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Aqua-Hot 600-D Installation Manual

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InstallatIon Manual

© 2008 Aqua-Hot Heating Systems Inc.

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Summary of Contents for Aqua-Hot 600-D

  • Page 1: Installation Manual

    InstallatIon Manual © 2008 Aqua-Hot Heating Systems Inc.

  • Page 2: Table Of Contents

    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 .............................
  • Page 3 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 ® 600-D Hydronic Heating System Installation Manual...

  • Page 4: General Information

    This installation manual is designed to aid in the instal- throughout this manual as a means of alerting the lation process of the Aqua-Hot 600-D Hydronic Heat- installer to important information. ing System by a trained and experienced installer. The...

  • Page 5: Aqua-Hot Hydronic Heating System

    Wet Weight ........... . approximately 303 lbs. — Page 2 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 6 Hydronic Heating system Figure 2 Figure 3 Wiring Harness Interlock Switch Domestic Water Access Panel Diesel-Burner Diesel-Burner Controller Drain Valve — Page 3 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 7 Valve Heating Zone Outlet Port 3 Engine Preheat Ports Heating Zone Outlet Port 2 Heating Zone Outlet Port 1 Diesel Fuel Inlet /Outlet Ports Figure 4 — Page 4 — ® © 2008 Aqua-Hot 600-D Hydronic Heating System Installation Manual...
  • Page 8 (Cut-Out) 17.48” Outline of (Center Mounting Tray of Holes) Motorhome Floor 3.83” Front of Aqua-Hot (Typical) 14.05” 2.37” (Cut-Out) (Typical) NOTE: All measurements are in inches. — Page 5 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 9: Section 1: Aqua-Hot Installation

    Reference the following illustrations for mounting Reference Figure 6. information: • Overall Aqua-Hot dimensions - Figure 8 Place the Aqua-Hot into the mounting tray. Reference • Mounting tray information - Figure 6 Figure 10. • I.D. Label noting the “Open Access”...

  • Page 10: Front View

    1: aqua-Hot Installation 1.30” Side View 2.0” Front View Figure 9 NOTE: All measurements are in inches. Bottom View Top View — Page 7 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 11 Aqua-Hot 600-D Tabs Rear of Mounting Tray Mounting Tray Slots Flange Figure 10 Aqua-Hot 600-D Access Cover Access Cover Combustion-Air Sleeve Mounting Tray Mounting Tray Flange — Page 8 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 12: Installing The Expansion Tank

    1: aqua-Hot Installation Installing the Expansion Tank: 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- Select a mounting location that allows for easy access sion of the heating solution from properly depositing and clear visibility whenever the particular storage bay into the expansion tank.

  • Page 13: Section 2: Hydronic Heating System

    Figure 12 Figure 13 Interior Zone Heating/Heat Exchanger Layout Cozy Return-Air Return-Air Return-Air Figure 14 Indicates generally recommended Cozy mounting locations for the Cozy Heat Exchangers — Page 10 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 14: Mounting The Heat Exchangers

    Heat Exchanger Aqua-Hot Heating System Heating Loop 2 Bathroom and Fresh Water Tank Bay Heating Loop 1 Bedroom Heating Loop 3 Kitchen and Living Room Figure 17 — Page 11 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 15 Tolerances on the dimensions 13.06 in. shown are as follows: .XX (i.e., 6.44 in.) = ± .030 .XXX (i.e., 6.500 in.) = ± .015 14.44 in. — Page 12 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 16: Wiring The Heat Exchangers

    +/- .030 To Aqua-Hot’s Terminal Block - (Ground) Black Wires To a chassis ground source 3.63 in. 14.44 in. 13.06 in. Figure 21 6.44 in. Mounting Tab — Page 13 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 17: Plumbing Requirements

    Loop 3.” Reference Figure 22. Heating Loop #1: Zone 1 Heating Loop #2: Zone 2,3,4 Heating Loop #3: Zone 5 Inlet Plumbing Lines Outlet Plumbing Lines Figure 22 — Page 14 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 18: Plumbing The Hydronic Heating System

    Rubber Coated/Closed-Type clamps are recommended when securing the plumbing lines. changer, it will significantly reduce the heat exchanger’s overall heating performance (heat output). Connect and tighten all interior plumbing lines, outlet and inlet, to the Aqua-Hot’s appropriate heating loop ports. Reference Figure 25. Cozy Heat Exchanger (Rear View) Outlet Port...
  • Page 19 Constant Tension Clamps Insert Inlet 3/4 in. Rubber 5/8 inch I.D. Coupler 3/4 inch O.D. PEX Plumbing Line Automotive Type Rubber Heater-Hose Coupler (3/4 inch I.D.) — Page 16 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 20 Inlet Plumbing Port Inlet Plumbing Port Inlet Plumbing Port Heating Loop 1 Heating Loop 2 Heating Loop 3 Outlet Plumbing Port Outlet Plumbing Port Outlet Plumbing Port — Page 17 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 21: Section 3: Thermostats

    NOTE: It is recommended that the wire numbers in Appendix plumbing system from freezing. A be used when installing the Aqua-Hot in order to Typically, only the bulb of the thermostat needs to be assist with differentiating between the separate heating...

  • Page 22: Room Thermostat Location

    Reference Appendix A. • drafts or dead spots behind doors and in corners NOTE: It is recommended that the wire numbers in Appendix • hot or cold air from ducts A be used when installing the Aqua-Hot in order to • radiant heat from the sun or appliances assist with differentiating between the separate heating • heat from concealed pipes and chimneys zones and to aid service personnel with troubleshoot- • unheated or uncooled areas such as an outside...

  • Page 23: Section 4: Domestic Water System

    Manufacturers of pressure-relief valves indicate that excessive weeping of these valves will cause the “seat” NOTE: The Aqua-Hot is equipped with a pressure-relief valve, in the valve to deteriorate, and, in turn, the valve will which releases excessive pressure in the domestic water fail prematurely.
  • Page 24 Pump To Cold Water Faucets AT - Indicates options for mounting an Domestic Accumulator Tank Cold Water INLET Domestic Hot Water OUTLET To Hot Water Faucets — Page 21 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 25: Section 5: Switch Panel

    Select a location in the interior of the coach that allows Cut out an opening for the switch panel plate. The for easy operator access. Aqua-Hot 600-D requires a 5 inch W x 1.25 inch H opening. Reference Figure 30. All electric installations, systems, and equipment...

  • Page 26: Switch Panel Wiring

    Pin # 3 to “Preheat-I” to Chassis Ground Pin # 5 “Electric” Switch to Electronic Controller connections Figure 31 “Engine Preheat” Switch to Electronic Controller connections — Page 23 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 27: Section 6: Fuel System

    50 ft. maximum distance Maximum Allowable Head Pressure 10 ft. Figure 33 — Page 24 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 28: Fuel System Installation

    Reference Figure 34. Both fuel lines should be laid as flat as possible and any Install and tighten the appropriate fuel fittings onto the extreme rises in height should be avoided in order to Aqua-Hot’s fuel ports, as well as the two ports of the eliminate any potential air-traps. fuel filter. Reference Figures 35 and 36. Run both fuel lines in areas where they cannot be...
  • Page 29 Output to the Input from Aqua-Hot’s Fuel NOTE: Reference Figure 27 for details on the Fuel Tank connections Fuel Tank/Fuel Reference Figure 29 for details on the Aqua-Hot’s Fuel Port connecti Inlet Port. Pick-Up Pipe. TOP VIEW: Reference of Fuel Filter Head Reference Figure 36.

  • Page 30: Section 7: Engine Preheat System

    The engine’s outlet port is where the engine’s coolant 5. Install and clamp both the inlet and outlet engine is transported to the Aqua-Hot. This port should be a low connection point on the engine block or a pres- plumbing lines/automotive-type heater hoses to the sure outlet port on the engine’s water pump.
  • Page 31 Hose Clamp Automotive Type Heater-Hose (M) NPT by ° Hose Barb Hose Clamp Automotive-Type Heater Hose Figure 37 Engine Preheat Outlet Engine Preheat Inlet Figure 38 — Page 28 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 32: Section 8: Exhaust System

    8: Exhaust system All Aqua-Hot exhaust system installations MUST utilize the two The Aqua-Hot’s exhaust is HOT and must be kept away black pipe nipples and the black pipe elbow, which are provided from any heat-sensitive material. with the heating system, in the configuration best suited for the particular recreational vehicle application. Failure to conform DO NOT direct exhaust downward as a fire may result could create a hazardous situation and will void the Aqua-Hot’s...

  • Page 33: Exhaust System Requirements

    8: Exhaust system Exhaust System Requirements: The Aqua-Hot is supplied with a 3 inch and a 4 inch black pipe nipple (1½ inch diameter) along with a 1½ inch exhaust elbow. Reference Figure 39. These three The exhaust must be able to freely exit away from the exhaust system components MUST BE utilized with vehicle without any obstructions.

  • Page 34: Installing The Exhaust System

    Mounting Tray Flange Exhaust Pipe 3-inch Nipple 4-inch Nipple Elbow Figure 41 Depth of Motorhome Bay Floor Mounting Tray Flange Exhaust Pipe 4-inch Nipple 3-inch Nipple Elbow — Page 31 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 35: Section 9: Electronic Controller Wiring

    Therefore, be sure to use care when wiring these The Aqua-Hot’s electronic controller is designed to particular components to the electronic controller. work with most electronic room thermostats; however, the chosen thermostat must produce a constant 12 Each heating zone “FAN”...

  • Page 36: Wiring Harness Connection

    Because the Aqua-Hot is designed to shut down in the event that the DC voltage level drops too low to DO NOT connect the 12 Volt-DC power to the Aqua-Hot if properly operate, it is imperative that the proper wire the vehicle requires welding.

  • Page 37: Connecting The 120 Volt-Ac Power

    Operating the NOTE: Each heating zone “FAN” circuit can supply up to Aqua-Hot without the antifreeze and water heating solution will 2.0 Amps of direct current. Each Aqua-Hot Cozy cause serious damage to the Aqua-Hot’s boiler tank.

  • Page 38: Section 10: Purging The Systems

    Failure to do so could result in an antifreeze spill in the Department at 1-800-685-4298. motorhome’s bay. Reference Figure 11. Open the Aqua-Hot’s drain valve located at the front of the heater. Reference Figure 46. Connect a piece of ½ inch PEX tubing (this piece...

  • Page 39: Purging The System By Grounding Zone Pumps

    10: Purging the system Fill the Aqua-Hot completely with the 50/50 mixture 4. Connect an alligator clip to the spade terminal on the of antifreeze and water heating solution. This will take circulation pump’s blue (negative) wire and clip the op- approximately 16 gallons of antifreeze and water heat- posite end of the cable to a ground source.

  • Page 40: Purging The Domestic Water System

    10: Purging the system 9. Check the Aqua-Hot’s expansion tank and top it off to NOTE: This procedure will purge the diesel-burner’s fuel sys- the cold level mark with the 50/50 antifreeze and water tem by allowing the heater’s fuel pump to complete its mixture, if necessary.

  • Page 41: Appendix A: Wiring Diagram

    Wiring Diagram © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 42 Wiring Diagram — Page A-1 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 43: Appendix B: Wire Gauge Information

    appendix B appendix B: Wire Gauge Information...
  • Page 44 12 Volts - 3% Drop Wire Sizes (gage) - Based on Minimum CM Area 24 Volts - 3% Drop Wire Sizes (gage) - Based on mInimum CM Area — Page B-1 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...

  • Page 45: Appendix C: Electronic Controller Features

    appendix C: appendix C: Electronic Controller Features...
  • Page 46 C: Electronic Controller Features Secondary 12 Volt-DC Battery Connection: Aqua-Hot will be protected in the event that the primary power is interrupted while the Diesel-Burner is operating (e.g., during a burn-cycle). This secondary 12 Volt-DC battery connection will The electronic controller is equipped with two 12 Volt-DC ensure completion of the required 3-minute “purge cycle”...

  • Page 47: Reset Button

    “Low Voltage Reset” Feature: straight, nonmetallic object to access the button through the Whenever the Aqua-Hot’s DC power is interrupted, the “low faceplate) or by turning OFF the diesel-burner switch on the voltage reset” red indicator light on the electronic controller will interior switch panel for approximately 30 seconds, then turning illuminate.

  • Page 48: Appendix D: Antifreeze Types

    appendix D appendix D: antifreeze types...
  • Page 49 “boiler” type antifreeze transfer heat, which is essential to the heating system’s in the Aqua-Hot. Propylene glycol is a safer alternative functionality and does not contain rust inhibitors. to the more toxic ethylene glycol antifreeze; however, Please note, however, that RV &...

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

    appendix E appendix E: antifreeze Mixture Water Quality Recommendations...
  • Page 51 In order to ensure maximum performance and longev- Hard water possesses a high-level of calcium and ity of an Aqua-Hot heating system’s boiler tank and magnesium ions, which deplete the propylene glycol an- associated components, it has been determined that tifreeze’s corrosion inhibitors.

  • Page 52: Appendix F: Antifreeze Terms And Mixture Ratio

    appendix F appendix F: antifreeze terms and Mixture Ratio...
  • Page 53 Aqua-Hot from providing adequate domes- Boiling Point: tic hot water and interior heating. The Aqua-Hot utilizes the antifreeze and water heat- Additionally, if the antifreeze and water heating solu- ing solution as a transportation means for the heat tion contains over 70 percent antifreeze, the freezing produced from the internal processes.
  • Page 54 F: antifreeze terms and Mixture Ratio Freezing Point Temperature (In Degrees Fahrenheit) — Page F-2 — © 2008 Aqua-Hot ® 600-D Hydronic Heating System Installation Manual...
  • Page 55 15549 East Highway 52 • Fort Lupton, Colorado 80621 1.800.685.4298 • Fax: 303.857.9000 • www.aqua-hot.com...

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