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-400-D02
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  • Page 1 Installation Manual Series AHE-400-D02 with...

  • Page 2: Table Of Contents

    Introduction Contents Caution Notes Caution Notes ................1 As you read this information, take particular note of the NOTICE, CAUTION, WARNING, and DANGER symbols when they appear. Introduction ..................2 This information is important for safe and efficient use of the System Features ................4 Aqua-Hot system.

  • 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 • A qualified installer or service technician must perform failing to follow instructions contained in this, and any other The Aqua-Hot 400D is a Hydronic (water-based) Heating equipment installation or service.

  • Page 4: System Features

    System Features Component Cut-Aways 12. Heating Zone 1 Outlet 1. Drain Valve 13. Heating Zone 2 Outlet 2. Zone 1 Circulation Pump 14. Wiring Harness Port 3. Zone 2 Circulation Pump 15. Aqua-Hot Reporter 4. Diesel Burner Controller 16. Electric Element 5.

  • 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 Upper Fitting Introduction: 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 SIDE VIEW 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 +1 (800) 685-4298 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 24.

  • 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 Outlet exchangers for optimal functionality. Do not deviate from these routing of the plumbing lines from each heating zone to the guidelines.

  • Page 11: Heat Exchangers Layout

    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: 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 13: 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 14: 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 15: Interior 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 16: Wiring The Aqua-Hot

    Introduction to Wiring Introduction to Wiring Wiring the Aqua-Hot J1 Plug: J7 Plug: 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 that provides constant 12V DC current to any zone inputs from the coach.
  • Page 17 Introduction to Wiring Introduction to Wiring Aqua-Hot Reporter The Aqua-Hot Reporter Home Screen Wire Insertion View Shown The J2 Plug is responsible for managing return signals from The home screen contains information about the Aqua- 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 18 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 19 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 20: Aqua-Hot Reporter

    Providing DC Power Providing AC Power Connecting the 400D to 12V DC Power Instructions: Connecting the 400D 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 21: 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 22: 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 23 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 24: Appendix A: System Schematics

    Purging the Heating Loop System Schematics Purging the Heating Loop System Schematics p. 44 ©Aqua-Hot® 400D Installation Manual Rev 220504 ©Aqua-Hot® 400D Installation Manual Rev 220504 p. 45...
  • Page 25 Purging the Heating Loop System Schematics Purging the Heating Loop System Schematics p. 46 ©Aqua-Hot® 400D Installation Manual Rev 220504 ©Aqua-Hot® 400D Installation Manual Rev 220504 p. 47...
  • Page 26 System Schematics System Schematics p. 48 ©Aqua-Hot® 400D Installation Manual Rev 220504 ©Aqua-Hot® 400D Installation Manual Rev 220504 p. 49...
  • Page 27 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 28: 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 29 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 30 Parts & Accessories Appendix Parts & Accessories Appendix PLX-100-836 PLX-100-900 PLX-CTB-270 PLX-A51-106 Pump Mounting Bracket Boost Pump Clamp, Hose, Constant Tension, 0.75” Bend Support, ⅝” PLX-120-626 PLX-200-103 PLX-A65-200 PLX-A65-300 Tube, ⅝”, Red O2 Barrier Pex 100 Ft. Fitting ½” (M) NPT x ¾” Barb Black Nylon Fitting, Brass Barb, ¾”...

  • Page 31: Warranty

    Warranty Parts & Accessories Appendix 2-YEAR LIMITED WARRANTY AQUA-HOT® HYDRONIC HEATING SYSTEM PLX-803-FSE PLX-664-730 Elbow Fitting, 90°, ½” PEX Fitting Fitting, Pipe Nipple, Exhaust, 1 ½” x 4” 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 32 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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