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Aqua-Hot AHE-100-04S-12 VDC Installation Manual

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Installation Manual
Model Numbers
AHE-100-04S - 12 VDC
AHE-130-04X - 12 VDC

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Summary of Contents for Aqua-Hot AHE-100-04S-12 VDC

  • Page 1 Installation Manual Model Numbers AHE-100-04S - 12 VDC AHE-130-04X - 12 VDC...

  • Page 2: Table Of Contents

    Mounting the Aqua-Hot ........
  • Page 3 Aqua-Hot and Inclusive Components ........
  • Page 4 Diesel Fuel Drain Valve Supply Diesel-Burner Controller Diesel Fuel Return Pressure-Relief Valve Hot Water Engine Figure 1 Outlet Coolant (Domestic Water) Cold Water Return Inlet Tempering Valve (Domestic Water) (Domestic Water) Page 1 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 5: Heating System Overview

    SECTION 1: HYDRONIC HEATING SYSTEM OVERVIEW Introduction Heating System Overview The Aqua-Hot Hydronic Heating System utilizes an FDA approved “GRAS” (Generally Recognized as Safe) Propylene Glycol based antifreeze and water heating solution as its heating medium. This heated solution is circulated by three centrifugal Circulation Pumps to the heating system’s Heat Exchangers whenever a Room and/or Bay...
  • Page 6 Heating Zone #3 Heating Zone #2 Heating Loop #3 Heating Zone #5 Supply Plumbing Lines Return Plumbing Lines Circulation Pump #1 Circulation Pump #2 Circulation Pump #3 Figure 2 Supply Ports Return Ports Page 3 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 7: Aqua-Hot Overview

    12 Volt-DC powered Diesel-Burner and a minimum of one 120 Volt-AC Electric Heating Element. As Vehicle Systems manufactures two separate models of the Aqua-Hot, the number and wattage of the Electric Heating Element(s) may vary; reference Section 2.2 for model differentiation information. These two heating sources maintain the temperature of the Aqua-Hot’s antifreeze and water heating...
  • Page 8 Vehicle Standards. To receive a copy of this Handbook and other pertinent RVIA Stan- dards, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive, P.O. Box 2999, Reston, VA 22090-0999, call them at (703) 620-6003, or visit them online at www.rvia.org. Page 5 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 9 Top - 6 inches Reference Figure 1 Install in strict compliance with local codes, NFPA 501c and manufacturer’s instructions. for Marking Plate locations. For additional product instllation information visit www.aqua-hot.com or call 1-800-685-4298 Page 6 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 10: Installation Procedures

    This will ensure that the domestic hot water lines will be as short as possible. Mount the Aqua-Hot near a Storage Bay Door so the Aqua-Hot’s Access Cover can be easily removed for product servicing, and the Heater can be easily accessed from outside the Motorhome.

  • Page 11: Mounting The Aqua-Hot

    Aqua-Hot Mounting the Aqua-Hot Mounting Once a mounting location for the Aqua-Hot has been selected, utilize the following illustrations for mounting information: - Overall Aqua-Hot Dimensions; reference Figure 5. - Required size and locations of the Combustion-Air Hole and Exhaust Holes;...
  • Page 12 SECTION 3: INSTALLATION PROCEDURES Aqua-Hot Combustion Air Overview Combustion-Air Intake Shutter Combustion-Air Hole in Aqua-Hot Cabinet Hose Clamp Combustion-Air Intake Sleeve Rubber Boot Combustion-Air Hole Figure 4 in Bay Floor Page 9 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 13 SECTION 3: INSTALLATION PROCEDURES Aqua-Hot Dimensions Access Cover Figure 5 Page 10 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 14 SECTION 3: INSTALLATION PROCEDURES Aqua-Hot TOP VIEW Mounting Template All "Mounting Bracket Holes" require a 0.312 inch hole. Mounting Holes Exhaust Hole Combustion Air Intake Hole Front of Aqua-Hot (Access Cover area) Figure 6 Page 11 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 15: Mounting The Interior Heat Exchangers Overview

    (e.g., dust, etc.). Reference Figures 10 and 12 for allowable Cozy-III mounting configurations. Cozy III Return-Air Return-Air Return-Air Indicates generally recommended Cozy III mounting locations for the Cozy III Heat Exchangers Figure 7 Page 12 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 16 Page 13 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 17 SECTION 3: INSTALLATION PROCEDURES Interior Heat Exchanger Location Overview CABINET/COUCH HEAT REGISTER EXCHANGER REGISTER COLD-AIR HOT-AIR RETURN OUTLET BASE-BOARD / TOE-KICK AREA Figure 8 Page 14 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 18 To the “Fan +” connection on the Electronic Controller - (Ground) Black Wires NOTE: Tolerance To the “Fan -” connection on +/- .030 the Electronic Controller 3.63 in. 14.44 in. 13.06 in. 6.44 in. Figure 9 Page 15 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 19 SECTION 3: INSTALLATION PROCEDURES Allowable Cozy III Heat Exchanger Vertical Mount Mounting Configurations Figure 10 Horizontal Mount Page 16 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 20: Mounting The Interior Heat Exchangers

    (heat output). B. Return-Air should be supplied from the same compartment as the Fresh Water Tank Heat Exchanger. Fresh Water Storage Tank Cold Air Return Optional Vent Heat Output Figure 11 Page 17 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 21 SECTION 3: INSTALLATION PROCEDURES Minimum Cozy III Heat Exchanger Clearance INTERIOR WALL/CABINET WALL 4 inch Minimum Clearance Required Figure 12 Page 18 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 22 Template .XXX (i.e., 6.500 in.)= +/- .015 6.44 in. 10.500 in. 14.44 in. 13.687 in. 13.06 in. 6.500 in. 2.812 in. 1.06 in. 3.500 in. 0.38 in. 5.50 in. Figure 13 Page 19 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 23: Mounting The Fresh Water Tank Heat Exchanger

    Once all Heat Exchangers have been mounted, a plan should be formulated for the Exchangers routing of the Plumbing Lines from each heating zone to the Aqua-Hot. The Plumbing Overview Lines are the roadways that carry the antifreeze and water heating solution from the Aqua-Hot to the Heat Exchangers in each heating zone;...
  • Page 24 Heat Exchanger, it will significantly reduce the Heat Exchanger’s overall heating performance (heat output). 4. Connect and tighten all interior Plumbing Lines, Supply and Return, to the Aqua-Hot’s appropriate Heating Zone ports; reference Figures 16A and 16B. Page 21 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 25 SECTION 3: INSTALLATION PROCEDURES Installing the Heat Exchanger Plumbing Cozy III Heat Exchanger (Rear View) “Return” Port Mounting (Highest Port) Bracket Mounting Bracket “Supply” Port (Lowest Port) Figure 14 Page 22 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 26 Coupler Return Insert Constant Tension Clamps Insert Supply 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.) Figure 15 Page 23 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 27 Heating Loop 2 Heating Return Port Loop 1 Compression Fitting Return Port Heating Loop 3 Suppply Port Heating Loop 2 Supply Port Heating Loop 1 Supply Port Figure 16B Figure 16A Page 24 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 28: Plumbing The Engine Preheat System Overview

    Preheat both ends. The labels should indicate whether the Plumbing Line is supplying Plumbing coolant to the Aqua-Hot or whether it will be returning heated coolant to the vehicle’s engine; reference Figures 1, 17, and 18. NOTES: A. Lay both Engine Preheat Lines as flat as possible and avoid any extreme rises in height.
  • Page 29 Engine Preheat "OUT" Port Circulation Pump T(ToTTop side of the engine) (Return) (Supply) (M) NPT/ Hose Barb Hose Clamp Automotive Type Heater-Hose ˚ (M)NPT / Hose Barb Hose Clamp Automotive Type Heater-Hose Figure 17 Page 26 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 30 Aqua-Hot’s Engine Preheating System; reference Figures 1 and 18. CAUTION: Be sure to use two wrenches when tightening these Plumbing Fittings. Failure to do so could result in serious damage to the Aqua-Hot’s internal Engine Preheating System. Attach and clamp the Engine’s Supply Plumbing Line to the Aqua-Hot’s “IN”...
  • Page 31 SECTION 3: INSTALLATION PROCEDURES Installing Engine Preheat Plumbing, continued Engine Coolant Engine Coolant Supply Port Return Port (OUT) (IN) Figure 18 Page 28 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 32: Domestic Hot Water Plumbing Overview

    3.12 Domestic Hot Water Plumbing Overview Water Plumbing One major feature of the Aqua-Hot is that it possesses the ability to provide a continuous Overview supply of domestic hot water. Because the Aqua-Hot heats the domestic water on- demand, there is no need for a separate Storage Type Water Heater. Adhering to the following guidelines will ensure maximum domestic hot water efficiency.

  • Page 33: Attaching Plumbing Lines To The Domestic Hot Water System

    Installing 3.13 Attaching Plumbing Lines to the Domestic Hot Water System Domestic The Aqua-Hot is equipped with a Tempering Valve, which regulates the temperature of Hot Water the hot water; reference Figure 19. Plumbing Connect a domestic water Plumbing Line from the Domestic Water Demand Pump/Water Manifold to the Cold Water Inlet port on the Aqua-Hot;...
  • Page 34 Cold Water INLET AT - Indicates options Fresh for mounting an Water Storage Accumulator Tank Tank Demand Pump Arrows indicate directional flow of To Cold Water domestic water Faucets Figure 20 Page 31 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 35: Wiring The Interior And Fresh Water Tank Heat Exchangers

    Heating Zone” (Heating Loop 2) ONLY. Heating Zone 1 is reserved electrically for the “Bedroom Heating Zone” (Heating Loop 1) ONLY. Reference Figure 2. All Switch connections are to be wired directly to the Aqua-Hot’s “Switch Panel Connections”; reference Figures 23A, 23B, 24A, and 24B and Appendix A. Both the “IND-LT(+)B3”...

  • Page 36: Mounting Locations For Interior Room Thermostats Overview

    Room/Kitchen/Heating Loop 1, etc.), run two wires from the closest Heat continued Exchanger to the Aqua-Hot’s Electronic Controller and then wire the other Heat Exchangers in-parallel; reference Figure 9 and Appendix A. Label the wires indicating the heating zone they pertain to (e.g., Living Room/ Kitchen, Bedroom, Fresh Water Tank, etc.)

  • Page 37: Mounting The Fresh Water Tank Thermostat Overview

    Mounting Black Wire Tabs (Connect to Heating Zone #3 “Therm O” on the Electronic Controller) Figure 21 Blue Wire (Connect to Heating Zone #3 “Therm I” Bulb on the Electronic Controller) Page 34 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 38 .150 (4x) 1.00 (3x) 1.50 2.75 Figure 22 AHE-130-04X Interior Switch Panel 6.50 6.00 5.25 3.00 2.50 1.50 1.00 (4x) .150 (4X) 1.50 2.75 4.25 * All dimensions listed are in inches Page 35 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 39 Switch to Electronic Controller connections connections Switch to Electronic Controller connections NOTE: The “Engine Preheat” and “Electric” switches require a Jumper Wire, which connects Terminal 2 to Terminal 4. Figure 23A Page 36 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 40 To the To the “IND-LT (-) B6” “Preheat-I” “Diesel-O” “Electric-I” Terminal on Terminal on Terminal on Terminal on the Electronic the Electronic the Electronic the Electronic Controller Controller Controller Controller Figure 23B Page 37 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 41 NOTE: The “Engine Preheat” and “Electric” switches require a Jumper Wire, which connects Terminal #2 to Terminal #4. The “Electric High/Low” switch also requires a Jumper Wire, which connects its Terminal #4 to Terminal #2 on the “Electric” switch. Page 38 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 42 Terminal on the “Diesel-O” Electronic Terminal on the to 1-Way to the Controller Electronic Plug “Electric-I” Controller Terminal on the to the Electronic “IND-LT(-) B6” Controller Terminal on the Electronic Controller Figure 24B Page 39 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 43: Installing And Wiring The Switch Panel

    3.21 Diesel-Burner’s Fuel System Overview Burner’s The Diesel-Burner is the Aqua-Hot’s primary heat source; therefore, care should be taken Fuel System when installing the fuel system. The diesel fuel supply should be drawn directly from the Vehicle’s main Fuel Tank or from a separate auxiliary Fuel Tank, if applicable.
  • Page 44 SECTION 3: INSTALLATION PROCEDURES Fuel System Specifications 33' max Maximum Allowable Suction/Lift height 6’6” max. 33' max Maximum Allowable Head Pressure 2’ Figure 25 Page 41 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 45: Installing The Diesel-Burner's Fuel System And Lines

    Fuel Pick-Up NOTE: The Fuel Pick-Up should not extend further than Figure 26 the Motorhome’s engine fuel supply pick-up and should be consistent with the on-board Generator’s fuel supply pick-up length. Page 42 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 46 SECTION 3: INSTALLATION PROCEDURES Diesel Fuel Ports Diesel Fuel Diesel Fuel Return Supply Figure 27 Page 43 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 47 Fuel Filter Head ��������� ������ �� ������ �� NOTE: Reference Figure 27 for details on the Fuel Tank connections. Figure 28B Reference Figure 28 for details on the Aqua-Hot’s Fuel Connections. Page 44 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 48: Overview And Installation Of The Aqua-Hot's Exhaust System

    Be sure to keep the exhaust away from the slideout areas. Reference RVIA’s ANSI/NFPA 1192 Handbook for additional information. D. From the Aqua-Hot’s 1-1/2 inch (F) NPT Exhaust Port, use a 1-3/4 inch I.D. (Inside Diameter) Exhaust Pipe; reference Figure 29.
  • Page 49 Nipple ˚ Bend 1.5 inch Black Pipe Exhaust Nipple Condensation drain hole location Figure 29 NOTE: A Condensation drain is not required if the Exhaust Pipe slopes away from the Heater. Page 46 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 50: Installing The Aqua-Hot's Expansion Bottle

    Mount the Expansion Bottle, as illustrated in Figure 30. Connect and clamp the Overflow Tubing from the Expansion Bottle to the Aqua-Hot’s Filler Neck Overflow Connection; reference Figure 30. NOTE: The Expansion Bottle can be mounted either above or below the top of the Aqua-Hot.

  • Page 51: Connecting 12 Volt-Dc Power To The Aqua-Hot

    A. If the combined length of the two 10 Gauge wires is in excess of 20 feet, reference Appendix B for proper wire gauge sizing. Please note that under full load conditions, the Aqua-Hot can draw as much as 15.33 Amps of VDC current. Because the Aqua-Hot is designed to shut down in the event that the VDC Voltage Level drops too low to properly operate, it is imperative that the proper wire gauge be determined and utilized.
  • Page 52 Heating Zones Status Pump #2 Pump #3 Low Battery Diesel-Burner Voltage Fault Status Low Temp Cutoff Status Overload Fault NOTE: Reference Appendix A for specific Electronic Controller details. Negative/Ground Figure 31 Page 49 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 53 Element Status Reset Engine Preheat Pump Pump #1 Low Voltage Heating Zones Status Pump #2 Reset Pump #3 Low Battery Voltage Fault Diesel-Burner Status Low Temp Cutoff Status Overload Fault Figure 32 Page 50 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 54: Bleeding The Interior/Fresh Water Tank Hydronic Heating System

    “Generally Recognized as Safe” by the FDA, it should never be used in the Aqua-Hot’s Hydronic Heating System. This type of antifreeze is not formulated to transfer heat, which is essential to the Heating System’s functionality and does not contain rust inhibitors.

  • Page 55: Bleeding The Domestic Water System

    2. Replace the Aqua-Hot’s Fill/Radiator Cap, but do not tighten completely. NOTE: The Fill Radiator Cap should remain loose during the Bleeding and Filling Procedure in order to allow air to escape from the top portion of the Aqua-Hot’s Heat Tank.
  • Page 56 Should a loss of pressure occur, check the connections at each Heat Exchanger using a soapy water solution, and Figure 33 watch for bubbles to appear, which indicates an air leak. Page 53 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 57: Bleeding The Engine Preheat System

    Circuit Breaker required) 120 Volt-AC power supplies to the Aqua-Hot’s VAC Service Input; reference Figure 34B. 2. Insert the wire(s) through the Aqua-Hot’s ROMEX Clamp and connect the 120 Volt-AC Power supply to the Aqua-Hot’s Electric Heating Element wires as illustrated in Figure 34A for the AHE-100-04S Model or Figure 34B for the AHE-130-04X Model.
  • Page 58 B1 + #1 FAN - C7-I C1-O #1 THERM-O B2 - #1 THERM-I B4 + B3 + B6 - DIESEL-O DIESEL-I ELECTRIC-O ELECTRIC-I PREHEAT-O PREHEAT-I IND-LT (+) B4 IN +12V IND-LT (-) Page 55 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 59 2000 Watt Electric Heating Figure 34B Element Electric Heating Element Access Cover N.C. ELECTRIC HEATING ELEMENT VAC HIGH LIMIT 120VAC,2000W VAC RELAY N.C. ELECTRIC HEATING ELEMENT VAC HIGH LIMIT 120VAC,2000W VAC RELAY Page 56 Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 60: Initial Activation Of The Aqua-Hot

    3.30 Initial Activation of the Aqua-Hot the Aqua-Hot Move the Aqua-Hot’s “Diesel” switch to the ON position. Do this by pressing the switch in an upward motion. NOTE: Activate the “Diesel” switch for approximately five seconds ONLY and then switch it OFF. This procedure will purge the Diesel-Burner’s fuel system by allowing the Heater’s Fuel-Pump to operate for approximately three minutes...

  • Page 61: Appendix A Wiring Diagrams

    APPENDIX A Wiring Diagrams...
  • Page 62 APPENDIX A Wiring Information (AHE-100-04S) �� ��� Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 63 APPENDIX A Wiring Information (AHE-130-04X) 12 VDC 12 VDC 7 BLK Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 64 24 WATTS MAX. ELECTRIC-O ELECTRIC-I BEDROOM PREHEAT-O PREHEAT-I HEATING ZONE #1 ���������� IND-LT (+) B4 IN +12V IND-LT (-) SWITCH PANEL ENGINE ELECTRIC DIESEL PREHEAT ��� TO 12VDC (OPTIONAL) POWER SUPPLY (I.E., BATTERY CONNECTIONS) Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 65 APPENDIX A Enlarged View of Switch Panel and Heating Zone Wiring (AHE-130-04X) THERMOSTAT E #5 E #4 E #3 THERMOSTAT E #2 THERMOSTAT E #1 THERMOSTAT E . I To the 1-Way Plugs Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...

  • Page 66: Appendix B Wire Gauge Information

    APPENDIX B Wire Gauge Information...

  • Page 67: Wire Gauge Chart

    F e e t ON CIRCUIT IN AMPS. 12 Volts - 3% Drop Wire Sizes (gage) - Based on Minimum CM Area 24 Volts - 3% Drop Wire Sizes (gage) - Based on mInimum CM Area Aqua-Hot™ Hydronic Heating System Installation Manual 07/05...
  • Page 68 �������������������������������������������������������������� 15549 East Highway 52 Fort Lupton, Colorado 80621 1-800-685-4298 Fax: 303-857-9000 © Copyright 2005 Vehicle Systems, Inc. All rights reserved. www.vehiclesys.com �����������...

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Ahe-130-04x-12 vdc

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