Airxcel Aqua-Hot 600 Series Installation Manual

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AHE-600-D04

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Page 1 Installation Manual Series AHE-600-D04 with...
Page 2: Table Of Contents
Introduction Contents Caution Notes Caution Notes ................1 As you read this information, take particular note of the NOTICE, CAUTION, WARNING and DANGER symbols when they appear. Introduction ..................2 This information is important for safe and efﬁ cient use of the System Features ................4 Aqua-Hot system.
Page 3: Introduction
Introduction Safety Features Read all instructions before installing the Aqua-Hot unit. Aqua- Low-Voltage Shutdown Hot Heating Systems is not liable for damage resulting from The Aqua-Hot Reporter is designed to operate between 11V failing to follow instructions contained in this, and any other DC and 16V DC.
Page 4 Introduction System Overview Important Notes: The Aqua-Hot 600D is a Hydronic (water-based) Heating • A qualiﬁ ed installer or service technician must perform System, a tank-less hot water system, and a diesel engine equipment installation or service. Contact Aqua-Hot for preheating system.
Page 5: System Features
System Features Figure 3 System Speciﬁ cations Diesel Burner Heat Input (Firing Rate) ........56,000 BTU/hr Fuel Consumption ............0.41 gal/hr Electric Element Power Consumption ............(2) 2000 W Voltage ............. 120V AC / 12V DC DC Power Consumption ...........184 W (maximum) Zone Heat Circulation Pumps ...................3 Power Consumption (max) .........21 W (each)
Page 6: Component Cut-Aways
Component Cut-Aways 1. Aqua-Hot Reporter 15. Engine Preheat Outlet 2. Interlock Switch 16. Engine Preheat Inlet 3. Zone 1 Circulation Pump 17. Air Release Valve 4. Zone 3 Circulation Pump 18. Access Cover 5. Zone 2 Circulation Pump Figure 4 19.
Page 7 Component Cut-Aways AC Wiring Ports Zone 1, 2, & 3 Inlet 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. Domestic Cold Water Inlet Product ID Label...
Page 8: Installing The Aqua-Hot
Support and Clearance Installing the Mounting Tray & Aqua-Hot 5. Secure the mounting tray into place prior to installing the 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 All measurements are in inches Bottom View Top View p. 8 ©Aqua-Hot® 600D Installation Manual...
Page 10: Installation Of The Expansion Tank
Fluid Expansion Bottle Fluid Expansion Tank Installation of the Expansion Tank Fill Cap Introduction: Upper Fitting 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...
Page 11: Exhaust System
Fluid Expansion Bottle Exhaust System Exhaust System Requirements Installation Procedure: NOTE: Should this particular application require more than 27.5 feet of exhaust pipe, please contact Aqua-Hot at 574-AIR-XCEL (574-247-9235) for assistance. 1. Run the exhaust pipe to the driver’s side or to the back The Aqua-Hot’s exhaust is HOT and must be kept away of the vehicle and ensure that the exhaust fumes cannot from any heat sensitive material(s).
Page 12 Fluid Expansion Bottle Exhaust System NOTE: A maximum of three 90° bends are allowed in the exhaust pipe. Also, the exhaust pipe cannot be longer than 27.5 feet. Figure 17 1.5 inch ID Black Pipe Exhaust Fitting 1.75” ID Automotive-Type Exhaust Pipe The two black pipe exhaust ﬁ...
Page 13 Fluid Expansion Bottle Exhaust System Depth of Motor Home Bay Floor Mounting Tray Flange Exhaust Pipe 3” Nipple 3” Nipple Elbow Depth of Motor Home Bay Floor Mounting Tray Flange Exhaust Pipe 3” Nipple 3” Nipple Elbow Figure 19 3” Black Pipe Nipple Installed Black Pipe Elbow 4”...
Page 14: Installing The Heat Exchangers
Installing Heat Exchangers Installation Requirements Heat Exchanger Locations and Clearances Cozy heat exchangers can be mounted in one of two conﬁ gurations: either ﬂ at on the ground, or vertically. Reference • Position the heat exchangers so that even heat is distributed Figure 21.
Page 15 Installing Heat Exchangers Locations and Clearances Mounting Tabs (both sides) Outlet Figure 24 Inlet 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 25 p. 14 ©Aqua-Hot®...
Page 16: Mounting The Heat Exchangers
Mounting the Heat Exchangers Locations and Clearances Mounting the Heat Exchangers 1. Cut out a 2.5” H x 10” W (7cm x 26cm) opening for each heat exchanger outlet and cold-air return grate as shown in Figure 27. Figure 26 2.
Page 17: Wiring The Heat Exchangers
Wiring Heat Exchangers 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...
Page 18: Plumbing The Heating Loop
Plumbing the Heating Loop Plumbing the Heating Loop Once all heat exchangers have been mounted, plan the Outlet 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 ¾”...
Page 19 Plumbing the Heating Loop Barbed Fittings Components Compression Fittings Components Barbed Fittings Components Installed Compression Fittings Components Installed Figure 36 Figure 35 Straight Connection Components 90° Connection Components Figure 38 Figure 37 p. 18 ©Aqua-Hot® 600D Installation Manual...
Page 20: Heat Exchangers Layout
Plumbing the Heating Loop Heat Exchangers Layout Figure 39 NOTE: This is just a sample for mounting locations of the NOTE: For the best performance, the ﬁ rst heat Cozy heat exchangers. Actual placement and quantity may exchanger should be placed where heat loss is the vary on the individual design of the RV.
Page 21: Engine Preheat
Plumbing the Heating Loop Engine Preheat Engine Preheat & Motor-aide System Plumbing Installation 1. Install both engine preheat plumbing lines and mark with The Aqua-Hot 600D includes a motor-aide feature that arrows and/or labels at both ends. uses the circulation of the motor home’s engine to transport NOTE: The labels should indicate whether the plumbing the antifreeze and water heating solution from the Aqua-Hot’s line is transporting coolant to the Aqua-Hot, or if it will...
Page 22 Plumbing the Heating Loop Engine Preheat Vehicle Engine Ideal Incoming Port Potential Outlet Port (top side of engine) From the Aqua-Hot’s To Aqua-Hot’s Engine Engine Preheat “ Outlet” Port Preheat “Inlet” Port (M) NPT by Hose Barb Hose Clamp Automotive-Type Heater Hose 45’...
Page 23: Diesel Fuel System
Plumbing the Heating Loop Fuel System Diesel Fuel System Fuel System Installation • Both fuel lines (supply and return) should be laid as The following section outlines the requirements for diesel ﬂ at as possible and any extreme rises in height should fuel delivery to the Aqua-Hot unit.
Page 24 Plumbing the Heating Loop Fuel System Fuel Supply 50 ft maximum distance Maximum Allowable Suction Height - 7 ft Figure 44 Fuel Return 50 ft maximum distance Maximum Allowable Head Pressure - 10 ft Figure 45 ©Aqua-Hot® 600D Installation Manual p.
Page 25 Plumbing the Heating Loop Fuel System TOP View Fuel Filter Output to the Input from Fuel Aqua-Hot’s Fuel Tank/Fuel Pick- Inlet Port Up Pipe Figure 46 ¼” NPT (F) ¼” NPT (F) Diesel Outlet Diesel Inlet Port Port Figure 47 p.
Page 26: Domestic Water System Requirements
Domestic Water System Domestic Water System Requirements Use the RVIA provided table below in order to determine the proper sizing of pipe and tubing required to ensure maximum efﬁ ciency. The size of the water supply piping and branch line •...
Page 27: 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 Diesel burner to provide adequate heat for hot water needs. The electric element(s) will provide light duty hot water. Risk of Severe Burn or Death from The tempering valve is integrated into the cabinet of the Scalds.
Page 28: Thermostats
Domestic Water System Thermostats Fresh Water Tank Thermostat Room Thermostat Locations Select a location that will ensure even heat distribution Select a location that will ensure even heat throughout each throughout the fresh water storage bay compartment in order to heating zone.
Page 29: Interior Switch Panel
Mounting the Aqua-Hot LCD Switch Panel Interior Switch Panel Switch Panel Mounting Select a location in the interior of the coach that allows for 1. Cut out a 5.5” W x 1.75” H opening for the switch panel easy operator access. The switch panel should be installed in plate.
Page 30 Mounting the Aqua-Hot LCD Switch Panel Figure 53 Switches Rear View Electric Element Diesel Burner Electric Element Engine Preheat High/Low Green Jumper Wire (see below) Electric Element High/Low Electric Element Engine Preheat Diesel Burner Switch Wire Harness Switch Wire Harness Switch Wire Harness Switch...
Page 31: Wiring The Aqua-Hot
Introduction to Wiring Wiring the Aqua-Hot J1 Plug: J1 Wire insertion view shown The J1 plug manages heating NOTE: Reference the Schematics starting on page zone inputs from the coach. 47 for more information. Heating Zone 1 is reserved This section will introduce the basic considerations, electrically for the “Bedroom practices, and information necessary to wire the Aqua-Hot to Heating Zone”...
Page 32 Introduction to Wiring Wire Insertion View Shown J7 Plug: The J9 plug is an optional use terminal The J7 plug manages zone fans and the burner switch indicator that provides constant 12V DC current to any light.. attachments which may be added to the coach. Wire Insertion View Shown Figure 57 Figure 56...
Page 33 Introduction to Wiring Aqua-Hot Reporter Wire Insertion View Shown The J2 Plug is responsible for managing return signals from J3 serves as the RV-C connection to the coach- within the coach. side comfort system (if applicable). The RV-C indicator light located on the back of the Reporter J2 Wire Insertion View Shown serves as a valuable diagnostic tool when the need to determine RV-C functionality arises.
Page 34: Aqua-Hot Reporter
Introduction to Wiring Aqua-Hot Reporter The Aqua-Hot Reporter Home Screen The home screen contains information about the Aqua- The Aqua-Hot Reporter is a new generation of command and Hot system status, as well as model and serial number control module that manages all functions of the Aqua-Hot from information.
Page 35 Conﬁ guring the Zones Aqua-Hot Reporter Heat Testing: Heartbeat Function The heat testing page of the Reporter will allow the electric Aqua-Hot Reporter units with at least ﬁ rmware version 1v5 and burner heating sub-systems to be independently and all Reporter 2.0 units are equipped with a “heartbeat” activated for troubleshooting and testing purposes.
Page 36 Conﬁ guring the Zones Aqua-Hot Reporter Boost Pumps Burner Master Control..........2.0A max Burner Thermostat Control........1.0A max Boost pump functionality changed with implementation of the Reporter 2.0. Connection Terminal Information On Reporter 1.0 units, any boost pumps at use within the coach required a relay connected to wires 3b and 5b in order RV-C Mating Connection to operate.
Page 37 Conﬁ guring the Zones Aqua-Hot Reporter Reporter Figure 70 Reporter Bottom View Figure 71 Reporter Back Side Board Power Board Power RV-C Network Burner Power (+) (Battery (Battery Indicator Light Negative) Positive) Figure 72 p. 36 ©Aqua-Hot® 600D Installation Manual...
Page 38: 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 39: Connecting The 600D To 12V Dc Power
Providing DC Power Connecting the 600D to 12V DC Power This section will outline the requirements, steps, and information necessary to connect the Aqua-Hot to the vehicle’s 12V DC power system. Follow all guidelines and pay attention to all notes contained herein. Failure to adhere to these guidelines Do NOT activate the diesel burner until the antifreeze and can inhibit unit performance, and may cause damage to the water heating solution has been added to the boiler tank and...
Page 40: Connecting The 600D To Ac Power
Providing AC Power Instructions: Connecting the 600D to 120V AC Power 1. Run two 12-2 ROMEX wires with ground wires, from The following section will detail how to connect the Aqua- two over-current protected (20 amp circuit breaker Hot to the vehicle’s AC electric system. Connect the 3-pin Molex required) 120 Volt-AC power supplies through the Aqua- connector to the coach-side AC electric system in order to utilize Hot’s cable clamp ﬁ...
Page 41: Filling The Aqua-Hot
Filling the Aqua-Hot Filling the Aqua-Hot 6. Locate the Reporter, and navigate to the “INPUTS FROM AQUA-HOT” page. Pay attention to the “LOW LEVEL SENSOR” item on this page. See Figure 80: Ensure that the overﬂ ow tube is connected from the Aqua-Hot’s expansion tank connection to the expansion tank’s bottom connection.
Page 42: Purging The Interior Heating Loop
Purging the Heating Loop Purging the Interior Heating Loop Purging the Domestic Water System In order to provide interior heat to the vehicle, antifreeze and water heating solution is circulated within an interior “heating loop” which distributes heat throughout the coach. During installation, it is possible that air may become trapped within the heating loop and hamper unit performance.
Page 43: First Operation
Purging the Heating Loop First Operation Aqua-Hot First Operation Activation Instructions 1. Make sure power supply to the Aqua-Hot is on. DO NOT activate the diesel 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 44: Winterizing
Purging the Heating Loop Winterizing the Aqua-Hot Winterizing the Aqua-Hot De-Winterization To de-winterize the Aqua-Hot system, completely ﬁ ll the fresh water storage tank. Open and close the interior and exterior faucets, one at a time, until only clear water is present. Not winterizing the Aqua-Hot when freezing temperatures are present will result in SERIOUS damage to the Aqua-Hot domestic water heating system.
Page 45: Operational Flow Chart
Purging the Heating Loop Operational Flow Chart Operational Flow Chart Heat Source is selected from the interior switch panel Electric Element switch Diesel burner switch is is turned ON turned ON The electric element The diesel burner ﬁ res, energizes, transferring transferring heat into heat into the antifreeze the antifreeze and water...
Page 46: Wire Sizing
Purging the Heating Loop Wire Sizes OVER-CURRENT PROTECTION ©Aqua-Hot® 600D Installation Manual p. 45...
Page 47: Appendix A: System Schematics
Purging the Heating Loop System Schematics p. 46 ©Aqua-Hot® 600D Installation Manual...
Page 53: Appendix B: Antifreeze
System Schematics Antifreeze Types Antifreeze Types concentrated propylene glycol for the Aqua-Hot’s antifreeze and water heating solution. The following information addresses the necessary usage Please note that this is only necessary when mixing of a propylene glycol based “boiler” type antifreeze in the concentrated propylene glycol antifreeze with water;...
Page 54 System Schematics Antifreeze the brand of propylene glycol antifreeze employed. Therefore, as water is an excellent heat conductor, it is added to the mixture. Propylene glycol antifreeze solution, mixed with distilled water, at a ratio of 35% to 50% is Rust and Anti-Corrosive Inhibitors recommended to provide the best performance combination of the aforementioned functions.
Page 55 Measuring Antifreeze Appendix Measuring Antifreeze Using a Refractometer Calibration Screw Prism Assembly Daylight Plate Assembly Eye Piece Properly Apply Antifreeze to the Prism Assembly Use the guide below to properly apply the propylene glycol mixture to the prism assembly of the refractometer. Once that is complete, peer through the eyeglass of the refractometer to continue to the next step.
Page 56: Appendix C: Parts & Accessories
Parts & Accessories Appendix AHE-600-D04 ELE-000-908 ELE-400-900 Panel, Switch, 4-Position ASM Boost Pump Harness ELX-500-510 ELX-700-007 Bay Thermostat Room Thermostat, Positive Off ©Aqua-Hot® 600D Installation Manual p. 55...
Page 57 Parts & Accessories Appendix EXE-103-0EX EXE-505-65A Heat Exchanger, Cozy III 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”...
Page 58 Parts & Accessories Appendix EXX-006-501 EXX-006-502 Grille, Medium, 3.5” x 15”, Black Grille, Small, 3.5” x 8.5”, Black PLE-622-902 PLX-000-200 Tank, 5 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 ©Aqua-Hot®...
Page 59 Parts & Accessories Appendix PLX-100-836 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-432-000 Hose, Molded, Elbow 90° Fitting, Straight, ½” PEX x ½” (M)NPT PSF p.
Page 60 Parts & Accessories Appendix PLX-664-730 PLX-664-750 Fitting, Pipe Nipple, Exhaust, 1 ½” x 4” Fitting, Exhaust Nipple, 1 ½” x 3” NPT PLX-803-000 PLX-803-ELB Fitting, Straight, ½” PEX x ½” (F) NPT Elbow Fitting, 90°, ½” PEX x ½” PSF PLX-803-FSE PLX-CTB-270 Elbow Fitting, 90°, ½”...
Page 61 Parts & Accessories Appendix PLX-A51-106 PLX-A65-200 Bend Support, ⅝” Fitting, Brass Barb, ¾” x ½” (M) NPT PLX-A65-300 PLX-T44-006 Fitting, Brass Barb, 90°, ¾” x ½” (M) NPT Fitting, Insert Modiﬁ ed Bras SME-102-000 Cozy Plenum Assembly p. 60 ©Aqua-Hot® 600D Installation Manual...
Page 62: Warranty
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, whichever is greater.
Page 63 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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