Aqua-Hot 675-D Installation Manual
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Aqua-Hot 675-D Installation Manual

Hydronic heating system
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INSTALLATION MANUAL
© 2011 Aqua-Hot Heating Systems Inc.

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Summary of Contents for Aqua-Hot 675-D

  • Page 1 INSTALLATION MANUAL © 2011 Aqua-Hot Heating Systems Inc.
  • Page 2 CAUTION: The Aqua-Hot tank and heating loop operate at 0.0 psi (zero pressure system). Air pressure applied to the tank MUST NOT exceed 20 psi. Excess pressure will result in internal damage. CAUTION: Before welding or plasma cutting on any coach;...

  • Page 3: Table Of Contents

    Introduction ............................5 Section 1: Aqua-Hot Hydronic Heating System Technical Information .......................... 6 Section 2: Aqua-Hot Installation Installing the Mounting Tray and the Aqua-Hot ................10 Overall Aqua-Hot Dimensions ......................11 Installing the Expansion Tank ......................14 Section 3: Hydronic Heating System Heat Exchanger Location and Clearances ..................
  • Page 4 Purging the System by Grounding the Zone Thermostat Connection ......... 44 Purging the Domestic Water System....................44 Section 12: Initial Start-Up Activating the Aqua-Hot ........................46 Appendices: Appendix A: Wiring Diagram ......................47 Appendix B: Wire Gauge Information ....................48 Appendix C: Electronic Controller Features ..................

  • Page 5: Introduction

    The same heating loop that preheats the diesel engine allows WARNING the Aqua-Hot system to take surplus heat generated by the mo- tor home’s diesel engine while running, and use it to heat the Aqua-Hot system.

  • Page 6: Section 1: Aqua-Hot Hydronic Heating System

    RVIA Standards, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive, P.O. Box 2999, Reston, VA 22090-0999, call them at (703) 620-6753, or visit them online at www.rvia.org. — Page 6 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 7 1: A ECTION YDRONIC EATING YSTEM Each Aqua-Hot heating system possesses an I.D. label on the heater, to what standard it has been tested, and important unit itself. This I.D. label details the specifications of the safety notices. Figure 2...
  • Page 8 Outlet Port Domestic Water Interlock Access panel Switch Zone 1 Circulation Pump Zone 3 Circulation Pump Zone 2 Circulation Pump Engine Preheat Pump Diesel Drain Valve Burner Diesel Burner Controller — Page 8 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 9 Wiring Harness Port Product ID Label Zone 1, 2 and 3 Domestic Water Outlet Ports Inlet/Outlet Ports Engine Preheat Inlet/Outlet Ports Diesel Fuel Inlet/Outlet Ports — Page 9 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 10: 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 must be installed in a compartment that is tighten to secure the mounting tray to the motorhome.
  • Page 11 2: A ECTION NSTALLATION Figure 7 — Page 11 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 12 2: A ECTION NSTALLATION Figure 8 — Page 12 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 13 2: A ECTION NSTALLATION Figure 9 — Page 13 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 14: Installing The Expansion Tank

    NOTE: Avoid any dips and bends in the overflow tubing from Installing the Expansion Tank: the Aqua-Hot to the expansion tank as air can become trapped in these dips and bends, preventing the expan- Select a mounting location that allows for easy access...

  • Page 15: Heat Exchanger Location And Clearances

    • NOTE: An accessory device is available for the Cozy Heat Exchanger for the purpose of redirecting the airflow from the heat exchanger. Reference Figures 17 and Figure 13 — Page 15 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 16: Section 3: Hydronic Heating System

    Indicates sample mounting locations for the Cozy heat exchangers. Actual placement and quan- tity vary based on the individual design of the coach. For specific design assistance, contact Aqua -Hot at 303-659-8221 Figure 15B — Page 16 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 17 Figure 18 Hose to direct Cozy Heat air to vent Exchanger Plenum Toe Kick Board Vent installed In toe-kick area — Page 17 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 18 3: H ECTION YDRONIC EATING YSTEM Figure 20 Figure 21 — Page 18 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 19: Wiring The Heat Exchangers

    (e.g., Living Room, Bathroom, Bedroom, etc.). 5. Connect all electronic controller wires to the positive and negative leads of the heat exchanger. Reference Figures 23 and 24. Figure 22 — Page 19 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 20 When wiring the heat exchangers in-parallel, the main 18- bine with the main wire to be powered or grounded, respec- gauge wire is split to allow the heat exchanger wires to com- tively. Figure 24 — Page 20 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 21: Plumbing Requirements

    The bedroom heat exchanger must be plumbed on zone to the Aqua-Hot. “Heating Loop 1.” Reference Figure 26. All plumbing lines should be laid as flat as possible, and Use ⅝...

  • Page 22: Plumbing The Hydronic Heating System

    5. Connect and tighten all interior plumbing lines, outlet Rubber Coated/Closed-Type clamps are recom- and inlet, to the Aqua-Hot’s appropriate heating loop mended when securing the plumbing lines. ports. Reference Figure 29 and Figure 30. 3. Connect and clamp the outlet line from the heater to the...
  • Page 23 3: H ECTION YDRONIC EATING YSTEM Figure 28 Figure 29 Inlet Heating Loop Connection Examples Barbed Fittings Components Compression Fitting Components Barb Fittings Components Installed Compression Fittings Components Installed — Page 23 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 24 3/4” Pex Tube Two Constant Tension Heater Band Clamps Hose Pex Insert Constant Tension Clamps Straight Connection Components 90⁰ Connection Components Straight Connection Components Installed 90⁰ Connection Components Installed — Page 24 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 25: Section 4: Thermostats

    Reference Figure NOTE: It is recommended that the wire numbers in Appen- dix A be used when installing the Aqua-Hot in order Do not mount the thermostat bulb in a drafty area or along to assist with differentiating between the separate the ceiling of the bay.

  • Page 26: Room Thermostats

    NOTE: It is recommended that the wire numbers in Appendix • drafts or dead spots behind doors and in corners A be used when installing the Aqua-Hot in order to • hot or cold air from ducts assist with differentiating between the separate heat- •...

  • Page 27: Section 5: Domestic Water System

    1. Connect a domestic water plumbing line from the domestic water demand pump/water manifold to the cold water inlet Use the RVIA-provided table below in order to determine the port on the Aqua-Hot. Reference Figures 33 and 34. proper sizing of pipe and tubing required to insure maximum efficiency.
  • Page 28 5: D ECTION OMESTIC ATER YSTEM Figure 33 Domestic Cold Domestic Hot Water Inlet Water Outlet Figure 34 — Page 28 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 29: Section 6: Switch Panel

    3. Move both switches to an OFF position by pressing them panel connection on the electronic controller. Reference in a downward motion. Appendix A. Reference Appendix A. Switch Panel Wiring: Figure 35 — Page 29 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 30 Pin# 5 To “Electric-O” Switch Electronic Controller Pin# 4 To “Electric-I” Pin# 5 To “Preheat-O” Pin# 6 To Chassis Ground Pin# 4 To “Preheat-I” Pin# 6 To Chassis Ground — Page 30 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 31: Section 7: Fuel System

    5. Install and tighten the appropriate fuel fittings onto the NOTE: If an auxiliary fuel tank is required, be sure to consult Aqua-Hot’s fuel ports, as well as the two ports of the fuel the ANSI/NFPA 1192 handbook concerning heating filter.
  • Page 32 7: F ECTION YSTEM Figure 39 — Page 32 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 33 7: F ECTION YSTEM Figure 40 Reference Reference Figure 41 Figure 38 Figure 41 1/4 NPT (F) 1/4 NPT (F) Diesel Outlet Port Diesel Inlet Port — Page 33 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 34: Section 8: Engine Preheat And Motoraide System

    Aqua-Hot’s boiler tank to the motorhome’s warm Use one-piece engine plumbing fittings in order to re- engine and back to the boiler tank. The Aqua-Hot 675-D duce the potential for coolant leaks. It is recommended also includes an engine preheat feature. This preheat...
  • Page 35 8: E & M ECTION NGINE REHEAT OTORAIDE YSTEM Figure 42 Figure 43 Engine Preheat Engine Preheat Inlet Outlet — Page 35 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 36: Section 9: Exhaust System

    DO NOT direct exhaust downward as a fire may result when parked in dry, grassy areas. The Aqua-Hot is supplied with a 3 inch and a 4 inch black pipe nipple (1½ inch diameter) along with a 1½ Exhaust must not terminate beneath the vehicle or beneath inch exhaust elbow.
  • Page 37 NOTE: A maximum of 27.5 feet with three 90⁰ bends are allowed in the exhaust pipe. A minimum of 1.75”ID automo- tive type exhaust pipe may be used. Figure 45 — Page 37 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 38 9: E ECTION XHAUST YSTEM Figure 46 — Page 38 — ® © 2011 Aqua-Hot 675-D Installation Manual...
  • Page 39 9: E ECTION XHAUST YSTEM Figure 47 3” Black Pipe Nipple Installed Black Pipe Elbow 4” Black Pipe Nipple Installed 2” Automotive Type Exhaust Pipe — Page 39 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 40: Section 10: Electronic Controller Wiring

    The Aqua-Hot’s electronic controller is designed to work with most electronic room thermostats; however, the chosen thermo- Each heating zone “FAN” circuit can supply up to 2.0 Amps of stat must produce a constant 12 Volt-DC output signal and direct current.

  • Page 41: Wiring Harness Connection

    All electric installations, systems, and equipment shall comply with Article 551, Parts I and III through DO NOT connect the 12 Volt-DC power to the Aqua-Hot if VI of NFPA 70, as well as the regulation of authorities the vehicle requires welding. Electrical welding will cause having jurisdiction and CSA Standard B139.

  • Page 42: Connecting The 12 Volt-Dc Power

    A. Determine the total maximum amperage draw of the 5. Connect both power and ground wires directly to the vehi- Aqua-Hot heating system by adding the total maxi- cle’s main battery disconnect. mum Amps of the installed heat exchangers (consult the heat exchanger manufacturer for Amp-draw infor- mation) to the Aqua-Hot heater’s 22 Amps.

  • Page 43: Section 11: Purging The Systems

    Aqua-Hot Heating Systems Product Applica- the motor home’s bay. Reference Figure 10. tion Department at 1-800-685-4298. 1. Open the Aqua-Hot’s drain valve located at the front of the Figure 52 heater. Reference Figure 53. 2. Connect a piece of 1/2 inch PEX-type tubing to the drain valve.

  • Page 44: Purging The System By Grounding The Zone Thermostat Connection

    Reference Figure 54. tube attached to the expansion tank connection on top of the Aqua-Hot. 9. Check the Aqua-Hot’s expansion tank and top it off to the cold level mark with the 50/50 antifreeze and water 5. Close the drain valve.
  • Page 45 10: P ECTION URGING THE YSTEMS Figure 54 Zone 1 Circulation Pump Zone 3 Circulation Pump Zone 2 Circulation Pump — Page 45 — ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 46: Section 12: Initial Start-Up

    Either or both heating sources will automati- cally maintain the temperature of the boiler tank’s antifreeze and water heating solution. The Aqua-Hot is now ready for normal operation and use. — Page 46 —...

  • Page 47: Appendix A: Wiring Diagram

    A: W PPENDIX IRING IAGRAM — Page 47 —...

  • Page 48: Appendix B: Wire Gauge Information

    B: W PPENDIX AUGE NFORMATION — Page 48 —...

  • Page 49: 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 pro- tected in the event that the primary power is interrupted while the Diesel-Burner is operating (e.g., during a burn-cycle).
  • Page 50 “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 diesel-burner switch on the interior switch panel for approxi- mately 30 seconds, then turning the switch back ON.

  • Page 51: Appendix D: Antifreeze Types

    These types of propylene glycol based antifreeze products of chemical rust inhibitors. Due to their potentially hazard- are formulated specifically for “winterizing” applications ous properties, they should never be used in the Aqua-Hot’s only. Although RV & Marine antifreeze is often “Generally Hydronic Heating System.

  • Page 52: Appendix F: Antifreeze Terms And Mixture Ratio

    -28ºF and a boil point of approximately 222ºF. gas. NOTE: As the installer of this Aqua-Hot system, you must refer to the information and chart in Appendix E Rust and Anti-Corrosive Inhibitors:...
  • Page 53 F: A PPENDIX NTIFREEZE ERMS AND IXTURE ATIO — Page 53 —...
  • Page 54 G: M PPENDIX EASURING ROPYLENE LYCOL SING A EFRACTOMETER ALIBRATE THE EFRACTOMETER Aqua-Hot Part Number MSX-907-162 Figure 1 Calibration Screw Eyepiece Daylight Plate Assembly Main Prism Assembly ® © 2011 Aqua-Hot 675-D Installation Manual...

  • Page 55: Appendix G: Measuring Propylene Glycol Using A Refractometer

    EFRACTOMETER SING THE REFRACTOMETER TO TEST ANTIFREEZE SAMPLE Warning Use extreme caution in gathering your antifreeze sample. When draining the Aqua-Hot heating system. extremely hot liquid may be in the Boiler Tank and could cause personal injury. Basic Operation 1. Open daylight plate, and place 2.
  • Page 56 15549 East Highway 52 | Fort Lupton, CO 80621 Toll free: 800.685.4298 | phone: 303.659.8221 | fax:303.857.9000 www.aquahot.com LTE-907-690 Rev B...

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