Aqua-hot 600-d User manual

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 ......................................................................................................... 18

Fresh Water Tank Thermostat Mounting........................................................................................................ 18

Fresh Water Tank Thermostat Wiring ............................................................................................................. 18

Room Thermostat Location.............................................................................................................................. 19

Room Thermostat Mounting ............................................................................................................................ 19

Room Thermostat Wiring.................................................................................................................................. 19

Section 4: Domestic Water System

Domestic Water System Requirements............................................................................................................ 20

Domestic Water System Plumbing ................................................................................................................... 20

Section 5: Switch Panel

Switch Panel Location ........................................................................................................................................ 22

Switch Panel Mounting....................................................................................................................................... 22

Switch Panel Wiring ............................................................................................................................................ 23

Table of Contents

Section 6: Fuel System

Fuel System Location .........................................................................................................................................24

Fuel System Requirements................................................................................................................................. 24

Fuel System Installation ..................................................................................................................................... 25

Section 7: Engine Preheat System

Engine Preheat System Location...................................................................................................................... 27

Engine Preheat System Plumbing Requirements ........................................................................................... 27

Engine Preheat System Plumbing Installation................................................................................................ 27

Section 8: Exhaust System

Exhaust System Requirements .......................................................................................................................... 30

Installing the Exhaust System ........................................................................................................................... 31

Section 9: Electronic Controller Wiring

Electronic Controller Wiring............................................................................................................................. 32

Wiring Harness Connection .............................................................................................................................. 33

Connecting the 12 Volt-DC Power .................................................................................................................. 33

Connecting the 120 Volt-AC Power................................................................................................................. 34

Section 10: Purging the Systems

Purging the Hydronic Heating System............................................................................................................. 35

Purging the System by Grounding Zone Pumps ........................................................................................... 36

Purging the Domestic Water System................................................................................................................ 37

Section 11: Initial Start-Up

Activating the Aqua-Hot.................................................................................................................................... 37

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

— Page 1 —

General Information

Introduction to the Aqua-Hot 600-D:

This installation manual is designed to aid in the instal-

lation process of the Aqua-Hot 600-D Hydronic Heat-

ing System by a trained and experienced installer. The

Aqua-Hot features a 12 Volt-DC powered diesel-burner

and two 120 Volt-AC, 2000 Watt electric heating ele-

ments. These heating sources are used in conjunction

with an FDA-approved “GRAS” (Generally Recog-

nized As Safe) propylene glycol based boiler antifreeze

and water heating solution in order to provide a con-

tinuous supply of domestic hot water, interior/fresh

water tank heating, independent interior zone heating,

motoraide, and engine preheating. Be sure to refer-

ence Figures 1 through 5 for a complete component

overview.

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 2 —

Aqua-Hot Hydronic Heating System

Diesel-Burner, Heat Input (Firing Rate)...............................56,000 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2) 120 Volt-AC/2000 watts

Zone Heat Circulation Pump specications............................(3) 12 Volt-DC/21 watts each

Number of Heating Zones .........................................maximum of 5, plus Engine Preheat

Domestic Water Heating Capacity...................................continuous/on-demand

Dimensions....................................................18.5”Hx18.5”Wx36.75”L

Dry Weight.....................................................approximately 186 lbs.

WetWeight....................................................approximately303lbs.

Figure 1

— Page 3 —

Aqua-Hot Hydronic Heating System

Wiring Harness

Domestic

Water Access

Panel

Drain Valve

Diesel-Burner

Interlock

Switch

Diesel-Burner

Controller

3069328

Figure 2

Figure 3

— Page 4 —

Aqua-Hot Hydronic Heating System

Product

I.D. Label

Heating Zone

Outlet Port 3

Wiring Harness Port

Figure 4

Expansion

Tank

Connection

Air-Release

Valve

Heating Zone

Outlet Port 2

Heating Zone

Outlet Port 1

Engine Preheat

Ports

Heating Zone

Inlet Ports

VAC Wiring

Ports

Domestic Water

Ports

Diesel Fuel

Inlet /Outlet

Ports

Aqua-Hot Hydronic Heating System

Diesel-Burner

Interlock Switch

Diesel-Burner

Controller

Figure 5

Figure 6

NOTE: All measurements are in inches.

CUT

OUT

Outline of Aqua-Hot

Front of Aqua-Hot

Motorhome Floor

Outline

2.37”

(Typical)

Ø .20”

(Typical 6 Places)

18.80”

(Overall)

37.00”

(Overall)

3.83”

(Typical)

1.02”

(Typical)

14.05”

(Cut-Out)

17.99”

(Cut-Out)

17.48”

(Center

of Holes)

17.48”

(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)

Zone 1

Circulation

Pump

Zone 2

Circulation

Pump

Zone 3

Circulation

Pump

Engine

Preheat

Circulation

Pump

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 8

  • Mountingtrayinformation-Figure6

  • I.D.Labelnotingthe“OpenAccess”

clearance requirement for the front of the heater

- Figure 2

  • Serviceaccessclearances-Figure7

2. Cut out the required mounting tray opening. Reference

Figure 6.

3. Installthemountingtrayangeintothecut-outopen-

ing. Reference Figure 6.

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. Reference Figure 9.

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 6.

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 6.

5. Place the Aqua-Hot into the mounting tray. Reference

Figure 10.

6. Install the combustion-air sleeve onto the diesel-burner’s

air intake. Reference Figure 8.

A) Slide the end of the combustion-air sleeve with the

clamp up through the mounting tray and underside

of the Aqua-Hot unit.

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 7

Figure 8

Combustion-Air

Sleeve

— Page 7 —

Side View

Front View

NOTE: All measurements

are in inches.

Top View

Bottom View

2.0”

1.30”

Section 1: Aqua-Hot Installation

Figure 9

Access

Cover Combustion-Air

Sleeve

Mounting Tray

Flange Mounting Tray

Aqua-Hot 600-D

Access

Cover

Section 1: Aqua-Hot Installation

Mounting Tray

Flange

Aqua-Hot 600-D

Tabs

Rear of

Mounting Tray

Slots

Figure 10

— Page 9 —

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 11.

1. Mount the expansion tank as illustrated in Figure 11.

2. Connectandclamptheoverowtubingfromthe

expansion tank to the Aqua-Hot’s expansion tank con-

nection. Reference Figure 11.

Figure 11

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

into 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.

Location and Clearances:

Place the heat exchangers so that even heat distribution

will be felt throughout the interior of the motorhome.

Reference Figures 12 through 19.

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. Reference Figure 12.

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 14 and 17 for mounting location

information.

Reference Figure 13 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 16.

Mounting Requirements:

Sufcientventilation(return-air)mustbesuppliedto

each interior heat exchanger. Reference Figures 14 and

15.

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

tnorF

yzoC

Cozy

Return-Air

Indicates generally recommended

mounting locations for the Cozy

Heat Exchangers

Interior Zone Heating/Heat Exchanger Layout

Figure 14

INTERIOR WALL/CABINET WALL

4 inch Minimum

Clearance

Required

Figure 12

Heat Output

Cold-Air Return

Optional

Vent

Fresh Water

Storage Tank

Figure 13

Section 2: Hydronic Heating System

— Page 11 —

Section 2: Hydronic Heating System

mooRgniviL regnahcxEtaeH

nehctiK regnahcxEtaeH

moordeB regnahcxEtaeH enignE

mooRgniviL regnahcxEtaeH

gnitaeherPenignE

moorhtaB regnahcxEtaeH

Heating Loop 2

Bathroom and

Fresh Water Tank Bay

Heating Loop 1

Bedroom

Generalized Motorhome Heating

System Floorplan

Fresh

Water Tank

Heat Exchanger

Heating Loop 3

Kitchen and Living Room

Aqua-Hot

Heating System

Figure 17

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 15.

2. Mount each heat exchanger permanently into place.

Reference Figures 18 and 19.

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 16

HEAT

EXCHANGER

HOT-AIR

OUTLET BASE-BOARD /TOE-KICK AREA

CABINET/COUCH

COLD-AIR

Figure 15

Section 2: Hydronic Heating System

Vertical Mount

Horizontal Mount Mounting Tab

Figure 18

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 19

— Page 13 —

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 21.

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 the same zone in-series.

5. Connect all electronic controller wires to the positive

and negative leads of the heat exchanger. Reference

Figure 21.

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 21

Figure 20

Reset Button

(Secondary

Power Source)

12 Volt-DC Screw

Terminal (Primary

Power Source)

12 Volt-DC Screw

Terminal

Ground Wire

Screw Terminal

Terminal

Strip/Plug

Pin Jumper

Electronic Controller Board

To Motorhome

From Hydronic Heating

System Wiring Harness

Wire

Loom

Wire

Loom

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 3.” Reference Figure 22.

The fresh water tank, and bathroom heat exchangers

(typically 3) must be plumbed together in-series on

“Heating Loop 2.” Reference Figure 22.

The bedroom heat exchanger must be plumbed on

“Heating Loop 1.” Reference Figure 22.

 Use⅝inchI.D.(InsideDiameter)plumbinglinesfor

all 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: Zone 1

Heating Loop #2: Zone 2,3,4

Heating Loop #3: Zone 5

Outlet Plumbing Lines

Inlet Plumbing Lines

Figure 22

— Page 15 —

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 23 and 24.

Then, connect each additional heat exchanger in the

same arrangement (low to high). Reference Figure 22.

4. Connect and clamp the inlet line from the heater to the

highest port on the last heat exchanger for both heating

loops. Reference Figure 22.

NOTE: Reference Figure 24 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 Figure 25.

Mounting

Bracket

Mounting

Bracket

Cozy Heat Exchanger

(Rear View)

Outlet Port

(Highest Port)

Inlet Port

(Lowest Port)

Figure 23

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

3/4 in. Rubber

Coupler

3/4 in. Rubber

Coupler

Figure 24

— Page 17 —

Section 2: Hydronic Heating System

Outlet Heating Loop

Ports

PEX Tube

PEX Insert

Compression Fitting

Inlet Heating Loop

Ports

PEX Tube

Inlet Plumbing Port

PEX Insert

Compression Fitting

PEX Tube

PEX Insert

Compression Fitting

Heating Loop 1

Outlet Plumbing Port

Heating Loop 2

Outlet Plumbing Port Heating Loop 3

Outlet Plumbing Port

Inlet Plumbing Port

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

PEX Insert

PEX Tube

PEX Insert

PEX Tube

Hose Barb Fitting

Heating Loop 3

Outlet Plumbing Port

Constant

Tension

Clamps

Rubber HoseRubber Hose

PEX Insert

Heating Loop

Inlet Plumbing Port

Figure 25

Heating Loop Connection Options

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