Aqua-Hot 400 Series Installation Manual

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400

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AHE-400-P02

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Page 1 Installation Manual Series AHE-400-P02 with...
Page 2: Table Of Contents
Thermostats ................23 risk of serious injury, or death could result if instructions are Interior Switch Panel ..............24 not followed. Wiring the Aqua-Hot ..............26 Aqua-Hot Reporter..............29 Reporter Manual Mode ............. 33 Connecting the 400P to 12V DC Power ........34 Connecting the 400P to AC Power ...........
Page 3: Introduction
The Reporter unit with ﬁ rmware 1v5 and later and all Reporter 2.0 units are equipped with a “heartbeat” • DO NOT connect the 12-volt DC power to the Aqua-Hot if the function that establishes a signal between the RV-C system vehicle requires welding.
Page 4 New Low Emissions Technology virtually Hot Water Priority System eliminates smoke and odor from the exhaust The Aqua-Hot 400P is a Hot Water Priority heating system. by reducing total hydrocarbon emission by Meaning that the 400P cannot heat the interior of the coach 82%, making Aqua-Hot the cleanest burning propane-powered and produce hot water simultaneously.
Page 5: System Features
Recreation Vehicle Industry Association, 1896 Preston White Drive, Hot, and provides a ready reference to speciﬁ cations, test PO Box 2999, Reston, VA 22090-0999. Call them at (703) 620- standards, and important safety notices. 6003 or visit online at www.rvia.org. p. 4 ©Aqua-Hot® 400P Installation Manual...
Page 6: Component Cut-Aways
NOTE: The top panel has been made transparent in the view above to aid in the explanation of the heater. DO NOT remove the top panel. Doing so risks irreparable damage to the Aqua-Hot. Only remove the service panels. Figure 5 Figure 6 ©Aqua-Hot®...
Page 7 Zone 1 & 2 Outlet Ports Figure 7 Propane Fuel Inlet & Outlet Ports The Aqua-Hot tank and heating loop operate at 0.0 PSI (zero pressure system). Air pressure applied to the tank MUST NOT exceed 20 PSI. Excess pressure will result in internal damage.
Page 8: Installing The Aqua-Hot
Aqua-Hot. Install the Aqua-Hot in a compartment that is completely 6. Place the Aqua-Hot securely into the mounting tray to closed off from living quarters and is accessible only from the ensure that the unit does not move or shift under normal exterior of the coach.
Page 9: Support & Clearances
Support and Clearance SIDE VIEW FRONT VIEW BOTTOM VIEW TOP VIEW All measurements are in inches REAR VIEW p. 8 ©Aqua-Hot® 400P Installation Manual...
Page 10: Installation Of The Expansion Tank
The ﬂ uid expansion tank is integral to the operation of the Hot Fluid Line Aqua-Hot. It provides an area for hot, expanded ﬂ uid to empty into, and also protects the Aqua-Hot from low-ﬂ uid, which could lead to catastrophic damage of the Aqua-Hot.
Page 11: Exhaust System
All Aqua-Hot exhaust system installations MUST utilize the • The Aqua-Hot is supplied with a 3 inch and 4 inch black pipe two black pipe nipples and black pipe elbow, which are nipple (1.5 inch diameter) along with a 1.5 inch exhaust provided with the heating system in the conﬁ...
Page 12 Exhaust System The two black pipe exhaust ﬁ ttings MUST be utilized with all installations! Failure to conform could create a hazardous situation and will void the Aqua-Hot ETL Product Listing. 1.5 inch ID Black Pipe Exhaust Fitting 2.0 inch ID Automotive Type Exhaust Pipe Figure 15 #8, ⅜”...
Page 13 Fluid Expansion Bottle Exhaust System Figure 18 3” Black Pipe Nipple Installed Black Pipe Elbow 4” Black Pipe Nipple Installed 2” Automotive Type Exhaust Pipe Figure 19 p. 12 ©Aqua-Hot® 400P Installation Manual...
Page 14: Installing The Heat Exchangers
Vertical Orientation Horizontal Orientation Figure 21 Figure 20 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. Figure 22 ©Aqua-Hot®...
Page 15 Locations and Clearances Mounting Tabs (both sides) Outlet Figure 23 Inlet 13.69 in 10.50 in 6.50 in 0.38 in 2.81 in 3.50 in 6.44 in 5.50 in 1.06 in 13.06 in 14.44 in Figure 24 p. 14 ©Aqua-Hot® 400P Installation Manual...
Page 16: Mounting The Heat Exchangers
NOTE: When wiring the heat exchangers in parallel, the main 18-gauge wire is split to allow the heat exchanger Figure 26 wires to combine with the main wire to be powered or grounded, respectively. ©Aqua-Hot® 400P Installation Manual p. 15...
Page 17: Wiring The Heat Exchangers
This section will explain in detail how to wire the heat exchangers for optimal functionality. Do not deviate from these guidelines. If a deviation is required, contact Aqua-Hot Heating Systems prior to installing these exchangers for express permission to proceed with modiﬁ cations.
Page 18: Plumbing The Heating Loop
Outlet Once all heat exchangers have been mounted, plan the routing of the plumbing lines from each heating zone to the Aqua-Hot. The following guidelines should be used when planning the coolant loop(s) for the heating zone. The order Hose PEX Insert ¾”...
Page 19 Plumbing the Heating Loop Barbed Fittings Components Compression Fittings Components Figure 34 Figure 35 Compression Fittings Components Installed Barbed Fittings Components Installed Figure 36 Figure 37 p. 18 ©Aqua-Hot® 400P Installation Manual...
Page 20: Heat Exchangers Layout
RV. For questions or greatest. The ﬁ rst heat exchanger will always output assistance, contact Aqua-Hot at 574-AIR-XCEL (574-247- the largest volume of heat as compared to subsequent 9235).
Page 21: Propane Fuel System
Ensure that all tubing and ﬁ tting obey all local, state, The following section outlines the requirements for propane and national codes regarding size and type. fuel delivery to the Aqua-Hot unit. Read and adhere to all of the • Ensure that the material used for the propane supply outlined requirements to ensure best, and safest performance line obey both the current ANSI 119.2 (NFPA 1192)
Page 22: Domestic Water System Requirements
Reference Figure 42. • The Aqua-Hot is equipped with a pressure relief valve and a Although the 400P is equipped with a pressure relief valve, tempering valve in order to provide safe hot water without the use of an accumulator tank will help prevent excessive chance of scalding or an over-pressurized system.
Page 23: Plumbing The Domestic Water System
Domestic Water System Plumbing the Domestic Water System The Aqua-Hot is also able to provide domestic hot water while the boiler tank is up at operating temperature. Activate the Propane burner to provide adequate heat for hot water needs. The electric element will provide light duty hot water.
Page 24: Thermostats
2. Once the thermostat has been completely wired, 1. Run two 18-gauge wires from each room thermostat permanently mount the thermostat in place. mounting location to the Aqua-Hot’s Reporter J1 & J9 Pin. Fresh Water Tank Thermostat Wiring 2. Insert the positive wire to the J9 Pin on the Reporter, and insert the ground wire to J1 Pin.
Page 25: Interior Switch Panel
3. Using four countersunk 3mm (#4) screws, secure the switch plate into place over the cutout just made. Coach Control Panel Screen: Newer Aqua-Hot units that come equipped with the Reporter Switch Panel Wiring may have a coach touch-screen display instead of the interior 1.
Page 26 Mounting the Aqua-Hot LCD Switch Panel Figure 46 Switches Rear View Electric Element Propane Burner JUMPER WIRE Switch Wire Harness Switch Wire Harness J9-2 J1-1 J1-2 J9-3 Chassis Ground J7-3 Chassis Ground NOTE: The Electric Element switch possesses jumper wires that advance from terminal 4 to terminal 10.
Page 27: Wiring The Aqua-Hot
Heating Zone 1 is reserved This section will introduce the basic considerations, electrically “Living practices, and information necessary to wire the Aqua-Hot to Room - Kitchen Heating Zone” any relevant coach-side systems. (Heating Loop 1) ONLY. Heating zones 2, 3, & 4 are reserved electrically for the “Bathroom,...
Page 28 Zone Fan 3 Ground J9-8 Zone 1 Thermostat ZONE 1 ZONE J7-1 Zone Zan 4 (Switched 12V+) J7-4 Zone Fan 4 Ground ZONE J7-10 Zone Fan 5 (Switched 12V+) J7-7 Zone Fan 5 Ground ©Aqua-Hot® 400P Installation Manual p. 27...
Page 29 000 FL 100 (Female) General 4COND 22AWG WHT SHLD E2104S.41.02 Cable Cable The parts listed above can be purchased from any major electronics retailer. Only the parts listed above are approved for use in the Aqua-Hot. p. 28 ©Aqua-Hot® 400P Installation Manual...
Page 30: Aqua-Hot Reporter
The home screen contains information about the Aqua- Hot system status, as well as model and serial number information. Figure 54 The Aqua-Hot Reporter is a new generation of command and control module that manages all functions of the Aqua-Hot from Figure 55 Fault Status start-up to shutdown.
Page 31 The fan testing section of the Reporter will allow the heat exchanger fans within the coach to be activated This serves as a safety feature to ensure that the Aqua-Hot independently of the rest of the Aqua-Hot. does not continue to operate if the coach loses power. Once power is restored to the coach and the Reporter unit, “BATTERY...
Page 32 12V DC power system. Mating connection components Mfg. Part Number Description Mate are not supplied by Aqua-Hot. Compatible part numbers and manufacturers are supplied below. The Reporter must be 1-480706-0 09P UMNL Plug operated to the below listed speciﬁ cations.
Page 33 Conﬁ guring the Zones Aqua-Hot Reporter Reporter Figure 63 Reporter Bottom View Figure 64 Reporter Back Side Board Power Board Power RV-C Network Burner Power (+) (Battery (Battery Indicator Light Negative) Positive) Figure 65 p. 32 ©Aqua-Hot® 400P Installation Manual...
Page 34: Reporter Manual Mode
Conﬁ guring the Zones Manual Mode RV-C Network Connectivity This mode can accessed under the test page of the Aqua-Hot Reporter (see below). The Reporter was designed to interface with the coach-side RV-C network to aid in the Aqua-Hot’s integration into the on- board RV-C network.
Page 35: Connecting The 400P To 12V Dc Power
Aqua-Hot and/or the coach. the heating system has been completely bled of air. Operating The Aqua-Hot is designed to shut down in the event that the Aqua-Hot without the heating solution will cause serious the DC voltage level drops too low to properly operate. It is damage to the Aqua-Hot’s boiler tank.
Page 36: Connecting The 400P To Ac Power
ﬁ tting and into the proper terminal. Reference connector to the coach-side AC electric system in order to utilize Figure 71 and the schematic on page 45. the Aqua-Hot’s AC heating element. 2. Secure the wires into their terminal by tightening the •...
Page 37: Filling The Aqua-Hot
Filling the Aqua-Hot Filling the Aqua-Hot Before the ﬁ rst activation of the Aqua-Hot, ﬁ ll the unit with antifreeze and water heating solution. Without the solution present, the Aqua-Hot will not operate, it will not deliver hot water, and it will not deliver heat. Follow the directions below to ﬁ...
Page 38: Purging The Interior Heating Loop/Water System
Purge Procedure: from the domestic water system. 1. Locate the ﬂ uid expansion tank of the Aqua-Hot. As any air is purged, it will exit through to this expansion tank. 2. Once the domestic water system is completely bled, check for any leaks in the system.
Page 39: Purging The Propane System
Please note that if an RV-C or multiplex system is used in lieu second light should be purged and stable. of the Aqua-Hot display, you must contact the manufacturer, or connect a display to the on-board RV-C network to perform this Internal Propane procedure.
Page 40: First Operation
First Operation Aqua-Hot First Operation Activation Instructions 1. Make sure power supply to the Aqua-Hot is on. DO NOT activate the propane burner until the antifreeze and water 2. Conﬁ rm that the antifreeze and distilled water heating heating solution has been added to the boiler tank, and the heating solution is adequately ﬁ...
Page 41: Winterizing
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. 1. Completely drain the fresh water storage tank.
Page 42: Flow Diagram
Heat exchanger fans activate, transferring heat into the coach interior The now cooled antifreeze and water solution is recirculated back to the boiler tank of the Aqua-Hot to be reheated. ©Aqua-Hot® 400P Installation Manual p. 41...
Page 43: Wire Sizing
Purging the Heating Loop Wire Sizes OVER-CURRENT PROTECTION p. 42 ©Aqua-Hot® 400P Installation Manual...
Page 44: Appendix A: System Schematics
Purging the Heating Loop System Schematics ©Aqua-Hot® 400P Installation Manual p. 43...
Page 50: Appendix B: Antifreeze
“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 51 Another major function of antifreeze solution is to provide exists within the heating solution, the water’s heat absorption protection to the internal metal components of the Aqua-Hot properties are compromised. Ultimately, this could inhibit the Hydronic Heating System from corrosion and rust. Antifreeze is...
Page 52 Refractometer Sight Glass Application of Propylene Glycol Upper Blue Field Poor Poor Good Boundary Line Adjust to 32°F Lower White Field ©Aqua-Hot® 400P Installation Manual p. 51...
Page 53: Appendix C: Parts & Accessories
Parts & Accessories Appendix AHE-400-D02 ELE-000-508 ELE-400-900 Panel, Switch, 2-Position ASM Boost Pump Harness ELX-500-510 ELX-700-007 Bay Thermostat Room Thermostat, Positive Off p. 52 ©Aqua-Hot® 400P Installation Manual...
Page 54 Heat Exchanger, Whisper Silent, 12V DC. EXX-006-500 EXX-013-100 Grille, Long, 3.5” x 21.5”, Black Nozzle, Round 4” w/o Connector, Black EXX-013-105 EXX-950-411 Nozzle, 4” Round w/ 2 ½” Connector, Black Grille, 10” x 2” Cozy ©Aqua-Hot® 400P Installation Manual p. 53...
Page 55 Grille, Small, 3.5” x 8.5”, Black PLE-070-401 PLX-000-200 Tank, 3 QT, Expansion Assembly Tube, ⅝” Safety Stripe, 12ft. PLX-000-820 PLX-000-835 Fitting, Elbow, 90°, ¾”, Barb, Black Nylon Fitting, Reducer ¾” to ⅝” Black Nylon p. 54 ©Aqua-Hot® 400P Installation Manual...
Page 56 PLX-100-900 Pump Mounting Bracket Boost Pump PLX-120-626 PLX-200-103 Tube, ⅝”, Red O2 Barrier Pex 100 Ft. Fitting ½” (M) NPT x ¾” Barb Black Nylon PLX-284-74V PLX-375-050 Hose, Molded, Elbow 90° Gas Ball Valve ©Aqua-Hot® 400P Installation Manual p. 55...
Page 57 PLX-664-750 PLX-803-000 Fitting, Exhaust Nipple, 1 ½” x 3” NPT Fitting, Straight, ½” PEX x ½” (F) NPT PLX-803-ELB PLX-803-FSE Elbow Fitting, 90°, ½” PEX x ½” PSF Elbow Fitting, 90°, ½” PEX Fitting p. 56 ©Aqua-Hot® 400P Installation Manual...
Page 58 Clamp, Hose, Constant Tension, 0.75” Bend Support, ⅝” PLX-A65-200 PLX-A65-300 Fitting, Brass Barb, ¾” x ½” (M) NPT Fitting, Brass Barb, 90°, ¾” x ½” (M) NPT PLX-T44-006 SME-102-000 Fitting, Insert Modiﬁ ed Bras Cozy Plenum Assembly ©Aqua-Hot® 400P Installation Manual p. 57...
Page 59: 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 60 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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