
Lines
AC Wiring
Port
3069328
Figure 2
Figure 3
Mounting Tray
AC Terminal
Block
Combustion-Air
Sleeve

— Page 4 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Domestic
Cold Water
Inlet
Back of Unit
Domestic Hot
Water Outlet
Engine
Preheat
Outlet (to
engine)
Engine
Preheat
Inlet
(from
engine)
Engine
Preheat
Circulation
Pump
Aqua-Hot Hydronic Heating System
Zone 1
Circulation
Pump
Zone 2
Circulation
Pump
Wiring Harness Port
Diesel-Burner
Drain Valve
AC Wiring
Port
Interlock Switch
Diesel-Burner
Controller
Figure 4
Figure 5
Product
I.D. Label

— Page 5 —
Aqua-Hot Hydronic Heating System
Diesel Fuel
Inlet /Outlet
Ports
Product
I.D. Label
Heating Zone
Outlet Ports
AC Wiring
Port
Wiring Harness Port
Air-Release
Valve
Expansion
Tank
Connection
Heating Zone
Inlet Ports
Figure 6
Figure 7
Motorhome Floor
Outline of
Mounting Tray
Additional Cross-Member
for Support (may be
necessary)
CUT
OUT
Outline of Aqua-Hot
Front of Aqua-Hot
Motorhome Floor
Outline
1.33”
(Typical)
2.30”
(Typical)
Ø .203”
(Typical 6 Places)
18.66”
(Overall)
30.35”
(Overall)
1.19”
(Front of Flange)
.95”
(Typical)
14.06”
(Cut-Out)
17.98”
(Cut-Out)
16.0”
(Center of Holes)
14.30”
(Center
of Holes)
14.14”
(Center
of Holes)
NOTE: All measurements are in inches
Motorhome Floor
Outline of
Mounting Tray
Additional Cross-Member
for Support (may be
necessary)
CUT
OUT
Outline of Aqua-Hot
Front of Aqua-Hot
Motorhome Floor
Outline
1.408
(Typical)
2.017
(Typical)
Ø .203
(Typical 6 Places)
18.129
(Overall)
27.249
(Overall)
1.240
(Typical)
1.031
(Typical)
14.095
(Cut-Out)
18.000
(Cut-Out)
15.313
(Center of Holes)
9.125
(Center
of Holes)
16.063
(Center
of Holes)

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© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
0 in.
0 in.
1 in.
Open Access Motorhome Bay
6 in. Minimum
Access Cover
Section 1: Aqua-Hot Installation
Installing the Mounting Tray and the Aqua-Hot:
1. Reference the following illustrations for mounting
information:
 • Overall Aqua-Hot dimensions - Figure 10
  • Mountingtrayinformation-Figure7
  • I.D.Labelnotingthe“OpenAccess”
clearance requirement for the front of the heater
- Figure 2
  • Serviceaccessclearances-Figure8
2. Cut out the required mounting tray opening. Reference
Figure 7.
3. Installthemountingtrayangeintothecut-outopen-
ing. Reference Figure 7.
NOTE: Be sure to secure the mounting tray into place prior to
installing the Aqua-Hot.
Be sure to mount the Aqua-Hot securely into the
mounting tray to ensure that the unit does not move or
shift under normal operating conditions.
Be sure the access cover fastener is removed from the
Aqua-Hot prior to placement into the installed mount-
ing tray.
Be sure to provide an adequate support system for
the mounting tray; if adequate support is not present,
a cross-member will need to be installed. Reference
Figure 7.
Inspect the area beneath the mounting location to
insure no structural members will interfere with the
cut-out for the mounting tray.
4. Insert a #10 machine screw into each of the embossed
holes in the mounting tray (total of six required) and
tighten to secure the mounting tray to the motorhome.
Reference Figure 7.
5. Place the Aqua-Hot into the mounting tray. Reference
Figure 11.
6. Install the combustion-air sleeve onto the diesel-burner’s
air intake. Reference Figure 9.
A) Slide the end of the combustion-air sleeve with the
clamp up through the mounting tray and underside
of the Aqua-Hot 450-D.
B) Loosen the adjustable clamp and slide over the
diesel-burner’s air intake.
C) Tighten the clamp to secure the sleeve to the
diesel-burner.
7. Re-install the access cover fastener and tighten once the
total installation procedure is complete.
Figure 8 Figure 9
Combustion-Air
Sleeve

— Page 7 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Side View
Front View
Rear View
NOTE: All measurements
are in inches.
Top View
Bottom View
450 --- DE⁄DM
Section 1: Aqua-Hot Installation
Figure 10

— Page 8 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Access
Cover
Fastener
Access
Cover
Combustion-Air
Sleeve
Mounting Tray
Flange
Mounting Tray
Aqua-Hot 450-D
Section 1: Aqua-Hot Installation
Mounting Tray
Flange
Aqua-Hot 450-D
Rear of
Mounting Tray
Slots
Figure 11
Tabs

— Page 9 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Installing the Expansion Tank:
Select a mounting location that allows for easy access
and clear visibility whenever the particular storage bay
door is open.
NOTE: The top of the expansion tank should always be
mounted at least 4 inches higher than the highest point
on the Aqua-Hot. Reference Figure 12.
1. Mount the expansion tank as illustrated in Figure 12.
2. Connectandclamptheoverowtubingfromthe
expansion tank to the Aqua-Hot’s expansion tank con-
nection. Reference Figure 12.
Figure 12
NOTE:Avoidanydipsandbendsintheoverowtubingfrom
the Aqua-Hot to the expansion tank as air can become
trapped in these dips and bends, preventing the expan-
sion of the heating solution from properly depositing
in the expansion tank.
3. Drillaholeinthebayoorandconnect(securewitha
clamp)alongenoughpieceof overowtubingsothat
it can be connected to the top of the expansion tank
andextendthroughthebayoor.
Fill to “Cold” level
mark with “GRAS”
approved 50/50
antifreeze/water
mixture.
Air-Release Valve
Expansion Tank
Connection
Expansion Tank
Mount top of expansion
tank at least 4 inches
higher than the Aqua-Hot.
Overow Tubing
Section 1: Aqua-Hot Installation
Overow tubing from
expansion tank to hole
drilled in motorhome oor.

— Page 10 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Location and Clearances:
Place the heat exchangers so that even heat distribution
will be felt throughout the interior of the motorhome.
Reference Figures 13 through 20.
NOTE:Forsingleslideoutcongurations,itisusuallysimplest
to place a heat exchanger on the opposite side of the
motorhome pointing towards the slideout.
Place the heat exchangers where they will be accessible
for potential servicing and cleaning.
Centralize and position a heat exchanger in the fresh
water storage tank plumbing bay.
NOTE: In order to achieve the best heating results, place the
heatexchangerasclosetotheoorof theplumbing
bay as possible (heat will naturally rise).
Reference Figures 15 and 18 for mounting location
information.
Reference Figure 14 for clearance information.
NOTE: An accessory device is available for the Cozy Heat Ex-
changerforthepurposeof redirectingtheairowfrom
the heat exchanger. Reference Figure 17.
Mounting Requirements:
Sufcientventilation(return-air)mustbesuppliedto
each interior heat exchanger. Reference Figures 15 and
16.
NOTE:Mountingtheheatexchangerswithoutsufcientventi-
lation will severely reduce their overall heating perfor-
mance (heat output).
  Inordertoprovidesufcientventilation,thereturn-
air registers must be the same size, or larger, than the
outlet-air registers.
Return-air must be supplied from the corresponding
interior heating zones.
Cozy
Cozy
Cozy
Cozy
tnorF
yzoC
Cozy
Return-Air
Return-Air
Return-Air
Indicates generally recommended
mounting locations for the Cozy
Heat Exchangers
Interior Zone Heating/Heat Exchanger Layout
Figure 15
INTERIOR WALL/CABINET WALL
4 inch Minimum
Clearance
Required
Figure 13
Heat Output
Cold-Air Return
Optional
Vent
Fresh Water
Storage Tank
Figure 14
Section 2: Hydronic Heating System

— Page 11 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Section 2: Hydronic Heating System
Living Room
Heat Exchanger
Living Room
Heat Exchanger
Kitchen
Heat Exchanger
Bathroom
Heat Exchanger
Fresh Water
Tank Heat
Exchanger
Aqua-Hot
Heating System
Heating Loop 1
Kitchen and Living Room
Heating Zone
Heating Loop 2
Bathroom, Bedroom,
and Fresh Water Tank Bay
Heating Zones
Engine
Preheating
Bedroom
Heat Exchanger Engine
Generalized Motorhome Heating System Floor Plan
Figure 18
Mounting the Heat Exchangers:
1. Cut out a 2.5 inch H x 10 inch W opening for each heat
exchanger outlet and cold-air return register. Reference
Figure 16.
2. Mount each heat exchanger permanently into place.
Reference Figures 19 and 20.
3. Install the hot-air outlet and cold-air return registers.
Reference Figure 16.
NOTE: Please note that a return air register may not be re-
quired; however, adequate return-air must be provided
to each particular heat exchanger. This means that the
total cross-sectional area of the return-air opening must
be equal to or greater than the cross-sectional area of
the hot-air outlet opening of the heat exchanger.
Figure 17
HEAT
EXCHANGER
HOT-AIR
OUTLET BASE-BOARD /TOE-KICK AREA
CABINET/COUCH
REGISTER
COLD-AIR
REGISTER
REGISTER
Figure 16

— Page 12 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Section 2: Hydronic Heating System
Vertical Mount
Horizontal Mount Mounting Tab
Figure 19
3.500 in.
5.50 in.
1.06 in.
0.38 in.
2.812 in.
6.500 in.
10.500 in.
13.687 in.
6.44 in.
13.06 in.
14.44 in.
NOTE:
Tolerances on the dimensions
shown are as follows:
.XX (i.e., 6.44 in.) = ± .030
.XXX (i.e., 6.500 in.) = ± .015
Figure 20

— Page 13 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Section 2: Hydronic Heating System
Wiring the Heat Exchangers:
1. Run two 18-gauge wires, red for (+) and black for (-),
from each particular heating zone’s heat exchanger to
the electronic controller. Reference Figure 22.
2. Label the wires indicating the heating zone they pertain
to (e.g., Living Room, Bathroom, Bedroom, etc.).
3. Insert all heat exchanger wires into the appropriate ter-
minal/heating zone location on the electronic control-
ler. Reference Figure 21 and Appendix A.
4. Wire all heat exchangers in a zone in-series. Reference
Figure 23 and Appendix A.
5. Connect all electronic controller wires to the positive
and negative leads of the heat exchanger. Reference
Figure 22.
NOTE: Tolerance
+/- .030
+ (Positive) Red Wires
To Aqua-Hot’s Terminal
Block
- (Ground) Black Wires
To a chassis ground source
Mounting Tab
3.63 in.
13.06 in.
6.44 in.
14.44 in.
Figure 22
Figure 21
Reset Button
(Secondary
Power Source)
12 Volt-DC Screw
Terminal
(Primary
Power Source)
12 Volt-DC Screw
Terminal
Ground Wire
Screw Terminal
Header
Terminal Strip/Plug
Pin Jumper
J4
J1
J3
J2
1
11
1
Electronic Controller Board
To Motorhome
From Hydronic Heating
System Wiring Harness
Wire
Loom
Wire
Loom
Wire
Loom
Wire
Loom

— Page 14 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Section 2: Hydronic Heating System
Plumbing Requirements:
Once all heat exchangers have been mounted, formu-
late a plan for the routing of the plumbing lines from
each heating zone to the Aqua-Hot.
 Allplumbinglinesshouldbelaidasataspossible,
and any extreme rises in height should be avoided to
eliminate any potential air-traps.
The kitchen and living room heat exchangers (typically
three) must be plumbed together in-series on “Heating
Loop 1.” Reference Figures 23 and 24.
The fresh water tank, bedroom, and bathroom heat
exchangers (typically 3) must be plumbed together in-
series on “Heating Loop 2.” Reference Figures 23 and
24.
 Use⅝inchI.D.(InsideDiameter)plumbinglinesfor
both heating loops.
Use wide-sweeping elbows or “bend supports” when-
ever the plumbing lines may be susceptible to kinking
(i.e., 90° bends).
Living Room
Heat Exchanger
Fresh Water Tank
Heat Exchanger
Bathroom Heat
Exchanger
Bedroom Heat
Exchanger
Living Room
Heat Exchanger
Kitchen Heat
Exchanger
Heating Loop #1
Heating Loop #2
Outgoing Plumbing Lines
Incoming Plumbing Lines
Heating Zone #1
Heating Zone #3 Heating Zone #2 Heating Zone #4
Figure 23

— Page 15 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Section 2: Hydronic Heating System
Plumbing the Hydronic Heating System:
1. Lay out the plumbing lines for all heat exchangers.
2. Label each line with the heating loop number and des-
ignate as an inlet or an outlet line.
NOTE: Run all plumbing lines in areas where they cannot be
pinched off or damaged under normal operating con-
ditions.
Be sure to secure all lines where necessary and apply
protectiveshieldinginareaswherechangmayoccur.
Rubber Coated/Closed-Type clamps are recommended
when securing the plumbing lines.
3. Connect and clamp the outlet line from the Aqua-
Hot to the lowest port on the closest heat exchanger
for both heating loops. Reference Figures 24 and 26.
Then, connect each additional heat exchanger in the
same arrangement (low to high). Reference Figure 23.
4. Connect and clamp the inlet line from the heater to the
highest port on the last heat exchanger for both heating
loops. Reference Figures 24 and 26.
NOTE: Reference Figure 25 for visual instructions on connect-
ing PEX-type tubing to each heat exchanger.
Plumbing heat exchangers in this manner will allow
air to escape naturally. If air is trapped in any heat ex-
changer,itwillsignicantlyreducetheheatexchanger’s
overall heating performance (heat output).
5. Connect and tighten all interior plumbing lines, outlet
and inlet, to the Aqua-Hot’s appropriate heating loop
ports. Reference Figures 23 and 26.
Mounting
Bracket
Mounting
Bracket
Cozy Heat Exchanger
(Rear View)
Outlet Port
(Highest Port)
Inlet Port
(Lowest Port)
Figure 24

— Page 16 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Section 2: Hydronic Heating System
Constant Tension
Clamps
Pex
Insert
Pex
Insert
Outlet
Inlet
5/8 inch I.D.
3/4 inch O.D.
5/8 inch I.D.
3/4 inch O.D.
Automotive Type Rubber
Heater-Hose Coupler
(3/4 inch I.D.)
Automotive Type Rubber
Heater-Hose Coupler
(3/4 inch I.D.)
PEX Plumbing Line
PEX Plumbing Line
3/4 in. Rubber
Coupler
3/4 in. Rubber
Coupler
Figure 25

— Page 17 —
© 2008 Aqua-Hot®450-DE/DM Hydronic Heating System Installation Manual
Outlet Heating Loop
Ports
Inlet Heating Loop
Ports
Constant
Tension
Clamps
Heating Loop 2
Outlet Plumbing Port
Heating Loop 1
Outlet Plumbing Port Heating Loop
Inlet Plumbing Port
Heating Loop
Inlet Plumbing Port
Constant
Tension
Clamps
Hose Barb Fitting
Rubber Hose
Rubber Hose
PEX Insert
PEX Tube
PEX Tube
PEX Insert
PEX Tube
Hose Barb Fitting
Hose Barb Fitting
Heating Loop 1
Outlet Plumbing Port
Heating Loop 2
Outlet Plumbing Port
Outlet Heating Loop
Ports
PEX Tube
PEX Insert
Compression Fitting
Inlet Heating Loop
Ports
PEX Tube
Inlet Plumbing Port
PEX Insert
Compression Fitting
Inlet Plumbing Port
Section 2: Hydronic Heating System
Figure 26