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Aqua-Hot AHE-100-04S-12 VDC, Installation Manual, Page: 18 / 68

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Aqua-Hot AHE-100-04S-12 VDC Installation Manual Download Page 18

Aqua-Hot™ Hydronic Heating System Installation Manual  07/05

Page  15

Interior Heat

Exchanger

Dimensions, 

Wiring, and 

Mounting 

Overview

Figure 9

13.06 in.

6.44 in.

14.44 in.

3.63 in.

NOTE:

  Tolerance 

+/- .030

+ (Positive) Red Wires

To the “

Fan +

” connection on 

the Electronic Controller

- (Ground) Black Wires

To the “

Fan -

” connection on 

the Electronic Controller

SECTION 3:  INSTALLATION PROCEDURES

Summary of Contents for AHE-100-04S-12 VDC

Page 1: ...Installation Manual Model Numbers AHE 100 04S 12 VDC AHE 130 04X 12 VDC...

Page 2: ...t Exchangers 32 3 16 Mounting Locations for Interior Room Thermostats Overview 33 3 17 Wiring the Interior Room Thermostats 33 3 18 Mounting the Fresh Water Tank Thermostat Overview 34 3 19 Wiring the...

Page 3: ...ne 26 Figure 18 Engine Coolant Supply and Return Port Locations 28 Figure 19 Attaching Plumbing Lines to the Domestic Hot Water System 30 Figure 20 Domestic Hot Water System Overview 31 Figure 21 Wiri...

Page 4: ...reheat Figure 1 Tempering Valve Domestic Water Heating Zones Supply and Return Ports Circulation Pump 1 Circulation Pump 2 Circulation Pump 3 Engine Preheat Circulation Pump Diesel Burner Engine Coola...

Page 5: ...ze and water heating solution as its heating medium This heated solution is circulated by three centrifugal Circulation Pumps to the heating system s Heat Exchangers whenever a Room and or Bay Thermos...

Page 6: ...om Heat Exchanger Fresh Water Tank Heat Exchanger Living Room Exchanger Living Room Heat Exchanger Kitchen Heat Exchanger Circulation Pump 1 Circulation Pump 2 Circulation Pump 3 Heating Zone 1 Heatin...

Page 7: ...stem The varying factor between these two models is the number of Electric Heating Elements featured as well as the wattage employed by each Electric Heating Element In order to determine which of the...

Page 8: ...12 VDC 21 watts ea Number of Heating Zones maximum of 5 plus Engine Preheat Domestic Water Heating Capacity continuous on demand Dimensions 18 5 H x 18 5 W x 36 75 L Dry Weight approximately 200 lbs...

Page 9: ...l Heating Element can be wired using flexible nonmetallic cable ROMEX USE COPPER CONDUCTORS ONLY Use 25 Amp fuse for over current protection for DC Power Supply Use 20 Amp Circuit Breaker for over cur...

Page 10: ...lines will be as short as possible D Mount the Aqua Hot near a Storage Bay Door so the Aqua Hot s Access Cover can be easily removed for product servicing and the Heater can be easily accessed from ou...

Page 11: ...Figure 6 Minimum Heater clearances reference the Aqua Hot s Marking Plate Figure 3 1 Drill all the necessary holes prior to mounting the Aqua Hot permanently into place reference Figure 6 NOTES A Be...

Page 12: ...nual 07 05 Page 9 Aqua Hot Combustion Air Overview Figure 4 Combustion Air Intake Shutter Combustion Air Hole in Aqua Hot Cabinet Hose Clamp Combustion Air Intake Sleeve Rubber Boot Combustion Air Hol...

Page 13: ...Aqua Hot Hydronic Heating System Installation Manual 07 05 Page 10 Aqua Hot Dimensions Figure 5 36 75 in 18 5 in 18 5 in Access Cover SECTION 3 INSTALLATION PROCEDURES...

Page 14: ...in ref 3 000 in 18 500 in ref 11 125 in 2 187 in 1 312 in 15 750 in 33 062 in 37 312 in 19 187 in 0 750 in 2 187 in 2 187 in 2 187 in All Mounting Bracket Holes require a 0 312 inch hole Mounting Hole...

Page 15: ...ting towards the Slideout B Sufficient ventilation return air must be supplied to each interior Heat Exchanger reference Figures 7 and 8 NOTES 1 Mounting Heat Exchangers without sufficient ventilation...

Page 16: ...anger Kitchen Heat Exchanger Bathroom Heat Exchanger Bedroom Heat Exchanger Engine Engine Preheating Fresh Water Tank Heat Exchanger Heating Loop 2 Bathroom and Fresh Water Tank Bay Heating Loop 1 Bed...

Page 17: ...ystem Installation Manual 07 05 Page 14 Interior Heat Exchanger Location Overview HEAT EXCHANGER HOT AIR OUTLET BASE BOARD TOE KICK AREA CABINET COUCH COLD AIR RETURN Figure 8 REGISTER REGISTER SECTIO...

Page 18: ...changer Dimensions Wiring and Mounting Overview Figure 9 13 06 in 6 44 in 14 44 in 3 63 in NOTE Tolerance 030 Positive Red Wires To the Fan connection on the Electronic Controller Ground Black Wires T...

Page 19: ...Aqua Hot Hydronic Heating System Installation Manual 07 05 Page 16 Allowable Cozy III Heat Exchanger Mounting Configurations Vertical Mount Figure 10 Horizontal Mount SECTION 3 INSTALLATION PROCEDURES...

Page 20: ...ger should be strategically placed in the domestic water plumbing area in order to prevent freezing of the plumbing lines and storage tank A Centralize and position the Fresh Water Tank Heat Exchanger...

Page 21: ...t Hydronic Heating System Installation Manual 07 05 Page 18 Minimum Cozy III Heat Exchanger Clearance Figure 12 INTERIOR WALL CABINET WALL 4 inch Minimum Clearance Required SECTION 3 INSTALLATION PROC...

Page 22: ...III Heat Exchanger Mounting Template 3 500 in 5 50 in 1 06 in 0 38 in 2 812 in 6 500 in 10 500 in 13 687 in 6 44 in 13 06 in 14 44 in NOTE Tolerances on the dimensions shown are as follows XX i e 6 44...

Page 23: ...rhome Heating System Floorplan in Section 3 4 for additional information C The Bedroom Heat Exchanger typically one is plumbed solely on Heating Loop 1 D Use 5 8 in I D Inside Diameter Plumbing Lines...

Page 24: ...ing to each Heat Exchanger NOTE Plumbing Heat Exchangers in this manner will allow air to escape naturally If air is trapped in any Heat Exchanger it will significantly reduce the Heat Exchanger s ove...

Page 25: ...Installation Manual 07 05 Page 22 Installing the Heat Exchanger Plumbing Figure 14 Mounting Bracket Mounting Bracket Cozy III Heat Exchanger Rear View Return Port Highest Port Supply Port Lowest Port...

Page 26: ...Rubber Coupler 3 4 in Rubber Coupler Constant Tension Clamps PEX Insert PEX Insert Return Supply 5 8 inch I D 3 4 inch O D 5 8 inch I D 3 4 inch O D Automotive Type Rubber Heater Hose Coupler 3 4 inc...

Page 27: ...ne Ports Figure 16A PEX Tube PEX Insert Compression Fitting Heating Loop 1 Supply Port Heating Loop 2 Supply Port Heating Loop 3 Suppply Port Return Heating Zone Ports Figure 16B PEX Tube PEX Insert C...

Page 28: ...ngine s coolant to the Aqua Hot s Engine Preheat Circulation Pump This port should be a low connection point on the Engine Block or a pressure outlet port on the Engine s Water Pump reference Figure 1...

Page 29: ...ne POTENTIAL SUPPLY PORT pressure outlet port Ideal Return Port T ToTTop side of the engine 45 M NPT Hose Barb Hose Clamp To the Aqua Hot s outlet Engine Preheat OUT Port Return Automotive Type Heater...

Page 30: ...nt be used on all Plumbing Fittings 5 Install and clamp both the Supply and Return engine Plumbing Lines Automotive Type Heater Hoses to the Engine s Plumbing Fittings reference Figure 17 6 Install an...

Page 31: ...Hydronic Heating System Installation Manual 07 05 Page 28 Installing Engine Preheat Plumbing continued Figure 18 Engine Coolant Supply Port IN Engine Coolant Return Port OUT SECTION 3 INSTALLATION PR...

Page 32: ...g Fixture at a flow rate sufficient to keep the Fixture in a clean and sanitary condition without any danger of back flow or siphoning The size of Water Supply Piping and Branch Line shall not be less...

Page 33: ...Vehicle Plumbing Systems To obtain a copy of this particular publication please contact RVIA at 703 620 6003 or visit them online at www rvia org 2 Connect a domestic water Plumbing Line from the Aqu...

Page 34: ...rview Domestic Hot Water OUTLET To Hot Water Faucets AT AT AT Demand Pump Arrows indicate directional flow of domestic water To Cold Water Faucets AT Indicates options for mounting an Accumulator Tank...

Page 35: ...onnections F The Aqua Hot s Electronic Controller is designed to work with most Electronic Room Thermostats however the chosen Thermostat must produce a constant 12 Volt DC output signal and must rece...

Page 36: ...est level if applicable NOTE Do not mount the thermostat where it can be affected by drafts or dead spots behind doors and in corners hot or cold air from ducts radiant heat from the sun or appliances...

Page 37: ...ation should allow for easy operator access reference Figure 21 3 19 Wiring the Fresh Water Tank Thermostat 1 Run two 16 Gauge wires from the Bay Thermostat s mounting location to the Aqua Hot s Elect...

Page 38: ...6 50 3 00 1 50 75 75 1 00 4x 1 50 2 75 4 25 AHE 130 04X Interior Switch Panel 4 50 5 00 25 2 50 25 150 4x 3 00 1 50 75 75 1 50 2 75 1 00 3x AHE 100 04S Interior Switch Panel Figure 22 3 75 5 25 All d...

Page 39: ...to Chassis Ground Switch to Electronic Controller connections Switch Electronic Controller Pin 1 Pin 2 Pin 6 to Electric O to Electric I to Chassis Ground Engine Preheat Switch Electric Switch Diesel...

Page 40: ...e Electronic Controller To the Electric O Terminal on the Electronic Controller To the Electric I Terminal on the Electronic Controller To the IND LT B3 Terminal on the Electronic Controller To the IN...

Page 41: ...r Pin 1 Pin 2 Pin 6 to Electric O to Electric I to Chassis Ground Engine Preheat Switch to Electronic Controller connections Switch Electronic Controller Pin 1 Pin 2 Pin 6 to Preheat O to Preheat I to...

Page 42: ...ronic Controller to the Preheat O Terminal on the Electronic Controller to the Preheat I Terminal on the Electronic Controller to the IND LT B6 Terminal on the Electronic Controller to the IND LT B3 T...

Page 43: ...sert all switch wires into the appropriate terminal switch panel connection on the Electronic Controller reference Appendix A 6 Permanently mount the Switch Panel in place 7 Be sure to move all three...

Page 44: ...c Heating System Installation Manual 07 05 Page 41 Fuel System Specifications 33 max 33 max Figure 25 Maximum Allowable Suction Lift height 6 6 max Maximum Allowable Head Pressure 2 SECTION 3 INSTALLA...

Page 45: ...nnot be pinched off kinked or damaged during normal operating conditions C Be sure to secure all Fuel Lines where necessary and apply protective shielding in areas where chafing may occur CAUTION A ki...

Page 46: ...Aqua Hot Hydronic Heating System Installation Manual 07 05 Page 43 Diesel Fuel Ports Figure 27 Diesel Fuel Supply Diesel Fuel Return SECTION 3 INSTALLATION PROCEDURES...

Page 47: ...ce Figure 27 for details on the Fuel Tank connections Reference Figure 28 for details on the Aqua Hot s Fuel Connections Figure 28A Fuel Filter Figure 28B NOTE Reference Figure 27 for details on the F...

Page 48: ...The Exhaust System MUST NOT terminate beneath the vehicle Failure to conform will void the Aqua Hot s UL listing 2 Angle the Exhaust Pipe towards the rear of the vehicle so that the exhaust fumes will...

Page 49: ...Figure 29 e p i P t s u a h x E e p y t e v i t o m o t u A D I h c n i 5 7 1 NOTE A Condensation drain is not required if the Exhaust Pipe slopes away from the Heater x a M t e e F 2 1 1 5 inch Black...

Page 50: ...Neck Overflow Connection reference Figure 30 NOTE The Expansion Bottle can be mounted either above or below the top of the Aqua Hot 3 Drill a hole in the Bay floor and connect secure with a clamp a l...

Page 51: ...that the VDC Voltage Level drops too low to properly operate it is imperative that the proper wire gauge be determined and utilized B The maximum allowable voltage drop for the 12 Volt DC Aqua Hot is...

Page 52: ...ones Status 5 4 3 2 1 Electric Heating Element Status Low Voltage Reset Low Tank Level Cutoff Heating Status Engine Preheat Pump Low Battery Voltage Fault Low Temp Cutoff Status Overload Fault Pump 2...

Page 53: ...Heating Element Status Low Tank Level Cutoff Heating Status Engine Preheat Pump Low Battery Voltage Fault Low Temp Cutoff Status Overload Fault Pump 2 Pump 1 Pump 3 Diesel Burner Status Low Voltage R...

Page 54: ...ropylene glycol based antifreeze products are formulated specifically to protect automotive engines against corrosion freezing temperatures and overheating They also have excellent heat transfer and t...

Page 55: ...lso if there is a shortage of antifreeze the Aqua Hot Hydronic Heating System is not as well protected in terms of freeze protection and anti rust anti corrosion protection 2 Replace the Aqua Hot s Fi...

Page 56: ...to 15 PSI then allow the air pressure to remain for 30 minutes and check for loss of pressure Should a loss of pressure occur check the connections at each Heat Exchanger using a soapy water solution...

Page 57: ...s been completely bled of air Operating the Aqua Hot without the antifreeze and water heating solution will cause serious damage to the Aqua Hot s Heat Tank NOTE All Electric Installations Systems and...

Page 58: ...p 3 1 1 JP 4 JP 3 JP 2 JP 1 14 BLK JUNCTION BOX TO 120 VAC L1 N G BLK 11 ORG 12 BLU 3 WHT 1 BLK GRN BLK BLK 3 WHT JP8 B4 IN JP5 12V JP7 GND 5 FAN 5 FAN 5 THERM O 5 THERM I 4 FAN 4 FAN 4 THERM 0 4 THER...

Page 59: ...R 4 C I R T C E L E W O L I H N R G T H W 3 L E N A P H C T I W S X O B N O I T C N U J N A F 5 N A F 5 O M R E H T 5 I M R E H T 5 N A F 4 N A F 4 0 M R E H T 4 I M R E H T 4 N A F 3 N A F 3 O M R E...

Page 60: ...ectric Elements vary by model locate the Marking Plate on the Aqua Hot reference Figure 1 for the Marking Plate locations as well as Figure 3 for additional information to determine which model is emp...

Page 61: ...Wiring Diagrams APPENDIX A...

Page 62: ...2 Circ Pump 1 1 1 JP 4 JP 3 JP 2 JP 1 OPTIONAL 14 BLK WHT WHT RED BLK BLU BLU RED BLK VIO VIO BLK RED ORG ORG BLK RED 1 2 4 6 1 2 4 6 1 2 6 4 TO 12VDC POWER SUPPLY I E BATTERY CONNECTIONS 12VDC 12VDC...

Page 63: ...L B D E R T H W T H W T H W 3 12 VDC L E N A P H C T I W S C D V 2 1 R O T O M C D V 2 1 3 P M U P N O I T A L U C R I C C D V 2 1 2 P M U P N O I T A L U C R I C C D V 2 1 1 P M U P N O I T A L U C...

Page 64: ...OPTIONAL WHT WHT RED BLK BLU BLU RED BLK VIO VIO BLK RED ORG ORG BLK RED 1 2 4 6 1 2 4 6 1 2 6 4 TO 12VDC POWER SUPPLY I E BATTERY CONNECTIONS SWITCH PANEL BLU BLU YEL ORG VIO BRN GRN WHT JP8 B4 IN JP...

Page 65: ...O I V K L B D E R U L B U L B K L B D E R T H W T H W L E N A P H C T I W S N A F 5 N A F 5 O M R E H T 5 I M R E H T 5 N A F 4 N A F 4 0 M R E H T 4 I M R E H T 4 N A F 3 N A F 3 O M R E H T 3 I M R...

Page 66: ...Wire Gauge Information APPENDIX B...

Page 67: ...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 4 0 100 4 2 2 1 0 2 0 3 0 4 0 5 18 18...

Page 68: ...www vehiclesys com 15549 East Highway 52 Fort Lupton Colorado 80621 1 800 685 4298 Fax 303 857 9000 Copyright 2005 Vehicle Systems Inc All rights reserved...

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