Aqua-Hot 400-LP Installation Manual

Hydronic (water based) heating system, and tank-less hot water system

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INSTALLATION MANUAL

400

SERIES

400-LP

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Page 1 INSTALLATION MANUAL SERIES 400-LP...
Page 3: Aqua-Hot 400-Lp Installation Manual
Caution Notes About the Aqua-Hot 400-LP As you read this Information, take particular note The Aqua-Hot 4OOLP is a hydronic (water based) heating of the NOTICE, CAUTION, WARNING and system, and tank-less hot water system. DANGER symbols when they appear. This infor-...
Page 4: Table Of Contents
Cut-Away Diagrams ............7 Installing the Exhaust System ....... 30-32 Section 2: Aqua-Hot Installation Section 9: Electronic Controller Wiring Installing the Mounting Tray and Aqua-Hot ....8 Electronic Controller Wiring ........33-34 Installing the Expansion Tank ........8 Wiring Harness Connection......... 34 Pressure Testing the Aqua-Hot ........
Page 5: Safety Instructions & Precautions
Read this Installation Manual before installing or using  Disconnect electric wiring to the Aqua-Hot System be- the Aqua-Hot System to reduce the risk of injury to per- fore welding or plasma cutting the coach to avoid dam- sons or damage to equipment.
Page 6: Heating System Features
Section #: Title Aqua-Hot Heating System Features 400-LP Features The product label attached to each Aqua-Hot provides a ready reference to specifications, test standards, and important safety notices. Propane Burner Heat Input (Firing Rate) 51,663 BTU/h Fuel Consumption (Continuous) 0.72 g/h...
Page 7: Cut-Away Diagrams
18. Zone 1 Circulation Pump 19. Zone 1 Inlet Port 20. Zone 2 Circulation Pump 21. Zone 2 Inlet Port NOTE: Service parts and accessories are available through Aqua-Hot Factory Authorized Service Center or at www.aquahot.com. 400-LP Installation Manual © Aqua-Hot®...
Page 8: Section 2: Aqua-Hot Installation
4. Insert a #10 machine screw into each of the embossed holes in the mounting tray (total of six required) and The Aqua-Hot tank and heating loop operate at 0.0 psi (zero tighten to secure the mounting tray to the motorhome.
Page 9: Aqua-Hot Measurement Diagrams
Section #: Title Aqua-Hot Installation Figure 1 400-LP Installation Manual © Aqua-Hot® — Page 9 —...
Page 12 Section #: Title Aqua-Hot Installation Figure 4 400LP Figure 5 1 in. 1/2 in. 1/2 in. 400-LP Installation Manual © Aqua-Hot®...
Page 13: Section 3: Hydronic Heating System
Reference Figure 6 for clearance information. Figure 6 NOTE: An accessory device is available for the Cozy Heat Exchanger for the purpose of redirecting the air- flow from the heat exchanger. Reference Figures 9 and Figure 5 400-LP Installation Manual © Aqua-Hot®...
Page 14: Heat Exchanger Floor Plan
Indicates sample mounting locations for the Cozy heat exchangers. Actual place- ment and quantity vary based on the individual design of the coach. For spe- cific design assistance, contact Aqua-Hot Generalized Motorhome Heating System Floor Plan at (303)-651-5500 Figure 7B 400-LP Installation Manual ©...
Page 15: Mounting The Heat Exchangers
Figure 8 Figure 10 1. Hose to direct air to vent 2. Cozy Heat Exchanger 3. Plenum 4. Vent Installed In Toe-Kick area 5. Toe Kick Board Figure 9 400-LP Installation Manual © Aqua-Hot®...
Page 16: Heat Exchanger Measurement Diagrams
Section #: Title Hydronic Heating System Figure 11 Figure 12 400-LP Installation Manual © Aqua-Hot®...
Page 17: Wiring The Heat Exchanger
Reference 3. Insert all heat exchanger wires into the appropriate ter- Figures 14 and 15. minal/heating zone location on the electronic controller. Reference Figure 13 and Appendix Figure 13 400-LP Installation Manual © Aqua-Hot®...
Page 18 Figure 14 Figure 15 When wiring the heat exchanger in- parallel, the main 18-gauge wire is split to allow the heat exchanger wires to combine with the main wire to be powered or grounded, respec- tively. 400-LP Installation Manual © Aqua-Hot®...
Page 19: Plumbing Requirements
(typically 3) must be plumbed together in-series ing zone to the Aqua-Hot. on “Heating Loop 2.” Reference Figure 16. All plumbing lines should be laid as flat as possible, and Use 5/8 inch I.D.
Page 20: Plumbing The Hydronic Heating System
5. Connect and tighten all interior plumbing lines, outlet Be sure to secure all lines where necessary and apply pro- and inlet, to the Aqua-Hot’s appropriate heating loop tective shielding in areas where chafing may occur. ports. Reference Figure 19 and Figure 20.
Page 21 Section #: Title Hydronic Heating System Figure 18 Figure 19 Inlet Heating Loop Connection Examples Barbed Fittings Components Compression Fitting Components Barb Fittings Components Installed Compression Fittings Components Installed 400-LP Installation Manual © Aqua-Hot®...
Page 22 Pex Tube Tension Clamp Pex Insert 3/4” Pex Tube Heater Two Constant Tension Hose Band Clamps Pex Insert Constant Tension Clamps 90⁰ Connection Components Straight Connection Components Straight Connection Components Installed 90⁰ Connection Components Installed 400-LP Installation Manual © Aqua-Hot®...
Page 23: Section 4: Thermostats
(usually in NOTE: It is recommended that the wire numbers in Appen- close proximity to the domestic water pump). Reference dix A be used when installing the Aqua-Hot in order to assist Figure 21. with differentiating between the separate heating zones Do not mount the thermostat bulb in a drafty area or and to aid service personnel with troubleshooting.
Page 24: Room Thermostat Locations
Unheated or uncooled areas such as an outside wall behind the thermostat NOTE: It is recommended that the wire numbers in Appen- dix A be used when installing the Aqua-Hot in order to assist with differentiation between the separate heating zones Figure 22 and aid service personnel with troubleshooting.
Page 25: Section 5: Domestic Water System
Refer- 1. Connect a domestic water plumbing line from the do- ence Figure 34. Although the Aqua-Hot is equipped with a mestic water demand pump/water manifold to the cold pressure-relief valve, the use of an accumulator tank will water inlet port on the Aqua-Hot.
Page 27: Section 6: Switch Panel
4. Insert all switch wires onto the appropriate terminal/ switch panel connection on the electronic controller. References Appendix A. Figure 25 5.00 .275 4.45 O .150 (4x) 2.88 1.205±.005 2.33 .800 .275 1.384 Mounting Holes R.250 (4x) 1.362 (total of four) .871±.005 (2x) 400-LP Installation Manual © Aqua-Hot®...
Page 28: Switch Panel Rear View
Section #: Title Switch Panel Aqua-Hot 400LP Switch Panel, Rear View Figure 26 Burner Electric Element Switch Switch Switch Electronic Controller Switch Electronic Controller Pin# 2 To “Electric-O” Pin# 2 To “Propane-I” Pin# 4 To “Electric-I” Pin# 4 To “Propane-O”...
Page 29: Section 7: Fuel System Fuel System Requirements
 Leaking propane can ignite or explode and result in installed on the Aqua-Hot’s propane inlet port. dangerous personal injury or death. NOTE: The fuel delivery system must meet the require- ments of “NFPA 1192 Standard Recreational Vehicles”.
Page 30: Section 8: Exhaust System
Section #: Title Exhaust System The Aqua-Hot’s exhaust is HOT and must be kept away from any heat-sensitive material. DO NOT direct exhaust downward as a fire may result when parked n dry, grassy areas. Exhaust must not terminate beneath the vehicle or be- neath an open able window or vent.
Page 32 Section #: Title Exhaust System Figure 29 #8, 3/8” Vehicle’s Exhaust Pipe #8, 3/8” Exhaust Tip Figure 30 Figure 37 Figure 31 400-LP Installation Manual © Aqua-Hot®...
Page 33: Section 9: Electronic Controller Wiring
The Aqua-Hot’s electronic controller is designed to work Each heating zone “FAN” circuit can supply up to 2.0 with most electronic room thermostats; however, the cho- amps of direct current. This 12 Volt-DC power source allows sen thermostats must produce a constant 12 Volt-DC output for Multiple Cozy III heat exchangers to be wired “in-...
Page 34: Wiring Harness Connection
Please note that under full-load conditions, the Aqua-Hot can draw as much as 20 amps of DC current. The Aqua-Hot is designed to shut down in the event that the DC voltage level drops too low to properly operate. It is im- perative that the proper wires Be sure to protect against accidental shorting (i.e., chassis...
Page 35: Connecting The 12V Dc Power
Connecting the 120 Volt-AC Power DO NOT activate the propane-burner until the antifreeze DO NOT connect the 12 Volt-DC power to the Aqua-Hot if and the water heating solution has been added to the boil- the vehicle requires welding. Electrical welding will cause er tank and the heating system has been completely bled serious damage to the propane-burner controller.
Page 36: Section 10: Purging The System
If assistance is needed in selecting an appropriate anti- freeze, please contact the Aqua-Hot Heating Systems Prod- uct Application Department at 1-800-685-4298. Figure 36 1. Locate the Aqua-Hot’s Drain Valve located at the front of Air Release Valve Expansion Tank Connection the heater. Reference Figure 36.
Page 37: Purging The System By Grounding The Zone
38. Figure 37 10. Open the drain valve and Turn the fluid transfer pump on, and fill the Aqua-Hot with the 50/50 mixture of anti- freeze and water heating solution until the Low Tank- Low Tank-Level Cut- Level Cutoff Light, on the Electronic Control Board is extinguished, reference Figure 37.
Page 39: Safety Instructions & Precautions
Section #: Title Safety Instructions & Precautions 400-LP Installation Manual © Aqua-Hot®...
Page 40: Purging The Propane System
(approximately cess cover to the mounting tray. 185°F). 4. Move the Aqua-Hot’s electric element switch to the ON NOTE: The main access cover must be installed prior to position in order to supply 120 Volt-AC power to the operation.
Page 42: Appendix B: Wire Gauge Information
Section #: Title Appendix B Wire Gauge Information 400-LP Installation Manual © Aqua-Hot®...
Page 43: Appendix C: Electronic Controller Features
This 12 Volt-DC battery connection is a product-safety feature that should be utilized whenever the Aqua- Hot’s main 12 Volt-DC power supply is connected to a battery disconnect switch. This feature will ensure that the Aqua-Hot will be protected in the event that the primary power is interrupted while the Propane-Burner is operating (e.g., during a burn- cycle).
Page 44 “Low Voltage Reset” Feature: Whenever the Aqua-Hot’s DC power is interrupted, the “low voltage reset” red indicator light on the electronic controller will illuminate. Reset the electronic controller by pressing the “low voltage reset” button on the electronic controller (use a thin, straight, nonmetallic object to access the button through the faceplate) or by turning OFF the propane-burner switch on the interior switch panel for approximately 30 seconds, then turning the switch back ON.
Page 45: Appendix D: Antifreeze Types
“boiler” type antifreeze in of an Aqua-Hot heating system’s boiler tank and associated the Aqua-Hot. Propylene glycol is a safer alternative to the components, it has been determined that there is a need to more toxic ethylene glycol antifreeze;...
Page 46: Appendix F: Antifreeze Terms & Mixture Ratio
Another major function of antifreeze solution is to pro- vide protection to the internal metal components of the Aq- NOTE: As the installer of this Aqua-Hot system, you must ua-Hot hydronic heating system from corrosion and rust. refer to the information and chart in Appendix E to deter-...
Page 48 Section #: Title Appendix G Measuring Propylene Glycol Using a Refractometer Calibrate the Refractometer Aqua-Hot Part Number MSX-907-162 Calibration Screw Eyepiece Daylight Plate Assembly Main Prism Assembly Calibration Operation 400-LP Installation Manual © Aqua-Hot®...
Page 49 (This allows the sample to adjust to the ambient temperature of the refrac- tometer). NOTE: Refractometers may have more than one scale. Make sure you are reading the scale marked “Propylene” for measuring the antifreeze solution in the Aqua-Hot System. 400-LP Installation Manual © Aqua-Hot®...
Page 50 HYDRONIC HEATING SYSTEM AHE-450-D 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. Replacement parts are warranted for the remainder of the Heater’s standard warranty coverage or for six months,...
Page 51 INSTALLATION MANUAL SERIES 09-01-2013 7501 Miller Drive, Fredrick, CO 80504 Visit us on line at www.aquahot.com Call us at (800) 685-4298 or (303) 651-5500 ©2013 Aqua-Hot Heating Systems Inc. Printed In U.S.A.

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Aqua-Hot 400-LP Installation Manual

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