Airxcel Aqua-Hot 100 Series Installation Manual

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100

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AHE-100-DE1

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Page 1 Installation Manual Series AHE-100-DE1...
Page 2: Table Of Contents
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 efﬁ cient use of the Declaration of Conformity ............4 Aqua-Hot system.
Page 3: Installation Checklist
Friday, between 8:00 to 16:00 CET. You can also email installation and user manuals installation or service. at info@airxcel.eu. Authorized Service Centers can also be found online at www.aquahot.com. Contact your authorized service or Aqua-Hot Heating Systems if you have any questions starting installation.
Page 4 Installation Checklist Introduction Completed Description Page No. House Power Sense wire connected 12VDC connected to Aqua-Hot 240VAC connected to Aqua-Hot Cozy’s installed 27-29 Cozy’s 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 Aqua-Hot LCD mounted in correct orientation Heating Zones conﬁ...
Page 5: Declaration Of Conformity
Declaration of Conformity Introduction DECLARATION OF CONFORMITY p. 4 ©Aqua-Hot® 100-DE1 Installation Manual...
Page 6: Introduction
Introduction Safety Features Read and understand all instructions installing the Aqua-Hot unit and the external diesel burner. Aqua-Hot Heating Systems is not liable for damage resulting from failing to Low-Voltage Shutdown follow instructions contained in this, and any other Aqua-Hot The Aqua-Hot Controller is designed to operate between documentation relevant to this unit.
Page 7 Introduction Safe Installation of the Diesel 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 8 Should additional assistance be needed, please contact Technical Support at +39 0424 1953311 from 08:00 to 16:00 CET Monday through Friday or email us at info@airxcel.eu. ©Aqua-Hot® 100-DE1 Installation Manual p. 7...
Page 9: System Features
System Features Figure 1 System Speciﬁ cations Electric Element Power Consumption ........1.5 kW (maximum) Voltage ................240V AC DC Power Consumption ............. 84 W (maximum) Zone Heat Circulation Pumps ...................1 Power Consumption (max) ............. 21W Voltage ................12V DC Heating Zones Maximum ..................3 Domestic Water Heating Maximum ..............
Page 10 System Features Figure 2 System Speciﬁ cations NOTE: This product label (shown above) is attached to the side of the burner and provides a ready reference to Diesel Burner speciﬁ cations, test standards, and important safety notices. Heat Flow ..............2.5 to 5 kW Diesel Fuel Consumption........0.31 to 0.49 l/hr Operating Pressure (med heat).........2.5 bar Flow Rate (minimum)............250 l/hr...
Page 11: Component Cut-Aways
Component Cut-Aways Aqua-Hot 100-DE1 1. Fluid Circulation Pump 2. Tempering Valve 3. Aqua-Hot Controller 4. Antifreeze and Water Heating Solution Tank 5. AC Electric Element Figure 4 6. AC Activation Relay Plate-to-plate Heat Exchanger 8. Three-Way Valve 9. Zone Air-Bleed Valve 10.
Page 12 Component Cut-Aways Aqua-Hot Diesel Burner 1. Combustion Air Fan 2. Fluid Outlet 3. Fluid Inlet 4. Combustion Chamber 5. Circulation Pump 6. Exhaust Gas Temperature Sensor Exhaust Outlet 8. Control Unit 9. Burner Motor 10. Fuel Inlet 11. Combustion Air Inlet 12.
Page 13: Installing The Aqua-Hot
Support and Clearance 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 side access panel Aqua-Hot to ensure its most optimal operation and location. of the Aqua-Hot.
Page 14: Installation Of The Expansion Bottle
Fluid Expansion Bottle Installation of the Expansion Bottle Fill Cap Introduction: Upper Fitting The ﬂ uid expansion bottle is integral to the operation of the Aqua-Hot. It provides an area for hot, expanded ﬂ uid to empty Hot Fluid Line into, and also protects the Aqua-Hot from low-ﬂ...
Page 15: Mounting The Burner To The Vehicle
Fluid Expansion Bottle Mounting the Burner Mounting the Burner to the Vehicle • The burner must be fastened on the bracket with at least 3 Install the external diesel burner in a location separate from the M5 bolts (see Figure 21). living spaces that protects the unit and allows service access •...
Page 16: Combustion Air & Exhaust Systems
Combustion Air System Fluid Expansion Bottle Combustion Air System Should this particular application require modiﬁ cation, please contact Aqua-Hot Heating Systems at +39 0424 1953311 for further assistance. The combustion air should not be supplied from living areas. The air intake opening must not point in the direction of travel. It also should be free from potential clogs from snow, debris, or water.
Page 17 Fluid Expansion Bottle Exhaust System Exhaust System Exhaust Outlet Requirements • The exhaust gas must be able to ﬂ ow freely. • The exhaust outlet must not be clogged with snow or debris. • Exhaust outlet must not face in the direction of travel. •...
Page 18: Burner Harness
Fluid Expansion Bottle Burner Harness Diesel Burner Wire Harness X6 Connector The diesel burner and connectors will need to be properly installed. Please note that the connectors will not ﬁ t in the incorrect positions. The connectors and information are shown below. X3 Connector Figure 30 X6 Plug:...
Page 19 Fluid Expansion Bottle Burner Harness Burner Wire Harness Diagram Figure 32 Burner Bottom View BURNER X6 BURNER X3 Figure 33 p. 18 ©Aqua-Hot® 100-DE1 Installation Manual...
Page 20: Connecting The Burner To The Aqua-Hot
Connecting to the Aqua-Hot Fluid Expansion Bottle Connecting the Burner to the Aqua-Hot Wires J6-3, J6-9, J6-12 and ground will terminate in a 4-pin receptacle connector like the one shown below. Reference the table below for more information. These instructions will cover the installation and connections for the diesel burner to the 100-DE1.
Page 21: Burner Connections
Fluid Expansion Bottle Burner Connections Burner Connections 15mm Self-Tapping Screw The burner comes pre-assembled, but the direction of the Coolant Connector supply or return connectors can be modiﬁ ed if needed. Housing Please reference the instructions below and the image in Figure •...
Page 22: Burner Plumbing Requirements
Plumbing Requirements Fluid Expansion Bottle Plumbing Requirements Diesel Burner Return Port The plumbing lines are how the ﬂ uid 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 Hose Clamps...
Page 23: Wiring The Aqua-Hot
Introduction to Wiring Wiring the Aqua-Hot Wiring the Aqua-Hot J8 Plug: The J8 plug is meant to handle the zone thermostats and House This section will introduce the basic considerations, Power Sense functionality. House power sense functionality will practices, and information necessary to wire the Aqua-Hot to be described in detail later in this manual.
Page 24 Introduction to Wiring Wiring the Aqua-Hot J3 Plug: The J3 plug connects to the on-board RVC system of the RV. It is a 4-pin connector with self contained power pins. See the diagram below for the crimping information for the J3 plug. Crimp these parts together using pliers.
Page 25: House Power Sense
House Power Sense House Power Sense Typical The typical use case in wiring the House Power Sense requires a constant 12V DC signal on Introduction: plug J3-1 for the House Power Sense. Plug J3 is the 4-position RVC plug. This is the easiest The Aqua-Hot Controller contains within it a fail-safe way to implement House Power Sense on functionality known as House Power Sense.
Page 26: Connecting The 100-De1 To 12V Dc Power
Providing DC Power Connecting the 100DE to 12V DC Power The section will outline the requirements, steps, and information necessary to connect the Aqua-Hot to the vehicle’s DO NOT connect 12V DC power to the Aqua-Hot if 12V DC power system. the vehicle requires welding.
Page 27: Connecting The Aqua-Hot To Ac Power
Providing AC Power Connecting the Aqua-Hot to AC Power AC Electric Connection The following section will detail how to connect the Aqua-Hot to the vehicle’s AC electric system. When the RV is connected to an AC power source (plugged into shore power or a generator), the Aqua-Hot boiler tank is heated by a 1.5kW electric heating element.
Page 28: Installing Heat Exchangers
Installing Heat Exchangers Installation Requirements Vertical Orientation Cozy heat exchangers can be mounted in one of two conﬁ gurations: either ﬂ at on the ground, or vertically. Reference Figure 55. Horizontal Orientation • Supply ventilation cross-sectional area of at least 74cm must be supplied to each heat exchanger.
Page 29: Heat Exchanger Locations And Clearances
Locations and Clearances Heat Exchanger Locations and Clearances • Position the heat exchangers so that even heat is distributed throughout the RV interior. • The ﬁ rst 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
Mounting the Heat Exchangers Locations and Clearances Mounting the Heat Exchangers Plenum Assembly 1. Cut out a 7cm x 26cm opening for each heat exchanger 1. Hot Air Outlet Vent 4. Cozy Heat Exchanger outlet and cold-air return grate as shown in Figure 60. 2.
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 modiﬁ...
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 100-DE1 requires a single Outlet ﬂ uid zone. The order of the heat exchangers should consider priority on the loop.
Page 33: Layout Example
Plumbing the Heating Loop Layout Example Aqua-Hot Heating System Diesel Burner Cozy #3 Cozy #2 Bedroom Kitchen Cozy #1 Living Space Figure 69 NOTE: This is just a sample for the layout of the diesel burner with the Aqua-Hot and heat exchangers. Actual placement may vary on the individual design of the RV.
Page 34: Domestic Water System Requirements
Domestic Water System Domestic Water System Requirements Plumbing the Domestic Water System • Reference any local standards and/or codes for relevant The Aqua-Hot is also able to provide domestic hot water regulatory information regarding the design of Domestic while the boiler tank is up at operating temperature. Activate Water Systems.
Page 35: Mounting The Aqua-Hot Lcd
Mounting the Aqua-Hot LCD Mounting Procedure: Mounting the Aqua-Hot LCD 1. Select a location within the RV. 2. Cut a 7,77cm x 13,08cm hole in the RV wall. 3. Route the corners of this cutout with a 64mm diameter bit. 4.
Page 36: Operating The Lcd
Mounting the Aqua-Hot LCD Operating the LCD Operating the LCD If the zone temperature is set, but this item is not set to ON, the zone heat exchanger will Introduction: not activate. This document will outline the basic operating instructions Section B: for the Aqua-Hot LCD Screen.
Page 37 Mounting the Aqua-Hot LCD Operating the LCD System Status (4): Module Options (5): This item will indicate the current operational status of the Tapping on the module options screen (the 3 lines on the Aqua-Hot. If any faults have triggered, those will be displayed bottom right of the home screen) will display the screen shown here.
Page 38: Confi Guring The Zones
Conﬁ guring the Zones Conﬁ guring the Zones Number of Zones (A): The Aqua-Hot can control between 1 and 3 heating zones within the RV. Modifying this Introduction: will set the Controller to manage 1, 2, or 3 heating zones. Once the heat exchangers and thermostats have been wired to the Aqua-Hot, the Controller must be conﬁ...
Page 39: Filling The Aqua-Hot
Filling the Aqua-Hot Filling the Aqua-Hot 8. On the LCD screen, navigate to the TESTING page, turn on the pump, and set the 3-way valve to “HOT WATER”. Before the ﬁ rst activation of the Aqua-Hot, ﬁ ll the unit with antifreeze and water heating solution.
Page 40: Purging The Interior Heating Loop
Purging the Heating Loop Purging the Interior Heating Loop 8. Tap “PUMP” to activate the ﬂ uid circulation pump, and if In order to provide interior heat to the vehicle, antifreeze applicable, “BOOST PUMP” to activate the zone boost and water heating solution is circulated within an interior pump.
Page 41: Fuel Supply
Purging the Heating Loop Fuel Supply Fuel Supply Fuel Standpipe Installation 1. Drill a 25mm hole through the top of the fuel tank. 2. Remove sharp pieces and smooth edges with sandpaper or an emery cloth. Failure to follow instructions on the fuel delivery system can 3.
Page 42: Fuel System
Purging the Heating Loop Fuel System 5. Max Delivery Height (5) = 3m 1. Fuel Line Coupler 6. Max Delivery Length (5 + 6) = 9m 2. Fuel Filter 7. Max Suction Length (7 + 8) = 3m 3. Fuel Pump 4.
Page 43 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 44: Fuel Purge Procedure
Purging the Heating Loop Fuel System Purge Fuel Purge Procedure: properly secured. 5. Ensure that the exhaust is well ventilated. The fuel lines should be automatically primed with the ﬁ rst 6. Turn the burner to ON at the screen (see below). The operation of the burner.
Page 45: External Diesel Burner Troubleshooting
Purging the Heating Loop Burner Troubleshooting External Diesel Burner Troubleshooting This section will cover any issues with the external diesel burner. The diesel burner is the primary heat source to the 100-DE1. The troubleshooting procedures listed below are arranged in order of repair complexity. Do not replace parts without correctly determining the failure.
Page 46 Purging the Heating Loop Burner Troubleshooting General Failure Symptoms of the Burner This section will cover the typical failures of the diesel 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 47: System Checks
Purging the Heating Loop System Checks System Checks 16. Check all plumbing connections for leaks. 17. Check that the fuses are in their proper, speciﬁ ed locations. 18. Make sure the fuse boxes are secure and protected from any water sources. 19.
Page 48: First Operation
Purging the Heating Loop First Operation Aqua-Hot First Operation The ﬁ rst operation of the burner with the Aqua-Hot may not light up perfectly. This is normal and may take a couple tries to get the fuel lines purged of air before a successful start-up. Activation Instructions (Electric Element): NOTE: Make sure to perform the fuel line purge procedure 1.
Page 49: Winterizing
Purging the Heating Loop Winterizing the Aqua-Hot Winterizing the Aqua-Hot Disinfecting the Domestic Water System 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- Hot domestic water heating system.
Page 51: Appendix A: System Schematics
Purging the Heating Loop System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. p. 50 ©Aqua-Hot® 100-DE1 Installation Manual...
Page 55: 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 56: Appendix C: Parts & Accessories
Parts & Accessories Appendix AHE-100-DE1 ELE-400-900 ELX-THM-309 Boost Pump Harness Thermistor, 10K, NTC, Room Temperature Sensor ELE-100-111 EXE-103-0EX Kit, RV-Side Controller Components Heat Exchanger, Cozy III ©Aqua-Hot® 100-DE1 Installation Manual p. 55...
Page 57 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 58 Parts & Accessories Appendix PLE-125-FL1 PLX-000-200 Kit, Fuel Line, 100-DE1 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. ©Aqua-Hot®...
Page 59 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” PEX x ½” PSF Elbow Fitting, 90°, ½”...
Page 60 Parts & Accessories Appendix PLX-CTB-270 PLX-A51-106 Clamp, Hose, Constant Tension, ¾” 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 Modiﬁ ed Bras Cozy Plenum Assembly ©Aqua-Hot®...
Page 61: 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 62 Installation Manual SERIES AIRXCEL EUROPE Via G. Apollonio 11 36061 Bassano Del Grappa - (VI) Italy Visit us online at www.aquahot.com Call us at +39 0424 1953311 ©2022 Aqua-Hot Heating Systems, LLC. Printed in the USA...

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