Aqua-Hot 400D Bedienungsanleitung

INSTALLATION MANUAL

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;

it is necessary to disconnect the electric wiring to

the Aqua-Hot System.

Failure to disconnect the wires from the

Aqua-Hot System before using a welder or a

plasma cutter on the coach may cause damage to

the Aqua-Hot.

TABLE OF CONTENTS

Aqua-Hot 400-D Installation Manual

Introduction...........................................................................................................................................5

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...........................................................................................................11

Installing the Expansion Tank............................................................................................................14

Section 3: Hydronic Heating System

Heat Exchanger Location and Clearances.........................................................................................15

Heat Exchanger Mounting Requirements.........................................................................................15

Mounting the Heat Exchangers..........................................................................................................16

Sample Heating System Floorplan......................................................................................................16

Wiring the Heat Exchangers ...............................................................................................................19

Plumbing Requirements.......................................................................................................................22

Plumbing the Hydronic Heating System...........................................................................................22

Section 4: Thermostats

Fresh Water Tank Thermostat............................................................................................................25

Room Thermostats...............................................................................................................................26

Section 5: Domestic Water System

Domestic Water System Requirements .............................................................................................27

Domestic Water System Plumbing.....................................................................................................27

Section 6: Switch Panel

Switch Panel Location..........................................................................................................................29

Switch Panel Mounting........................................................................................................................29

Switch Panel Wiring..............................................................................................................................29

Section 7: Fuel System

Fuel Filter Location ..............................................................................................................................31

Fuel System Requirements...................................................................................................................31

Fuel System Installation.......................................................................................................................31

Section 8: Exhaust System

Exhaust System Requirements............................................................................................................36

Installing the Exhaust System .............................................................................................................36

Section 9: Electronic Controller Wiring

Electronic Controller Wiring……………………………………………………………...40

Wiring Harness Connection………………………………………………………………41

Connecting the 12 Volt-DC Power……………………………………………………….42

Section 10 Purging the Systems

Purging the Hydronic Heating System...............................................................................................43

Purging the System by Grounding the Zone Thermostat Connection.........................................44

Purging the Domestic Water System..................................................................................................44

Section 11: Initial Start-Up

Activating the Aqua-Hot......................................................................................................................46

Appendices:

Appendix A: Wiring Diagram .............................................................................................................47

Appendix B: Wire Gauge Information..............................................................................................48

Appendix C: Electronic Controller Features ....................................................................................49

Appendix D: Antifreeze Types ...........................................................................................................51

Appendix E: Antifreeze Mixture Water Quality Recommendations.............................................51

Appendix F: Antifreeze Terms and Mixture Ratio ..........................................................................52

Appendix G: Measuring Propylene Glycol Levels Using a Refractometer..................................54

TABLE OF CONTENTS (CONTINUED)

INTRODUCTION

Danger, Warning, Caution, and Note Boxes:

Danger, Warning, Caution, and Note boxes appear throughout

this manual as a means of alerting the installer to important

information.

INDICATES THAT PERSONAL INJURY IS LIKELY OR IMMI-

NENT.

Indicates that serious damage to the heater will occur and

personal injury is possible as well.

Indicates that damage to the heater is possible.

NOTE: Indicates information that requires special attention by

the installer.

— Page 5 —

CAUTION:

! DANGER !

WARNING

The Aqua-Hot 400D is a hydronic (water based) heating sys-

tem, and a tank-less hot water system.

The heating system provides moist, quiet, comfortable, interior

heat with up to five separate, thermostatically-controlled tem-

perature zones, and prevents tank and line freezing in the bays.

The tank-less hot water system produces 75 gallons per hour of

continuous, on-demand, hot water.

This TribridHot™ designated system uses one or a combina-

tion of heat sources to heat FDA-approved Generally Recog-

nized as Safe (GRAS) propylene glycol based antifreeze solu-

tion in the Aqua-Hot’s boiler tank.

The 400D uses one 120 Volt-AC, 1650 Watt electric element to

heat the system when shore power is available, and a 12 Volt-

DC powered diesel burner provides heat when dry camping.

The heat sources can be used separately or together.

New Low Emissions Technology virtually eliminates smoke

and smell from the exhaust by reducing total hydrocarbon

emission by 82% making Aqua-Hot the cleanest burning diesel

powered hydronic system available.

Please note that all Danger, Warning, Caution, and Note boxes,

appearing as needed throughout this manual, must be reviewed

and adhered to during the installation procedure in order to

avoid potential hazards, which could result in injury, death,

product damage, or property damage.

Should additional assistance be needed, please contact the

Product Application Department at 1-800-685-4298, Monday

through Friday, between the hours of 7:00 AM and 4:00 PM

Mountain Time.

SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM

Diesel Burner, Heat Input (Firing Rate).................................................................................................................................45,000 BTU/hr

Diesel Burner, Fuel Consumption (Continuous Operation)........................................................................................................0.40 gal/hr

Heater, Voltage/Maximum Power Consumption......................................................................................................12 Volt-DC/60 watts

Electric Heating Element specifications.................................................................................................................120 Volt-AC/1650 watts

Zone Heat Circulation Pump specifications.................................................................................................(2) 12 Volt-DC/21 watts each

Number of Heating Zones........................................................................................................................................................Maximum of 5

Domestic Water Heating Capacity ........................................................................................................................Continuous/On-Demand

Dimensions.................................................................................................................................................................12”H x 18.5”W x 29.5”L

Dry Weight......................................................................................................................................................................approximately 127 lbs.

Wet Weight.....................................................................................................................................................................approximately 184 lbs.

NOTE: All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Asso-

ciation’s (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle Standards. To receive a copy of this handbook

and other pertinent 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.

Figure 1

— Page 6 —

SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM

Each Aqua-Hot heating system possesses an I.D. label on the

unit itself. This I.D. label details the specifications of the heater, to what standard it has been tested, and important

safety notices.

Figure 2

— Page 7 —

Figure 3

Wiring Harness and

Harness Port

Diesel Fuel

Lines

Drain Valve

AC Terminal

Block

VAC Ac-

cess Panel

AC Terminal

Port

Diesel

Burner

Heating Zone 1

Outlet Port

Heating Zone 2

Outlet Port

Product ID

Label

Zone 1

Circulation

Pump

Zone 2

Circulation

Pump

Diesel

Burner

Controller

Figure 4

Domestic Hot

Water Outlet

Domestic Cold

Water Inlet

SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM

— Page 8 —

SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM

— Page 9 —

Figure 5

AC Wiring Port

Zone 1 and 2

Outlet Ports

Product ID Label

Diesel Fuel

Inlet/Outlet

Ports

Zone 1 and 2

Inlet Ports Air Release

Valve

Expansion Tank

Connection

Wiring Harness Port

WARNING!

The Aqua-Hot

tank and heating

loop operate at 0.0

psi (zero pressure

system). Air pres-

sure applied to the

tank MUST NOT

exceed 20 psi. Ex-

cess pressure will

result in internal

damage.

4. Insert a #10 machine screw into each of the embossed

holes in the mounting tray (total of six required) and

tighten to secure the mounting tray to the motor home.

NOTE: Secure the mounting tray into place prior to install-

ing the Aqua-Hot.

Remove the access cover fastener from the Aqua-

Hot prior to installation of the Aqua-Hot into the

mounting tray.

Mount the Aqua-Hot securely into the mounting

tray to ensure that the unit does not move or

shift under normal operating conditions

5. Place the Aqua-Hot into the mounting tray. Reference

Figure 9.

NOTE: Remove the bolt securing the front of the access cover

to the mounting tray; this bolt will need to be re-

installed once the total installation procedure is com-

plete. Remove the access cover.

SECTION 2: AQUA-HOT INSTALLATION

Installing the Mounting Tray and the Aqua-Hot:

The Aqua-Hot must be installed in a compartment that is

completely closed-off from living quarters and accessible

only from the outdoors.

1. Reference the following illustrations for mounting infor-

mation:

•

Overall Aqua-Hot dimensions - Figure 7

• Mounting tray information - Figure 8

• I.D. Label noting the “Open Access”

clearance requirement for the front of the heater

- Figure 5

• Service access clearances - Figure 6

NOTE: Be sure to complete the following when installing the

Aqua-Hot:

Inspect the area beneath the mounting location to

ensure 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.

2. Cut out the required mounting tray opening. Reference

Figure 8.

3. Install the mounting tray flange into the cut-out opening.

Reference Figure 8.

. Figure 6

— Page 10 —

1/2 in

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