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Aqua-Hot 375-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 375-D

  • Page 1: Installation Manual

    InstallatIon Manual © 2008 Aqua-Hot Heating Systems Inc.

  • Page 2: Table Of Contents

    Section 1: Aqua-Hot Hydronic Heating System Technical Information ...........................2 Section 2: Aqua-Hot Installation Installing the Mounting Tray and the Aqua-Hot ................5 Overall Aqua-Hot Dimensions ......................6 Installing the Cable-Clamp Fittings ..................... 8 Installing the Wires into the Terminal Blocks ................... 8 Installing the Expansion Tank ......................9...
  • Page 3 Appendix B: Wire Gauge Information ....................B-1 Appendix C: Antifreeze Types ......................C-1 Appendix D: Antifreeze Mixture Water Quality Recommendations ..........D-1 Appendix E: Antifreeze Terms and Mixture Ratio ................. E-1 © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 4: Introduction

    Product Application Department at 1-800-685- the installer. 4298, Monday through Friday, between the hours of 8:00 AM and 5:00 PM Mountain Standard Time. — Page 1 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 5: Section 1: Aqua-Hot Hydronic Heating System

    RVIA Standards, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive, P.O. Box 2999, Reston, VA 22090-0999, call them at (703) 620-6003, or visit them online at www.rvia.org. — Page 2 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 6 Zone 1 and 2 Diesel Fuel outlet Ports Inlet/outlet Ports Hot Water outlet Port Cold Water Inlet Port air-Release Valve Expansion tank Connection terminal Block access area — Page 3 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 7 18.07 necessary) (Cut-Out) Front of Aqua-Hot Outline of Mounting Tray 14.17 1.95 (Cut-Out) 1.23 (Typical) (Typical) Motorhome Floor notE: all measurements are in inches. — Page 4 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 8: Section 2: Aqua-Hot Installation

    2: aqua-Hot Installation Installing the Mounting Tray and the Aqua-Hot: the cut-out for the mounting tray. The Aqua-Hot must be installed in a compartment that is • Verify that an adequate support system has been completely closed-off from living quarters and accessible provided for the Aqua-Hot.

  • Page 9: Top View

    Side View 27.25 (Overall) 18.07 17.81 (Cut-Out) 17.50 14.17 1.95 (Cut-Out) 1.23 (Typical) Bottom View 2.05 Front View NOTE: All measurements are in inches. — Page 6 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 10 Front of Mounting Tray Mounting Tray Flange 1.5 inch Black Pipe Exhaust Figure 8 Fittings Mounting Tray Tabs Mounting Tray Back of Mounting Flange Tray Slots — Page 7 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 11: Installing The Cable-Clamp Fittings

    NOTE: It is recommended that the wire numbers in Appendix plication. Reference Figure 9. A be used when installing the Aqua-Hot in order to assist with differentiating between the separate heating 2. Remove the terminal block access cover and set aside...

  • Page 12: Installing The Expansion Tank

    NOTE: Avoid any dips and bends in the overflow tubing from and clear visibility whenever the particular storage bay the Aqua-Hot to the expansion tank as air can become door is open. trapped in these dips and bends, preventing the expan-...

  • Page 13: Section 3: Hydronic Heating System

    Clearance Required Figure 14 Interior Zone Heating/Heat Exchanger Layout Cozy Return-Air Return-Air Return-Air Indicates generally recommended Cozy mounting locations for the Cozy Heat Exchangers — Page 10 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 14: Mounting The Heat Exchangers

    Heating System Heating Loop 2 Bathroom, Bedroom, Heating Loop 1 and Fresh Water Tank Bay Kitchen and Living Room Heating Zones Heating Zone Figure 17 — Page 11 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 15 Figure 19 13.69 in. 10.50 in. 2.81 in. 6.50 in. 0.38 in. 3.50 in. 6.44 in. 5.50 in. 1.06 in. 13.06 in. 14.44 in. — Page 12 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 16: Wiring The Heat Exchangers

    Terminal for Heating Zone 1’s positive heat Attach each zone wire ran in step 2 to the Aqua-Hot exchanger wire (F1). terminal block - position F1 for zone 1 and position F2 for zone 2. Reference Figure 20. Tighten the screw in the terminal to secure the wire in place.

  • Page 17: Plumbing Requirements

    Loop 1.” Reference Figure 22. Heating Loop #1 Heating Zone #1 Heating Loop #2 Heating Zone #3 Heating Zone #2 Outgoing Plumbing Lines Incoming Plumbing Lines Figure 22 — Page 14 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 18: Plumbing The Hydronic Heating System

    (low to high). Cozy Heat Exchanger (Rear View) Outlet Port Figure 23 Mounting (Highest Port) Bracket Mounting Bracket Inlet Port (Lowest Port) — Page 15 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 19 Loop Ports Loop Ports Loop Ports Loop Ports (with installed (with installed barb (with installed (with installed barb compression fittings) fittings) compression fittings) fittings) — Page 16 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 20: Section 4: Thermostats

    Refer- ence Figure 26. Splice the wire from position T3 on the Aqua-Hot’s ter- minal block to the fresh water tank thermostat’s black Do not mount the thermostat bulb in a drafty area.

  • Page 21: Room Thermostats

    Be sure to then turn OFF both interior room thermo- stats. Figure 28 Zone 1 thermostat Positive Connection Zone 2 thermostat Positive Connection — Page 18 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 22: Section 5: Domestic Water System

    “weeping” of the valve. Manufacturers of pressure-relief valves indicate that NOTE: The Aqua-Hot is equipped with a pressure-relief valve, excessive weeping of these valves will cause the “seat” which releases excessive pressure in the domestic water...
  • Page 23 OUTLET Domestic AT - Indicates options Cold Water for mounting an INLET Accumulator Tank. Fresh To Cold Water Faucets Water Storage Demand Tank Pump — Page 20 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 24: Section 6: Switch Panel

    NOTE: It is recommended that the wire numbers in Appendix porates a blinking fault indicator light (Diesel-Burner switch only), which indicates a diesel-burner malfunc- A be used when installing the Aqua-Hot in order to tion. assist with differentiating between the separate heating zones and to aid service personnel with troubleshoot- ing.
  • Page 25 Terminal Block D1 Pin 4 Jump to Pin 1 Pin 4 Terminal Block L+ Pin 6 Chassis Ground Pin 6 Terminal Block L- Figure 33 — Page 22 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 26: Section 7: Fuel System

    Also, be sure to reference the ANSI/NFPA 1192 hand- Install and tighten the appropriate fuel fittings onto the book for information regarding fuel distribution system Aqua-Hot’s fuel ports, as well as the two ports of the specifications. fuel filter. Reference Figures 37 and 38.
  • Page 27 50 ft. maximum distance Maximum Allowable Suction Height 7 feet Figure 35 50 ft. maximum distance Maximum Allowable Head Pressure 10 ft. Figure 36 — Page 24 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 28 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 connectio Inlet Port. Pick-Up Pipe. TOP VIEW: of Fuel Filter Head...

  • Page 29: Section 8: Exhaust System

    8: Exhaust system The Aqua-Hot’s exhaust is hot and must be kept away from any heat-sensitive material. • Use standard 2.0 inch automotive-type exhaust piping and avoid bends, if possible. Reference Figure 39. DO NOT direct exhaust downward as a fire may result when parked in dry, grassy areas.
  • Page 30 Exhaust Elbow 1.5 inch and Nipples Exhaust Assembly Port — Page 27 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 31 Mounting Tray Flange Exhaust Pipe 3-inch Nipple 4-inch Nipple Elbow Depth of Motorhome Bay Floor Mounting Tray Flange Exhaust Pipe 4-inch Nipple 3-inch Nipple Elbow — Page 28 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 32: Section 9: Power Source Wiring

    Connecting the 12 Volt-DC Power: DC wire. Connecting the 120 Volt-AC Power: DO NOT connect the 12 Volt-DC power to the Aqua-Hot if the vehicle requires welding. Electrical welding will cause serious Follow the instructions in this section for “Installing damage to the diesel-burner controller.
  • Page 33 Cable-Clamp Fittings (optional placement) Figure 43 Positive/Power In-line Fuse NOTE: Reference Appendix A for specific wiring Aqua-Hot’s 12 details. Volt-DC Terminal Block Negative/Ground — Page 30 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 34: Section 10: Purging The Systems

    Reference Appendices C through E for additional information regarding the antifreeze and water heat- Ensure that the overflow tube is connected from the Aqua-Hot’s ing solution. Be sure to use a “GRAS” boiler-type expansion tank connection to the expansion tank’s bottom con- propylene glycol based antifreeze rather than an RV and nection and from the expansion tank’s top connection through...

  • Page 35: Purging The System By Grounding The Zone Circulation Pumps

    Aqua-Hot. 9. Check the Aqua-Hot’s expansion tank and top it off to When refilling, open the air-release valve located on the cold level mark with the 50/50 antifreeze and water the expansion tank connection to release air pockets.
  • Page 36 Blue disconnected from the Wire’s Spade Terminal opposing wire Opposite end of the Alligator Cable to be connected to a ground source — Page 33 — © 2008 Aqua-Hot ® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 37: Section 11: Initial Start-Up

    11: Initial start-up Activating the Aqua-Hot: Reinstall the Aqua-Hot’s main access cover and the fas- tener, which secures the front of the Aqua-Hot’s access cover to the mounting tray. NOTE: The main access cover must be installed prior to opera- tion;...

  • Page 38: Appendix A: Wiring Diagram

    appendix a Wiring Diagram...
  • Page 39 Wiring Diagram © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 40: Appendix B: Wire Gauge Information

    appendix B Wire Gauge Information...
  • Page 41 IN AMPS. 12 Volts - 3% Drop Wire Sizes (gage) - Based on Minimum CM Area 24 Volts - 3% Drop Wire Sizes (gage) - Based on mInimum CM Area © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 42: Appendix C: Antifreeze Types

    appendix C antifreeze types...
  • Page 43 Although RV & Marine antifreeze is often Hot’s Hydronic Heating System. “Generally Recognized as Safe” by the FDA, it should never be used in the Aqua-Hot’s Hydronic Heating © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 44: Appendix D: Antifreeze Mixture Water Quality Recommendations

    appendix D antifreeze Mixture Water Quality Recommendations...
  • Page 45 © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A...

  • Page 46: Appendix E: Antifreeze Terms And Mixture Ratio

    appendix E antifreeze terms and Mixture Ratio...
  • Page 47 Therefore, a higher boiling point is desired in order to combat the loss of efficiency, which allows the antifreeze to transport the heat created from © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 48 E: antifreeze terms and Mixture Ratio Freezing Point Temperature (In Degrees Fahrenheit) © 2008 Aqua-Hot® 375-D Hydronic Heating System Installation Manual Rev. A...
  • Page 49 15549 East Highway 52 • Fort Lupton, Colorado 80621 1.800.685.4298 • Fax: 303.857.9000 • www.aqua-hot.com...

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