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Aqua-Hot 375D Installation Manual

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

© 2011 Aqua-Hot Heating Systems Inc.

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Summary of Contents for Aqua-Hot 375D

  • Page 1: Installation Manual

    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

    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 ......................12 Installing the Cable-Clamp Fittings ....................14 Installing the Wires into the Terminal Blocks .................. 14 Installing the Expansion Tank ......................
  • Page 4 Purging the System by Grounding the Zone Thermostat Connection ......... 42 Purging the Domestic Water System....................43 Section 11: Initial Start-Up Activating the Aqua-Hot ........................46 Appendices: Appendix A: Wiring Diagram ......................47 Appendix B: Wire Gauge Information ....................48 Appendix C: Antifreeze Types ......................

  • Page 5: Introduction

    NTRODUCTION The Aqua-Hot 375D is a hydronic (water based) heating sys- Danger, Warning, Caution, and Note Boxes: tem, and a tank-less hot water system. Danger, Warning, Caution, and Note boxes appear through- The heating system provides moist, quiet, comfortable, inte-...

  • 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) 620-6003, or visit them online at www.rvia.org. — Page 6 — ® © 2011 Aqua-Hot 375-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 ECTION YDRONIC EATING YSTEM CAUTION: The Aqua-Hot tank and heating loop operate at 0.0 psi (zero pressure system). Air pressure ap- plied to the tank MUST NOT exceed 20 psi. Ex- Figure 3 cess pressure will result in internal damage.
  • Page 9 YDRONIC EATING YSTEM Figure 4 Interlock Switch Domestic Water Assembly Zone 1 Relay Zone 2 Relay Fuse Block Diesel Burner Zone 2 Controller Circulation Pump Drain Valve Diesel Burner — Page 9 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 10: Section 2: Aqua-Hot Installation

    Installing the Mounting Tray and the Aqua-Hot: tion: • Overall Aqua-Hot dimensions - Figure 8 The Aqua-Hot must be installed in a compartment that is • Mounting tray information - Figure 7 completely closed-off from living quarters and accessible • I.D. Label noting the “Open Access”...
  • Page 11 2: A ECTION NSTALLATION Figure 6 Underside of Mounting Tray Mounting Tray Flange (Installed in cut-out) Figure 7 — Page 11 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 12 2: A ECTION NSTALLATION Figure 8 — Page 12 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 13 2: A ECTION NSTALLATION Figure 9 — Page 13 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 14: Installing The Cable-Clamp Fittings

    4. Hand tighten the cable clamps on each of the cable- clamp fittings. 5. Re-install the terminal block access cover and tighten the screws securing the cover to the Aqua-Hot. NOTE: A ferrule is required if stranded wire is being used to connect to the terminal block...

  • Page 15: Installing The Expansion Tank

    NOTE: Avoid dips and bends in the overflow tubing from the Installing the Expansion Tank: 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 and...

  • Page 16: Section 3: Hydronic Heating System

    Figure 15 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 — Page 16 — ® © 2011 Aqua-Hot...

  • Page 17: Mounting The Heat Exchangers

    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 375-D Installation Manual...
  • Page 18 3: H ECTION YDRONIC EATING YSTEM Figure 20 Figure 21 — Page 18 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 19: Sample Heating System Floorplan

    3: H ECTION YDRONIC EATING YSTEM Figure 19 — Page 19 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 20: Wiring The Heat Exchangers

    Terminal for Heating Zone 2’s positive heat 4. Attach each zone wire ran in step 2 to the Aqua-Hot exchanger wire (F2) terminal block - position F1 for zone 1 and position F2 for zone 2. Reference Figure 22. Tighten the screw in NOTE: It is recommended that the wire numbers in Appendix the terminal to secure the wire in place.
  • Page 21 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 25 — Page 21 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 22: Plumbing Requirements

    Once all heat exchangers have been mounted, formulate a “Heating Loop 2.” Reference Figure 26. plan for the routing of the plumbing lines from each heating zone to the Aqua-Hot. Use 5/8 inch I.D. (Inside Diameter) plumbing lines for both heating loops.

  • Page 23: Plumbing The Hydronic Heating System

    5. Connect and tighten all interior plumbing lines, outlet cur. and inlet, to the Aqua-Hot’s appropriate heating loop ports. Reference Figure 29 and Figure 30. Rubber Coated/Closed-Type clamps are recom- NOTE: The inlet and outlet plumbing lines can be installed mended when securing the plumbing lines.
  • Page 24 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 24 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 25 3/4” Two Constant Tension Pex Tube Heater Band Clamps Hose Pex Insert Constant Tension Clamps Straight Connection Components 90⁰ Connection Components 90⁰ Connection Components Installed Straight Connection Components Installed — Page 25 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 26: Section 4: Thermostats

    (positions T3 and P2) to the fresh-water tank thermostat. the ceiling of the bay. 2. Splice the wire from position T3 on the Aqua-Hot’s ter- The selected mounting location should allow for easy opera- minal block to the fresh water tank thermostat’s black tor access and should be as low in the bay area as possible.

  • Page 27: Room Thermostats

    Room Thermostat Wiring: NOTE: The selected location should prevent the thermostat from being affected by: 1. Run one 18-gauge wire from each room thermostat mounting location to the Aqua-Hot terminal block. • drafts or dead spots behind doors and in corners •...

  • Page 28: Section 5: Domestic Water System

    1. Connect a domestic water plumbing line from the do- mestic water demand pump/water manifold to the cold Use the RVIA-provided table below in order to determine water inlet port on the Aqua-Hot. Reference Figures 33 the proper sizing of pipe and tubing required to insure maxi- and 34.
  • Page 29 5: D ECTION OMESTIC ATER YSTEM Figure 33 1/2 NPT (F) - Domestic Hot Water Outlet 1/2 Inch Pex Tube Outside Diameter Domestic Cold Water Inlet Figure 34 — Page 29 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 30: Section 6: Switch Panel

    (Diesel- NOTE: It is recommended that the wire numbers in Appendix Burner switch only), which indicates a diesel-burner A be used when installing the Aqua-Hot in order to malfunction. aid service personnel with troubleshooting.
  • Page 31 Jump to Pin # 5 Pin# 6 Terminal Block L- Pin# 6 Chassis Ground Burner Switch to Electric Element Switch to Terminal Block connections Terminal Block connections Figure 37 — Page 31 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 32: Section 7: Fuel System

    Figure 40. All fuel-fitting hardware (i.e., at the vehicle’s fuel tank, fuel filter, and Aqua-Hot fuel parts) must be 1/4 inch NPT or greater with a 3/8 inch barbed fitting. Fuel fittings less than 1/4 inch NPT may restrict fuel flow, thereby compromising the diesel-burner’s per-...
  • Page 33 7: F ECTION YSTEM Figure 39 — Page 33 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 34 7: F ECTION YSTEM Figure 40 Reference Reference Figure 41 Figure 38 Figure 41 ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 35: Section 8: Exhaust System

    Installing the Exhaust System: an openable window or vent. The Aqua-Hot is supplied with a 3-inch and a 4-inch black DO NOT terminate the exhaust pipe within the awning pipe nipple (1.5 inch diameter) along with a 1.5 inch exhaust area of the motorhome, if applicable.
  • Page 36 8: E ECTION XHAUST YSTEM Figure 42 Figure 43 — Page 36 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 37 8: E ECTION XHAUST YSTEM Figure 44 — Page 37 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 38 8: E ECTION XHAUST YSTEM Figure 45 3” Black Pipe Nipple Installed Black Pipe Elbow 4” Black Pipe Nipple Installed 2” Automotive Type Exhaust Pipe — Page 38 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 39: Section 9: Power Source Wiring

    1. Follow the instructions in this section for “Installing the Wires into the Terminal Blocks” for the 120 Volt- DO NOT connect the 12 Volt-DC power to the Aqua-Hot if AC wires. the vehicle requires welding. Electrical welding will cause serious damage to the burner controller.
  • Page 40 Tighten the terminal block screws to 5 inch-pounds using a slotted blade, no larger than 1/8”, when attaching the 120V AC wires to the terminal block. Figure 48 Main Battery Disconnect — Page 40 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 41: Section 10: Purging The Systems

    “GRAS” (Generally Recognized as Safe) by the tection, and anti-corrosion and rust protection, a mixture of FDA shall be used in the Aqua-Hot’s hydronic heating sys- “GRAS” approved propylene glycol antifreeze and water is tem. Failure to use the above specified antifreeze type recommended.

  • Page 42: Purging The System By Grounding The Zone Thermostat Connection

    See Appendix F on Page 52. loop, then remove the wire from the ground source. 4. Open the Aqua-Hot’s drain valve located at the front of 6. Open the drain valve and completely fill the Aqua-Hot’s the heater. Reference Figure 50.

  • Page 43: Purging The Domestic Water System

    Figure 51 Terminal Block for Switches, Heat Exchanger Fans and Thermostats Figure 52 Zone 1 Thermostat Connection Terminal Zone 2 Thermostat Connection Terminal — Page 43 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 44 10: P ECTION URGING THE YSTEMS This Page Intentionally Left Blank — Page 44 — ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 45 10: P ECTION URGING THE YSTEMS This Page Intentionally Left Blank — Page 45 — ® © 2011 Aqua-Hot 375-D Installation Manual...

  • Page 46: Section 11: Initial Start-Up

    When turning on the diesel burner switch inside the tem by allowing the heater’s fuel pump to complete its coach, if the Aqua-Hot fails to start and the light on the normal 30-150 second shutdown/purge cycle. burner switch blinks 8 times (8 code), the following...

  • 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 49: Appendix C: 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 50: Appendix E: Antifreeze Terms And Mixture Ratio

    -28ºF and a boil point of approximately 222ºF. rather than utilized for the function of the heating system. NOTE: As the installer of this Aqua-Hot system, you must Therefore, a higher boiling point is desired in order to com-...
  • Page 51 E: A PPENDIX NTIFREEZE ERMS AND IXTURE ATIO — Page 51 —...

  • Page 52: Appendix F: Measuring Propylene Glycol Using A Refractometer

    F: 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 375-D Installation Manual...
  • Page 53 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 54 OTES ® © 2011 Aqua-Hot 375-D Installation Manual...
  • Page 55 OTES ® © 2011 Aqua-Hot 375-D Installation Manual...
  • 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-907-722 Rev B...

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