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© 2008 Aqua-Hot

®

375-D Hydronic Heating System Installation Manual Rev. A

1/2 NPT (F) - Domestic

Hot Water Outlet

5/8 inch Pex Tube

(Outside Diameter)

Domestic Cold Water Inlet

section 5: Domestic Water system

Figure 29

To Hot Water Faucets

Domestic

Hot Water

OUTLET

Fresh

Water Storage

Tank

Demand

Pump

Domestic

Cold Water

INLET

Arrows indicate directional flow of

domestic water

To Cold Water

Faucets

Aqua-Hot 375-D Heater

AT -

Indicates options

for mounting an

Accumulator Tank.

Figure 30

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Summary of Contents for 375D

Page 1: ...2008 Aqua Hot Heating Systems Inc Installation Manual...

Page 2: ...ces 10 Mounting Requirements 10 Mounting the Heat Exchangers 11 Wiring the Heat Exchangers 13 Plumbing Requirements 14 Plumbing the Hydronic Heating System 15 Section 4 Thermostats Fresh Water Tank Th...

Page 3: ...urging the Hydronic Heating System 31 Purging the System by Grounding the Zone Circulation Pumps 32 Purging the Domestic Water System 32 Section 11 Initial Start Up Activating the Aqua Hot 34 Appendic...

Page 4: ...anger Warning Caution and Note boxes appearing as needed throughout this manual must be reviewed and adhered to during the in stallation procedure in order to avoid potential hazards which could resul...

Page 5: ...each Number of Heating Zones maximum of 2 plus Bay Heat Exchanger Domestic Water Heating Capacity continuous on demand Dimensions 16 75 H x 18 W x 29 5 L Dry Weight approximately 155 lbs Wet Weight ap...

Page 6: ...protection for the DC power supply Use a circuit breaker that cuts power at 20 Amps maximum for over current protection for the 120 VAC power supply Mount the Heater near a bay storage door so that t...

Page 7: ...Tray Additional Cross Member for Support may be necessary CUT OUT Outline of Aqua Hot Front of Aqua Hot Motorhome Floor Outline 1 408 Typical 2 017 Typical 203 Typical 6 Places 18 129 Overall 27 249 O...

Page 8: ...the mounting location to insure that no structural members will interfere with the cut out for the mounting tray Verify that an adequate support system has been provided for the Aqua Hot Secure the mo...

Page 9: ...ection 2 Aqua Hot Installation Top View 18 00 27 25 Side View Front View 17 81 17 50 2 05 Side View 1 5 INCH BLACK PIPE EXHAUST FITTING 27 25 14 35 NOTE All measurements are in inches Bottom View 1 95...

Page 10: ...lation Manual Rev A Section 2 Aqua Hot Installation Front of Mounting Tray Back of Mounting Tray Access Cover Mounting Tray Flange 1 5 inch Black Pipe Exhaust Fittings Mounting Tray Mounting Tray Moto...

Page 11: ...the Aqua Hot in order to assist with differentiating between the separate heating zones and to aid service personnel with troubleshoot ing 1 Loosen the cable clamps on the installed cable clamp fittin...

Page 12: ...e highest point on the Aqua Hot s boiler tank Reference Figure 11 1 Mount the expansion tank as illustrated in Figure 11 2 Connect and clamp the overflow tubing from the Figure 11 expansion tank to th...

Page 13: ...ormation Reference Figure 13 for clearance information NOTE An accessory device is available for the Cozy Heat Ex changer for the purpose of redirecting the airflow from the heat exchanger Reference F...

Page 14: ...Heat Exchanger Bathroom Heat Exchanger Fresh Water Tank Heat Exchanger Aqua Hot 375 D Heating System Heating Loop 1 Kitchen and Living Room Heating Zone Heating Loop 2 Bathroom Bedroom and Fresh Water...

Page 15: ...ic Heating System Installation Manual Rev A Section 3 Hydronic Heating System Vertical Mount Horizontal Mount Mounting Tab Figure 18 3 50 in 5 50 in 1 06 in 0 38 in 2 81 in 6 50 in 10 50 in 13 69 in 6...

Page 16: ...sure that the wire end farthest from the Aqua Hot is either attached to the last heat exchanger or covered to prevent additional connections 4 Attach each zone wire ran in step 2 to the Aqua Hot term...

Page 17: ...routing of the plumbing lines from each heating zone to the Aqua Hot All plumbing lines should be laid as flat as possible and any extreme rises in height should be avoided to eliminate any potential...

Page 18: ...ops Reference Figure 23 Then connect each additional heat exchanger in the same arrangement low to high 4 Connect and clamp the inlet line from the heater to the highest port on the last heat exchange...

Page 19: ...ater Hose Coupler 3 4 inch I D PEX Plumbing Line PEX Plumbing Line 3 4 in Rubber Coupler 3 4 in Rubber Coupler Figure 24 Inlet Heating Loop Ports with installed barb fittings Outlet Heating Loop Ports...

Page 20: ...tats Fresh Water Tank Thermostat Locations Select a location that will ensure even heat distribution throughout the fresh water storage tank bay com partment in order to prevent the domestic water and...

Page 21: ...rmostat Mounting Once the room thermostat has been wired permanent ly mount the thermostat in place Be sure to then turn OFF both interior room thermo stats Section 4 Thermostats Room Thermostat Wirin...

Page 22: ...er using fixture when computing pipe sizes NOTE As stated directly from the ANSI A119 2 NFPA 501C Standard on Recreation Vehicles 1993 Edition Piping Systems shall be sized to provide an adequate quan...

Page 23: ...ameter Domestic Cold Water Inlet Section 5 Domestic Water System Figure 29 To Hot Water Faucets Domestic Hot Water OUTLET Fresh Water Storage Tank Demand Pump Domestic Cold Water INLET Arrows indicate...

Page 24: ...d motion Switch Panel Wiring 1 Run 16 gauge wires from the switch panel to the termi nal access block NOTE It is recommended that the wire numbers in Appendix A be used when installing the Aqua Hot in...

Page 25: ...OCATION Pin 1 Terminal Block A0 Pin 2 Terminal Block A1 Pin 4 Jump to Pin 1 Pin 6 Chassis Ground SWITCH MOUNT LOCATION Pin 1 Terminal Block D0 Pin 2 Terminal Block D1 Pin 4 Terminal Block L Pin 6 Term...

Page 26: ...strict fuel flow thereby compromising the diesel burner s performance Fuel System Installation 1 Run two 3 8 inch fuel lines from the fuel tank inlet and outlet ports to the Aqua Hot Both fuel lines s...

Page 27: ...375 D Hydronic Heating System Installation Manual Rev A 50 ft maximum distance 50 ft maximum distance Maximum Allowable Suction Height 7 feet Maximum Allowable Head Pressure 10 ft Figure 36 Section 7...

Page 28: ...l Pick Up Pipe Output to the Aqua Hot s Fuel Inlet Port TOP VIEW of Fuel Filter Head Fuel Filter Input from Fuel Tank Fuel Pick Up Pipe reference Figure 27 Output to the Aqua Hot s Fuel Inlet Port ref...

Page 29: ...thout any obstructions Angle the exhaust pipe towards the rear of the vehicle so that the exhaust fumes will naturally move away while the vehicle is in motion Use standard 2 0 inch automotive type ex...

Page 30: ...ck pipe exhaust fittings MUST be utilized with all installations Failure to conform could create a hazardous situation and will void the Aqua Hot s ETL product listing Figure 39 Section 8 Exhaust Syst...

Page 31: ...nstallation Manual Rev A Section 8 Exhaust System 3 inch Nipple Mounting Tray Flange 4 inch Nipple Exhaust Pipe Elbow Depth of Motorhome Bay Floor 3 inch Nipple 4 inch Nipple Mounting Tray Flange Exha...

Page 32: ...E All electric installations systems and equipment shall comply with Article 551 Parts I and III through VI of NFPA 70 as well as the regulation of authorities having jurisdiction and CSA Standard B13...

Page 33: ...n line Fuse Positive Power Negative Ground NOTE Reference Appendix A for specific wiring details Aqua Hot s 12 Volt DC Terminal Block Figure 43 Figure 42 120 Volt AC Terminal Block 12 Volt DC Terminal...

Page 34: ...alve located at the front of the heater Reference Figure 45 2 Connect a piece of 1 2 inch PEX type tubing to the drain valve This piece should be long enough to trans port the antifreeze and water hea...

Page 35: ...rce therefore disconnect the alligator clip from the ground source during the antifreeze and water heating solution filling procedure 5 Allow the circulation pump to operate for approxi mately 1 3 min...

Page 36: ...rom the opposing wire Alligator Clip to be connected to the Blue Wire s Spade Terminal Opposite end of the Alligator Cable to be connected to a ground source Red positive wire will not be disconnected...

Page 37: ...shutdown purge cycle 3 After the purge cycle has ended repeat once more 4 Move the diesel burner switch to the ON position and leave it on in order to activate the diesel burner NOTE It will take appr...

Page 38: ...Wiring Diagram Appendix A...

Page 39: ...2008 Aqua Hot 375 D Hydronic Heating System Installation Manual Rev A A 1 Appendix A Wiring Diagram...

Page 40: ...Wire Gauge Information Appendix B...

Page 41: ...0 3 0 4 0 4 0 4 0 4 0 50 6 6 4 4 2 2 1 0 2 0 2 0 3 0 3 0 4 0 4 0 4 0 60 6 4 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 4 0 70 6 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 80 6 4 2 2 1 0 3 0 3 0 4 0 4 0 90 4 2 2 1 0 2 0 3 0 4 0...

Page 42: ...Antifreeze Types Appendix C...

Page 43: ...specifically for winterizing appli cations only Although RV Marine antifreeze is often Generally Recognized as Safe by the FDA it should never be used in the Aqua Hot s Hydronic Heating System This t...

Page 44: ...Antifreeze Mixture Water Quality Recommendations Appendix D...

Page 45: ...e mixed antifreeze are responsible for the use of high quality distilled de ionized or soft water when preparing their antifreeze for sale Hard water possesses a high level of calcium and magnesium io...

Page 46: ...Antifreeze Terms and Mixture Ratio Appendix E...

Page 47: ...iling point is reached a loss of efficiency occurs because the heat produced is expelled rather than utilized for the function of the heating system Therefore a higher boiling point is desired in orde...

Page 48: ...stallation Manual Rev A E 2 10 0 20 40 60 20 30 10 20 30 40 50 60 Freezing Point Temperature In Degrees Fahrenheit l o c y l G e n e l y p o r P f o e g a t n e c r e P n o i t u l o S n i 28 7 8 19 2...

Page 49: ...15549 East Highway 52 Fort Lupton Colorado 80621 1 800 685 4298 Fax 303 857 9000 www aqua hot com...

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