Airxcel Aqua-Hot 100 Series Installation Manual
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Airxcel Aqua-Hot 100 Series Installation Manual

Airxcel Aqua-Hot 100 Series Installation Manual

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Installation Manual
100
Series
AHE-125-DN1

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Summary of Contents for Airxcel Aqua-Hot 100 Series

  • Page 1 Installation Manual Series AHE-125-DN1...

  • 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 efficient use of the Introduction ..................4 Aqua-Hot system.

  • Page 3: Installation Checklist

    Installation Checklist Introduction Installation Checklist Introduction Introduction: WARNING! Completed Description Page No. The following table is a checklist of important items that Read and understand all instructions before installing the need to be completed for a successful install of the 125-DN1 Aqua-Hot unit and the external diesel burner.

  • Page 4: Introduction

    Introduction Introduction Safety Features Safe Installation of the Diesel Burner Read and understand all instructions before installing the Exhaust System Aqua-Hot unit and the external diesel burner. Aqua-Hot Heating Be sure to become familiar with the installation process and the Systems is not liable for damage resulting from failing to Low-Voltage Shutdown documentation before installing in the vehicle.

  • Page 5: System Features

    Introduction System Features Important Notes: System Overview • A qualified installer or service technician must perform equipment installation or service. Contact Aqua-Hot for The Aqua-Hot 125D is a Hydronic Heating System that can Factory Authorized Service Centers or Certified Technicians provide heat and hot water on demand using a built-in electric located near you at www.aquahot.com/service-help, or call heating element and an external diesel burner.

  • Page 6: Component Cut-Aways

    System Features Component Cut-Aways Aqua-Hot 125DN 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 Figure 2 10.

  • Page 7: Installing The Aqua-Hot

    Component Cut-Aways Support and Clearance Installing the Aqua-Hot Support and Clearances Aqua-Hot Diesel Burner Install the Aqua-Hot in a compartment which protects the Make the following considerations when supporting the 1. Combustion Air Fan unit and allows service access to the top and front panel of the Aqua-Hot to ensure its most optimal operation and location.

  • Page 8: Installation Of The Expansion Bottle

    Fluid Expansion Bottle Fluid Expansion Bottle Mounting the Burner Installation of the Expansion Bottle Fill Cap Introduction: Mounting the Burner to the Vehicle The fluid expansion bottle is integral to the operation of the Upper Fitting • The burner must be fastened on the bracket with at least 3 Aqua-Hot.

  • Page 9: Mounting The High Altitude Bypass

    Fluid Expansion Bottle High Altitude Bypass Fluid Expansion Bottle High Altitude Bypass Mounting the High Altitude Bypass High Altitude Bypass Assembly The High Altitude Bypass is to modify the diesel fuel amount Line From Fuel Pump Fuel Filter Line to Burner when the RV is at an elevation of over 5,000 ft.
  • Page 10 Combustion Air System Fluid Expansion Bottle Fluid Expansion Bottle Exhaust System Combustion Air System Exhaust System Should this particular application require modification, please Exhaust Outlet Requirements contact Aqua-Hot Heating Systems at 574-AIR-XCEL (574-274- • The exhaust gas must be able to flow freely. 9235) for further assistance.
  • Page 11 Fluid Expansion Bottle Burner Harness Fluid Expansion Bottle Burner Harness Diesel Burner Wire Harness X1 Connector X6 Connector The diesel burner and connectors will need to be properly installed. Please note that the connectors will not fit in the incorrect positions. The connectors and information are shown below.

  • Page 12: Burner Harness

    Fluid Expansion Bottle Burner Harness Connecting to the Aqua-Hot Fluid Expansion Bottle Burner Wire Harness Diagram Connecting the Burner to the Aqua-Hot Locate the Aqua-Hot wire harness plug (Part Number ELE- These instructions will cover the installation and connections 102-210). The connectors for the Aqua-Hot harness and for the diesel burner to the 125DN.

  • Page 13: Burner Connections

    Fluid Expansion Bottle Burner Connections Plumbing Requirements Fluid Expansion Bottle Burner Connections Plumbing Requirements Diesel Burner 15mm Self-Tapping Screw Return Port The burner comes pre-assembled, but the direction of the The plumbing lines are how the fluid is transferred from the Coolant Connector supply or return connectors can be modified if needed.

  • Page 14: Wiring The Aqua-Hot

    Introduction to Wiring Wiring the Aqua-Hot Introduction to Wiring Wiring the Aqua-Hot Wiring the Aqua-Hot J8 Plug: J3 Plug: The J8 plug is meant to handle the zone thermostats and House The J3 plug connects to the on-board RVC system of the RV. It is This section will introduce the basic considerations, Power Sense functionality.

  • Page 15: House Power Sense

    House Power Sense Providing DC Power Connecting the 125D to 12V DC Power House Power Sense Typical Positive/Power 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 In-Line is the 4-position RVC plug.

  • Page 16: Connecting The Aqua-Hot To Ac Power

    Providing AC Power Installing Heat Exchangers Connecting the Aqua-Hot to AC Power Installation Requirements Vertical Orientation AC Electric Connection The following section will detail how to connect the Aqua- Cozy heat exchangers can be mounted in one of two Hot to the vehicle’s AC electric system. Connect the 3-pin Molex configurations: either flat on the ground, or vertically.

  • Page 17: Heat Exchanger Locations And Clearances

    Locations and Clearances Mounting the Heat Exchangers Locations and Clearances Heat Exchanger Locations and Mounting the Heat Exchangers Clearances 1. Cut out a 2.5” x 10” (7cm x 26cm) opening for each heat exchanger outlet and cold-air return grate as shown in •...

  • Page 18: Wiring The Heat Exchangers

    Wiring Heat Exchangers Plumbing the Heating Loop Plumbing the Heating Zone Wiring the Heat Exchangers The following guidelines should be used when planning the coolant loop for the heating zone. The 125D requires a single This section will explain in detail how to wire the heat fluid zone.

  • Page 19: Domestic Water System Requirements

    Plumbing the Heating Loop Layout Example Domestic Water System Aqua-Hot Domestic Water System Requirements Plumbing the Domestic Water System Heating System Diesel Burner Cozy #3 Cozy #2 Bedroom Kitchen • Reference A119.2/NFPA 501C Standard on Recreational The Aqua-Hot is also able to provide domestic hot water Cozy #1 Vehicles 1993 Edition for relevant regulatory information while the boiler tank is up at operating temperature.

  • Page 20: Mounting The Aqua-Hot Lcd

    Mounting the Aqua-Hot LCD Mounting the Aqua-Hot LCD Operating the LCD Mounting the Aqua-Hot LCD Mounting Procedure: Operating the LCD If the zone temperature is set, but this item 1. Select a location within the RV. is not set to ON, the zone heat exchanger will Introduction: 2.

  • Page 21: Configuring The Zones

    Mounting the Aqua-Hot LCD Operating the LCD Configuring the Zones Configuring the Zones System Status (4): Module Options (5): Number of Zones (A): The Aqua-Hot can control between 1 and 3 This item will indicate the current operational status Tapping on the module options screen (the 3 lines on the heating zones within the RV.

  • Page 22: Filling The Aqua-Hot

    Filling the Aqua-Hot Purging the Heating Loop Filling the Aqua-Hot Purging the Interior Heating Loop 8. On the LCD screen, navigate to the TESTING page, turn on the pump, and set the 3-way valve to “HOT WATER”. 8. Tap “PUMP” to activate the fluid circulation pump, and if Before the first activation of the Aqua-Hot, fill the unit with In order to provide interior heat to the vehicle, antifreeze applicable, “BOOST PUMP”...

  • Page 23: Fuel Supply

    Purging the Heating Loop Fuel Supply Purging the Heating Loop Fuel System Fuel Supply Fuel Standpipe Installation 1. Drill a 1 in 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 cause damage to the Aqua-Hot 125DN, the diesel burner, or 3.
  • Page 24 Purging the Heating Loop Fuel System Purging the Heating Loop Fuel System Burner Bottom View Fuel Line Connection Fuel Line to Coupler Hose A Clamp B Bubble Figure 94 Figure 92 NOTE: The fuel lines must be secured and supported properly to avoid air traps or bubbles.

  • Page 25: Fuel Purge Procedure

    Purging the Heating Loop Fuel System Purge Purging the Heating Loop Burner Troubleshooting External Diesel Burner Troubleshooting Fuel Purge Procedure: • Ground goes to Pin #1 This section will cover any issues with the external diesel burner. The diesel burner is the primary heat source to the 125GN. The fuel lines should be automatically primed with the first •...

  • Page 26: System Checks

    Purging the Heating Loop Burner Troubleshooting Purging the Heating Loop System Checks General Failure Symptoms of the Burner System Checks 16. Check all plumbing connections for leaks. 17. Check that the fuses are in their proper, specified locations. This section will cover the typical failures of the diesel burner. Refer to the table more fails and their remedies. 18.

  • Page 27: Winterizing

    Purging the Heating Loop First Operation Purging the Heating Loop Winterizing the Aqua-Hot Aqua-Hot First Operation Winterizing the Aqua-Hot The first 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.

  • Page 28: Flow Diagram

    Purging the Heating Loop Flow Diagram Purging the Heating Loop System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. p. 52 ©Aqua-Hot® 125DN Installation Manual REV 220419 ©Aqua-Hot® 125DN Installation Manual REV 220419 p. 53...
  • Page 29 Purging the Heating Loop System Schematics Purging the Heating Loop System Schematics p. 54 ©Aqua-Hot® 125DN Installation Manual REV 220419 ©Aqua-Hot® 125DN Installation Manual REV 220419 p. 55...
  • Page 30 Purging the Heating Loop System Schematics Purging the Heating Loop System Schematics p. 56 ©Aqua-Hot® 125DN Installation Manual REV 220419 ©Aqua-Hot® 125DN Installation Manual REV 220419 p. 57...

  • Page 31: Appendix B: Measuring Antifreeze

    System Schematics System Schematics 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.

  • Page 32: Appendix C: Parts & Accessories

    Parts & Accessories 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 route you to the Aqua-Hot web store for purchase. EXE-505-65A EXX-006-500 Heat Exchanger, Whisper Silent, 12V DC.
  • Page 33 Parts & Accessories Appendix Parts & Accessories Appendix PLE-125-FL1 PLX-000-200 PLX-200-103 PLX-284-74V Kit, Fuel Line, 125DN Tube, ⅝” Safety Stripe, 12ft. Fitting ½” (M) NPT x ¾” Barb Black Nylon Hose, Molded, Elbow 90° PLX-000-820 PLX-000-835 PLX-432-000 PLX-803-000 Fitting, Elbow, 90°, ¾”, Barb, Black Nylon Fitting, Reducer ¾”...

  • Page 34: Warranty

    Warranty Parts & Accessories Appendix 2-YEAR LIMITED WARRANTY AQUA-HOT® HYDRONIC HEATING SYSTEM PLX-CTB-270 PLX-A51-106 Clamp, Hose, Constant Tension, ¾” Bend Support, ⅝” 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 35 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...

This manual is also suitable for:

Aqua-hot 125-dn1Ahe-125-dn1Aqua-hot 125d

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