Aqua-Hot 450-DE Series, Installation Manual

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

Page 2: ...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 Locatio...

Page 3: ...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 Hyd...

Page 4: ...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...

Page 5: ...gal hr Heater Voltage Maximum Power Consumption 12 Volt DC 60 watts Electric Heating Element specifications 120 Volt AC 1650 watts Zone Heat Circulation Pump specifications 2 12 Volt DC 21 watts each...

Page 6: ...ing 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...

Page 7: ...ater 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 Har...

Page 8: ...8 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 Fl...

Page 9: ...rom 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...

Page 10: ...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 Fi...

Page 11: ...g 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 45...

Page 12: ...e 12 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 fr...

Page 13: ...formation 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 17 Mounting Requirements Sufficient ven...

Page 14: ...ut 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...

Page 15: ...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 th...

Page 16: ...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 R...

Page 17: ...er 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...

Page 18: ...eat 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...

Page 19: ...onstant 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...

Page 20: ...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 P...

Page 21: ...e a 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 27 6 0 10 20 30...

Page 22: ...o 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 recommended that the wire n...

Page 23: ...a 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 adequat...

Page 24: ...ndicate 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...

Page 25: ...e 31 4 45 5 00 275 2 33 275 150 4x 2 88 1 205 80 702 1 362 2 724 871 3x 3 595 5 4 3 1 5 4 3 1 5 4 3 1 Mounting Holes total of four Switch panel mounting requirements for Aqua Hot 450 DM All measuremen...

Page 26: ...ctronic Controller Pin 1 Pin 3 Pin 5 to Diesel I to Diesel O to IND LT B6 Pin 4 to IND LT B3 Jumper Wire Jumper Wire NOTE The Engine Preheat and Electric Element switches possess Jumper Wires which ad...

Page 27: ...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 35 Use a minimum...

Page 28: ...ply protective shielding in areas where chafing may occur 450 DE DM 50 ft maximum distance 50 ft maximum distance Maximum Allowable Suction Height 7 feet Figure 36 3 Label both fuel lines indicating w...

Page 29: ...VIEW of Fuel Filter Head Section 6 Fuel System Figure 38 Figure 37 Fuel Inlet Port Fuel Outlet Port Fuel Filter Input from Fuel Tank Fuel Pick Up Pipe reference Figure 27 Output to the Aqua Hot s Fue...

Page 30: ...the potential for air traps Run both plumbing lines in areas where they cannot be pinched off or damaged during normal operating conditions Secure both plumbing lines where necessary and apply protec...

Page 31: ...AL 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 Hot s Eng...

Page 32: ...haust 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 Hot s...

Page 33: ...ve type exhaust piping and avoid bends if possible Reference Figure 41 A maximum of two 90 exhaust pipe bends are al lowed Reference Figure 41 Do not use galvanized pipe or fittings only black iron pi...

Page 34: ...ting Tray Flange Exhaust Pipe Elbow Depth of Motorhome Bay Floor 450 DE DM 450 DE DM Figure 43 Installing the Exhaust System 1 Run the exhaust pipe to the driver s side of the vehicle and ensure that...

Page 35: ...erefore 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 source...

Page 36: ...as much as 22 Amps of DC current Because the Aqua Hot is designed to shut down in the event that the DC voltage level drops too low to properly operate it is imperative that the proper wire gauge be d...

Page 37: ...whether they are a power or a ground wire 3 Attach the VDC power wires onto the appropriate ter minal battery connections on the electronic controller Reference Appendix A 4 Connect both power and gro...

Page 38: ...nd not through the top of the unit in order to avoid air traps Reference Figure 48 1 Open the Aqua Hot s drain valve located at the front of the heater Reference Figure 48 2 Connect a piece of inch PE...

Page 39: ...from the ground source during the antifreeze and water heating solution filling procedure 5 Allow the circulation pump to operate for approxi mately 1 3 minutes in order to purge the corresponding hea...

Page 40: ...he 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 This p...

Page 41: ...2008 Aqua Hot 450 DE DM Hydronic Heating System Installation Manual Appendix A Wiring Diagram Appendix A...

Page 42: ...2008 Aqua Hot 450 DE DM Hydronic Heating System Installation Manual Page A 1 Appendix A Wiring Diagram...

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

Page 44: ...3 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...

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

Page 46: ...ery 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 di...

Page 47: ...he electronic 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...

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

Page 49: ...ed 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...

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

Page 51: ...ntifreeze 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 hi...

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

Page 53: ...oiling 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 ord...

Page 54: ...Installation 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...

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