Airxcel Aqua-Hot 600 Series Installation Manual Download Page 22

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Plumbing the Heating Loop

©Aqua-Hot®

600D Installation Manual

p. 21

Engine Preheat

Figure 41

Vehicle Engine

Ideal Incoming Port

(top side of engine)

Potential Outlet Port

To Aqua-Hot’s Engine

Preheat “Inlet” Port

(M) NPT by

Hose Barb

Hose Clamp

Automotive-Type

Heater Hose

45’ (M) NPT by

Hose Barb

Hose Clamp

Automotive-Type

Heater Hose

From the Aqua-Hot’s

Engine Preheat “ Outlet” Port

Figure 42

Engine

Preheat

Outlet

Engine

Preheat

Inlet

Top View of Aqua-Hot

Summary of Contents for Aqua-Hot 600 Series

Page 1: ...Installation Manual 600Series AHE 600 D04 with...

Page 2: ...ections similar to this one to draw attention to features and practices which should be observed Contents Caution Notes 1 Introduction 2 System Features 4 Component Cut Aways 5 Installing the Aqua Hot...

Page 3: ...ured Read all instructions before installing the Aqua Hot unit Aqua Hot Heating Systems is not liable for damage resulting from failing to follow instructions contained in this and any other Aqua Hot...

Page 4: ...aking Aqua Hot the cleanest burning diesel powered hydronic heating system available Should additional assistance be needed please contact the Technical Support at 574 AIR XCEL 574 247 9235 Monday thr...

Page 5: ...nsions US 18 5 H x 18 5 W x 36 75 L Dry Weight 186lbs Wet Weight 303lbs All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Association s RVIA ANSI...

Page 6: ...ngine Preheat Pump 7 Diesel Burner 8 Fluid Drain Valve 9 Diesel Burner Controller 10 Domestic Water Thermostat Access Panel 11 Domestic Water Assembly 12 Heating Zone 1 Outlet 13 Heating Zone 2 Outlet...

Page 7: ...rate 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 Figure 9 Diesel Fuel Inlet Outlet Ports Zone 1 2 3 Inlet Por...

Page 8: ...total and tighten to secure the mounting tray to the coach NOTE Inspect the area near the mounting location to ensure that no structural members will interfere with the cut out for the mounting tray...

Page 9: ...Support and Clearance Aqua Hot 600D Installation Manual p 8 All measurements are in inches Side View Front View Bottom View Top View...

Page 10: ...n as shown in Figure 15 3 Drill a hole in the bay oor and connect a long enough piece of over ow tubing so that it can be connected to the top of the expansion tank and extend through the bay oor Secu...

Page 11: ...e nipple Exhaust System The Aqua Hot s exhaust is HOT and must be kept away from any heat sensitive material s Do NOT direct exhaust downward as a re may result when parked in dry grassy areas All Aqu...

Page 12: ...ipe exhaust ttings MUST be utilized with all installations Failure to conform could create a hazardous situation and will void the Aqua Hot ETL Product Listing View from Underneath Aqua Hot 1 5 inch E...

Page 13: ...ure 20 3 Black Pipe Nipple Installed Black Pipe Elbow 4 Black Pipe Nipple Installed 2 Automotive Type Exhaust Pipe Depth of Motor Home Bay Floor Exhaust Pipe 3 Nipple Elbow 3 Nipple Mounting Tray Flan...

Page 14: ...2 Heat Exchanger Locations and Clearances Position the heat exchangers so that even heat is distributed throughout the coach interior The rst heat exchanger on the loop will output the most interior h...

Page 15: ...nces Aqua Hot 600D Installation Manual p 14 Mounting Tabs both sides Inlet Outlet Figure 25 Figure 24 Installing Heat Exchangers 13 69 in 10 50 in 6 50 in 2 81 in 0 38 in 3 50 in 5 50 in 1 06 in 14 44...

Page 16: ...m assembly may be purchased to redirect air via ducting Refer to Figure 26 28 1 2 3 4 5 1 Hot Air Outlet Vent 2 Air Ducting Hose 3 Plenum 4 Cozy Heat Exchanger 5 Toe Kick Board Mounting the Heat Excha...

Page 17: ...r as shown in Figure 32 2 Wire each heat exchanger independently to the J7 plug of the Reporter 3 Pin out information is shown below NOTE Night mode functionality of the new controller requires that t...

Page 18: ...umbing lines can be installed with a straight tting or an elbow See Figure 34 for reference Instructions 1 Layout the plumbing lines for all heat exchangers 2 Label each line with the heating loop num...

Page 19: ...ion Manual p 18 Figure 35 Figure 37 Figure 36 Figure 38 Barbed Fittings Components Compression Fittings Components Barbed Fittings Components Installed Compression Fittings Components Installed 90 Con...

Page 20: ...rst heat exchanger will always output the largest volume of heat as compared to subsequent exchangers NOTE This is just a sample for mounting locations of the Cozy heat exchangers Actual placement and...

Page 21: ...nes in areas where they cannot be pinched offor damaged during normaloperatingconditions Use one piece engine plumbing ttings in order to reduce the potential for coolant leaks It is recommended that...

Page 22: ...t top side of engine Potential Outlet Port To Aqua Hot s Engine Preheat Inlet Port M NPT by Hose Barb Hose Clamp Automotive Type Heater Hose 45 M NPT by Hose Barb Hose Clamp Automotive Type Heater Hos...

Page 23: ...and any extreme rises in height should be avoided in order to eliminate any potential air traps Run both fuel lines in areas where they cannot be pinched kinked or damaged during normal operation Run...

Page 24: ...Loop Aqua Hot 600D Installation Manual p 23 Fuel System Fuel Supply Fuel Return Figure 44 Figure 45 50 ft maximum distance Maximum Allowable Head Pressure 10 ft 50 ft maximum distance Maximum Allowabl...

Page 25: ...op Aqua Hot 600D Installation Manual p 24 Fuel System NPT F Diesel Inlet Port NPT F Diesel Outlet Port Output to the Aqua Hot s Fuel Inlet Port Input from Fuel Tank Fuel Pick Up Pipe TOP View Fuel Fil...

Page 26: ...f ciency The size of the water supply piping and branch line shall not be less than speci ed in the table below Please note it may be necessary to utilize an accumulator tank within the domestic water...

Page 27: ...that releases excessive pressure in the domestic water system Instructions 1 Connect a domestic water plumbing line from the domestic water demand pump water manifold to the cold water inlet port blu...

Page 28: ...esh Water Tank Thermostat Wiring 1 Run two 18 gauge wires from the thermostat s mounting location to the Aqua Hot s Reporter J1 J9 Pin 2 Insert the positive wire 86 to the J9 6 Pin on the Reporter and...

Page 29: ...l as the regulation of authorities having jurisdiction and CSA Standard B139 Switch Panel Mounting 1 Cut out a 5 5 W x 1 75 H opening for the switch panel plate Reference Figure 52 2 Once the switch p...

Page 30: ...ire Harness 2 J1 1 4 J9 3 10 J7 3 9 Chassis Ground Switch Pin Wire Harness 2 J9 1 4 J1 4 9 Chassis Ground Figure 53 Switch Pin Wire Harness 2 J9 2 4 J1 3 9 Chassis Ground Engine Preheat Electric Eleme...

Page 31: ...nal local regulations Improper installation can cause property damage injury or death Figure 54 NOTE Reference the Schematics starting on page 47 for more information J8 Wire Insertion View Shown 6 5...

Page 32: ...2V 80 J7 4 Zone Fan 4 Ground 81 J7 10 Zone Fan 5 Switched 12V 76 J7 7 Zone Fan 5 Ground 78 Figure 57 Figure 56 Wire Insertion View Shown 12 11 10 9 8 7 6 5 4 3 2 1 ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 J...

Page 33: ...serves as a valuable diagnostic tool when the need to determine RV C functionality arises Wire Insertion View Shown J3 Pin No Description 1 2 3 4 12V DC Current Out Optional CAN HIGH CAN LOW Ground F...

Page 34: ...ll be explained in detail Basic Features The Home Screen is the rst screen shown on the Reporter Reporter 1 0 and Reporter 2 0 home screens do differ The most substantial difference between the Report...

Page 35: ...nue to operate if the coach loses power Once power is restored to the coach and the Reporter unit BATTERY DISCONNECT SWITCH OFF will be displayed in the fault log indicating that the Reporter has lost...

Page 36: ...he minimum current rating is the minimum requirement for what will operate the Reporter Operating at this current rating will not provide suf cient power to any components dependent upon the Reporter...

Page 37: ...stallation Manual p 36 Figure 72 Aqua Hot Reporter Reporter Figure 70 Figure 71 Reporter Bottom View J8 J2 J7 J9 J3 J1 Burner Power RV C Network Indicator Light Board Power Battery Negative Board Powe...

Page 38: ...days without any user intervention Pressing the reset button at any time while enabled will reset the timer and run for an additional 3 days All heating zones are linked together and can be run at 25...

Page 39: ...ua Hot s coach side power connection The 12 volt supply to the heater must be routed directly from the battery All power circuits must be protected with fuses or automatic circuit breakers Reference t...

Page 40: ...reaker minimum The 120V AC must be separate from 12V DC It must be possible to disconnect the power to the boiler either an easily accessible plug or a circuit breaker Please refer to the schematic on...

Page 41: ...ate the following items Exterior uid pump a diagram pump if possible The Aqua Hot uid expansion tank A bucket or pale 2 Fill the bucket with the heating solution Ensure the uid expansion tank is conne...

Page 42: ...ating loop purge procedure These pumps will remain active for a maximum of 5 minutes They will need to be reactivated as needed until the purge procedure is complete at least 20 minutes 5 Continue to...

Page 43: ...emperature 185 F NOTE Both the 12V DC diesel burner and the electric heating element are thermostatically controlled Either or both will automatically maintain the temperature of the boiler tank s ant...

Page 44: ...S antifreeze rated for winterization is used when winterizing this unit The warranty does not cover freeze damage NOTE The Aqua Hot can continue to be used for interior heat once the domestic hot wate...

Page 45: ...ngine preheat switch is moved to the ON position A hot water faucet is opened signaling to the Aqua Hot to generate domestic hot water Engine coolant is circulat ed through the Aqua Hot s boiler tank...

Page 46: ...Purging the Heating Loop Aqua Hot 600D Installation Manual p 45 Wire Sizes OVER CURRENT PROTECTION...

Page 47: ...Purging the Heating Loop Aqua Hot 600D Installation Manual p 46 System Schematics POWER INPUT PUMPS SAFETIES AND CONTROLS...

Page 48: ...Purging the Heating Loop Aqua Hot 600D Installation Manual p 47 System Schematics DIESEL BURNER...

Page 49: ...Purging the Heating Loop Aqua Hot 600D Installation Manual p 48 System Schematics ELECTRIC ELEMENT HIGH LIMIT THERMOSTATS...

Page 50: ...Purging the Heating Loop Aqua Hot 600D Installation Manual p 49 System Schematics SWITCH PANEL...

Page 51: ...System Schematics Aqua Hot 600D Installation Manual p 50 HEAT EXCHANGERS...

Page 52: ...System Schematics Aqua Hot 600D Installation Manual p 51 HEATING ZONE THERMOSTATS...

Page 53: ...eating system s boiler tank and associated components it has been determined that there is a need to use distilled deionized or soft water in combination with concentrated propylene glycol for the Aqu...

Page 54: ...however propylene glycol itself does not possess acceptable heat transfer characteristics Therefore as water is an excellent heat conductor it is added to the mixture Propylene glycol antifreeze solut...

Page 55: ...oundary Line Once the glycol solution has been properly applied adjust the calibration screw until the boundary line labeled Propylene Glycol is set to 32 F The graphic to the right has been designed...

Page 56: ...Aqua Hot 600D Installation Manual p 55 Parts Accessories AHE 600 D04 ELE 000 908 Panel Switch 4 Position ASM ELX 700 007 Room Thermostat Positive Off ELE 400 900 Boost Pump Harness ELX 500 510 Bay Th...

Page 57: ...ssories EXX 950 411 Grille 10 x 2 Cozy EXX 006 500 Grille Long 3 5 x 21 5 Black EXE 505 65A Heat Exchanger Whisper Silent 12V DC EXX 013 100 Nozzle Round 4 w o Connector Black EXX 013 105 Nozzle 4 Rou...

Page 58: ...01 Grille Medium 3 5 x 15 Black Parts Accessories EXX 006 502 Grille Small 3 5 x 8 5 Black PLX 000 200 Tube Safety Stripe 12ft PLX 000 820 Fitting Elbow 90 Barb Black Nylon PLX 000 835 Fitting Reducer...

Page 59: ...58 Parts Accessories PLX 200 103 Fitting M NPT x Barb Black Nylon PLX 432 000 Fitting Straight PEX x M NPT PSF PLX 100 900 Boost Pump PLX 284 74V Hose Molded Elbow 90 PLX 120 626 Tube Red O2 Barrier...

Page 60: ...itting Pipe Nipple Exhaust 1 x 4 Parts Accessories PLX 803 ELB Elbow Fitting 90 PEX x PSF PLX 803 FSE Elbow Fitting 90 PEX Fitting PLX CTB 270 Clamp Hose Constant Tension 0 75 PLX 803 000 Fitting Stra...

Page 61: ...Installation Manual p 60 Parts Accessories PLX T44 006 Fitting Insert Modi ed Bras SME 102 000 Cozy Plenum Assembly PLX A65 200 Fitting Brass Barb x M NPT PLX A65 300 Fitting Brass Barb 90 x M NPT PL...

Page 62: ...such defects which would occur in the manufacturing of the product Thus problems due to improper speci cations improper installations improper use the use of accessory parts or parts not authorized by...

Page 63: ...eating 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 Installation Manual...

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