Aqua-Hot 600-D, Installation Manual

Page 1: ...2008 Aqua Hot Heating Systems Inc Installation Manual...

Page 2: ...quirements 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...

Page 3: ...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 Purgin...

Page 4: ...ures 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 s...

Page 5: ...lectric Heating Element specifications 2 120 Volt AC 2000 watts Zone Heat Circulation Pump specifications 3 12 Volt DC 21 watts each Number of Heating Zones maximum of 5 plus Engine Preheat Domestic W...

Page 6: ...600 D Hydronic Heating System Installation Manual Aqua Hot Hydronic Heating System Wiring Harness Domestic Water Access Panel Drain Valve Diesel Burner Interlock Switch Diesel Burner Controller 30693...

Page 7: ...ness 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...

Page 8: ...5 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 CU...

Page 9: ...a 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...

Page 10: ...Page 7 2008 Aqua Hot 600 D Hydronic Heating System Installation Manual 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...

Page 11: ...stem Installation Manual Page 8 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 Ta...

Page 12: ...1 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 preventing the expan sion of the heating solution from...

Page 13: ...rance information NOTE An accessory device is available for the Cozy Heat Ex changer for the purpose of redirecting the airflow from the heat exchanger Reference Figure 16 Mounting Requirements Suffic...

Page 14: ...tem 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 perman...

Page 15: ...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...

Page 16: ...tronic 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 exc...

Page 17: ...ating 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...

Page 18: ...sest 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...

Page 19: ...stant 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 C...

Page 20: ...ing 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 H...

Page 21: ...location for the thermostat based upon the previous location information 2 Once the thermostat has been completely wired permanently mount the thermostat in place Reference Figure 26 6 0 10 20 30 0 0...

Page 22: ...l interior room thermo stats Room Thermostat Wiring 1 Run two 18 gauge wires from each room thermostat mounting location to the Aqua Hot s electronic con troller Reference Appendix A NOTE It is recomm...

Page 23: ...water using fixture when computing pipe sizes NOTE As stated directly from the ANSI A119 2 NFPA 501C Standard on Recreation Vehicles 1993 Edition Piping Systems shall be sized to provide an adequate...

Page 24: ...te directional flow of domestic water To Hot Water Faucets Domestic Hot Water OUTLET Fresh Water Storage Tank Domestic Cold Water INLET To Cold Water Faucets Demand Pump AT Indicates options for mount...

Page 25: ...70 as well as the regulation of authorities having jurisdiction and CSA Standard B139 Figure 30 Switch Panel Mounting 1 Cut out an opening for the switch panel plate The Aqua Hot 600 D requires a 5 i...

Page 26: ...oller Pin 1 Pin 3 Pin 5 to Diesel O to Diesel I to IND LT B6 Pin 4 to IND LT B3 Jumper Wire Jumper Wire Jumper Wire to 1 Way Plug Switch Panel Wiring 1 Run 16 gauge wires from the switch panel to the...

Page 27: ...cations Also be sure to reference the ANSI NFPA 1192 hand book for information regarding fuel distribution system specifications Fuel head pressure should not exceed 10 feet Refer ence Figure 33 Use a...

Page 28: ...ary and apply protective shielding in areas where chafing may occur 50 ft maximum distance 50 ft maximum distance Maximum Allowable Suction Height 7 feet Figure 34 3 Label both fuel lines indicating w...

Page 29: ...Figure 34 Output to the Aqua Hot s Fuel Inlet Port Reference Figure 36 TOP VIEW of Fuel Filter Head Fuel Filter Input from Fuel Tank Fuel Pick Up Pipe reference Figure 27 Output to the Aqua Hot s Fue...

Page 30: ...s Secure both plumbing lines where necessary and apply protective shielding in areas where chafing may occur NOTE Rubber coated closed type clamps are recommended when securing the plumbing lines Use...

Page 31: ...POTENTIAL OUTLET PORT pressure outlet port Ideal Return Port T ToTTop side of the engine Hose Clamp Automotive Type Heater Hose Automotive Type Heater Hose Hose Clamp M NPT by Hose Barb To the Aqua Ho...

Page 32: ...e exhaust pipe cannot be longer than 20 feet The two black pipe exhaust fittings MUST be utilized with all installations Failure to conform could create a hazardous situation and will void the Aqua Ho...

Page 33: ...type exhaust piping and avoid bends if possible Reference Figure 39 A maximum of two 90 exhaust pipe bends are al lowed Reference Figure 39 Do not use galvanized pipe or fittings only black iron pipe...

Page 34: ...ple Mounting Tray Flange Exhaust Pipe Elbow Depth of Motorhome Bay Floor Figure 41 Installing the Exhaust System 1 Run the exhaust pipe to the driver s side of the vehicle and ensure that the exhaust...

Page 35: ...Therefore be sure to use care when wiring these particular components to the electronic controller Each heating zone FAN circuit can supply up to 2 0 Amps of direct current This 12 Volt DC power sourc...

Page 36: ...Connection 1 Attach the wiring harness connectors to the electronic controller Reference Figure 43 and Appendix A 2 Tighten the screw type fasteners on the terminal strips to secure them to the elect...

Page 37: ...Hot s electronic controller Reference Appendix A and Figure 45 3 Label the wires indicating whether they are a power or a ground wire 4 Attach the DC power wires onto the appropriate ter minal battery...

Page 38: ...drain valve located at the front of the heater Reference Figure 46 2 Connect a piece of inch PEX tubing this piece should be long enough to be used to transport the antifreeze and water heating soluti...

Page 39: ...urce NOTE The circulation pump will activate as soon as the pump is connected to a ground source therefore disconnect the alligator clip from the ground source during the antifreeze and water heating...

Page 40: ...vent the Aqua Hot from operating whenever the main access cover is not properly installed 2 Move the diesel burner switch to the ON position for approximately ten seconds ONLY then switch it OFF NOTE...

Page 41: ...2008 Aqua Hot 600 D Hydronic Heating System Installation Manual Appendix A Wiring Diagram Appendix A...

Page 42: ...2008 Aqua Hot 600 D Hydronic Heating System Installation Manual Page A 1 Appendix A Wiring Diagram...

Page 43: ...Appendix B Appendix B Wire Gauge Information...

Page 44: ...0 3 0 4 0 4 0 4 0 4 0 50 6 6 4 4 2 2 1 0 2 0 2 0 3 0 3 0 4 0 4 0 4 0 60 6 4 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 4 0 70 6 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 80 6 4 2 2 1 0 3 0 3 0 4 0 4 0 90 4 2 2 1 0 2 0 3 0 4 0...

Page 45: ...Appendix C Appendix C Electronic Controller Features...

Page 46: ...y connection will ensure completion of the required 3 minute purge cycle of the Aqua Hot s diesel burner NOTE This illustration details the proper wiring requirements for the usage of the battery disc...

Page 47: ...ic controller use a thin straight nonmetallic object to access the button through the faceplate or by turning OFF the diesel burner switch on the interior switch panel for approximately 30 seconds the...

Page 48: ...Appendix D Appendix D Antifreeze Types...

Page 49: ...specifically for winterizing appli cations only Although RV Marine antifreeze is often Generally Recognized as Safe by the FDA it should never be used in the Aqua Hot s Hydronic Heating System This t...

Page 50: ...Appendix E Appendix E Antifreeze Mixture Water Quality Recommendations...

Page 51: ...ifreeze with water suppliers of pre mixed antifreeze are responsible for the use of high quality distilled de ionized or soft water when preparing their antifreeze for sale Hard water possesses a high...

Page 52: ...Appendix F Appendix F Antifreeze Terms and Mixture Ratio...

Page 53: ...ling point is reached a loss of efficiency occurs because the heat produced is expelled rather than utilized for the function of the heating system Therefore a higher boiling point is desired in order...

Page 54: ...stallation Manual Page F 2 Appendix F Antifreeze Terms and Mixture Ratio 10 0 20 40 60 20 30 10 20 30 40 50 60 Freezing Point Temperature In Degrees Fahrenheit l o c y l G e n e l y p o r P f o e g a...

Page 55: ...15549 East Highway 52 Fort Lupton Colorado 80621 1 800 685 4298 Fax 303 857 9000 www aqua hot com...