Plumbing the Heating Loop
Wiring Heat Exchangers
©Aqua-Hot®
400D Installation Manual
Rev 220504
©Aqua-Hot®
400D Installation Manual
Rev 220504
p. 17
p. 16
Wiring the Heat Exchangers
This section will explain in detail how to wire the heat
exchangers for optimal functionality. Do not deviate from these
guidelines. If a deviation is required, contact Aqua-Hot Heating
Systems prior to installing these exchangers for express
permission to proceed with modifications.
1. Wire each heat exchanger (in a heating zone) in parallel to
one another as shown in Figure 30.
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 the heat exchangers be wired directly into the controller.
Zone Fan Number
Supply (+) Pin
Number
Ground (-) Pin
Number
1
J7-12
J7-9
2
J7-2
J7-5
3
J7-11
J7-8
4
J7-1
J7-4
5
J7-10
J7-7
Connector Part Numbers
Part Number
Manufacturer
Description
1-480706-0
TE Connectivity
J7 Plug Housing
350550-1
TE Connectivity
J7 Socket Terminal
J7 Mating Plug
Figure 28
Figure 29
Figure 30
12
11
9
8
7
6
5
4
J7 Wire insertion view shown
3
2
1
10
Plumbing the Heating Loop
Once all heat exchangers have been mounted, plan the
routing of the plumbing lines from each heating zone to the
Aqua-Hot. The following guidelines should be used when
planning the coolant loop(s) for the heating zone. The order
of the heat exchangers should consider priority on the loop(s).
Failure to adhere to these installation principles can hinder the
operation of the heat exchangers.
•
All plumbing should be installed as flatly as possible.
• Extreme rises in height should be avoided to avoid any
potential air traps.
•
Use ⅝” ID (Inside Diameter) plumbing lines, ¾” SAE J20
type coolant hose, heater hose, or PEX tubing for the
heating loop(s).
• Use wide-sweeping elbows or “bend supports” whenever
the plumbing lines may be susceptible to kinking.
• Plumbing lines should be run in areas where there is no
reasonable possibility that they can be pinched off or
damaged under normal operating conditions.
• Secure all lines where necessary and apply
protective shielding in areas where chafing may
occur.
• Rubber coated/closed-type clamps are
recommended when securing the plumbing lines.
• Inlet and outlet plumbing lines can be installed with
a straight fitting or an elbow.
• See Figure 32 for reference.
Instructions:
1. Layout the plumbing lines for all heat exchangers.
2. Label each line with the heating loop number and
designate as an outlet or an inlet line.
3. Connect and clamp the outlet line from the heater
to the lowest port (inlet port) with the longest run for
both heating loops.
4.
Connect and clamp a line from the first heat
exchanger’s highest port, and connect the other
end to the next heat exchanger’s lowest point.
5. Connect each additional heat exchanger in the
same arrangement.
6. Connect and clamp the inlet line from the heater
to the highest port on the last heat exchanger to
complete the heating loop.
Figure 32
Inlet
Outlet
PEX Insert
Hose
Clamps
¾” Coupler
Figure 31
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 exchanger’s overall heating
performance.
Heating Loop #1
Heating Loop #2
Heating Zone #1
Heating Zone #3 Heating Zone #2
Heating Zone #4
Incoming Plumbing Lines
Outgoing Plumbing Lines
NOTE:
The kitchen and living room heat exchangers
must be plumbed together
in-series
on “Heating Loop
1”. The fresh water tank, bedroom, and bathroom
heat exchangers must be plumbed together
in-series
on “Heating Loop 2”. See the diagram in Figure 32.
Living R
oom
Living R
oom
Kitchen
Bedr
oom
Bathr
oom
Fresh W
ater
Tank
J7 Socket Terminal
