Hydro-Hot HHE-200-07E User manual

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
OWNER’S MANUAL
MODEL NUMBERS
HHE-200-07E
HHE-500-07M
®

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Vehicle Systems, Inc.
Warranty Department
15549 East Highway 52
Ft. Lupton, CO 80621
Please Mail To:
CUTHEREANDMAILIN
OWNER’S INFORMATION
Owner’s Name:
Address:
City: State: Zip Code:
Telephone:
Coach Model:
Coach Date of Purchase:
Hydro-Hot Model No:
Hydro-Hot Serial No:
Vehicle Systems Warranty Department
15549 East Highway 52
Ft. Lupton, CO 80621

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
TABLE OF CONTENTS
1.0 Overview
2.0 Operating Instructions
2.1 Identifying your model of Hydro-Hot
2.2 Activating the Hydro-Hot Heating System
2.3 Zone Thermostat(s) Operation
2.4 Using the Domestic Hot Water System
2.5 Using the Engine Preheat System (HHE-200 Model Only)
2.6 Precautions
3.0 Maintenance
3.1 Maintenance Schedule
4.0 Winterization
4.1 Domestic Hot Water System
5.0 Troubleshooting
6.0 Electronic Controller Diagnostic
Page 1-1
The Hydro-Hot Motor Coach Heating System is an on-board Hydronic
Heating System (heating with hot water) that provides a continuous, on-
demand supply of domestic hot water, as well as interior zone heating where
and when it is needed. Both heating features are accomplished by a unique
Diesel-Fired Burner and an AC powered Electric Heating Element (120 VAC).
These two heating sources maintain the temperature of the Hydro-Hot's
solution of water and antifreeze. In addition, the Hydro-Hot has been
designed to preheat the vehicle's engine prior to starting (HHE-200 Model
Only). This optional feature provides easy engine start-up whenever cool
weather conditions are present. Be sure to review Figures 1 and 2for
complete component overview.
SECTION 1: OVERVIEW
Hydro-Hot
Overview
HeatingZones
Status
#5
#4
#
3
#2
#1
ElectricHeating
ElementStatus LowVoltage
Reset
Emergency
Cutoff
Hydro-Hot
HeatingStatus
EnginePreheat
Pump
LowBattery
VoltageFault
LowTemp
CutoffStatus
OverloadFault
Circulation
Pump#2
Circulation
Pump#1
Circualation
Pump#3
Diesel-Burner
Status
TM
Hydro-Hot
Hydro-Hot
ByVehicle Systems, Inc.
Motor Coach Heating Specialists
Electronic
Controller
Diesel Electric
Hydro-Hot
By VehicleSystems
Engine
Preheat
COLD
HOT
Hydro-Hot
TM
A
ccess Cover
Electronic
Controller
Switches
Expansion
Tank
Figure 1

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Page 2-1
SECTION 2: OPERATING INSTRUCTIONS
Please read the complete Owner’s Manual prior to operating your
Hydro-Hot Heating System. Also, be sure to fill out and mail in your
Owner’s Information Card located at the front of this manual.
Model
I.D. 2.1 Identifying Your Model Of Hydro-Hot
The Hydro-Hot is available in three different models. All three models
of Hydro-Hot come standard with the continuous Domestic Hot and
Interior / Bay Heating features. The Engine Preheat and Motoraide
options are available on the HHE-200 and HHE-500 series, respec-
tively. Be sure to identify your specific model of Hydro-Hot prior to
readingthismanual.
HHE-200 - Equipped with the Engine Preheat feature.
HHE-500 - Equipped with the Motoraide feature.
To find out what model Hydro-Hot you have, simply locate the Heater
and find the I.D. Sticker (located on the right-hand corner on top of the
Heater) and locate the rectangle box that is labeled “Model Number.”
Page 2-2
SECTION 2: OPERATING INSTRUCTIONS
2.2 Activating The Hydro-Hot Heating System
Diesel-Burner
Turn the “Diesel” Control Switch ON, Figure 3. This procedure will
activate the Diesel-Burner and the Indicator Light located on the Switch.
Please contact your specific motorhome manufacturer for the exact
Diesel Control Switch location. Allow 10-20 minutes for the System to
reach operating temperature. Please note that the Diesel-Burner is the
main heat source for heating both the interior and the domestic hot water.
So, be sure to leave this switch ON during normal heating requirements.
Electric Heating Element
Turn the “Electric” Control Switch ON, Figure 3. This procedure will
activate the Electric Heating Element and the Indicator Light located on
the Switch. The 120 VAC Electric Heating Element is wired directly into
your coaches 120 VAC electrical system and is operational whenever
VAC power is available. Allow 1-2 hours for the System to reach
operating temperature. Please note that the Electric Heating Element will
adequately provide all your heating needs only for low heating demand
situations, such as when moderate ambient temperatures exist and/or
when there is a low demand for domestic hot water.
Heat
Source

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
2.3 Zone Thermostat(s) Operation
Interior Room Thermostats
Simply adjust each Room Thermostat to the desired temperature. Then
whenever a Room Thermostat “calls-for-heat” the Hydro-Hot’s
Circulation Pump(s) and Interior Zone Fans will be activated. These
devices together will supply warmth and comfort to each interior heating
zone. Please contact your specific motorhome manufacturer for the exact
room thermostat location(s).
NOTE: Interior zone heating and bay heating will not operate if the Hydro-
Hot’s water and antifreeze solution is cold or if domestic hot water is being
used on a continuous basis (i.e. during showers).
Bay Thermostat
Simply adjust the Bay Thermostat to approximately 40 degrees
Fahrenheit. This will prevent freezing of the domestic water storage
system. Please contact your specific motorhome manufacturer for the
exact Bay Thermostat location.
Page 2-3
SECTION 2: OPERATING INSTRUCTIONS
Comfort
Control
Heat
Source,
continued
NOTE: Both the Diesel Burner and the 120 VAC Electric Heating Element
are thermostatically controlled. Either, or both, heating sources will
automatically maintain the temperature of the Hydro-Hot's water and
antifreeze solution between approximately 160-190 degrees Fahrenheit.
So simply choose how you want to heat your coach/hot water and just
leave the Switch(s) (Diesel, Electric, or both) ON.
Page 2-4
SECTION 2: OPERATING INSTRUCTIONS
Engine
Preheat 2.5 Using the Engine Preheat System
Engine Preheat (HHE-200 Model Only)
When the Hydro-Hot is at operating temperature, and the “Diesel” and/or
“Electric” Switch(s) is ON, follow these simple instructions:
A. Turn the Hydro-Hot's “Engine Preheat” Switch ON, Figure 3. This
procedure will activate the Engine Preheat Circulation Pump and the
NOTE: The Hydro-Hot’s “Domestic Water Priority System” disables the
interior Zone Heating Fans, Zone Circulation Pumps, and the Engine
Preheat Pump (if applicable) whenever domestic hot water is being
used on a continuous basis (i.e. during showers). The Hydro-Hot will
automatically enable these systems, within a few minutes, after the
demand for continuous domestic hot water ceases.
Hot Water 2.4 Using the Domestic Hot Water System
When the Hydro-Hot is at operating temperature, the domestic water is
automatically heated as it is being used. Because the Hydro-Hot does not
store any hot water simply open any hot water faucet and a continuous
supply of domestic hot water will be present within a few seconds. This hot
water feature is continuous and is accomplished by the Hydro-Hot’s Mixer
Valve and Intergal Domestic Hot Water System. Please note that the
“Diesel” Control Switch must be ON to get an unlimited supply of hot water
(i.e. during showers).

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Page 2-5
SECTION 2: OPERATING INSTRUCTIONS
Engine
Preheat,
continued
indicator light located on the Switch. Circulating the engine's coolant
through the Engine Preheat System will adequately warm the engine
for easy start-ups on cool mornings. Please contact your specific
motorhome manufacturer for exact “Engine Preheat” Switch loca-
tion.
NOTE: Allow approximately 1 to 2 hours of engine preheating run
time. Time will be shortest when the “Diesel” Switch is “ON.”
B. Turn OFF the Hydro-Hot's “Engine Preheat” whenever engine
preheating is not desired.
Page 2-6
2.6 Precautions
CAUTIONS:
• The Hydro-Hot's Exhaust is HOT!
• DO NOT park in areas where dry conditions exist underneath the
vehicle, as a fire may result (i.e. dry grassy fields) .
• DO NOT operate the Hydro-Hot’s Diesel-Fired Burner inside an
enclosedbuilding.
•Operating the Hydro-Hot Diesel Burner or the 120 VAC Electric
Heating Element without the water and antifreeze solution will cause
serious damage to the Heater.
•The Heater should be switched OFF when refueling.
SECTION 2: OPERATING INSTRUCTIONS
Important
Information
NOTE: Supplemental Heat (HHE-200 & HHE-500 Models Only)
The Hydro-Hot's Engine Preheating System acts as a supplemental
heating source, in addition to the Diesel Burner and the 120 VAC
Electric Heating Element. While traveling, the engine's heated coolant
will automatically pass through the Engine Preheat / Motoraide System,
transferring heat into the Hydro-Hot's Heat Tank. This design feature
reduces the total operating hours of the Diesel-Burner and the 120 VAC
Electric Heating Element.
Engine
Preheat,
continued
Figure 2
Diesel Electric
Hydro-Hot By Vehicle Systems
Engine
Preheat

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
4.1 Domestic Hot Water System
The Hydro-Hot's domestic hot water system must be completely drained of
domestic water any time the heater is stored where freezing temperatures
may be experienced.
NOTE: The Hydro-Hot can still be used for interior zone heating even if
the domestic hot water system has been drained and winterized.
CAUTION: Not winterizing your Hydro-Hot, when freezing temperatures
are present, will result in serious damage to the Hydro-Hot's domestic
hot water system.
Follow the instructions listed below when winterizing the Hydro-Hot’s
domestic water system:
A. Completely drain the fresh water storage tank.
NOTE: If your coach is equipped with appliances that use fresh water (i.e.
ice makers, water purifiers, etc.) follow the manufacturer's
recommendation for winterization.
B. Disconnect the domestic water demand pump's suction line from the
fresh water storage tank.
C. Attach an adequate piece of hose onto the suction side of the domestic
waterdemandpump.
D. Place the opposite end of the hose into an adequate supply of FDA
approved RV-Antifreeze; approximately 2 gallons will be required.
SECTION 4: WINTERIZATION
Storage
Page 4-1
Upkeep 3.1 Maintenance Schedule
Monthly
Check the Hydro-Hot's solution of water and antifreeze to ensure that it
is at the proper level. Do this by visually checking the coolant level in
the Hydro-Hot's Expansion Tank, Figure 1. This should be checked
only when the Hydro-Hot is at operating temperature, HOT.
Annually
CAUTION: Before cleaning or servicing, disconnect all power supplies.
It is ideal to have your Hydro-Hot tuned-up yearly. A tune-up should
consist of a Fuel Nozzle and Fuel Filter replacement and a thorough
cleaning of the Combustion Chamber, if necessary. This simple tune-up
will keep your Hydro-Hot running smoothly throughout the year. This
annual tune-up will also allow service personnel to inspect for wear and
tear of other components.
CAUTION: Operating the Hydro-Hot’s Diesel Burner or the 120 VAC
Electric Heating Element without the water and antifreeze solution will
cause serious damage to the Heater.
SECTION 3: MAINTENANCE
Page 3-1

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
SECTION 5: TROUBLE SHOOTING
A. Check the Hydro-Hot’s Electronic Controller for any RED lights
indicating a fault condition. See Figure 4 and Section 6 to
identify these fault conditions.
B. Check for loose wire connections or plugs on the Electronic
Controller’s plug-in terminals. Please note that the Electronic
Controller’s cover panel can be easily removed by unscrewing
the four cover screws.
C. Remove the Hydro-Hot’sAccess Cover and check for loose plug
connectors on the Diesel Burner's control unit (located on the
under side), see Figure 1.
D. If your Hydro-Hot still fails to operate, contact Vehicle System's
Technical Support Department at 1-800-685-4298 for addi-
tional trouble shooting information or visit our website at
www.hydro-hot.com.
If the Hydro-Hot’s Diesel Switch “Indicator Light” does not illuminate and the
Diesel Burner is not functioning locate the Electronic Controller, Figure 4, and
check the following:
Page 5-1
Page 4-2
E. Open/close all interior and exterior water faucets, one at a time, until only
pure RV-Antifreeze is present. Perform this procedure for both hot and cold
faucets.
F. Remove the hose and reconnect the domestic water demand pump's
suction line to the fresh water storage tank.
G. Disconnect all electrical power supplies to the Hydro-Hot during storage.
NOTE: 1. For de-winterization, fill the fresh water storage tank with fresh
water. Open/close all interior and exterior water faucets, one at a time, until
only clear water is present/visible.
2. The Hydro-Hot’s Electronic Controller must be reset anytime VDC
power is too low for the Hydro-Hot to properly operate or anytime this power
source has been switched off or disconnected. To reset the Electronic
Controller simply depress the “Low Voltage Reset” button located on the
Electronic Controller (use a small screwdriver or thin straight object to access
the reset button through the small hole on the Faceplate).
SECTION 4: WINTERIZATION
CAUTION: If you’re disinfecting your potable water system, after de-winteriz-
ing, be sure to follow RVIA’s “Instruction for Disinfection of Potable Water
Systems on Recreation Vehicles.” These instructions can be found in the
ANSI A119.2 Handbook for Recreational Vehicle Standards. To receive a
copy of this RVIAStandard, write to: Recreation Vehicle Industry Associa-
tion, 1896 Preston White Drive, P.O. Box 2999, Reston, VA 20195-0999, or
visit the RVIAwebsite at www.rvia.com.
Storage,
continued

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Heating Zones
Status
#5
#4
#3
#2
#1
Electric Heating
Element Status LowVoltage
Reset
Emergency
Cutoff
Hydro-Hot
Heating Status
Engine Preheat
Pump
Electronic
Controller
Low Battery
Voltage Fault
LowTemp
Cutoff Status
Overload Fault
Circulation
Pump #2
Circulation
Pump #1
Stir Pump
Diesel-Burner
Status
TM
By Vehicle Systems, Inc.
Motor Coach Heating Specialists
Page 5-2
SECTION 6: ELECTRONIC CONTROLLER DIAGNOSTICS
Emergency Cutoff:
This indicator light will illuminate RED when the 120 VAC Electric Heating
Element and Diesel Burner are off due to a low water and antifreeze solution
level inside the Hydro-Hot’s Heat Tank. This fault will automatically reset when
the low level condition is corrected.
Low Battery Voltage Fault:
This indicator light illuminates RED when VDC voltage is too low for the Hydro-
Hot properly operate. The fault must be manually reset once proper voltage is
restored to the VDC battery system, see Low Voltage Reset.
Low Voltage Reset:
The Hydro-Hot must be manually reset whenever the Low Battery Voltage
Fault Indicator has been activated. To reset the Electronic Controller simply
depress the “Low Voltage Reset” button located on the Electronic Controller
(use small screwdriver or thin straight object to access the reset button
through the small hole on the Faceplate).
Low Temperature Cutoff Status:
This indicator light illuminates GREEN whenever heat is available for interior
zone heating. Whenever this indicator light is OFF this indicates domestic hot
water is being used on a continuous basis (i.e. during showers).
NOTE: The Hydro-Hot will not supply both interior zone heating and a
continuous supply of domestic hot water simultaneously. This is what is
called the “Domestic Water Priority System”.
Page 6-1
Figure 3

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
SECTION 6: ELECTRONIC CONTROLLER DIAGNOSTICS
Overload Fault:
This indicator light will illuminate RED under the following conditions:
1. The Hydro-Hot is off due to an electrical overload condition (short) in the
main VDC power supply circuit.
2. The Hydro-Hot is off due to a combination of high electrical VDC power
loads and a high surface temperature of the Electronic Controller.
The Hydro-Hot will automatically restart once the electrical overload (short)
and/or high heat condition is corrected.
Heating Zones Status:
These five indicator lights (separately) illuminate GREEN whenever a Zone
Thermostat calls-for-heat. The GREEN light also indicates that DC power is
being supplied to the interior Zone Heating Fans. If any of the five indicator
lights are illuminating RED this indicates an electrical overload condition
(short) in that particular heating zone.
NOTE: A short in either the Zone Thermostat or a particular Zone
Heating Fan circuit can cause the indicator light to illuminate RED.
Page 6-2
SECTION 6: ELECTRONIC CONTROLLER DIAGNOSTICS
Circulation Pumps #1, #2, and the Stir Pump:
These indicator lights (separately) illuminate GREEN whenever a Zone
Circulation Pump is operating. If any of the lights are illuminating RED this
indicates an electrical overload condition (short) in that particular pump’s
electrical circuit.
NOTES: 1. The Circulation Pumps (separately) are activated
whenever a Zone Thermostat calls for heat.
2. The Stir Pump is activated whenever domestic hot
water is being used on a continuous basis (i.e. during showers).
Page 6-3

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Page 6-4
WARRANTYPOLICY
Vehicle Systems Inc. warrants the HYDRO-HOT Heater, to the original owner, to be free from
defects in material and workmanship under design usage and service conditions for a period of two
(2) years on parts and labor beginning on the date of purchase of the vehicle. Replacement parts
are covered for the remainder of the heating systems warranty or for six months (180 days) which
ever is greater.
This warranty does not apply to damage or failure of the HYDRO-HOT Heater or the vehicle
into which it was installed due to improper installation, assembly, maintenance, abuse,
neglect, accident, or the use of parts not supplied by Vehicle Systems Inc. Vehicle Systems
is not responsible for incidental or consequential damages.
The intent of this warranty is to protect the end user of the heating system from such defects, which
would occur in the manufacture of the product. The warranty is not intended to protect the end
user from problems, which are outside the ability of Vehicle Systems’ control.
To obtain warranty repair authorization or for additional information please contact our Technical
Support Department at 1-800-685-4298 (8 AM to 5 PM) Mountain Standard Time.
- FOR HYDRO-HOT MODELS -
SECTION 6: ELECTRONIC CONTROLLER DIAGNOSTICS
Engine Preheat Pump: (HHE-200 Model Only)
This indicator light illuminates GREEN whenever the Engine Preheat Pump is
activated. If the light is illuminating RED this indicates an electrical overload
condition (short) in the pump’s electrical circuit.
Hydro-Hot Heating Status:
This indicator light illuminates GREEN whenever the Hydro-Hot’s Heat Tank is
being heated by either the Diesel-Burner or the 120 VAC Electric Heating
Element. When the light is off, no heat is being supplied to the Hydro-Hot’s
Heat Tank.
NOTE: The Hydro-Hot will automatically activate either or both heating
sources (i.e. Diesel-Burner, 120 VAC Electric Heating Element, or both)
providing that both switches are in their ON position. So simply choose
how you want to heat your coach/hot water and just leave the switch(s)
(Diesel, Electric, or both) ON.
Electrical Heating Element Status:
This indicator light illuminates GREEN whenever VAC Power is being supplied
to the Hydro-Hot’s 120 VAC Electric Heating Element. If the light is
illuminating RED this indicates an electrical overload condition (short) in the
Electric Heating Element’s VDC powered electrical circuit.

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
OWNER’S SERVICE LOG:
(Continued)
Date Scheduled Service Service Center
Date Scheduled Service Service Center
OWNER’S SERVICE LOG:

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
OWNER’S SERVICE LOG:
OWNER’S SERVICE LOG:
(Continued)
Date Scheduled Service Service Center
(Continued)
Date Scheduled Service Service Center

Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Hydro-Hot™ Motor Coach Heating System Owner's Manual 06/02
Motor Coach Heating SpecialistsMotor Coach Heating Specialists
Motor Coach Heating SpecialistsMotor Coach Heating Specialists
Motor Coach Heating Specialists
··
··
·
Manufacturers and DistributorsManufacturers and Distributors
Manufacturers and DistributorsManufacturers and Distributors
Manufacturers and Distributors
15549 East Highway 52 ••
••
•Fort Lupton, Colorado 80621 ••
••
•1-800-685-4298 ••
••
•Fax: [phone]


Copyright 2002 Vehicle Systems, Inc.All rights reserved
www.hydro-hot.com
LTE-VHS-222