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Aqua-Hot 100 Series Installation Manual

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Installation Manual
100
SERIES
AHM-125-D02
DIESEL

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Summary of Contents for Aqua-Hot 100 Series

  • Page 1 Installation Manual SERIES AHM-125-D02 DIESEL...

  • Page 2: Table Of Contents

    Burner Harness ................. 26 Coach-Side Harness & RV-C ............27 WARNING signals a hazardous situation where potential harm, Connecting the Aqua-Hot to AC Power ........28 risk of serious injury, or death could result if instructions are Configuring the Zones ............... 29 not followed.

  • Page 3: Installation Checklist

    Read and understand all instructions before installing the The following table is a checklist of important items that need Aqua-Hot unit and the external diesel burner. Aqua-Hot Heating to be completed for a successful install of the M125D Aqua- Systems is not liable for damage resulting from failing to Hot heater in your RV.

  • Page 4: Introduction

    If the system senses low fluid levels, the heating system will shut down all fans, heat sources, and pumps until the unit • DO NOT connect the 12-volt DC power to the Aqua-Hot if the is adequately refilled. vehicle requires welding.
  • Page 5 Take care in placing the burner with enough space from vehicle parts As with any appliance, allow the Aqua-Hot to and that the burner will have ample ventilation. completely shut down BEFORE disengaging •...
  • Page 6 To get the Aqua-Hot to temperature, turn the electric heating element and/or the external diesel burner to the “ON” position on the Aqua-Hot LCD screen (shown below), or on the RV control panel. It may take up to 20 minutes to get to operating temperature before heat or hot water are available.

  • Page 7: System Features

    NOTE: Control Panel “Quiet Mode” reduces heat exchanger NOTE: This product label is attached to the side of the power consumption by 20% Aqua-Hot, and provides a ready reference to specifications, test standards, and important safety notices. Domestic Water Heating Maximum .................
  • Page 8 All vehicle installations must comply with the requirements Physical Specifications listed in the Recreational Vehicle Industry Association’s (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle Dimensions ..........8.8”L x 3.4”W x 6.9”H Standards. Weight ..................6.3 lbs ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 7...

  • Page 9: Component Cut-Aways

    Component Cut-Aways Aqua-Hot M125D Heating System 1. Heating Solution Tank 11. Aqua-Hot Controller 2. Plate-to-Plate Heat Exchanger 12. LCD Screen 3. Tempering Valve 13. AC High-Limit Thermostat 4. Three-Way Valve 14. Float Switch 5. Cozy Heat Exchanger 15. AC Activation Relay 6.
  • Page 10 18. Coolant outlet Pipe 8. Over-Heat Sensor 19. Coolant Inlet Pipe 9. Burner Controller 10. Air Inlet Pipe 20. Burner 21. Diesel Fuel Filter 11. Muffler Figure 7 Figure 8 Figure 9 Figure 10 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 9...

  • Page 11: Installing The Aqua-Hot

    Support and Clearance Interior Components Installing the Aqua-Hot Boiler Tank Install the Aqua-Hot in a compartment which protects the unit • The boiler tank must be the highest point in the system. and components, and allows service access to the Aqua-Hot. •...

  • Page 12: Interior Components

    1. The provided P-Clamps use the coolant lines to mount the valve. Choose a location and wait to mount the valve after plumbing the system. 2. Apply a hot surface warning decal in an unobstructed P-Clamps location near the valve. Figure 15 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 11...
  • Page 13 • Choose a location safe from dust and moisture. • This component is rated for the heat generated by the other Aqua-Hot components and can be in the same compartment. • Ensure enough space surrounding the controller to route wiring with sufficient strain relief.
  • Page 14 It is not recommended to place a heat exchanger on the slide-out section of any vehicle due to the high probability of damage occurring to the heating loop from moving parts. Figure 20 Figure 21 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 13...

  • Page 15: Heat Exchangers

    Avoid locations close to windows and doors. Mounting 1. Choose a location for the thermistor. 2. Drill the two mount holes and a third hole for the wires. Figure 25 Attach the thermistor using two fasteners. p. 14 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 16: Mounting The Burner To The Vehicle

    5.65” (1) M6-95 Bolt 4.85” 5.28” Figure 28 6.125” Figure 26 Before drilling holes in the vehicle, consult the manufacturer for recommendations and limitations. Do NOT weld to the vehicle frame. Figure 29 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 15...
  • Page 17 1. Locate the coolant pump. The pump mount should be attached to the pump. Diesel Burner Circulation 2. Using the provided self-drilling screw, attach the pump Diesel Burner Supply Port Pump to the mount location. Figure 33 p. 16 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 18: Combustion Air & Exhaust System

    See page 18 for 7 Protective Hoods more information. 8 Air Filter Figure 35 NOTE: Should this particular application require modification, please contact Aqua- Hot Heating Systems at 574-AIR-XCEL (574-274-9235) for further assistance. ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 17...
  • Page 19 A similar slit may be cut into the end of the Slit in Exhaust tube connecting to the muffler if it will not Pipe tighten properly on the burner. Reference the image to the right and Figure 37. Figure 37 p. 18 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 20: Fuel System

    4. Tighten the nut making sure the standpipe port is aimed filter is accurate with the flow correctly. of fuel. • It is recommended to replace the filter once a year or after extended period of non-use. Figure 39 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 19...
  • Page 21 Check that all clamps are tight. • Prevent abrasion and vibration along the length of the fuel line. 8. Attach the fuel line to the vehicle in several places along the length of the line. Prevent any sagging. p. 20 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...
  • Page 22 (shown above in Figure 44). Using soapy water or PAM on the fuel lines can assist in sliding the couplers on. Fuel Pump to Fuel Hose Fuel Hose to Burner Inlet Fuel Hose to Fuel Line to Fuel Pickup Damper Figure 45 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 21...

  • Page 23: Plumbing The Heating Zone

    9. Using the provided tee fitting, connect the high side of the final Cozy heat exchanger and the “Stir” port on the 3-way valve to the “Coolant in” port on the tank. p. 22 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 24: Plumbing Example

    Figure 46 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. For questions or assistance, contact Aqua-Hot at 574-AIR-XCEL (574-247-9235).

  • Page 25: Domestic Water System

    Vehicles 1993 Edition for relevant regulatory information regarding the design of Domestic Water Systems. • The Aqua-Hot is equipped with a pressure relief valve and a tempering valve in order to provide safe hot water without chance of scalding or an over-pressurized system.

  • Page 26: Connecting The M125D To 12V Dc Power

    Connecting the M125D to 12V DC Power Below are the requirements, steps, and information necessary to connect the Aqua-Hot to the RV’s 12V DC power system. Failure to adhere to these guidelines can inhibit unit performance and may cause damage to the Aqua-Hot and/or the RV.

  • Page 27: Burner Harness

    Mount the fuse holder in a safe and easy to access location. 8. The small, black, 4-wire plug is not used. 9. The small gage red and black striped wire near the fuse holder is not used and can be cut off. Figure 49 p. 26 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 28: Coach-Side Harness & Rv-C

    1. Refer to Figure 50 for harness installation. 2. Connect the opposite end of the RVC cable to the 2. Connect J7 and J8 plugs to the Aqua-hot controller terminating resistor (Figure 50). 3. Connect each zone thermostat, these are not polarity 3.

  • Page 29: 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-Hot to the vehicle’s AC electric system. The Aqua-Hot utilizes Molex 19403 and 19045 series connectors for the AC electrical circuit. Connect the 3-pin Molex connector to the coach-side AC electric AC Electric Connection system in order to utilize the Aqua-Hot’s AC heating element.

  • Page 30: 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...

  • Page 31: 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.

  • Page 32: Fuel System Fill Procedure

    Filling the Aqua-Hot Fuel System Purge Fuel System Fill Procedure Perform this procedure once the burner and Aqua-Hot are completely installed and the Aqua-Hot is adequately filled and purged. • Ensure all fuel system connections have been made. 4. Repeat steps 1-3 until fuel reaches the burner. A rumble from the burner will be heard and the exhaust temperature •...
  • Page 33 Filling the Aqua-Hot First Operation Aqua-Hot First Operation Activation Instructions (Electric Element): Activation Instructions (Burner): 1. Place a bucket under the tank overflow tube. As the tank 1. Place a bucket under the tank overflow tube. As the tank heats for the first time after filling, any excess coolant will heats for the first time after filling, any excess coolant will be vented through the overflow tube.

  • Page 34: First Operation

    Filling the Aqua-Hot First Operation Interior Heating Zones Hot Water System Procedure Procedure 1. At the LCD screen tap the burner switch to “ON” wait for the 1. At the LCD screen, tap the burner switch to “ON” wait for burner to ignite and boiler tank to heat up.

  • Page 35: Winterizing

    Ensure that only non- toxic RV antifreeze (FDA approved “GRAS” antifreeze) NOTE: The Aqua-Hot can continue to be used for interior heat rated for winterization is used when winterizing this unit. once the domestic hot water system has been winterized.
  • Page 36 System Schematics Filling the Aqua-Hot NOTE: All connectors are shown from Pin insertion side. ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 35...
  • Page 37 System Schematics Filling the Aqua-Hot p. 36 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 38: Appendix A: System Schematics

    System Schematics Filling the Aqua-Hot ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 37...
  • Page 39 System Schematics Filling the Aqua-Hot p. 38 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...

  • Page 40: Appendix B: Measuring Antifreeze

    Application of Ethylene Glycol Application of Propylene Glycol Refractometer Sight Glass Upper Blue Field Poor Poor Good Poor Poor Good Boundary Line Lower White Field Adjust to 32°F ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 39...

  • Page 41: Appendix C: Parts & Accessories

    Appendix AHM-125-D02 125 Series Diesel 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. 40 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...
  • Page 42 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” x 15”, Black ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 41...
  • Page 43 RV-Side Wire Harness (optional) Tube, ¾” Safety Stripe 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. 42 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...
  • Page 44 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” PEX Fitting ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 43...
  • Page 45 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-000-755 SME-102-000 Elbow Swivel Fitting, ½” Barb x ½” NPT Cozy Plenum Assembly p. 44 ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202...
  • Page 46 5kW Belief Diesel Burner Fuel Kit (Included with First Install Kit) (Included with M125D Burner) ELE-102-111 HDX-102-113 Clamp, (10.5mm), Soft Hose and Tube Clamp, ⅜ to (11.3mm), Soft Hose and Tube MSX-907-162 52545k146 Refractometer Clamp, 15mm-17mm, Stainless Steel ©Aqua-Hot® AHM-125-D02 Installation Manual REV221202 p. 45...

  • Page 47: Warranty

    Thus, problems due to improper specifications, improper installations, improper use, the use of accessory parts or parts not authorized by Aqua-Hot Heating Systems Inc., repair by unauthorized persons, and damage or abuse of the heater are specially excluded from warranty coverage.
  • Page 48 Installation Manual SERIES AHM-125-D02 DIESEL 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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