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Aqua-Hot 200 Series Installation Manual

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INSTALLATION MANUAL
200
SERIES
200P, 250P and 250D

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Summary of Contents for Aqua-Hot 200 Series

  • Page 1 INSTALLATION MANUAL SERIES 200P, 250P and 250D...

  • Page 3: Table Of Contents

    Connecting the 250D to DC Power ......32 Connecting the 250P or 250D to AC Power ....33 Purging the System Purging the Hydronic Heating System ......34 Initial Start Up Activating the Aqua-Hot ..........35 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 4: Cautions And Introductions

    Introduction and Cautions About the Aqua-Hot 200 Series Caution Notes The Aqua-Hot 200P, 250P, and 250D are hydronic (water As you read this information, take particular note of the NO- based) heating systems that provide interior heat and tank- TICE, CAUTION, WARNING, and DANGER symbols when they less, continuous hot water in one small, easy to install pack- appear.

  • Page 5: Safety Precautions And Instructions

    Section #: Title Safety and Precautions • The Aqua-Hot Heating System DO NOT connect the 12V DC power to the Aqua-Hot if the RV or home requires welding Read and understand all instructions before installing this • At maximum operating temperatures, the coolant will be unit.
  • Page 6 200P Safety & Precautions p. 4 ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 7 Section #: Title 250P Safety and Precautions ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 8: Heating System Features

    Recreational Vehicle Industry Association 1896 Preston White Dr PO Box 2999, Reston, VA 22090-0999 Or contact them by phone at +1 (703) 620-6003, or online at Figure 1 www.rvia.org, or www.nfpa.org p. 6 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 9: 250D Components

    9. Interlock Switch 10. 3-Way Valve 11. Diesel Burner Assembly 12. Boiler Tank 13. Tempering Valve 14. Diesel Burner Controller 15. Zone Circulation Pump 16. Drain Valve 17. Access Cover Screw Figure 3 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 10: 200P/250P Components

    9. Propane Burner Assembly 10. Tempering Valve 11. Boiler Tank 12. 3-Way Valve 13. Propane Burner Controller 14. Interlock Switch 15. Drain Valve 16. Zone Circulation Pump 17. Access Cover Screw Figure 4 p. 8 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 11: Aqua-Hot Installation

    2. Cut out the required mounting flange opening. Reference figure 6 on the next page. 3. Install the flange located on the bottom of the Aqua-Hot 17.2” into the cutout opening. Reference figure 8 and figure 9 4. Take the angle brackets and included 1/4-20 bolts and 15.2”...

  • Page 12: Aqua-Hot Measurement Diagrams

    2” 12.57” Figure 6 22.44” NOTE: The mounting flange of the Aqua-Hot is not centered on the body of the heater. Reference figure 6 for correct di- mensions to construct the surface on which the Aqua-Hot will be mounted. Additional cross-members are required if the existing struc- ture is unable to support 104 lbs.

  • Page 13: Mounting Brackets

    NOTE: Angle mounting bracket must be flush to the underside of the coach floor and flush to the heater flange. Tighten bolts to roughly 76 in-lbs. 1/4-20 Bolt and lock washer Heater Flange Mounting Bracket Figure 9 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 14: Installing The Expansion Bottle

    The Aqua-Hot tank and heating loop operates at 0.0 psi 2. Mount the expansion tank as illustrated in figure 10. (zero pressure system). Air pressure applied to the tank 3.

  • Page 15: Heat Exchanger Floor Plan

    NOTE: The fifth heat exchanger should be placed in the bathroom, as it is typically the smallest area and therefore requires the least amount of heat volume to maintain temperature. Bedroom Heat Exchanger 4 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 16: Heat Exchanger Installation Requirements

    It is never acceptable for the supply air to a heat exchanger to be drawn from the bay area. Horizontal and vertical mounting options shown above Figure 11 Figure 12 p. 14 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 17: Mounting The Heat Exchangers

    14. The plenum allows only the desired 3. Plenum outlets to be opened by removing the metal insert on the vent. 4. Cozy heat exchanger 5. Toe kick board Figure 13 Figure 14 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 18: Location, Clearances And Boost Pump

    Please note, however, that an additional boost pump is required to provide adequate fluid pressure to allow the 6th heat exchanger to operate as intended. Figure 16 p. 16 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 19: Wiring The Heat Exchangers

    5. Repeat the above with the ground wire. 6. Reference figure 18. Diesel Harness Plug Propane Harness Plug Wire-insertion view shown Figure 17 12V DC Power (Pin 7) Ground (Pin 8) Figure 18 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 20: Plumbing The Hydronic Heating System

    (in through the bottom, out through the top.) (Both sides)  Connect and clamp the inlet line from the heater to the Figure 20 highest port on the last heat exchanger to complete the heating loop. p. 18 ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 21 Section #: Title Heat Exchanger Installation NOTE: The AC relay enclo- sure has been suppressed in this view to allow an unob- structed view of constant tension clamps. Figure 21 Figure 22 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 22: Domestic Water System

    Vehicles, 1993 Edition for domestic water systems. The Aqua-Hot is equipped with a pressure-relief valve, Aqua-Hot systems contain copper tubing and are not com- which releases the excessive pressure in the domestic water patible with prolonged exposure to sodium hypochlorite system, if necessary.

  • Page 23: Switch Panel

    Appendices A, B, and C for additional wiring information. 4. Run the wires from the switch to Pins #3 and #4 on the eight-way connector at the Aqua-Hot 5” Ø .150 x4 4.45” 2.88” 2.33” Figure 24 .275” ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 24: 250D Switch Panel Rear View

    NOTE: The AC control circuit connec- tions have been integrated into the 12- Pin Mate-N-Lock receptacle, differing from the 250P. Receptacle Housing Information Mfg: TE Connectivity Part No: 1-480709-0 Common Name: Mate-N-Lock Wire Insertion View Shown p. 22 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 25: 200P/250P Switch Panel Rear View

    Pin 1 Pin 2 8-pin Harness Plug 2-pin AC Control Switch Plug Manufacturer: TE Connectivity Manufacturer: TE Connectivity Part No: 163007 Part No: 180908 Common name: 8-Way Fastin Receptacle Common Name: Fastin-Faston Series ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 26: Propane Fuel Specifications

    The following section outlines requirements for pro- sizing, use NFPA 54/ANSI Z223.1, which ensures the com- pane fuel delivery to the Aqua-Hot unit. Please read and ad- plete vehicle gas demand/pipe sizing is considered during the here to all of the outlined requirements to ensure best perfor- layout of the fuel system.

  • Page 27: Fuel System

    • All fuel-fitting hardware (at the vehicle fuel tank, fuel filter, Fuel System Requirements and Aqua-Hot parts) must be 1/4” NPT or greater with a • The diesel fuel supply should be drawn directly from the barbed fitting. Fuel fittings that are less than 1/4” NPT vehicle’s main fuel tank if applicable...
  • Page 28 Fuel System Installation  Run two 1/4” fuel lines from the fuel tank inlet and outlet ports to the Aqua-Hot. Label both fuel lines indicating whether the line is incoming, or outgoing.  Install and tighten the fuel fittings onto the two ports of the fuel filter.

  • Page 29: Exhaust System

    These requirements must be adhered to in order to create optimal operating conditions for the Aqua-Hot unit. Exhaust from the Aqua-Hot is very HOT and must be kept away from any heat sensitive materials. Failure to do so may Should the particular application require modification of ex- result in a fire.
  • Page 30 Exhaust System 2” I.D. Automotive Type Exhaust Pipe (Aluminized Steel) Figure 32 Exhaust Clamp 1.5” NPT Black Pipe Elbow Figure 33 1.5” NPT Black Pipe Nipple p. 28 ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 31 Exhaust Pipe Exhaust Pipe Flange Flange Exhaust Tip Exhaust Tip 3” Nipple Elbow 4” Nipple Elbow Figure 35 NOTE: Exhaust must terminate at least 3 ft. from any coach openings (e.g. doors and windows.) ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 32: Wiring Specifications Wiring Harness Pin-Out

    Electric Switch Power (250D Only) System Power Blue Burner Indicator Light (250D Only) System Power Green Optional Boost Pump (250D Only) Signal to valve and interior heat relay (#2 &#3) Orange p. 30 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 33: Connecting The 200P And 250P To Dc Power

    - The Red + wire must be fused with a 25A fuse to protect the heater from over-current DO NOT connect 12V DC power to the Aqua-Hot if the vehicle 2. Crimp the appropriate terminals called out in Table 1 to requires welding.

  • Page 34: Connecting The 250D To Dc Power

    - The Red + wire must be fused with a 25A fuse to protect the Aqua-Hot from an over-current condition DO NOT connect 12V DC power to the Aqua-Hot if the vehicle 2. Crimp the appropriate terminals called out in Table 2 to requires welding.

  • Page 35: Connecting The 250P Or 250D To Ac Power

    Aqua-Hot into your coach-side 120V AC power system. Included are examples of plugs and connections, as well as mating part numbers, and location call-outs. 1. Route three 120V AC power source wires to the Aqua-Hot AC Relay Enclosure heater 2.

  • Page 36: Purging The System

    50/50 7. Continue filling the Aqua-Hot until the fluid level is about mixture of “GRAS” approved propylene-glycol based antifreeze mid-way between the “Hot” and “Cold” lines on the expan- and distilled or de-ionized water is recommended.

  • Page 37: Initial Start Up Activating The Aqua-Hot

    Once the heater has been brought to temperature by the electric element and/or 12V DC burner, activate interior The first start-up of the Aqua-Hot may not light-up heat by adjusting the room thermostat up until the heat ex- perfectly. This is normal! On propane systems, fuel lines may changers activate.

  • Page 38: Appendix A: 250P Wiring Schematic

    Appx. A: 250P Schematic p. 36 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 39: Appendix B: 200P Wiring Schematic

    Section #: Title Appx. B: 200P Schematic ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 40: Aqua-Hot Hydronic Heating System Appendix C: 250D Wiring Diagram

    Appx. C: 250D Schematic p. 38 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 41: Appendix D: Measuring Antifreeze Concentration

    Application of Propylene Glycol Boundary Line Adjust to 32°F Lower White Field Poor Poor Good ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 42: Parts And Accessories

    250 Series Diesel w/Electric Element (1kW @120V AC) Aqua-Hot 200 Series Propane EXE-103-0EX AHE-250-P01 Heat Exchanger, Cozy III 250 Series Propane w/Electric Element (1kW @120V AC) ELE-000-508 MSE-200-EXH Panel, Switch, 2 Position ASM Exhaust Kit p. 40 ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 43 Parts and Accessories EXX-013-100 PLX-CTB-270 Nozzle, Round 4” w/o Connector, Black Clamp, Hose, Constant Tension, 0.75” SME-102-000 PLX-T44-006 Cozy Plenum Assembly Fitting, Insert Modified Brass ELX-700-007 PLX-284-74V Room Thermostat, Positive Off Hose, Molded, Elbow 90° ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 44 Grille, 10” x 2” Cozy Grille, Long, 3.5” x 21.5”, Black EXX-006-501 EXX-006-502 Grille, Medium, 3.5” x 15”, Black Grille, Small, 3.5” x 8.5”, Black PLX-000-443 PLX-A51-106 Tube, 5/8” Safety Stripe, 12ft. Bend Support, 5/8” p. 42 ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 45 Fitting, Elbow, 90°, 3/4”, Barb, Black Nylon Fitting 1/2” (M) NPT x 3/4” Barb Black Nylon PLX-000-835 PLX-432-000 Fitting, Reducer 3/4” to 5/8” Black Nylon Fitting, Straight, 1/2” PEX x 1/2” (M)NPT PSF ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 46 PLX-803-ELB PLX-803-FSE Elbow Fitting, 90°, 1/2” PEX x 1/2” PSF Elbow Fitting, 90°, 1/2” PEX Fitting EXE-505-65A PLX-664-730 Fitting, Pipe Nipple, Exhaust, 1-1/2” x 4” Heat Exchanger, Whisper Silent, 12V DC p. 44 ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 47 Fitting, Exhaust Nipple, 1-1/2” x 3” NPT Nozzle, 4” Round, w/ 2-1/2” Connector, Black SME-400-015 MSX-300-300 Tip, Exhaust End Anti-freeze, 1-gallon, green boiler MSX-300-270 MSX-300-275 Anti-freeze, 1-gallon, pink boiler Propylene Glycol Concentrate, Pink ©Aqua-Hot® 200 Series Installation Manual Rev. E...
  • Page 48 Parts and Accessories ELE-400-900 PLX-100-900 Boost Pump Boost Pump Harness PLE-063-200 Overflow Bottle Kit, (Tank, hose, clamp, tie, labels) ELX-500-510 Low Temperature Thermostat Assembly p. 46 ©Aqua-Hot® 200 Series Installation Manual Rev. E...

  • Page 49: Warranty

    2-YEAR LIMITED WARRANTY AQUA-HOT® HYDRONIC HEATING SYSTEM Aqua-Hot Heating Systems Inc. warrants the Aqua-Hot Heater to be free from defects in material and workmanship under normal use and service for a period of two years on both parts and labor commencing upon the original date of registration of the vehicle. Replacement parts are warranted for the remainder of the Heater’s standard warranty coverage or for six months,...
  • Page 50 INSTALLATION MANUAL SERIES 200P, 250P and 250D Aqua-Hot Heating Systems, Inc. 7501 Miller Drive, Frederick, CO 80504 Visit us on line at www.aquahot.com Call us at (800) 685-4298 or (303) 651-5500 ©2018 Aqua-Hot Heating Systems Inc. Printed In U.S.A.

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