Airxcel Aqua-Hot 100 Series Installation Manual

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Installation manual (62 pages)

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Installation Manual

100

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AHE-125-GN1

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Page 1 Installation Manual Series AHE-125-GN1...
Page 2: Table Of Contents
Caution Notes Introduction Contents Caution Notes Caution Notes ................1 As you read this information, take particular note of the NOTICE, Installation Checklist ..............2 CAUTION, WARNING, and DANGER symbols when they appear. This information is important for safe and efficient use of the Introduction ..................4 Aqua-Hot system.
Page 3: Installation Checklist
Installation Checklist Introduction Introduction: WARNING! Read and understand all instructions before installing the The following table is a checklist of important items that Aqua-Hot unit and the external gas burner. Aqua-Hot Heating need to be completed for a successful install of the 125-GN1 Systems is not liable for damage resulting from failing to Aqua-Hot heater in your RV.
Page 4 Installation Checklist Introduction Completed Description Page No. RV Thermostats OR Thermistors wired to Aqua-Hot 22-23 House Power Sense wire connected 12VDC connected to Aqua-Hot 120VAC connected to Aqua-Hot Cozy heat exchangers installed 27-29 Cozy heat exchangers wired Cozy’s plumbed (in the bottom port, out through the top port) Domestic Water System plumbed to the Aqua-Hot Domestic Water Flow through the Aqua-Hot regulated to 0.8 GPM Attach Terminating Resistor to LCD Screen RVC Cable...
Page 5: Introduction
Introduction Safety Features Read all instructions before installing the Aqua-Hot unit and the external gas burner. Aqua-Hot Heating Systems is not liable for damage resulting from failing to follow instructions contained Low-Voltage Shutdown in this, and any other Aqua-Hot documentation relevant to this The Aqua-Hot Controller is designed to operate between 11V DC and 16V DC.
Page 6 Introduction Safe Installation of the Gas Burner Exhaust System Be sure to become familiar with the installation process and the documentation before installing in the vehicle. • Make sure to protect the burner during installation. Do not drop or stand on the burner. •...
Page 7 Introduction System Overview Important Notes: • A qualified installer or service technician must perform The Aqua-Hot 125GN is a Hydronic Heating System that can equipment installation or service. Contact Aqua-Hot for provide heat and hot water on demand using a built-in electric Factory Authorized Service Centers or Certified Technicians heating element and an external gas burner.
Page 8: System Features
System Features Figure 1 System Specifications Electric Element Power Consumption ........1500 W (maximum) Voltage ................110V AC DC Power Power Consumption .......... 57 W (maximum) Zone Heat Circulation Pumps ...................1 Power Consumption (max) ..........20W/1.7A Voltage ................12V DC Interior Heating Maximum Heating Zones .............3 Cozy ............
Page 9 System Features NOTE: This product label is attached to the top of the burner and provides a ready reference to specifications, test standards, and important safety notices. Figure 2 System Specifications TECHNICAL SPECIFICATIONS Heating Medium Ethylene Glycol/Distilled Water Gasoline Burner High Power Operation: 5000W Thermal Power (W) Heat Flow ..........5,188 to 17,060 BTU/hr...
Page 10: Component Cut-Aways
Component Cut-Aways Aqua-Hot 125GN 1. Fluid Circulation Pump 2. Tempering Valve 3. Aqua-Hot Controller 4. Antifreeze and Water Heating Solution Tank Figure 4 5. AC Electric Element 6. AC Activation Relay Plate-to-plate Heat Exchanger 8. Three-Way Valve 9. Zone Air-Bleed Valve 10.
Page 11 Component Cut-Aways Belief Gas Burner 1. Combustion Air Fan 12. Fuel Pipe 2. Burner Outer Casing 13. Coolant Pump 3. Burner Inner Casing 14. Fuse 4. Combustion Chamber 15. Main Wire Harness 5. Glow Plug Connector 6. Flame Sensor 16. Fuel Pump Temperature sensor 17.
Page 12: Installing The Aqua-Hot
Support and Clearance Installing the Aqua-Hot Installing the Aqua-Hot Support and Clearances Install the Aqua-Hot in a compartment which protects the Make the following considerations when supporting the unit and allows service access to the top and front panel of the Aqua-Hot to ensure its most optimal operation and location.
Page 13: Installation Of The Expansion Bottle
Fluid Expansion Bottle Installation of the Expansion Bottle The fluid expansion bottle is integral to the operation of the mounting location in the RV. Please only use the length Aqua-Hot. It provides an area for hot, expanded fluid to empty of hose provided, or less, if the bottle is not mounted to into, and also protects the Aqua-Hot from low-fluid, which could the side of the Aqua-Hot.
Page 14: Mounting The Burner To The Vehicle
Fluid Expansion Bottle Mounting the Burner Mounting the Burner to the Vehicle Install the external gas burner in a location separate from the • The burner can be oriented to suit different orientations/ living spaces that protects the unit, and also allows service positions, however it should not exceed an angle greater access to the burner.
Page 15: Combustion Air & Exhaust System
Combustion Air System Fluid Expansion Bottle Combustion Air System The combustion air should not be supplied from living areas. The combustion air intake may be installed in the same The air intake opening must not point in the direction of travel. compartment as the vehicle’s fuel tank, but the air intake must It also should be free from potential clogs from snow, debris, or come from the exterior.
Page 16 Fluid Expansion Bottle Exhaust System Exhaust System The exhaust pipe should be cut to form two sections: the exhaust pipe and exhaust tail-pipe. The muffler will be installed in the middle and fixed with the muffler holder. It may not be fastened to temperature-sensitive vehicle parts.
Page 17: Burner Harness
Fluid Expansion Bottle Burner Harness Gas Burner Wire Harness B3 Connector The gas burner and connectors will need to be properly installed. Please note that the connectors will not fit in incorrect positions. The connectors and information are shown below. B1 Connector Figure 29 B3 Plug:...
Page 18 Fluid Expansion Bottle Burner Harness B2 Connector K_Line Converter Figure 31 Figure 34 B2 Plug: K_Line Converter: The B2 plug is the connector for the converter. The K_Line converter connects the burner to the Aqua-Hot. The LEDs show the operation of the converter. They can be found on Converter Side Connector the side of the converter.
Page 19 Fluid Expansion Bottle Burner Harness NOTE: It is recommended to mount the K_Line Converter using double-sided Velcro on the Aqua-Hot Cabinet, either on the top, in-between ports, or either side of the cabinet where space allows. Figure 36 p. 18 ©Aqua-Hot®...
Page 20: Connecting The Burner To The Aqua-Hot
Connecting to the Aqua-Hot Fluid Expansion Bottle Connecting the Burner to the Aqua-Hot These instructions will cover the installation and power connections for the gas burner to the 125GN. Installation Instructions 1. Mock-up the locations for the gas burner and the Aqua-Hot 8.
Page 21: Burner Connections
Fluid Expansion Bottle Burner Connections Burner Connections Please reference the instructions below and the image in Figure 42. • The circulation pump inlet should be below the coolant outlet port to eliminate air in the line when installing. • Verify the inlet and outlet ports on the burner prior to installing hoses. The correct direction of the coolant flow must be determined.
Page 22: Burner Plumbing Requirements
Plumbing Requirements Fluid Expansion Bottle Plumbing Requirements Hose Clamps The plumbing lines are how the fluid is transferred from the Aqua-Hot to the burner and back to the Aqua-Hot to transport heat to domestic water and to the interior of the RV. Properly installing the coolant hoses to the Aqua-Hot from the burner are integral to the correct and safe operation of the heating system.
Page 23: Wiring The Aqua-Hot To The Rv
Introduction to Wiring Wiring the Aqua-Hot Wiring the Aqua-Hot This section will introduce the basic considerations, practices, and information necessary to wire the Aqua-Hot to any relevant RV-side systems. The following section will outline the basic pin out information for the two RV-side plugs. J8 Plug J7 Plug The J8 plug is meant to handle the zone thermostats and House...
Page 24 Introduction to Wiring Wiring the Aqua-Hot Wiring the Aqua-Hot (continued) The following section will outline the basic pin out information for the RV-C system of the RV. J3 Plug The J3 plug connects to the on-board RV-C system of the RV. It is a 4-pin connector with self contained power pins.
Page 25: House Power Sense
House Power Sense House Power Sense The Aqua-Hot Controller contains within it a fail-safe functionality known as House Power Sense. This functionality serves as a live signal to the Aqua-Hot allowing it to continue operating. If power is lost to the on-board RV-C network or other on-board control systems, the Controller is signaled to shut down operation until a 12V DC power signal is returned to the unit.
Page 26: Connecting The 125Gn To 12V Dc Power
Providing DC Power Connecting the 125GN to 12V DC Power Positive/Power In-Line DO NOT connect 12V DC power to the Aqua-Hot if Fuse the vehicle requires welding. Electrical welding will cause serious, irreversible damage to the Main Battery Vehicle Battery Aqua-Hot.
Page 27: Connecting The Aqua-Hot To Ac Power
Providing AC Power Connecting the Aqua-Hot to AC Power The following section will detail how to connect the Aqua- AC Electric Connection Hot to the vehicle’s AC electric system. Connect the 3-pin Molex connector to the coach-side AC electric system in order to utilize the Aqua-Hot’s AC heating element.
Page 28: Installing Heat Exchangers
Installing Heat Exchangers Heat Exchanger Installation Requirements Cozy heat exchangers can be mounted in one of two configurations: either flat on the ground, or vertically. Reference Vertical Orientation Figure 58. • Supply ventilation cross-sectional area of at least 29in (74cm ) must be supplied to each heat exchanger.
Page 29: Heat Exchanger Locations & Clearances
Locations and Clearances Heat Exchanger Locations and Clearances • Position the heat exchangers so that even heat is distributed throughout the RV interior. • The first heat exchanger on the loop will output the most interior heat. • It is best practice to place the heat exchanger in an area where it can be easily accessed for maintenance.
Page 30: Mounting The Heat Exchangers
Locations and Clearances Mounting the Heat Exchangers Mounting the Heat Exchangers 1. Cut out a 2.5” x 10” (7cm x 26cm) opening for each heat Plenum Assembly exchanger outlet and cold-air return grate as shown in Figure 63. 1. Hot Air Outlet Vent 4.
Page 31: 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 modifications.
Page 32: Plumbing The Heating Loop
Plumbing the Heating Loop Plumbing the Heating Zone The following guidelines should be used when planning the coolant loop for the heating zone. The 125GN requires a single fluid zone. The order of the heat exchangers should consider priority on the loop. Failure to adhere to these installation Outlet principles can hinder the operation of the heat exchangers.
Page 33: Layout Example
Plumbing the Heating Loop Layout Example Aqua-Hot Heating System Gas Burner Cozy #3 Cozy #2 Bedroom Kitchen Cozy #1 Living Space Figure 72 NOTE: This is just a sample for the layout of the gas burner with the Aqua-Hot and heat exchangers. Actual placement may vary on the individual design of the RV.
Page 34: Domestic Water System
Domestic Water System Domestic Water System Requirements Plumbing the Domestic Water System • Reference A119.2/NFPA 501C Standard on Recreational The Aqua-Hot is also able to provide domestic hot water Vehicles 1993 Edition for relevant regulatory information while the boiler tank is up at operating temperature. Activate regarding the design of Domestic Water Systems.
Page 35: Mounting The Aqua-Hot Lcd
Mounting the Aqua-Hot LCD Mounting the Aqua-Hot LCD This following section will explain in detail how to mount the Aqua-Hot LCD on the interior of the RV. Mounting Considerations: 3.5” LCD Diagnostic Screen • Purchase the necessary RV-C connection parts according to the table below.
Page 36: Rv-C Network Connectivity
Mounting the Aqua-Hot LCD RV-C Network Connectivity RV-C Network Connectivity The Aqua-Hot LCD is designed to interface with the RV-side 3.5in LCD Display RV-C network to aid in the Aqua-Hot’s integration into the on- board RV-C network. There is an indicator light on the back of the LCD which Network Cable shows the current status of the LCD’s connection to the RV-C network.
Page 37: Operating The Lcd & Aqua-Hot
Mounting the Aqua-Hot LCD Operating the LCD Operating the LCD & Aqua-Hot This section will outline the basic operating instructions for the Aqua-Hot LCD Screen. Climate Pages: The climate pages are for all intents and purposes the If the zone temperature is set, but this item “Home”...
Page 38 Mounting the Aqua-Hot LCD Operating the LCD System Status (4): This item will indicate the current operational status of the Aqua-Hot. If any faults have triggered, those will be displayed here. During normal operation, this should display either INTERIOR HEAT or HOT WATER relating to the priority and position of the 3-way valve.
Page 39: Configuring The Zones
Configuring the Zones Configuring the Zones Once the heat exchangers and thermostats have been wired to the Aqua-Hot, the Controller must be configured in order to correctly manage these zones. Configuration: Zone Settings (B): In order to configure these zones for first use, locate the Zone settings will change the way each zone is Aqua-Hot LCD screen and navigate to the Aqua-Hot Diagnostics labeled on the home screen of the LCD, as...
Page 40: Filling The Aqua-Hot
Filling the Aqua-Hot Filling the Aqua-Hot Before the first activation of the Aqua-Hot, fill the unit with antifreeze and water heating solution. Without the solution present, the Aqua-Hot will not operate. Follow the directions below to fill the Aqua-Hot with antifreeze and water heating solution. A mixture of 50/50 Ethylene Glycol antifreeze and distilled water is recommended.
Page 41: Purging The Interior Heating Loop
Purging the Heating Loop Purging the Interior Heating Loop During installation, it is possible that air may become trapped within the heating loop and hamper unit performance. Follow this procedure to purge any air from the interior heating loop. Purge Procedure 1.
Page 42: Fuel Supply
Purging the Heating Loop Fuel Supply Fuel Supply Failure to follow instructions on the fuel delivery system can cause damage to the Aqua-Hot 125GN, the gas burner, or the RV. It may cause serious personal injury. Please follow instructions carefully. NOTE: The First Install Kit includes all the couplers, clamps, and fuel lines needed for a proper install of the fuel system.
Page 43: Fuel System
Purging the Heating Loop Fuel System Figure 90 NOTE: The diagram above is not drawn to scale. It is simply a reference for proper installation of the fuel system for the Belief Gas Burner. Fuel Lines Requirements • The fuel line must be secured to the connections and couplers by hose clamps.
Page 44 Purging the Heating Loop Fuel System CORRECT CORRECT WRONG Bubble WRONG Bubble NOTE: The fuel lines must be secured and supported properly to avoid air Fuel Line to Coupler Hose traps or bubbles. Avoid unnecessary dips or bends, the line should not run A Clamp B Coupler C Fuel Hose...
Page 45 Purging the Heating Loop Fuel System Fuel Clamps The fuel lines and couplers must be properly crimped to avoid leaks NOTE: The Cinch Clamp Crimping Tool is provided in or air in the fuel system. Below are images of what properly crimped the First Install Kit.
Page 46: Fuel Purge Procedure
Purging the Heating Loop Fuel System Purge Fuel Purge Procedure Perform this procedure once the burner and Aqua-Hot are completely installed and the Aqua-Hot is adequately filled and purged. The fuel lines should be automatically primed with the first • Ground goes to Pin #1 operation of the burner.
Page 47: Gas Burner Troubleshooting
Purging the Heating Loop Burner Troubleshooting External Gas Burner Troubleshooting The troubleshooting procedures listed below are arranged in order of repair complexity. Do not replace parts without correctly determining the failure. Follow the directions below in order to troubleshoot the gas burner. Do not skip through the troubleshooting steps, as this may needlessly complicate unit diagnosis and repair.
Page 48 Purging the Heating Loop Burner Troubleshooting External Gas Burner Faults & Remedies Fault Fault Fault Cause Remedy Fault Cause Remedy Code Code Burner: Voltage too high (exceeds • Check power supply • Wait for flame sensor 16V) Burner: Failed to Ignite cooling Combustion chamber •...
Page 49 Purging the Heating Loop Burner Troubleshooting General Failure Symptoms of the Burner This section will cover the typical failures of the gas burner. Refer to the table more fails and their remedies. Failure Symptom Possible Cause Remedy No combustion after start or automatic Switch off burner and switch back on.
Page 50: System Checks
Purging the Heating Loop System Checks System Checks Please do the following checks prior to the first operation to confirm the installation was done properly and safely. 1. Confirm that the Aqua-Hot 125GN is fully and properly 21. The standpipe should not interfere with the vehicle fuel installed.
Page 51: First Operation
Purging the Heating Loop First Operation Aqua-Hot First Operation Activation Instructions (Electric Element): The first operation of the burner with the Aqua-Hot may not light up perfectly. It may take 5-6 starts for the burner to ignite for 1. Make sure power supply to the Aqua-Hot is on. the first start-up after installation, because the fuel pump needs to fill the fuel lines leading to the burner for ignition.
Page 52: Winterizing
Purging the Heating Loop Winterizing the Aqua-Hot Winterizing the Aqua-Hot The Aqua-Hot’s domestic water heating system must be completely drained of domestic water at any time the heater is stored where freezing temperatures may be experienced. Please follow these instructions when winterizing the Aqua- Not winterizing the Aqua-Hot when freezing temperatures Hot domestic water heating system.
Page 54: Appendix A: System Schematics
Purging the Heating Loop System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. ©Aqua-Hot® 125-GN1 Installation Manual REV 220427 p. 53...
Page 58: Appendix B: Measuring Antifreeze
Measuring Antifreeze Appendix Measuring Antifreeze Using a Refractometer 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 ethylene 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 59: Appendix C: Parts & Accessories
Parts & Accessories Appendix AHE-125-GN1 100 Series Gasoline with Electric Element (1500W / 120V AC) ELE-400-900 ELX-THM-309 Boost Pump Harness Thermistor, 10K NTC, Room Temperature Sensor ELX-700-007 EXE-103-0EX Room Thermostat, Positive Off Heat Exchanger, Cozy III p. 58 ©Aqua-Hot® 125-GN1 Installation Manual REV 220427...
Page 60 Parts & Accessories Appendix EXE-505-65A EXX-006-500 Heat Exchanger, Whisper Silent, 12V DC. 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”...
Page 61 Parts & Accessories Appendix ELE-125-200 PLX-000-200 RV-Side Wire Harness ( optional ) 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 PLX-100-900 PLX-120-626 Boost Pump Tube, ⅝”, Red O2 Barrier Pex 100 Ft. p.
Page 62 Parts & Accessories Appendix PLX-200-103 PLX-284-74V Fitting ½” (M) NPT x ¾ ” Barb Black Nylon Hose, Molded, Elbow 90° PLX-432-000 PLX-803-000 Fitting, Straight, ½” PEX x ½” (M)NPT PSF Fitting, Straight, ½” PEX x ½” (F) NPT PLX-803-ELB PLX-803-FSE Elbow Fitting, 90°, ½”...
Page 63 Parts & Accessories Appendix PLX-CTB-270 PLX-A51-106 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 Modified Brass Cozy Plenum Assembly p.
Page 64 Parts & Accessories Appendix Clamp Crimp Tool for Fuel Line Install 5kW Belief Gasoline Burner Fuel Kit (Included with First Install Kit) (Included with 125GN Burner) HDX-102-111 HDX-102-113 Clamp, ⅜ to (11.3mm), Soft Hose and Tube Clamp, (10.5mm), Soft Hose and Tube MSX-907-162 Refractometer ©Aqua-Hot®...
Page 65: 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 ma- terial 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.
Page 66 Installation Manual SERIES Aqua-Hot Heating Systems, LLC 7501 Miller Drive, Frederick, CO 80504 Visit us online at www.aquahot.com Call us at (800) 685-4298 or (303) 651-5500 ©2022 Aqua-Hot Heating Systems, LLC. Printed in the USA...

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