Aqua-Hot 450-DE Installation Manual
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Aqua-Hot 450-DE Installation Manual

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InstallatIon Manual
© 2008 Aqua-Hot Heating Systems Inc.

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Summary of Contents for Aqua-Hot 450-DE

  • Page 1 InstallatIon Manual © 2008 Aqua-Hot Heating Systems Inc.

  • Page 2: Table Of Contents

    Danger, Warning, Caution, and Note Boxes ..................... 1 Aqua-Hot Hydronic Heating System Technical Information ............................2 Section 1: Aqua-Hot Installation Installing the Mounting Tray and the Aqua-Hot ....................5 Installing the Expansion Tank ..........................9 Section 2: Hydronic Heating System Location and Clearances ............................ 10 Mounting Requirements .............................
  • Page 3 Appendix B: Wire Gauge Information ......................B-1 Appendix C: Electronic Controller Features ....................C-1 Appendix D: Antifreeze Types........................D-1 Appendix E: Antifreeze Mixture Water Quality Recommendations ............E-1 Appendix F: Antifreeze Terms and Mixture Ratio ..................F-1 © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 4: General Information

    Indicates that serious damage to the heater will heating, independent interior zone heating, and engine occur and personal injury is possible as well. preheating, applicable for the 450-DE model only. Be sure to reference Figures 1 through 6 for a complete component overview.

  • Page 5: Aqua-Hot Hydronic Heating System

    Wet Weight ........... . approximately 184 lbs. — Page 2 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 6 Diesel AC Terminal Fuel Block Lines VAC Access Panel Diesel-Burner Diesel-Burner Controller Interlock Combustion-Air Zone 1 Zone 2 Switch Sleeve Circulation Circulation Pump Pump Mounting Tray — Page 3 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 7 Figure 5 Engine Preheat Circulation Pump Domestic Cold Water Engine Inlet Preheat Outlet (to engine) Engine Preheat Inlet (from engine) Domestic Hot Water Outlet Back of unit — Page 4 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 8 Aqua-Hot Hydronic Heating System Heating Zone Inlet Ports Product I.D. Label Expansion Air-Release Tank Valve Connection AC Wiring 18.129 Port (Overall) 15.313 1.031 1.408 (Center of Holes) (Typical) (Typical) Wiring Harness Port Motorhome Floor Outline Outline of Aqua-Hot Heating Zone Ø...

  • Page 9: Section 1: Aqua-Hot Installation

    Reference the following illustrations for mounting Reference Figure 7. information: • Overall Aqua-Hot dimensions - Figure 10 Place the Aqua-Hot into the mounting tray. Reference • Mounting tray information - Figure 7 Figure 11. • I.D. Label noting the “Open Access”...
  • Page 10 Section 1: Aqua-Hot Installation 450 --- DE⁄DM Side View Front View NOTE: All measurements are in inches. Top View Bottom View Figure 10 Rear View — Page 7 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 11 Aqua-Hot 450-D Tabs Rear of Mounting Tray Mounting Tray Flange Slots Aqua-Hot 450-D Figure 11 Combustion-Air Sleeve Access Cover Fastener Mounting Tray Access Cover Mounting Tray Flange — Page 8 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 12: Installing The Expansion Tank

    Section 1: Aqua-Hot Installation Installing the Expansion Tank: NOTE: Avoid any dips and bends in the overflow tubing from the Aqua-Hot to the expansion tank as air can become Select a mounting location that allows for easy access trapped in these dips and bends, preventing the expan- and clear visibility whenever the particular storage bay sion of the heating solution from properly depositing door is open.

  • Page 13: Section 2: Hydronic Heating System

    Figure 13 Figure 14 Interior Zone Heating/Heat Exchanger Layout Cozy Return-Air Return-Air Return-Air Figure 15 Indicates generally recommended Cozy mounting locations for the Cozy Heat Exchangers — Page 10 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 14: Mounting The Heat Exchangers

    Aqua-Hot Heating System Heating Loop 2 Bathroom, Bedroom, Heating Loop 1 and Fresh Water Tank Bay Kitchen and Living Room Heating Zones Heating Zone Figure 18 — Page 11 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 15 Tolerances on the dimensions 13.06 in. shown are as follows: .XX (i.e., 6.44 in.) = ± .030 .XXX (i.e., 6.500 in.) = ± .015 14.44 in. — Page 12 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 16: Wiring The Heat Exchangers

    +/- .030 To Aqua-Hot’s Terminal Block - (Ground) Black Wires To a chassis ground source 3.63 in. 14.44 in. 13.06 in. Figure 22 6.44 in. Mounting Tab — Page 13 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 17: Plumbing Requirements

    Heating Loop #1 Heating Zone #1 Heating Loop #2 Heating Zone #3 Heating Zone #2 Heating Zone #4 Incoming Plumbing Lines Outgoing Plumbing Lines Figure 23 — Page 14 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 18: Plumbing The Hydronic Heating System

    (heat output). Connect and tighten all interior plumbing lines, outlet and inlet, to the Aqua-Hot’s appropriate heating loop ports. Reference Figures 23 and 26. Cozy Heat Exchanger (Rear View) Outlet Port...
  • Page 19 Constant Tension Clamps Insert Inlet 3/4 in. Rubber 5/8 inch I.D. Coupler 3/4 inch O.D. PEX Plumbing Line Automotive Type Rubber Heater-Hose Coupler (3/4 inch I.D.) — Page 16 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 20 Hose Barb Fitting Hose Barb Fitting Heating Loop 1 Heating Loop 2 Outlet Plumbing Port Outlet Plumbing Port Heating Loop Heating Loop Inlet Plumbing Port Inlet Plumbing Port — Page 17 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 21: Section 3: Thermostats

    NOTE: It is recommended that the wire numbers in Appendix plumbing system from freezing. A be used when installing the Aqua-Hot in order to Typically only the bulb of the thermostat needs to be assist with differentiating between the separate heating...

  • Page 22: Room Thermostat Location

    Reference Appendix A. • drafts or dead spots behind doors and in corners NOTE: It is recommended that the wire numbers in Appendix • hot or cold air from ducts A be used when installing the Aqua-Hot in order to • radiant heat from the sun or appliances assist with differentiating between the separate heating • heat from concealed pipes and chimneys zones and to aid service personnel with troubleshoot- • unheated or uncooled areas such as an outside...

  • Page 23: Section 4: Domestic Water System

    Manufacturers of pressure-relief valves indicate that excessive weeping of these valves will cause the “seat” NOTE: The Aqua-Hot is equipped with a pressure-relief valve, in the valve to deteriorate, and, in turn, the valve will which releases excessive pressure in the domestic water fail prematurely.
  • Page 24 To Cold Water Faucets Domestic Cold Water AT - Indicates options INLET for mounting an Accumulator Tank. Domestic Hot Water OUTLET Figure 30 To Hot Water Faucets — Page 21 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 25: Section 5: Switch Panel

    Cut out an opening for the switch panel plate. The for easy operator access. Aqua-Hot 450 DM requires an 2.25 inch W x 1.25 inch H opening. The Aqua-Hot 450 DE requires a 3.75 inch All electric installations, systems, and equipment W x 1.25 inch H opening.

  • Page 26: Switch Panel Wiring

    Insert all switch wires into the appropriate terminal/ Pin # 5 to “IND-LT (-) B6” switch panel connection on the electronic controller. Figure 32 Reference Appendix A. 450-DE Interior Switch Panel Rear View Engine Preheat Diesel-Burner Electric Element Switch Switch...

  • Page 27: Section 6: Fuel System

    50 ft. maximum distance Maximum Allowable Head Pressure 10 ft. Figure 35 450 --- DE/DM — Page 24 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 28: Fuel System Installation

    Reference Figure 34. Both fuel lines should be laid as flat as possible and any Install and tighten the appropriate fuel fittings onto the extreme rises in height should be avoided in order to Aqua-Hot’s fuel ports, as well as the two ports of the eliminate any potential air-traps. fuel filter. Reference Figures 37 and 38. Run both fuel lines in areas where they cannot be...
  • Page 29 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 connections. Inlet Port. Pick-Up Pipe. TOP VIEW: Reference of Fuel Filter Head Reference Figure 38.

  • Page 30: Section 7: Engine Preheat And Motoraide System

    5. Install and clamp both the inlet and outlet engine The engine’s outlet port is where the engine’s coolant plumbing lines/automotive-type heater hoses to the is transported to the Aqua-Hot. This port should be a engine’s plumbing fittings. Reference Figure 40. low connection point on the engine block or a pres- sure outlet port on the engine’s water pump.
  • Page 31 Automotive Type Heater-Hose (M) NPT by ° Hose Barb Hose Clamp Automotive-Type Heater Hose Engine Preheat Circulation Pump Engine Preheat Outlet Engine Preheat Inlet Figure 40 — Page 28 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 32: Section 8: Exhaust System

    Section 8: Exhaust System All Aqua-Hot exhaust system installations MUST utilize the two The Aqua-Hot’s exhaust is HOT and must be kept away black pipe nipples and the black pipe elbow, which are provided from any heat-sensitive material. with the heating system, in the configuration best suited for the particular recreational vehicle application. Failure to conform DO NOT direct exhaust downward as a fire may result could create a hazardous situation and will void the Aqua-Hot’s...

  • Page 33: Exhaust System Requirements

    Section 8: Exhaust System Exhaust System Requirements: The Aqua-Hot is supplied with a 3 inch and a 4 inch black pipe nipple (1½ inch diameter) along with a 1½ inch exhaust elbow. Reference Figure 42. These three The exhaust must be able to freely exit away from the exhaust system components MUST BE utilized with vehicle without any obstructions.

  • Page 34: Installing The Exhaust System

    Exhaust Pipe 3-inch Nipple 4-inch Nipple Elbow Figure 43 450 --- DE/DM Depth of Motorhome Bay Floor Mounting Tray Flange Exhaust Pipe 4-inch Nipple 3-inch Nipple Elbow — Page 31 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 35: Section 9: Electronic Controller Wiring

    All switch connections are to be wired directly to the present whenever a switch is activated or whenever a Aqua-Hot’s interior switch panel. Reference Figures 44 thermostat is calling for heat. Reference Appendix A. and 44 and Appendix A. Both the “IND-LT (+) B3”...

  • Page 36: Wiring Harness Connection

    Article 551, Parts I and III through VI of NFPA 70, as well as the regulation of authorities DO NOT connect the 12 Volt-DC power to the Aqua-Hot having jurisdiction and CSA Standard B139. if the vehicle requires welding. Electrical welding will cause...

  • Page 37: Connecting The 12 Volt-Dc Power

    DO NOT activate the diesel-burner until the antifreeze and water heating solution has been added to the boiler tank DO NOT connect the 12 Volt-DC power to the Aqua-Hot if and the heating system has been completely bled of air.

  • Page 38: Section 10: Purging The Systems

    “GRAS” (Generally Recognized as Safe) by the protection, and anti-corrosion and rust protection, a FDA shall be used in the Aqua-Hot’s hydronic heating 50/50 mixture of “GRAS” approved boiler type pro- system. Failure to use the above specified antifreeze type pylene glycol antifreeze and water is recommended.
  • Page 39 Section 10: Purging the System Fill the Aqua-Hot completely with the 50/50 mixture NOTE: The circulation pump will activate as soon as the pump of antifreeze and water heating solution. This will take is connected to a ground source; therefore, disconnect approximately 5 gallons;...

  • Page 40: Purging The Domestic Water System

    Section 10: Purging the System 9. Check the Aqua-Hot’s expansion tank and top it off to NOTE: This procedure will purge the diesel-burner’s fuel sys- the cold level mark with the 50/50 antifreeze and water tem by allowing the heater’s fuel pump to complete its mixture, if necessary.

  • Page 41: Appendix A: Wiring Diagram

    Appendix A Appendix A: Wiring Diagram © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 42 Appendix A: Wiring Diagram — Page A-1 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 43: Appendix B: Wire Gauge Information

    Appendix B Appendix B: Wire Gauge Information...
  • Page 44 12 Volts - 3% Drop Wire Sizes (gage) - Based on Minimum CM Area 24 Volts - 3% Drop Wire Sizes (gage) - Based on mInimum CM Area — Page B-1 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...

  • Page 45: Appendix C: Electronic Controller Features

    Appendix C: Appendix C: Electronic Controller Features...
  • Page 46 Secondary 12 Volt-DC Battery Connection: The electronic controller is equipped with two 12 Volt-DC Aqua-Hot will be protected in the event that the primary power is interrupted while the Diesel-Burner is operating (e.g., during a power source connections, which allow for a secondary 12 Volt-DC battery connection.
  • Page 47 “Low Voltage Reset” Feature: straight, nonmetallic object to access the button through the Whenever the Aqua-Hot’s DC power is interrupted, the “low faceplate) or by turning OFF the diesel-burner switch on the voltage reset” red indicator light on the electronic controller will interior switch panel for approximately 30 seconds, then turning illuminate.

  • Page 48: Appendix D: Antifreeze Types

    Appendix D Appendix D: Antifreeze Types...
  • Page 49 “boiler” type antifreeze transfer heat, which is essential to the heating system’s in the Aqua-Hot. Propylene glycol is a safer alternative functionality and does not contain rust inhibitors. to the more toxic ethylene glycol antifreeze; however, Please note, however, that RV &...

  • Page 50: Appendix E: Antifreeze Mixture Water Quality Recommendations

    Appendix E Appendix E: Antifreeze Mixture Water Quality Recommendations...
  • Page 51 In order to ensure maximum performance and longev- Hard water possesses a high-level of calcium and ity of an Aqua-Hot heating system’s boiler tank and magnesium ions, which deplete the propylene glycol an- associated components, it has been determined that tifreeze’s corrosion inhibitors.

  • Page 52: Appendix F: Antifreeze Terms And Mixture Ratio

    Appendix F Appendix F: Antifreeze Terms and Mixture Ratio...
  • Page 53 Aqua-Hot from providing adequate domes- Boiling Point: tic hot water and interior heating. The Aqua-Hot utilizes the antifreeze and water heat- Additionally, if the antifreeze and water heating solu- ing solution as a transportation means for the heat tion contains over 70 percent antifreeze, the freezing produced from the internal processes.
  • Page 54 Appendix F: Antifreeze Terms and Mixture Ratio Freezing Point Temperature (In Degrees Fahrenheit) — Page F-2 — © 2008 Aqua-Hot ® 450-DE/DM Hydronic Heating System Installation Manual...
  • Page 55 15549 East Highway 52 • Fort Lupton, Colorado 80621 1.800.685.4298 • Fax: 303.857.9000 • www.aqua-hot.com...

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450-dm

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