Airxcel Aqua-Hot 400 Series Installation Manual
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Airxcel Aqua-Hot 400 Series Installation Manual

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Installation Manual
400
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AHE-450-DE5
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  • Page 1 Installation Manual Series AHE-450-DE5 with...

  • Page 2: Table Of Contents

    Introduction Contents Caution Notes As you read this information, take particular note of the NOTICE, Caution Notes ................1 CAUTION, WARNING, and DANGER symbols when they appear. Introduction ..................2 This information is important for safe and efficient use of the Aqua-Hot system. System Features ................4 NOTICE signals a situation where potential damage to the Component Cut-Aways ..............5...

  • Page 3: Introduction

    Introduction Introduction Safety Features System Overview Read all instructions before installing the Aqua-Hot unit. Aqua- Important Notes: 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 The Aqua-Hot 450D is a Hydronic (water-based) Heating •...

  • Page 4: System Features

    System Features Component Cut-Aways 14. Wiring Harness & 1. Drain Valve Harness Port 2. Zone 1 Circulation Pump 15. Aqua-Hot Reporter 3. Zone 2 Circulation Pump 16. Domestic Water Coil 4. Diesel Burner Controller 17. Heating Loop Coil 5. Combustion Air Sleeve Figure 3 18.

  • Page 5: Installing The Aqua-Hot

    Component Cut-Aways Support and Clearance Installing the Mounting Tray & Aqua-Hot 5. Secure the mounting tray into place prior to installing the Aqua-Hot. Expansion Tank Install the Aqua-Hot in a compartment that is completely Connection 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 6: Installation Of The Expansion Tank

    Support and Clearance Fluid Expansion Bottle Fluid Expansion Tank Installation of the Expansion Tank Fill Cap Introduction: Upper Fitting The fluid expansion tank is integral to the operation of the Hot Fluid Line Aqua-Hot. It provides an area for hot, expanded fluid to empty into, and also protects the Aqua-Hot from low-fluid, which could lead to catastrophic damage of the Aqua-Hot.

  • Page 7: Exhaust System

    Fluid Expansion Bottle 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. The two black pipe exhaust fittings MUST be utilized with all installations! Failure to conform could create 1.

  • Page 8: Installing The Heat Exchangers

    Fluid Expansion Bottle Exhaust System Installing Heat Exchangers Installation Requirements Heat Exchanger Locations and Clearances Cozy heat exchangers can be mounted in one of two configurations: either flat on the ground, or vertically. Reference • Position the heat exchangers so that even heat is distributed Figure 19.

  • Page 9: Mounting The Heat Exchangers

    Installing Heat Exchangers Locations and Clearances 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 25.

  • Page 10: Wiring The Heat Exchangers

    Wiring Heat Exchangers Plumbing the Heating Loop Wiring the Heat Exchangers Plumbing the Heating Loop This section will explain in detail how to wire the heat Once all heat exchangers have been mounted, plan the exchangers for optimal functionality. Do not deviate from these routing of the plumbing lines from each heating zone to the Outlet guidelines.

  • Page 11: Plumbing The Heating Loop

    Plumbing the Heating Loop Plumbing the Heating Loop Heat Exchangers Layout Barbed Fittings Components Compression Fittings Components Figure 37 NOTE: This is just a sample for mounting locations of the NOTE: For the best performance, the first 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 12: Engine Preheat

    Plumbing the Heating Loop Engine Preheat Plumbing the Heating Loop Engine Preheat Vehicle Engine Engine Preheat & Motor-aide System Plumbing Installation 1. Install both engine preheat plumbing lines and mark with Ideal Incoming Port Potential Outlet Port The Aqua-Hot 450D includes a motor-aide feature that arrows and/or labels at both ends.

  • Page 13: Diesel Fuel System

    Plumbing the Heating Loop Fuel System Plumbing the Heating Loop Fuel System Diesel Fuel System Fuel System Installation Fuel Supply • Both fuel lines (supply and return) should be laid as The following section outlines the requirements for diesel flat as possible and any extreme rises in height should fuel delivery to the Aqua-Hot unit.

  • Page 14: Domestic Water System Requirements

    Plumbing the Heating Loop Fuel System Domestic Water System Domestic Water System Requirements Use the RVIA provided table below in order to determine the TOP View proper sizing of pipe and tubing required to ensure maximum Fuel Filter efficiency. The size of the water supply piping and branch line •...

  • Page 15: Plumbing The Domestic Water System

    Domestic Water System Domestic Water System Thermostats Plumbing the Domestic Water System Fresh Water Tank Thermostat Room Thermostat Locations The Aqua-Hot is also able to provide domestic hot water Select a location that will ensure even heat distribution Select a location that will ensure even heat throughout each while the boiler tank is up at operating temperature.

  • Page 16: Switch Panel

    Mounting the Aqua-Hot LCD Switch Panel Mounting the Aqua-Hot LCD Switch Panel Interior Switch Panel Switch Panel Mounting 1. Cut out a 3.75” W x 1.25” H opening for the switch Select a location in the interior of the coach that allows for panel plate.

  • Page 17: Wiring The Aqua-Hot

    Introduction to Wiring Introduction to Wiring Wiring the Aqua-Hot J1 Plug: J7 Plug: J9 Wire Insertion View Shown J1 Wire insertion view shown The J9 plug is an optional use terminal The J1 plug manages heating The J7 plug manages zone fans and the burner switch indicator NOTE: Reference the Schematics starting on Page 46 for that provides constant 12V DC current to any zone inputs from the coach.
  • Page 18 Introduction to Wiring Introduction to Wiring Aqua-Hot Reporter The Aqua-Hot Reporter Home Screen Wire Insertion View Shown The home screen contains information about the Aqua- The J2 Plug is responsible for managing return signals from J3 serves as the RV-C connection to the coach- Hot system status, as well as model and serial number side comfort system (if applicable).
  • Page 19 Configuring the Zones Aqua-Hot Reporter Configuring the Zones Aqua-Hot Reporter Heat Testing: Heartbeat Function Boost Pumps Burner Master Control..........2.0A max Burner Thermostat Control........1.0A max The heat testing page of the Reporter will allow the electric Aqua-Hot Reporter units with at least firmware version 1v5 Boost pump functionality...
  • Page 20 Configuring the Zones Aqua-Hot Reporter Configuring the Zones Manual Mode Reporter 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 21: Aqua-Hot Reporter

    Providing DC Power Providing AC Power Connecting the 450D to 12V DC Power Instructions: Connecting the 450D to 120V AC Power This section will outline the requirements, steps, and 1. Route and insert three 120V AC power source wires into The following section will detail how to connect the Aqua- information necessary to connect the Aqua-Hot to the vehicle’s the AC terminal block through the AC wiring port’s cable...

  • Page 22: Filling The Aqua-Hot

    Filling the Aqua-Hot Purging the Heating Loop Filling the Aqua-Hot Purging the Interior Heating Loop Purging the Domestic Water System Before the first activation of the Aqua-Hot, fill the unit with In order to provide interior heat to the vehicle, antifreeze and antifreeze and water heating solution.

  • Page 23: First Operation

    Purging the Heating Loop First Operation Purging the Heating Loop Winterizing the Aqua-Hot Aqua-Hot First Operation Winterizing the Aqua-Hot The Aqua-Hot’s domestic water heating system must be Activation Instructions completely drained of domestic water at any time the heater is stored where freezing temperatures may be experienced.
  • Page 24 Operational Flow Diagram Purging the Heating Loop Purging the Heating Loop Wire Sizes 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 fires, energizes, transferring transferring heat into...

  • Page 25: Appendix A: System Schematics

    Purging the Heating Loop System Schematics Purging the Heating Loop System Schematics p. 46 ©Aqua-Hot® 450D Installation Manual REV 220504 ©Aqua-Hot® 450D Installation Manual REV 220504 p. 47...
  • Page 26 Purging the Heating Loop System Schematics Purging the Heating Loop System Schematics p. 48 ©Aqua-Hot® 450D Installation Manual REV 220504 ©Aqua-Hot® 450D Installation Manual REV 220504 p. 49...
  • Page 27 System Schematics System Schematics p. 50 ©Aqua-Hot® 450D Installation Manual REV 220504 ©Aqua-Hot® 450D Installation Manual REV 220504 p. 51...
  • Page 28 System Schematics Antifreeze Types System Schematics Antifreeze Antifreeze Types concentrated propylene glycol for the Aqua-Hot’s antifreeze and the brand of propylene glycol antifreeze employed. Therefore, as water is an excellent heat conductor, it is water heating solution. added to the mixture. Propylene glycol antifreeze solution, The following information addresses the necessary usage mixed with distilled water, at a ratio of 35% to 50% is Rust and Anti-Corrosive Inhibitors...

  • Page 29: Appendix C: Parts & Accessories

    Measuring Antifreeze Appendix Parts & Accessories Appendix NOTE: Service parts and accessories are available through Aqua-Hot Factory Authorized Service Centers or www.aquahot.com. Click on the part number to direct you to the Aqua-Hot webstore to purchase. Measuring Antifreeze Using a Refractometer Calibration Screw Prism Assembly Daylight Plate...
  • Page 30 Parts & Accessories Appendix Parts & Accessories Appendix EXE-103-0EX EXE-505-65A EXX-006-501 EXX-006-502 Heat Exchanger, Cozy III Heat Exchanger, Whisper Silent, 12V DC. Grille, Medium, 3.5” x 15”, Black Grille, Small, 3.5” x 8.5”, Black PLE-070-401 PLX-000-200 EXX-006-500 EXX-013-100 Tank, 3 QT, Expansion Assembly Tube, ⅝”...
  • Page 31 Parts & Accessories Appendix Parts & Accessories Appendix PLX-100-836 PLX-100-900 PLX-664-730 PLX-664-750 Pump Mounting Bracket Boost Pump Fitting, Pipe Nipple, Exhaust, 1 ½” x 4” Fitting, Exhaust Nipple, 1 ½” x 3” NPT PLX-120-626 PLX-200-103 PLX-803-000 PLX-803-ELB Tube, ⅝”, Red O2 Barrier Pex 100 Ft. Fitting ½”...

  • Page 32: Warranty

    Warranty Parts & Accessories Appendix 2-YEAR LIMITED WARRANTY AQUA-HOT® HYDRONIC HEATING SYSTEM PLX-A51-106 PLX-A65-200 Bend Support, ⅝” Fitting, Brass Barb, ¾” x ½” (M) NPT 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.
  • Page 33 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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Aqua-hot 400d

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