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Aqua-Hot 200 Series Installation Manual

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Installation Manual
200
Series
AHE-250-D01

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Summary of Contents for Aqua-Hot 200 Series

  • Page 1 Installation Manual Series AHE-250-D01...

  • Page 2: Table Of Contents

    Exhaust System ................. 23 Pin-Out Information ..............26 Connecting the 250D to 12V DC Power ........27 Connecting the Aqua-Hot to AC Power ........28 Filling/Purging the Aqua-Hot 250D .......... 29 DANGER signals a situation where immediate risk of serious First Operation ................30 injury or death will result if instructions are not followed.

  • Page 3: Introduction

    The Aqua-Hot’s exhaust is HOT and must be kept away from (574-247-9235). heat sensitive material. • DO NOT connect the 12-volt DC power to the Aqua-Hot if the vehicle requires welding. • At maximum operating temperature, the coolant will be very hot and scalding.
  • Page 4 Aqua-Hot’s boiler tank. based antifreeze and distilled water solution that is stored in the Aqua-Hot’s boiler tank. This fl uid solution must be up to The heater also employs a 12V DC diesel burner as the operating temperature before the Aqua-Hot will provide interior primary heating source.

  • Page 5: System Features

    NOTE: This product label is attached to the side of the listed in the Recreational Vehicle Industry Association’s Aqua-Hot, and provides a ready reference to specifi cations, (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle test standards, and important safety notices.

  • Page 6: Component Cut-Aways

    DO 15. 120V AC Connection NOT remove these panels. Doing so risks irreparable damage to the Aqua-Hot. Only remove the service panel for service. 16. Boiler Tank 17. Domestic Hot-Water Coil 18.

  • Page 7: Installing The 250D

    2. Cut out the required mounting fl ange opening Reference Figure 4. 3. Install the fl ange located on the bottom of the Aqua-Hot into the cutout opening. Reference Figure 6 & 7. 4. Take the angle brackets and included ¼-20 bolts and washers.

  • Page 8: Support And Clearance

    12.625” 2” 12.57” Figure 4 NOTE: The mounting fl ange of the Aqua-Hot is not centered on the body of the heater. Reference Figure 4 for the correct dimensions to construct the surface on which the Aqua-Hot will be mounted.
  • Page 9 Support and Clearance Seat the Aqua-Hot in the Flange cutout Coach Bay Floor ¼-20 Bolt and Lock Washer Figure 6 Mounting Brackets on both sides, front, and rear NOTE: Angle mounting bracket must be fl ush to the underside of the coach fl oor and fl ush to the heater fl ange.

  • Page 10: Installation Of The Expansion Bottle

    Upper Fitting The fl uid expansion bottle is integral to the operation of the Aqua-Hot. It provides an area for hot, expanded fl uid to empty Hot Fluid Line into, and also protects the Aqua-Hot from low-fl uid, which could lead to catastrophic damage of the Aqua-Hot.

  • Page 11: Heat Exchanger Layout

    NOTE: For the best performance, the fi rst heat exchanger should be placed where heat loss is the greatest. The fi rst heat exchanger will always output the largest volume of heat as compared to subsequent exchangers. Aqua-Hot Unit Heat Exchanger 2 Living Area Heat Exchanger 3...

  • Page 12: Installing Heat Exchangers

    (reference Figure 23). Figure 12 13.69 in 10.50 in 0.38 in 6.50 in 2.81 in 3.50 in 6.44 in 5.50 in 1.06 in 13.06 in 14.44 in Figure 13 ©Aqua-Hot® 250 Diesel Series Installation Manual p. 11...

  • Page 13: Mounting The Heat Exchangers

    Refer to Figure 14 & 16. 1. Hot Air Outlet Vent 2. Air Ducting Hose 3. Plenum 4. Cozy Heat Exchanger 5. Toe Kick Board Figure 15 Figure 16 p. 12 ©Aqua-Hot® 250 Diesel Series Installation Manual...

  • Page 14: Heat Exchanger Locations And Clearances

    fl uid pressure to allow the 6th heat exchanger to operate as intended. Aqua-Hot advises against placing a heat exchanger on the slide-out section of any vehicle due to the high probability of damage occurring to the heating loop from moving parts.

  • Page 15: Wiring The Heat Exchangers

    When choosing a zone control for the heat exchangers, the guidelines. If a deviation is required, contact Aqua-Hot Heating following guidelines must be adhered to, or the Aqua-Hot will Systems prior to installing these exchangers for express not function correctly in any mode of operation.

  • Page 16: Plumbing The Heating Zone

    fl ow of the plumbing to and from heat exchangers. arrangement. Placement and quantity may vary depending on the coach. 6. Connect and clamp the inlet line from the heater to the Aqua-Hot highest port on the Heating System last heat exchanger to complete the heating Cozy #1 loop.
  • Page 17 Wiring Heat Exchangers Heat Exchanger Install Figure 25 NOTE: The AC relay enclosure has been hidden in these views to allow an unobstructed view of the constant tension clamps. Figure 26 p. 16 ©Aqua-Hot® 250 Diesel Series Installation Manual...

  • Page 18: Domestic Water System Requirements

    The electric element will only provide light duty hot water. • The Aqua-Hot is equipped with a pressure relief valve and a The tempering valve is integrated into the cabinet of the tempering valve in order to provide safe hot water without Aqua-Hot, and is set upon departure from the Aqua-Hot factory.

  • Page 19: Interior Switch Panel

    Coach Control Panel Screen: 4. Move both switches to the OFF position by pressing Newer Aqua-Hot units may have a coach touch-screen them in a downward motion. display instead of the interior switch panel. This section is only for the installation and wiring for the interior switch panel.
  • Page 20 Pin 4 and Pin 10 as depicted. Chassis Ground Chassis Ground Wire Insertion View Shown Receptacle Housing Information Manufacturer Part No. Description TE Connectivity 1-480709-0 Mate-N-Lock Figure 30 ©Aqua-Hot® 250 Diesel Series Installation Manual p. 19...

  • Page 21: Diesel Fuel System

    A 10 Micron diesel fuel fi lter must be installed at the diesel extreme rises in height should be avoided to eliminate fuel source at all times during the operation of the Aqua-Hot any potential air traps. 250D. This fuel fi lter ensures clean fuel is delivered to the fuel nozzle at all times.
  • Page 22 3. Install and tighten the appropriate fuel fi ttings onto the Aqua-Hot’s fuel ports. 4. Connect the Aqua-Hot’s fuel lines to the fuel tank. 5. Cut the fuel line at the fuel fi lter mounting location and Input from Fuel Output to the connect the fuel lines as illustrated in Figure 32.
  • Page 23 Domestic Water System Diesel Fuel System Fuel Supply 30 ft. Maximum Distance Maximum Allowable Suction Height 7 feet Figure 34 Fuel Return 20 ft. Maximum Distance Maximum Allowable Head Pressure 10 ft. Figure 35 p. 22 ©Aqua-Hot® 250 Diesel Series Installation Manual...

  • Page 24: Exhaust System

    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 result in a fi re.
  • Page 25 NOTE: Total exhaust length shall not exceed 30 ft, and shall contain no more than two 90° pipe bends. Exhaust Clamp Figure 36 1.5” NPT Black Pipe Elbow 1.5” NPT Black Pipe Nipple Figure 37 p. 24 ©Aqua-Hot® 250 Diesel Series Installation Manual...
  • Page 26 Flange Flange 3” Nipple Exhaust Tip Elbow Exhaust Tip 4” Nipple Elbow Figure 38 Figure 39 NOTE: Exhaust must terminate at least 3 ft from any coach openings (doors and windows). ©Aqua-Hot® 250 Diesel Series Installation Manual p. 25...

  • Page 27: Pin-Out Information

    Introduction to Wiring Pin-Out Information 200 Series Pin-Out Information The following section serves to provide electrical information particularly pertaining to pin-out confi gurations to assist in correctly wiring the coach-side electrical connections. Installation must be performed by a professional installer or technician as per national/local regulations.

  • Page 28: Connecting The 250D To 12V 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 2. Crimp the appropriate terminals called out in Table 1 to the vehicle requires welding.

  • Page 29: Connecting The Aqua-Hot To Ac Power

    Reference Figure 41 A119.2/NFPA 501C Standard on Recreational Vehicles 1993 Edition. 1. Route three 120V AC power source wires to the Aqua-Hot • The boiler must be connected to a 120V AC supply heater. permanently and be protected with a 20A breaker (minimum).

  • Page 30: Filling/Purging The Aqua-Hot 250D

    5. Attach the fl uid expansion hose and the expansion bottle to the expansion tank port located on top of the Aqua-Hot. Before the fi rst activation of the Aqua-Hot, fi ll the unit with Secure the hose as shown on Page 9.

  • Page 31: First Operation

    Activation Instructions (Burner) 1. Make sure there are no blockages or debris to the exhaust The fi rst start-up of the Aqua-Hot may not light up perfectly. outlet or combustion air inlet. This is normal. On the diesel systems, fuel lines may not have been bled of air prior to the fi...

  • Page 32: Winterizing

    “GRAS” antifreeze) rated for winterization is used when system overview. winterizing this unit. The warranty does not cover freeze damage. NOTE: The Aqua-Hot can continue to be used for interior heat De-Winterization: once the domestic hot water system has been winterized.

  • Page 33: Appendix A: System Schematics

    Filling the Aqua-Hot System Schematic p. 32 ©Aqua-Hot® 250 Diesel Series Installation Manual...

  • Page 34: Appendix B: Measuring Antifreeze

    Refractometer Sight Glass Application of Propylene Glycol Upper Blue Field Poor Poor Good Boundary Line Adjust to 32°F Lower White Field ©Aqua-Hot® 250 Diesel Series Installation Manual p. 33...
  • Page 35 “boiler” type antifreeze in the concentrated propylene glycol antifreeze with water; suppliers Aqua-Hot. Propylene glycol is a safer alternative to the more of premixed antifreeze are responsible for the use of high- toxic ethylene glycol antifreeze; however, as mandated by...
  • Page 36 Generally Recognized As Safe (“GRAS”) by the FDA could Therefore, as water is an excellent heat conductor, it is result in serious bodily harm to damage to the Aqua-Hot added to the mixture. Propylene glycol antifreeze solution, system.

  • Page 37: Appendix C: Parts & Accessories

    Parts & Accessories Appendix AHE-250-D01 250 Series Diesel w/ Electric Element (1kW @ 120V AC) ELE-400-900 ELE-000-508 Boost Pump Harness Panel, Switch, 2-Position ASM ELX-700-007 EXE-103-0EX Room Thermostat, Positive Off Heat Exchanger, Cozy III p. 36 ©Aqua-Hot® 250 Diesel Series Installation Manual...
  • Page 38 Grille, Long, 3.5” x 21.5”, Black EXX-013-100 EXX-013-105 Nozzle, 4” Round w/ 2-½” Connector, Black Nozzle, Round 4” w/o Connector, Black EXX-950-411 EXX-006-501 Grille, 10” x 2” Cozy Grille, Medium, 3.5” x 15”, Black ©Aqua-Hot® 250 Diesel Series Installation Manual p. 37...
  • Page 39 Overfl ow Bottle Kit (Tank, Hose, Clamp, Tie, Labels). PLX-000-200 PLX-000-820 Tube, ⅝” Safety Stripe, 12ft. Fitting, Elbow, 90°, ¾”, Barb, Black Nylon PLX-000-835 PLX-100-836 Fitting, Reducer ¾” to ⅝” Black Nylon Pump Mounting Bracket p. 38 ©Aqua-Hot® 250 Diesel Series Installation Manual...
  • Page 40 PLX-200-103 PLX-284-74V Fitting ½” (M) NPT x ¾” Barb Black Nylon Hose, Molded, Elbow 90° PLX-432-000 PLX-664-730 Fitting, Straight, ½” PEX x ½” (M)NPT PSF Fitting, Pipe Nipple, Exhaust, 1-½” x 4” ©Aqua-Hot® 250 Diesel Series Installation Manual p. 39...
  • Page 41 Fitting, Straight, ½” PEX x ½” (F) NPT PLX-803-FSE PLX-803-ELB Elbow Fitting, 90°, ½” PEX x ½” PSF Elbow Fitting, 90°, ½” PEX Fitting PLX-CTB-270 PLX-A51-106 Clamp, Hose, Constant Tension, 0.75” Bend Support, ⅝” p. 40 ©Aqua-Hot® 250 Diesel Series Installation Manual...
  • Page 42 Parts & Accessories Appendix PLX-A65-200 PLX-A65-300 Fitting, Brass Barb, 90°, ¾” x ½” (M) NPT Fitting, Brass Barb, ¾” x ½” (M) NPT PLX-T44-006 SME-102-000 Fitting, Insert Modifi ed Bras Cozy Plenum Assembly ©Aqua-Hot® 250 Diesel Series Installation Manual p. 41...
  • Page 43 Parts & Accessories Appendix MSE-200-EXH MSX-300-270 Exhaust Kit Boiler Antifreeze, 1-gallon, Pink MSX-300-300 Boiler Antifreeze, 1-gallon, Green p. 42 ©Aqua-Hot® 250 Diesel Series Installation Manual...

  • Page 44: Warranty

    Thus, problems due to improper specifi cations, improper installations, improper use, the use of accessory parts or parts not authorized by Aqua-Hot Heating Systems Inc., repair by unauthorized persons, and damage or abuse of the heater are specially excluded from warranty coverage.
  • Page 45 Installation Manual SERIES Aqua-Hot Heating Systems, LLC 7501 Miller Drive, Frederick, CO 80504 Visit us online at www.aquahot.com Call us at 574-AIR-XCEL (574-247-9235) ©2021 Aqua-Hot Heating Systems, LLC. Printed in the USA...

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