AHE-100-04S, 120-04X, and 130-04X Installation Manual 11-16-04 · 2017-04-10 · Aqua-Hot™...

Installation ManualModel Numbers

AHE-100-04S - 12 VDCAHE-130-04X - 12 VDC

Section 1 Hydronic Heating System Overview

1.1 Heating System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Section 2 Aqua-Hot Overview

2.1 Aqua-Hot Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Aqua-Hot Model Differentiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Section 3 Installation Procedures

3.1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.2 Mounting the Aqua-Hot Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.3 Mounting the Aqua-Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.4 Mounting the Interior Heat Exchangers Overview . . . . . . . . . . . . . . . . . 12 3.5 Mounting the Interior Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.6 Mounting the Fresh Water Tank Heat Exchanger Overview. . . . . . . . . . 17 3.7 Mounting the Fresh Water Tank Heat Exchanger . . . . . . . . . . . . . . . . . . 20 3.8 Plumbing the Heat Exchangers Overview . . . . . . . . . . . . . . . . . . . . . . . 20 3.9 Installing the Interior/Fresh Water Tank Plumbing Lines. . . . . . . . . . . . . 20 3.10 Plumbing the Engine Preheat System Overview . . . . . . . . . . . . . . . . . . 25 3.11 Attaching Plumbing Lines to the Vehicle’s Engine . . . . . . . . . . . . . . . . . 25 3.12 Domestic Hot Water Plumbing Overview . . . . . . . . . . . . . . . . . . . . . . . . 29 3.13 Attaching Plumbing Lines to the Domestic Hot Water System . . . . . . . . 30 3.14 Electronic Controller Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3.15 Wiring the Interior and Fresh Water Tank Heat 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 Fresh Water Tank Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 34 3.20 Installing and Wiring the Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 40 3.21 Diesel-Burner’s Fuel System Overview . . . . . . . . . . . . . . . . . . . . . . . . . 40 3.22 Installing the Diesel-Burner’s Fuel System and Lines . . . . . . . . . . . . . . 42 3.23 Overview and Installation of the Aqua-Hot’s Exhaust System . . . . . . . . 45 3.24 Installing the Aqua-Hot’s Expansion Bottle . . . . . . . . . . . . . . . . . . . . . . . 47 3.25 Connecting 12 Volt-DC Power to the Aqua-Hot . . . . . . . . . . . . . . . . . . . 48 3.26 Bleeding the Interior/Fresh Water Tank Hydronic Heating System. . . . . 51 3.27 Bleeding the Domestic Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.28 Bleeding the Engine Preheat System . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 3.29 Connecting 120 Volt-AC Power to the Aqua-Hot . . . . . . . . . . . . . . . . . . 54 3.30 Initial Activation of the Aqua-Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Appendix A Wiring Diagrams

AHE-100-04S Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1AHE-130-04X Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2AHE-100-04S Enlarged View of Switch Panel and Heating Zone Wiring . . . . . . . . . . . . . . . . . . . A3AHE-130-04X Enlarged View of Switch Panel and Heating Zone Wiring . . . . . . . . . . . . . . . . . . . A4

Appendix B Wire Gauge Information

Wire Gauge Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1

Page

TABLE OF CONTENTS

Referenced Illustrations

Figure 1: Aqua-Hot and Inclusive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Figure 2: Heat Exchanger Heating Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Figure 3: Aqua-Hot Marking Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 4: Aqua-Hot Combustion Air Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Figure 5: Aqua-Hot Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Figure 6: Aqua-Hot Mounting Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 7: Interior Heat Exchanger Mounting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Figure 8: Interior Heat Exchanger Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Figure 9: Interior Heat Exchanger Dimensions, Wiring, and Mounting . . . . . . . . . . . . . . . . . . 15Figure 10: Allowable Cozy III Heat Exchanger Mounting Configurations. . . . . . . . . . . . . . . . . . 16Figure 11: Fresh Water Storage Tank’s Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Figure 12: Minimum Cozy III Heat Exchanger Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Figure 13: Cozy III Heat Exchanger Mounting Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Figure 14: Heat Exchanger Plumbing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Figure 15: Installing the Heat Exchanger Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Figure 16A: “Supply” Heating Loop Ports and Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Figure 16B: “Return” Heating Loop Ports and Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Figure 17: Installing the Engine Preheat Plumbing on the Vehicle’s Engine . . . . . . . . . . . . . . . 26Figure 18: Engine Coolant Supply and Return Port Locations. . . . . . . . . . . . . . . . . . . . . . . . . . 28Figure 19: Attaching Plumbing Lines to the Domestic Hot Water System . . . . . . . . . . . . . . . . . 30Figure 20: Domestic Hot Water System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Figure 21: Wiring the Fresh Water Tank Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Figure 22: Switch Panel Mounting Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Figure 23A: AHE-100-04S Switch Panel and Indicator Light Wiring . . . . . . . . . . . . . . . . . . . . . . 36Figure 23B: AHE-100-04S Switch Panel Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Figure 24A: AHE-130-04X Switch Panel and Indicator Light Wiring . . . . . . . . . . . . . . . . . . . . . . 38Figure 24B: AHE-130-04X Switch Panel Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Figure 25: Fuel System Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Figure 26: Installing the Diesel-Burner’s Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Figure 27: Diesel Fuel Supply and Return Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Figure 28A: Fuel Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Figure 28B: Fuel Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Figure 29: Exhaust System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Figure 30: Installing the Expansion Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Figure 31: VDC Power Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Figure 32: Low Voltage Reset Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Figure 33: Air-Pressure Testing the Hydronic Heating System . . . . . . . . . . . . . . . . . . . . . . . . . 53Figure 34A: AHE-100-04S VAC Power Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Figure 34B: AHE-130-04X VAC Power Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Generalized Motorhome Heating System Floorplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Page

TABLE OF CONTENTS (continued)

Aqua-Hot™ Hydronic Heating System Installation Manual 07/05Page 1

ELECTRONIC CONTROLLER

��R

toH

dloC

Heating ZonesStatus

#5

#4

#3

#2

#1

Electric HeatingElement Status

Low Voltage

Reset

Low Tank-LevelCutoff

Heating Status

Engine PreheatPump

Low BatteryVoltage Fault

Low TempCutoff Status

Overload Fault

Pump #2

Pump #1

Pump #3

Diesel-BurnerStatus

Motor Coach Heating Specialists

ElectronicController

Switch Panel

Diesel Electric EnginePreheat

��

Figure 1Tempering Valve(Domestic Water)

Heating ZonesSupply and Return

Ports

CirculationPump #1

CirculationPump #2

CirculationPump #3

Engine PreheatCirculation

Pump

Diesel-Burner

Engine CoolantSupply

Diesel FuelSupply

Diesel FuelReturn

Hot WaterOutlet

(Domestic Water) Cold WaterInlet

(Domestic Water)

Engine CoolantReturn

Pressure-ReliefValve

Diesel-BurnerController

Boiler TankDrain Valve

Electric HeatingElement Access

Panel

MarkingPlates

Thermostat/AC RelayAccess Panel

Hour Meter

VAC AccessPanel

VAC ServiceInput

Fill/RadiatorCap

Aqua-Hotand InclusiveComponents

ExpansionBottle

AQUA-HOT HYDRONIC HEATING SYSTEM


Introduction 1.1 Heating System Overview

The Aqua-Hot Hydronic Heating System utilizes an FDA approved “GRAS” (Generally Recognized as Safe) Propylene Glycol based antifreeze 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 Thermostat “calls-for-heat.” As the heated solution is circulated through the Heat Exchangers, heat is transferred from the heating loop to the exchangers and delivered to each independent heating zone.

SECTION 1: HYDRONIC HEATING SYSTEM OVERVIEW


Figure 2Supply Ports

Return Ports

Independent(Heat Exchanger)Heating Zones

Bedroom

Heat Exchanger

Bathroom 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

Heating Zone #2 Heating Zone #3

Heating Zone #5

Heating Loop #1

Heating Loop #2

Supply Plumbing Lines Return Plumbing Lines

Heating Loop #3

SECTION 1: HYDRONIC HEATING SYSTEM OVERVIEW


Aqua-HotOverview

Aqua-HotModelDifferentiation

2.1 Aqua-Hot Overview

The Aqua-Hot Hydronic Heating System combines a continuous supply of domestic hot water and interior heating into one space-saving design. Both heating features are accomplished by a 12 Volt-DC powered Diesel-Burner and a minimum of one 120 Volt-AC Electric Heating Element. As Vehicle Systems manufactures two separate models of the Aqua-Hot, the number and wattage of the Electric Heating Element(s) may vary; reference Section 2.2 for model differentiation information. These two heating sources maintain the temperature of the Aqua-Hot’s antifreeze and water heating solution. The antifreeze and water heating solution captures and stores the heat produced by the heating system, thereby providing continuous domestic hot water, as well as interior/fresh water tank heating. The Aqua-Hot has also been designed to preheat the vehicle’s engine prior to starting, which provides easy engine start-up when cool weather conditions exist.

2.2 Aqua-Hot Model Differentiation

Vehicle Systems, Inc. manufactures two individual models of the Aqua-Hot Hydronic Heating System. 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 following Aqua-Hot models has been employed, locate the Marking Plate on the Heating System (reference Figures 1 and 3 for Marking Plate information) and view the Model Number Box.

AHE-100-04S

This model features a single 120 VAC/1650 Watt Electric Heating Element. Diesel-Burner, Heat Input (Firing Rate) 50,000 BTU/hr

Diesel-Burner, Fuel Consumption (ContinuousOperation) 0.40 gal/hr

Diesel-Burner, Voltage/Power Consumption 12 VDC/60 watts

Electric Heating Element specifications 120 VAC/1650 watts

Circulation Zone Pump specifications (3) 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.

NOTE: All vehicle installations must comply with the requirements listed in the Recre-ational Vehicle Industry Association’s (RVIA) ANSI/NFPA 1192 Handbook for Recre-ational 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.

SECTION 2: AQUA-HOT OVERVIEW


Aqua-HotModelDifferentiation,continued

AHE-130-04X

This model features two 120 VAC/2000 Watt Electric Heating Elements.

Diesel-Burner, Heat Input (Firing Rate) 50,000 BTU/hr

Diesel-Burner, Fuel Consumption (ContinuousOperation) 0.40 gal/hr

Diesel-Burner, Voltage/Power Consumption 12 VDC/60 watts

Electric Heating Element specifications (2) 120 VAC/2000 watts

Circulation Zone Pump specifications (3) 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.

NOTE: All vehicle installations must comply with the requirements listed in the Recre-ational Vehicle Industry Association’s (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle Standards. To receive a copy of this Handbook and other pertinent RVIA Stan-dards, 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.



Aqua-HotMarking Plate

Figure 3

AHE-100 04S 12 VDC / 184 Watts

Model Number Diesel-Burner / DC Power

Serial Number Electric Heating Element / AC Power

Manufactured Date Fuel Type / Firing Rate

AH04-637 120 VAC, 60 Hz / 1.65 kW

06-04 DIESEL / 50,000 BTU

R

Testing Engineers International

Listing No. 02L01

Complies with the requirements of UL 307A

Made in U.S.A.

�

By Vehicle Systems, Inc. Ft. Lupton, CO 80621

Manufactured Date Box

Serial Number Box

Model Number Box

Reference Figure 1 for Marking Plate

locations.

For Installation Only in Compartment Completely Closed Off from Living Quarters and AccessibleOnly from the Outdoors.

Exhaust system MUST NOT terminate beneath the vehicle or under an openable window or vent.

Combustion Air MUST BE supplied from outside the vehicle.

CAUTION: This appliance operates on both AC and DC Electrical Power.

The AC Powered Electrical 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 current protection for AC Power Supply.

Mount Heater near a Bay / Storage Door so Access Cover can be easily removed

Minimum Heater clearancesFront (Decal Sides) - Open AccessBack (non-Decal sides) - 0 inches

Top - 6 inches

Install in strict compliance with local codes, NFPA501c and manufacturer’s instructions.

For additional product instllation information visit www.vehiclesys.com or call 1-800-685-4298

Use 25 Amp fuse for over current protection for DC Power Supply.

Use 20 Amp Circuit Breaker for over current protection for AC Power Supply

Mount Heater near a Bay / Storage Door so Access Cover can be easily removed

Minimum Heater clearancesFront (Decal Sides) - Open AccessBack (non-Decal sides) - 0 inches

Top - 6 inches

Install in strict compliance with local codes, NFPA501c and manufacturer’s instructions.

For additional product instllation information visit www.aqua-hot.com or call 1-800-685-4298



InstallationProcedure

3.1 Installation Procedure

All installations must be done in strict compliance with all applicable Codes, Laws, and Regulations having the force of Law.

3.2 Mounting the Aqua-Hot Overview

Because Motorhome applications will vary, the Aqua-Hot’s permanent mounting location should be chosen carefully. Adhering to the guidelines listed below will ensure maximum system performance and safe operation.

A. The permanent mounting location must be capable of supporting a minimum of 400 lbs. Inspect the area beneath the mounting location to ensure no structural members will interfere with the Exhaust and Combustion-Air Intake Holes.

B. Because combustion-air must be drawn from outside the motorhome, the Aqua- Hot cannot be installed anywhere inside the passenger compartment or any living area.

C. Centralize the Aqua-Hot nearest the area where Domestic Hot Water will be used most frequently (i.e., Bathroom and Kitchen areas); reference Figure 7 and the “Generalized Motorhome Heating System Floorplan” in Section 3.4. This will ensure that the domestic hot water 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 outside the Motorhome. Mounting the Aqua-Hot in this location will also ensure a minimal length of Exhaust Pipe (reference Section 3.23, “Overview and Installation of the Aqua-Hot’s Exhaust System,” for details).

E. The Aqua-Hot’s Exhaust must be able to freely exit away from the Vehicle without any obstructions. In addition, the Exhaust Pipe is hot and must be kept away from any heat sensitive material.

F. Adequate ventilation from underneath the Motorhome must be supplied to the Aqua-Hot at all times. This will ensure the Diesel-Burner receives a sufficient supply of combustion-air.

CAUTION: The combustion air cannot be supplied from any compartment possibly containing combustible gases (e.g., Battery gases, Gasoline fumes, Propane fumes, etc.).

NOTE: Although preinstalled, the Combustion-Air Intake Sleeve MUST BE UTILIZED in order for the product to comply with the UL 307A listing; reference Figure 4.

G. The permanent mounting location must allow for mounting of the Electronic Controller within the allowable wire harness length; reference Section 3.14 for specific mounting details.

Mountingthe Aqua-HotOverview

!

SECTION 3: INSTALLATION PROCEDURES


Aqua-HotMounting

3.3 Mounting the Aqua-Hot

Once a mounting location for the Aqua-Hot has been selected, utilize the following illustrations for mounting information:

- Overall Aqua-Hot Dimensions; reference Figure 5.

- Required size and locations of the Combustion-Air Hole and Exhaust Holes; reference Figure 6.

- Required size and location of the Mounting Bracket Holes; reference 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 sure to drill the holes for the Exhaust System and Combustion-Air Intake prior to placing the Aqua-Hot into the permanent mounting position. B. Be sure to utilize all four Mounting Brackets to ensure that the Aqua-Hot does not move or shift under normal operating conditions.

2. Place the Aqua-Hot into the permanent mounting position.

3. Using 1/4 inch Bolts (total of eight required), fasten down the Aqua-Hot.



Aqua-HotCombustionAir Overview

Figure 4

Combustion-AirIntake Shutter

Combustion-AirHole in Aqua-Hot

Cabinet

Hose Clamp

Combustion-AirIntake Sleeve

Rubber Boot

Combustion-Air Holein Bay Floor



Aqua-Hot Dimensions

Figure 5

36.75 in.

18.5 in.

18.5 in.

Access Cover



Aqua-HotMountingTemplate

9.25

0 in

.

3.75

0 in

.

9.25

0 in

.

16.7

50 in

.

36.5

00 in

. (re

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3.00

0 in

.18

.500

in. (

ref.)

11.1

25 in

.

2.18

7 in

.

1.31

2 in

.

15.7

50 in

.

33.0

62 in

.

37.

312

in.

19.1

87 in

.

0.75

0 in

.

2.18

7 in

.2.

187

in.

2.18

7 in

.

All "MountingBracket Holes"require a 0.312

inch hole.

MountingHoles

ExhaustHole

TOP VIEW

Figure 6

CombustionAir Intake

Hole

6.75

0 in

.

Front of Aqua-Hot(Access Cover area)



Mountingthe InteriorHeat ExchangersOverview

3.4 Mounting the Interior Heat Exchangers Overview

Adhering to the guidelines listed below will ensure maximum interior heating efficiency and even-heat distribution throughout each interior Heating Zone (i.e., Living Room, Kitchen, Bedroom, and Bathroom).

A. Space the Heat Exchangers so that even-heat distribution will be felt throughout the interior; reference Figure 7 and the “Generalized Motorhome Heating System Floorplan” in this section of the manual.

NOTE: For “Slideout” configurations, it is simplest to place a Heat Exchanger(s) on the opposite side of the Motorhome pointing 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 will severely reduce their overall heating performance (heat output).

2. In order to provide sufficient ventilation, the “return-air” registers must be the same size, or larger, than the outlet-air registers.

3. “Return-Air” must be supplied from the corresponding interior heating zones.

C. Allow for easy access to all Heat Exchangers for potential servicing and cleaning (e.g., dust, etc.). Reference Figures 10 and 12 for allowable Cozy-III mounting configurations.

Figure 7

Cozy IIIC

ozy

III

Coz

yIII

Cozy III

tnorF

II yz

oC

ICozy III

Return-Air

Return-AirReturn-Air

Indicates generally recommendedmounting locations for the Cozy III

Heat Exchangers



Livi

ng R

oom

Hea

t Exc

hang

er

Livi

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oom

Hea

t Exc

hang

er

Kitc

hen

Hea

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hang

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Bat

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eat E

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nger

Bed

room

Hea

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Engi

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rehe

atin

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ank

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Hea

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ank

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Hea

ting

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Hea

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Gen

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Syst

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plan


Interior HeatExchangerLocationOverview

HEATEXCHANGER

HOT-AIROUTLET BASE-BOARD / TOE-KICK AREA

CABINET/COUCH

COLD-AIRRETURN

Figure 8

REGISTER

REGISTER



Interior HeatExchangerDimensions, Wiring, and Mounting Overview

Figure 9

13.06 in.

6.44 in.

14.44 in.3.63 in.

NOTE: Tolerance +/- .030

+ (Positive) Red WiresTo the “Fan +” connection on

the Electronic Controller- (Ground) Black Wires

To the “Fan -” connection on the Electronic Controller



Allowable Cozy III Heat ExchangerMountingConfigurations

Vertical Mount

Figure 10

Horizontal Mount



Interior HeatExchanger Mounting

3.5 Mounting the Interior Heat Exchangers

Once all permanent mounting locations have been selected, cut out the opening for each hot-air and cold-air register and fasten each Heat Exchanger permanently in place. Please reference Figure 8 for suggested Heat Exchanger mounting locations.

1. Cut out a 2.5 inch x 10 inch opening for each Cozy III hot-air outlet and cold-air return register; reference Figures 7 and 8.

2. Mount each Heat Exchanger permanently into place; reference Figures 9, 10, and 12.

3. Install the hot-air outlet and cold-air return registers; reference Figure 8.

3.6 Mounting the Fresh Water Tank Heat Exchanger Overview

The Fresh Water Tank Heat Exchanger 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 in the Domestic Water Storage Tank Plumbing Bay area so even-heat distribution will be achieved; reference Figure 11.

NOTE: In order to achieve the best heating results, place the Heat Exchanger as close to the floor of the Plumbing Bay as possible (heat will naturally rise).

B. Sufficient ventilation (cold-air return) must be supplied to the Fresh Water Tank Heat Exchanger; reference Figure 11.

NOTES:

A. Mounting the Heat Exchanger without sufficient ventilation will severely reduce its overall performance (heat output).

B. Return-Air should be supplied from the same compartment as the Fresh Water Tank Heat Exchanger.

Fresh WaterTank HeatExchangerMounting

Heat Output

Cold Air Return

OptionalVent

Figure 11

Fresh WaterStorage Tank



MinimumCozy III HeatExchangerClearance

Figure 12

INTERIOR WALL/CABINET WALL

4 inch MinimumClearanceRequired



Cozy III HeatExchangerMountingTemplate

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 in.) = +/- .030.XXX (i.e., 6.500 in.)= +/- .015

Figure 13



Fresh WaterTank HeatExchanger

3.7 Mounting the Fresh Water Tank Heat Exchanger

Once a permanent mounting location for the Fresh Water Tank Heat Exchanger has been selected, fasten the Heat Exchanger permanently in place. Please reference Section 3.6 and use Figures 8, 10, 11, 12, and 13 for mounting information.

3.8 Plumbing the Heat Exchangers Overview

Once all Heat Exchangers have been mounted, a plan should be formulated for the routing of the Plumbing Lines from each heating zone to the Aqua-Hot. The Plumbing Lines are the roadways that carry the antifreeze and water heating solution from the Aqua-Hot to the Heat Exchangers in each heating zone; reference Figures 2 and 7. Adhering to the guidelines listed below will ensure maximum heating performance (heat output):

A. The Kitchen and Living Room Heat Exchangers (typically three) must be plumbed together in-series on “Heating Loop #3.” Be sure to reference Figure 2 and the “Generalized Motorhome Heating System Floorplan” in Section 3.4 for additional information.

B. The Fresh Water Tank and Bathroom Heat Exchangers (typically two) must be plumbed together in-series on “Heating Loop #2.” Be sure to reference Figure 2 and the “Generalized Motorhome 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 for all Heating Zones.

E. Use wide-sweeping elbows or “Bend-Supports” whenever Plumbing Lines may be susceptible to kinking (i.e., 90° bends).

3.9 Installing the Interior/Fresh Water Tank Plumbing Lines

1. Prior to installing the Plumbing Lines, mark each line with arrows and/or labels at both ends. This can be done while the lines are being laid out in order to indicate which Heating Loop the Plumbing Lines pertain to (i.e., Heating Loop 1, Heating Loop 2, or Heating Loop 3) and whether the Plumbing Line is a Supply or a Return line; reference Figures 2, 16A, and 16B.

NOTES:

A. All Plumbing Lines should be laid as flat as possible, and any extreme rises in height should be avoided.

B. Run all Plumbing Lines in areas where they cannot be pinched off or damaged under normal operating conditions.

C. Be sure to secure all Lines where necessary and apply protective shielding in areas where chafing may occur.

D. Vehicle Systems suggests using Rubber Coated/Closed-Type Clamps when securing the Plumbing Lines.

2. Connect and clamp the Supply line from the Heater to the lowest port on each Heat Exchanger in each heating zone; reference Figures 2 and 14.

Plumbingthe HeatExchangersOverview

Installingthe Interior/Fresh WaterTank Plumbing



3. Connect and clamp the Return line from the Heater to the highest port on each Heat Exchanger; reference Figures 2 and 14.

NOTE: Reference Figure 15 for visual instructions on how to properly connect PEX type tubing 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 overall heating performance (heat output).

4. Connect and tighten all interior Plumbing Lines, Supply and Return, to the Aqua-Hot’s appropriate Heating Zone ports; reference Figures 16A and 16B.

Installingthe Interior/Fresh waterTank Plumbing,continued



Installingthe HeatExchangerPlumbing

Figure 14

MountingBracket

MountingBracket

Cozy III Heat Exchanger(Rear View)

“Return” Port(Highest Port)

“Supply” Port(Lowest Port)



Installingthe HeatExchangerPlumbing,continued

Figure 15

3/4 in. RubberCoupler

3/4 in. RubberCoupler

Constant TensionClamps

PEXInsert

PEXInsert

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 inch I.D.)

Automotive Type Rubber Heater-Hose Coupler

(3/4 inch I.D.)PEX Plumbing Line

PEX Plumbing Line



Installingthe HeatExchangerPlumbing,continued

“Supply” Heating Zone Ports

Figure 16A

PEX Tube

PEX Insert

CompressionFitting

HeatingLoop 1Supply Port

HeatingLoop 2Supply Port

HeatingLoop 3 Suppply Port

“Return” Heating ZonePorts

Figure 16B

PEX Tube

PEX Insert

Compression Fitting

HeatingLoop 1Return Port





3.10 Plumbing the Engine Preheat System Overview

Engine preheating is accomplished by a “Water-to-Water” Heat Exchanger that is an integral part of the Aqua-Hot’s Heat-Tank. Adhering to the guidelines listed below will ensure maximum engine preheating efficiency.

A. The Supply and Return ports on the vehicle’s engine should be kept as far apart as possible. This will ensure that the entire engine is thoroughly preheated; reference Figure 17. If assistance is needed in determining the best Supply and Return ports for a specific engine, please contact Vehicle Systems’ Product Application Support Department at 1-800-685-4298 or contact the specific Engine‘s Manufacturer.

NOTES:

1. The engine’s coolant should be allowed to flow as freely as possible to maximize the Aqua-Hot’s engine preheating system.

2. The engine’s Return port returns the heated coolant to the Engine Block from the Aqua-Hot. This port should be a high connection point on the Engine Block or a suction port on the engine’s Water Pump; reference Figure 17.

3. The engine’s Supply port supplies the engine’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 17.

B. Use 3/4 in. I.D. (Inside Diameter) Plumbing Lines/Automotive type Heater-Hose for the engine preheating system.

3.11 Attaching Plumbing Lines to the Vehicle’s Engine

1. Install both engine preheat Plumbing Lines and mark with Arrows and/or Labels at both ends. The labels should indicate whether the Plumbing Line is supplying coolant to the Aqua-Hot or whether it will be returning heated coolant to the vehicle’s engine; reference Figures 1, 17, and 18.

NOTES:

A. Lay both Engine Preheat Lines as flat as possible and avoid any extreme rises in height. This will eliminate the potential for air traps.

B. Run both Plumbing Lines in areas where they cannot be pinched off or damaged during normal operating conditions.

C. Be sure to secure both Plumbing Lines where necessary and apply protective shielding in areas where chafing may occur.

D. Vehicle Systems suggests using Rubber Coated/Closed-Type Clamps when securing the Plumbing Lines.

2. Drain the Engine’s Coolant.

3. Remove the selected Supply and Return port “Plugs” from the engine.

Engine PreheatPlumbingOverview

Installing EnginePreheatPlumbing



Installing EnginePreheat Plumbing,continued

Figure 17

VEHICLE'SENGINE

IDEAL"RETURN" PORT

(top side of engine)

POTENTIAL"SUPPLY" PORT

(pressure outlet port)

Ideal Return PortT(ToTTop side of the engine)

45˚ (M)NPT /Hose Barb

Hose Clamp

To the Aqua-Hot's outletEngine Preheat "OUT" Port

(Return)

Automotive TypeHeater-Hose

Automotive TypeHeater-Hose

Hose Clamp

(M) NPT/Hose Barb

To the Aqua-Hot’sEngine Preheat

“IN” on Engine PreheatCirculation Pump

(Supply)



InstallingEnginePreheatPlumbing,continued

NOTE: Should one or both of the selected engine ports already have Plumbing Fittings attached to them, it may be necessary to “tee” into those existing Plumbing Fittings. If assistance is needed for a specific engine, please contact Vehicle Systems’ Product Application Support Department at 1-800-685-4298.

4. Install and tighten the Plumbing Fittings into the Supply and Return ports on the Vehicle’s Engine.

NOTE: One-piece Plumbing Fittings are recommended in order to reduce the potential for coolant leaks. It is also suggested that Pipe Thread Sealant 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 and tighten the Plumbing Fittings into the “IN” and “OUT” ports on the Aqua-Hot’s Engine Preheating System; reference Figures 1 and 18.

CAUTION: Be sure to use two wrenches when tightening these Plumbing Fittings. Failure to do so could result in serious damage to the Aqua-Hot’s internal Engine Preheating System.

7. Attach and clamp the Engine’s Supply Plumbing Line to the Aqua-Hot’s “IN” connection; reference Figure 18.

8. Attach and clamp the Engine’s Return Plumbing Line to the Aqua-Hot’s “OUT” connection; reference Figure 18.

9. After all Plumbing Lines, Fittings, and Connections have been tightened, refill the Engine’s Coolant System.

!



InstallingEnginePreheatPlumbing,continued

Figure 18

Engine CoolantSupply Port

(IN)

Engine CoolantReturn Port

(OUT)



Domestic HotWater PlumbingOverview

3.12 Domestic Hot Water Plumbing Overview

One major feature of the Aqua-Hot is that it possesses the ability to provide a continuous supply of domestic hot water. Because the Aqua-Hot heats the domestic water on-demand, there is no need for a separate Storage Type Water Heater. Adhering to the following guidelines will ensure maximum domestic hot water efficiency.

A. The following information concerning the sizing of Water Supply Piping was taken directly from the ANSI A119.2/NFPA 501C Standard on Recreation Vehicles, 1993 Edition. This information should be used as a general guideline:

“Piping Systems shall be sized to provide an adequate quantity of Water to each Plumbing 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 than shown in Table 4-6.5.1.

NOTE: A Water Heater or Ice Maker shall not be counted as a Water-Using Fixture when computing pipe sizes.

Table 4-6.5.1 Minimum Size Tubing and Pipe for Water Distribution Systems*

* Minimum size for toilet water supply line shall not be less than the size recommended by the toilet manufacturer** 12-feet (3.7 m) maximum length allowable only from water service connection to a single fixture.*** 6-feet (1.8 m) maximum length.

NOTE: The Aqua-Hot is equipped with a Pressure-Relief Valve, which releases excessive pressure in the domestic water system, if necessary.

Number ofFixtures

1234

5 or more

Inner Dia.(inches)

1/4**1/4***

3/83/81/2

Outer Dia.(inches)

3/8**3/8***

1/21/25/8

Iron Pipe Size(inches)

3/83/81/21/21/2

Tubing Pipe



InstallingDomesticHot WaterPlumbing

ElectronicControllerOverview

The Aqua-Hot is equipped with a Tempering Valve, which regulates the temperature of the hot water; reference Figure 19.

1. Connect a domestic water Plumbing Line from the Domestic Water Demand Pump/Water Manifold to the Cold Water Inlet port on the Aqua-Hot; reference Figures 19 and 20.

NOTE: Please note that it may be necessary to utilize an Accumulator Tank within the Domestic Water System; reference Figure 20. Although the Aqua-Hot is equipped with a Pressure-Relief Valve, the utilization of an Accumulator Tank will help prevent excessive “weeping” of the aforementioned valve, if applicable. Manufacturers of Pressure-Relief Valves indicate that excessive weeping of these valves will cause the “seat” in the valve to deteriorate, and, in turn, the valve will fail prematurely. For additional information regarding Accumulator Tanks, please be sure to reference the Recreational Vehicle Industry Association’s (RVIA) technical publication titled “Recreational 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 Aqua-Hot’s Hot Water Outlet port to the hot water system’s Distribution Lines/Water Manifold; reference Figures 19 and 20.

3.14 Electronic Controller Overview

The Aqua-Hot utilizes an Electronic Controller (E.C.) to monitor specific heater activities, supply electrical power to specific internal and external components, and control the overall operation of the heater. The following are important installation details regarding the Electronic Controller. Please read this section thoroughly for specific details.

NOTE: Please reference Appendix A for specific wiring information pertaining to the precise model of Aqua-Hot being installed.

A. All Electronic Controller Fan Power connections (and two switch connections) possess a “(+)” or a “(-)” symbol, which indicates that they are Polarity Sensitive. Therefore, be sure to use care when wiring these particular components to the Electronic Controller.

3.13 Attaching Plumbing Lines to the Domestic Hot Water System

Figure 19

Pressure ReliefValve

TemperingValve

Cold WaterInlet

(Domestic Water)

Hot WaterOutlet

(Domestic Water)



Domestic HotWater SystemOverview

DomesticHot WaterOUTLET

To Hot Water Faucets

AT

ATATDemandPump

Arrows indicate directional flow ofdomestic water

To Cold WaterFaucets

AT - Indicates options for mounting an Accumulator Tank

DomesticCold Water

INLET

Figure 20

FreshWater Storage

Tank



Electronic ControllerOverview,continued

B. All Electronic Controller Thermostat and Switch connections (excluding two) possess an “(I)” or an “(O)” symbol. The “(O)” symbol indicates a positive 12 Volt-DC output to a particular Thermostat or Switch, while the “(I)” symbol indicates a positive 12 Volt-DC input signal from a particular Thermostat or Switch. The 12 Volt-DC output signal is always present as long as the Electronic Controller is powered by a 12 Volt-DC Power Source, while the 12 Volt-DC input signal is only present whenever a Switch is activated or whenever a Thermostat is “calling for heat”; reference Appendix A.

C. Each heating zone “FAN” circuit can supply up to 2.0 Amps of Direct Current. This 12 Volt-DC allows for multiple Cozy III Heat Exchangers to be wired “in-parallel” (e.g., Heating Zone 5); reference Figure 2, Appendix A, and the “Generalized Motorhome Heating System Floorplan” in Section 3.4.

D. Heating Zone 5 is reserved electrically for the “Living Room/Kitchen Heating Zone” (Heating Loop 3) ONLY; Heating Zones 2, 3, and 4 are reserved electrically for the “Bathroom, Fresh Water, and Optional Heating Zone” Tank Heating Zone” (Heating Loop 2) ONLY. Heating Zone 1 is reserved electrically for the “Bedroom Heating Zone” (Heating Loop 1) ONLY. Reference Figure 2.

E. All Switch connections are to be wired directly to the Aqua-Hot’s “Switch Panel Connections”; reference Figures 23A, 23B, 24A, and 24B and Appendix A. Both the “IND-LT(+)B3” and the “IND-LT(-)B6” connections are reserved electrically ONLY for the “Diesel” Switch connections.

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 receive its 12 Volt-DC Power Supply from the Aqua-Hot’s Electronic Controller (i.e., “THERM O”). This will ensure that the Thermostat/Electronic Controller is properly fuse protected.

G. Be sure to use the wire colors illustrated in Appendix A. This will ensure installation consistency, differentiate the separate Heating Zones, and assist Service Personnel with troubleshooting.

H. The Electronic Controller can be either recessed or surface mounted. Cut out an opening of 7.25 inches x 10.25 inches for recessed mounting and be sure to utilize all four mounting tabs.

NOTES:

A. Be sure to fasten the wire harness connections to the Electronic Controller by securing the screw-type fasteners on the Terminal Strip/Plug of the Wiring Harness to the Header on the Electronic Controller.

B. Be sure to secure the wire harness connections at the Electronic Controller by clamping the wire harness permanently into place.

3.15 Wiring the Interior and Fresh Water Tank Heat Exchangers

The Aqua-Hot’s Electronic Controller is designed to supply 12 Volt-DC Electrical Power, as well as a ground source (negative), to all Interior and Fresh Water Tank Heat Exchang-ers. Therefore, whenever a particular heating zone Thermostat “calls for heat,” the Aqua-Hot’s Electronic Controller will output a 12 Volt-DC power supply and provide ground to each Heat Exchanger in that heating zone.

NOTE: DO NOT use a “chassis ground” as a ground source for any of the Heat Exchangers. Ground MUST BE supplied by the Aqua-Hot’s Electronic Controller.

WiringInterior/Bay HeatExchangers



WiringInterior/Bay HeatExchangers,continued

1. Run two 16 Gauge Wires, Red for (+) and Black for (-), from each particular Heating Zone’s Heat Exchanger(s) to the Aqua-Hot’s Electronic Controller.

NOTE: For heating zones with multiple Heat Exchangers (e.g., Living Room/Kitchen/Heating Loop 1, etc.), run two wires from the closest Heat Exchanger to the Aqua-Hot’s Electronic Controller and then wire the other Heat Exchangers in-parallel; reference Figure 9 and Appendix A.

2. Label the wires indicating the heating zone they pertain to (e.g., Living Room/ Kitchen, Bedroom, Fresh Water Tank, etc.)

3. Insert all Heat Exchanger wires into the appropriate terminal/heating zone location on the Electronic Controller (e.g., “#3 FAN +/#3 FAN -,” for the Fresh Water Tank Heating Zone, etc.); reference Appendix A.

4. Connect all Electronic Controller “FAN” wires to the positive and negative leads of each Heat Exchanger; reference Figure 9 and Appendix A.

3.16 Mounting Locations for Interior Room Thermostats Overview

The mounting locations for the Interior Thermostats and/or the Electronic Thermostat’s Temperature Sensors should be selected carefully to ensure even-heat distribution throughout each heating zone.

A. Locate each Thermostat at approximately chest 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 - heat from concealed pipes and chimneys - unheated (uncooled) areas such as an outside wall behind the thermostat

3.17 Wiring the Interior Room Thermostats

1. Run two 16 Gauge wires from each interior room thermostat mounting location to the Aqua-Hot’s Electronic Controller.

NOTE: Be sure to use the wire colors illustrated in Appendix A. This will ensure installation consistency, differentiate the separate Heating Zones, and assist Service Personnel with troubleshooting.

2. Insert all interior room thermostat wires into the appropriate terminal/heating zone location on the Electronic Controller; reference Appendix A.

3. Connect all wires to the appropriate leads of each room thermostat.

NOTE: 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 receive its 12 Volt-DC Power Supply from the Aqua-Hot’s Electronic Controller (i.e., THERM O”). This will ensure that the Thermostat/Electronic Controller is properly fuse protected.

4. Permanently mount all interior room thermostats in place.

5. Be sure to turn OFF all interior room thermostats at this time.

MountingLocationsfor InteriorThermostats

Wiring InteriorThermostats



MountingLocation for FreshWater TankThermostat

3.18 Mounting the Fresh Water Tank Thermostat Overview

The mounting location of the Bay Thermostat should be selected carefully to ensure even-heat distribution throughout the Bay compartment. The Low-Temp Thermostat is specifically designed as a means of preventing the domestic hot water from freezing; therefore, it has a maximum temperature setting of 50°F.

A. Centralize the Low-Temp Thermostat in the Fresh Water Tank storage compartment.

NOTES:

1. Only the “Bulb” of the Low-Temp Thermostat needs to be physically mounted in the area requiring heat; reference Figure 21.

2. Do not mount the Thermostat “Bulb” in a drafty area.

3. The selected Thermostat body mounting location 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 Electronic Controller.

NOTE: Be sure to use the wire colors illustrated in Appendix A. This will ensure installation consistency, differentiate the separate Heating Zones, and assist Service Personnel with troubleshooting.

2. Insert both Thermostat wires into the appropriate terminal/heating zone location on the Electronic Controller; reference Appendix A.

3. Connect both wires to the appropriate leads of the Low-Temp Thermostat; reference Figure 21.

4. Permanently mount the Low-Temp Thermostat in place; reference Figure 21.

Wiringthe FreshWater TankThermostat

6

0 1020

30

00

F

Bulb

Mounting Tabs

Black Wire(Connect to Heating Zone #3 “Therm

O” on the Electronic Controller)

Blue Wire(Connect to Heating Zone #3 “Therm I”

on the Electronic Controller)

Figure 21



Switch PanelMountingTemplate

6.00 .25

.25

2.50

.150 (4X)

6.50

3.001.50

.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)

3.001.50

.75

.75 1.50

2.75

1.00 (3x)

AHE-100-04S Interior Switch Panel

Figure 22

3.75

5.25

* All dimensions listed are in inches

6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1



Switch Paneland IndicatorLight WiringOverviewAHE-100-04SModel ONLY

Figure 23A

Switch PanelBack Side View

6 6 6

4 4 4

2 2 2

1 1 1

Switch to Electronic Controllerconnections

Switch Electronic Controller

Pin # 1

Pin # 2

Pin # 6

to “Preheat-O”

to “Preheat-I”

to Chassis Ground



Pin # 1

Pin # 2

Pin # 6

to “Electric-O”

to “Electric-I”

to Chassis Ground

“Engine Preheat”Switch

“Electric”Switch

“Diesel”Switch



Pin # 1

Pin # 2

Pin # 6

to “Diesel-I”

to “Diesel-O”

to “IND-LT (-) B6”

Pin # 4 to “IND-LT (+) B3”

Jum

per W

ire

Jum

per W

ire

NOTE: The “Engine Preheat” and “Electric” switches require a Jumper Wire, which connects Terminal 2 to Terminal 4.



Switch Paneland IndicatorLight WiringOverviewAHE-100-04SModel ONLY

ENGINE

PREHEATELECTRIC DIESEL

+

-

1

26

4+

--

+

��

To the “Preheat-O”Terminal on

the ElectronicController

To the “Preheat-I”Terminal on


To the “Electric-O”Terminal on


To the “Electric-I”

Terminal onthe Electronic

Controller

To the “IND-LT (+) B3”


Controller

To the “IND-LT (-) B6”


Controller

To the “Diesel-O”


Controller

To the “Diesel-I”


Controller

AHE-100-04S Switch Panel

Figure 23B

Jum

per W

ire

1

26

4 1

26

4

Jum

per W

ire



Switch Paneland IndicatorLight Wiring OverviewAHE-130-04XModel ONLY


6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1



“Diesel”Switch

“Electric High/Low”

Switch

“Electric High/Low” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to 1-Way Plug

to Chassis Ground

“Electric” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to “Electric-O”

to “Electric-I”

to Chassis Ground

“Engine Preheat” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to “Preheat-O”

to “Preheat-I”

to Chassis Ground

“Diesel” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to “Diesel-O”

to “Diesel-I”



Figure 24A

Jum

per W

ire

Jum

per W

ire

Jumper Wire

NOTE: The “Engine Preheat” and “Electric” switches require a Jumper Wire, which connects Terminal #2 to Terminal #4. The “Electric High/Low” switch also requires a Jumper Wire, which connects its Terminal #4 to Terminal #2 on the “Electric” switch.

to 1-Way Plug



Switch Paneland IndicatorLight Wiring OverviewAHE-130-04XModel ONLY


6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1



“Diesel”Switch

“Electric High/Low”

Switch

“Electric High/Low” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to 1-Way Plug

to Chassis Ground

“Electric” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to “Electric-O”

to “Electric-I”

to Chassis Ground

“Engine Preheat” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to “Preheat-O”

to “Preheat-I”

to Chassis Ground

“Diesel” Switch to Electronic Controller connections


Pin # 1

Pin # 2

Pin # 6

to “Diesel-O”

to “Diesel-I”



Figure 24A

Jum

per W

ire

Jum

per W

ire

Jumper Wire

NOTE: The “Engine Preheat” and “Electric” switches require a Jumper Wire, which connects Terminal #2 to Terminal #4. The “Electric High/Low” switch also requires a Jumper Wire, which connects its Terminal #4 to Terminal #2 on the “Electric” switch.

to 1-Way Plug

Switch Paneland IndicatorLight Wiring DiagramAHE-130-04XModel ONLY

GND

6

4

2

1

6

4

2

1

6

4

2

1

6

4

2

1

to 1-WayPlug

to 1-WayPlug

to the “Electric-O”

Terminal on the Electronic Controller

to the “Electric-I”


to the “Preheat-O”


to the “Preheat-I”


to the “IND-LT(-) B6” Terminal on the

Electronic Controller

to the “IND-LT(+) B3” Terminal on the

Electronic Controller

to the “Diesel-I”


to the “Diesel-O”


AHE-130-04X Switch Panel

Figure 24B

ELECTRICHI / LOW ELECTRIC

ENGINEPREHEAT DIESEL

Jum

per W

ire

Jumper Wire

Jumper Wire



Installing/Wiring theSwitch Panel

3.20 Installing and Wiring the Switch Panel

The chosen location for the Switch Panel should allow for easy operator access. Also, because the “Diesel” switch incorporates a fault light, which indicates a Diesel-Burner malfunction, the Switch Panel should be easily visible to the operator.

1. Cut out an opening for the Switch Panel Plate; reference Figure 22. AHE-100-04S: 3.75 in. W x 1.50 in. H AHE-130-04X: 5.25 in. W x 1.50 in. H

2. Run eight 16 Gauge wires from the Switch Panel to the Electronic Controller.

NOTE: Be sure to use the wire colors illustrated in Appendix A. This will ensure installation consistency, differentiate between the separate switches and assist Service Personnel with troubleshooting.

3. Strip and crimp insulated female terminals onto each wire at the Switch Panel location. Also, be sure to prepare the necessary Jumper Wires.

4. Connect all switch wires as illustrated in Figure 23A and 23B for the AHE-100-04S Model and Figure 24A and 24B for the AHE-130-04X Model. Reference Appendix A for additional wiring information.

5. Insert 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 switches to their OFF position by pressing them in a downward motion.

3.21 Diesel-Burner’s Fuel System Overview

The Diesel-Burner is the Aqua-Hot’s primary heat source; therefore, care should be taken when installing the fuel system.

A. The diesel fuel supply should be drawn directly from the Vehicle’s main Fuel Tank or from a separate auxiliary Fuel Tank, if applicable. The Fuel Tank should be equipped with a dedicated fuel pick-up (”Supply” port and “Return” port); reference Figure 26.

NOTES:

1. If an auxiliary Fuel Tank is required, be sure to consult the ANSI/NFPA 1192 Handbook concerning Diesel Fuel System specifications.

2. These particular Aqua-Hot Hydronic Heating System models utilized two unique Fuel Filters; therefore, please reference Figures 28A and 28B in order to determine the Fuel Filter utilized in the particular model being installed.

B. Fuel head pressure should not exceed 2 feet; reference Figure 25.

C. Use 1/4 inch I.D. (Inside Diameter) Fuel Lines.

D. The combined length of the supply and return Fuel Lines should not exceed 66 feet in total length; reference Figure 25.

Diesel-Burner’sFuel System



Fuel SystemSpecifications

33' max

33' max

Figure 25

MaximumAllowable Suction/Lift

height 6’6” max.

MaximumAllowable

Head Pressure2’



Diesel-Burner’sFuel System,continued

E. Mount the Fuel Filter in a location that provides easy access for changing the Filter Element and for catching any potential fuel spillage when servicing.

F. Be sure to securely tighten all fuel fittings so that air cannot enter into the fuel system. Air in the fuel system will cause excessive “White Smoke” emissions.

3.22 Installing the Diesel-Burner’s Fuel System and Lines

1. Run two 1/4 inch I.D. (Inside Diameter) Fuel Lines from the Fuel Tank/Fuel Pick-Up to the Aqua-Hot.

NOTES:

A. Both Fuel Lines should be laid as flat as possible, and any extreme rises in height should be avoided. This procedure will eliminate any potential air-traps.

B. Run both Fuel Lines in areas where they cannot 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 kinked Fuel Line (Return side) will increase the fuel pressure to hazardous levels and may cause a Fuel Line to rupture. A kinked Fuel Line could also severely damage the Diesel-Burner’s internal fuel system.

2. Label both Fuel Lines indicating whether they are a Supply line or a Return line.

3. Connect the Supply and Return lines to the Fuel Tank/Fuel Pick-Up; reference Figure 26.

RETURN PORT:from the Aqua-Hot's"Return" Port, see

Figure 27.Dedicated

Fuel Pick-Up

Figure 26

Installingthe Diesel-Burner’s FuelLines

!

SUPPLY PORT:to the Aqua-Hot’s

Fuel Filter, see Figures 28A and 28B.

NOTE: The Fuel Pick-Upshould not extend further than the Motorhome’s engine fuelsupply pick-up and should

be consistent with theon-board Generator’s

fuel supply pick-up length.



DieselFuel Ports

Figure 27

Diesel FuelSupply

Diesel FuelReturn



Fuel Filters

2

1

4

3

NOTE:

Fuel Filter TOP VIEW:of Fuel Filter Head

Plug

Plug

Reference Figure 27 for detailson the Fuel Tank connections.Reference Figure 28 for detailson the Aqua-Hot’s Fuel Connections.

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Figure 28A

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Figure 28BNOTE: Reference Figure 27 for details on the Fuel

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Aqua-Hot’s Fuel Connections.

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TOP VIEW:of Fuel Filter Head



Installing theDiesel-Burner’sFuel Lines,continued

4. Install and tighten the appropriate fuel fittings into the Aqua-Hot’s Fuel Ports, as well as the two selected ports of the Fuel Filter; reference Figures 27, 28A, and 28B.

5. Connect the Supply and Return lines to the Aqua-Hot’s fuel port connections; reference Figures 1 and 27.

6. Cut the Supply line at the Fuel Filter mounting location and connect the Fuel Lines as illustrated in Figures 28A and 28B.

3.23 Overview and Installation of the Aqua-Hot’s Exhaust System

WARNING: The Aqua-Hot’s exhaust is hot and must be kept away from any heat sensitive material. DO NOT direct exhaust downward as a fire may result when parked in dry, grassy areas. In addition, the exhaust must not terminate beneath the vehicle or beneath an openable window or vent. Refer to “Internal Combustion Engine Exhaust Pipe Termination” Section 3-4.3 in the RVIA Standards Manual for additional exhaust system information.

A. The exhaust must be able to freely exit away from the vehicle without any obstructions.

B. Run the Exhaust Pipe to the driver’s side of the vehicle and ensure that the exhaust fumes cannot enter into the passenger compartment.

NOTES:

1. 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 naturally move away while the vehicle is in motion.

C. DO NOT terminate the Exhaust Pipe within the awning area of the Motorhome, if applicable. Be sure to keep the exhaust away from the slideout areas. Reference RVIA’s ANSI/NFPA 1192 Handbook for additional information.

D. From the Aqua-Hot’s 1-1/2 inch (F) NPT Exhaust Port, use a 1-3/4 inch I.D. (Inside Diameter) Exhaust Pipe; reference Figure 29.

NOTES:

1. Be sure to use standard Automotive Type Exhaust piping and avoid bends, if possible.

2. The total length of Exhaust Pipe should not exceed 12 feet. Should your particular application require more than 12 feet of Exhaust Pipe, please contact Vehicle Systems’ Product Application Support Department at 1-800-685-4298 for assistance.

3. A maximum of two 90° Exhaust Pipe bends is allowed.

E. A condensation drain must be provided in the exhaust system. This can be accomplished by drilling a small hole (approximately 1/8 inch diameter) at the Exhaust Pipe’s lowest point (slightly sloping the Exhaust Pipe away from the Aqua-Hot will achieve the same results); reference Figure 29.

F. Be sure to secure the end of the Exhaust Pipe to the vehicle with the proper Exhaust Hanger/support hardware.

ExhaustSystemOverview/Installation

!



ExhaustSystemOverview

90˚ Bend

Condensation drainhole location

Figure 29

epiP tsuahxE epyt evitomotuA .D.I hcni 57.1

NOTE: A Condensation drain is not required if the Exhaust Pipe slopes away from the Heater.

.xaM teeF 211.5 inch Black Pipe Exhaust Nipple

1.5 inch Black Pipe Exhaust Nipple

NOTE: A maximumof two 90º bends

is allowed.



Installing theExpansion Tank

3.24 Installing the Aqua-Hot’s Expansion Bottle

The selected mounting location for the Expansion Bottle should allow for easy access (i.e., for filling) and clear visibility whenever the particular Storage Bay door is open.

1. Mount the Expansion Bottle, as illustrated in Figure 30.

2. Connect and clamp the Overflow Tubing from the Expansion Bottle to the Aqua-Hot’s Filler 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 large enough piece of Overflow Tubing so that it can be connected to the top of the Expansion Bottle and extend through the Bay floor; reference Figure 30.

FULL HOT

FULL COLD

NOTICE:Use only a non-toxic Propylene Glycol basedBoiler Antifreeze. For more information call

1-800-685-4298

Filler NeckOverflow

Connection

TensionClamp

OverflowTube

TensionClamp

ExpansionBottle

OverflowTube

Overflow Tubehole in Bay

Floor

Figure 30



VDC PowerInstallation

3.25 Connecting 12 Volt-DC Power to the Aqua-Hot

WARNINGS:

A. Do not activate the Aqua-Hot’s Diesel-Burner until the antifreeze and water heating solution has been added to the Aqua-Hot’s Heat Tank and the heating system has 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.

B. Do not connect the 12 Volt-DC Power or the Ground Wires to the Aqua-Hot if the Vehicle requires welding. Electrical welding will cause serious damage to the Diesel-Burner’s Controller and the Aqua-Hot’s Electronic Controller.

NOTE: All Electric Installations, Systems, and Equipment must comply with Article 551, Part A and other Sections of NFPA 70, “National Electrical Code.”

1. Run two 10 Gauge wires, Red for (+) and Black for (-), from the Vehicle’s Batteries to the Aqua-Hot’s Electronic Controller; reference Appendix A and Figure 31.

NOTES:

A. If the combined length of the two 10 Gauge wires is in excess of 20 feet, reference Appendix B for proper wire gauge sizing. Please note that under full load conditions, the Aqua-Hot can draw as much as 15.33 Amps of VDC current. Because the Aqua-Hot is designed to shut down in the event 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 0.75 Volts-DC. Please reference Appendix B to ensure proper wire gauge sizing is utilized.

NOTE: Be sure to use the wire colors illustrated in Appendix A. This will ensure installation consistency, differentiate between the two Power Wires, and assist Service Personnel with troubleshooting.

2. Attach the VDC Power wires onto the appropriate terminal/battery connection on the Electronic Controller; reference Appendix A.

3. Connect both Power and Ground wires directly to the Vehicle’s batteries.

NOTE: Be sure to protect against accidental shorting (i.e., chassis shorting) by incorporating a 25-Amp rated In-Line Fuse into the Power wire at the Battery location; reference Figure 31.

NOTE: The Aqua-Hot’s Electronic Controller must be reset anytime VDC Power is disconnected and then reconnected to the heater. The Electronic Controller can be reset either by depressing the “Low Voltage Reset” button located on the Electronic Controller (use a thin, straight object to access the reset button through the small hole in the faceplate) or by turning OFF the “Diesel” switch on the Heater’s Interior Switch Panel for approximately 30 seconds, then turning the switch back ON. Reference Figure 32 for the location of the “Low Voltage Reset” button on the Electronic Controller.

!



VDC PowerOverview

Negative/Ground

Positive/Power

25 Amp Fuse

Figure 31


Heating ZonesStatus

#5

#4

#3

#2

#1


Low Voltage

Reset


Heating Status

Engine PreheatPump



Overload Fault

Pump #2

Pump #1

Pump #3

Diesel-BurnerStatus

Motor Coach Heating Specialists

®

NOTE: Reference Appendix A for specific Electronic Controller details.



Low VoltageReset Button

#5

#4

#3

#2

#1



Heating Status

Engine PreheatPump



Overload Fault

Pump #2

Pump #1

Pump #3

Diesel-BurnerStatus

Low Voltage

Reset

Heating ZonesStatus


Low Voltage

Reset

Figure 32



SystemBleeding

3.26 Bleeding the Interior/Fresh Water Tank Hydronic Heating System

It is necessary to utilize a propylene glycol based “boiler” type antifreeze in the Aqua-Hot Hydronic Heating Systems. Propylene glycol is a safer alternative to the more toxic ethylene glycol antifreeze; however, as mandated by IAPMO (International Association of Plumbing and Mechanical Officials), only those propylene glycol based “boiler” type antifreezes deemed “Generally Recognized as Safe” (GRAS) by the FDA can be utilized.

NOTE: Because of the significant impact various types of antifreeze can have on a Hydronic Heating System - including the level of safety provided, Vehicle Systems, Inc. has recognized a need to provide an explanation regarding two additional prominent types of antifreeze/coolant available. The following information should be utilized as an educational means of ensuring that the proper type of propylene glycol based antifreeze is selected:

RV & Marine Antifreeze: These types of propylene glycol based antifreeze products are formulated specifically for “winterizing” applications 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 type of antifreeze is not formulated to transfer heat, which is essential to the Heating System’s functionality and does not contain rust inhibitors.

Automotive Antifreeze/Coolant: These type of propylene glycol based antifreeze products are formulated specifically to protect automotive engines against corrosion, freezing temperatures, and overheating. They also have excellent heat transfer and thermal conductivity characteristics. Although these types of antifreeze products are considered less toxic and safer than ethylene glycol for people, pets, and the environment, they are not “GRAS” (Generally Recognized as Safe) rated by the FDA. Therefore, they must be marked with a “harmful if swallowed warning. This additional warning is required because these types of antifreeze products contain high levels of chemical rust inhibitors. Due to their potentially hazardous properties, they should never be used in the Aqua-Hot’s Hydronic Heating System.

Prior to bleeding the Aqua-Hot Hydronic Heating System with the proper solution of antifreeze and water, it is recommended that the plumbing system be tested for potential leaks. The following instructions detail how to properly perform a plumbing system pressure test:

A. Remove the Aqua-Hot’s Radiator Cap and replace it with a ”Cooling System Pressure Tester”; reference Figure 33. Please note that these types of Pressure Testing products can typically be obtained from a local Automotive Parts Supplier.

B. Apply 15 pounds (PSI) of air pressure to the Aqua-Hot’s Hydronic Heating System.

NOTE: DO NOT exceed 15 PSI of air pressure, as this could cause damage to the internal plumbing components of the Aqua-Hot.

C. Allow the air pressure to remain in the plumbing system for a minimum of 30 minutes.

D. After the minimum 30 minute interval has expired, check the “Cooling System Pressure Tester’s” gauge for any loss of pressure.



SystemBleeding,continued

Domestic Water SystemBleeding

NOTE: Should it be discovered that a loss of pressure has occurred, be sure to check all plumbing system connections for leaks (air leaks, in the form of bubbles, can be visually detected by applying a solution of soapy water to each plumbing system connection).

E. If applicable, repair all plumbing leaks.

1. Remove the Aqua-Hot’s Fill/Radiator Cap and completely fill the Heat Tank by pouring in 16 gallons of a 50/50 antifreeze and water heating solution.

NOTE: As antifreeze itself does not possess acceptable heat transfer characteristics, water is added to the antifreeze due to its excellent heat conduction properties. In order to provide the best freeze protection, boil-over protection, and anti-corrosion and rust protection, a 50/50 mixture ratio of propylene glycol antifreeze and water is recommended to provide the best performance combination of the aforementioned functions. If excess propylene glycol exists within an antifreeze and water heating solution, the water’s heat absorption properties are compromised, which could ultimately inhibit the Aqua-Hot Hydronic Heating System from providing adequate domestic hot water and interior heating. Also, 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 Fill/Radiator Cap, but do not tighten completely.

NOTE: The Fill Radiator Cap should remain loose during the Bleeding and Filling Procedure in order to allow air to escape from the top portion of the Aqua-Hot’s Heat Tank.

3. To activate one of the Aqua-Hot’s Circulation Pumps, switch ON any Interior Zone Thermostat to its maximum temperature setting. Allow the Circulation Pump to operate for approximately one minute, then switch it OFF. This will fill the Heating System’s plumbing lines.

4. Again, remove the Aqua-Hot’s Fill/Radiator Cap and completely fill the Heat Tank with additional antifreeze and water heating solution.

5. Repeat steps 3 and 4 for all Heating Loops until all air has been completely bled from the entire Hydronic Heating System.

6. Once all air has been bled from the Hydronic Heating System and the Aqua-Hot’s Heat Tank has been completely filled, completely tighten the Fill/Radiator Cap.

3.27 Bleeding the Domestic Water System

NOTE: Verify that the Domestic Water Tank is full prior to bleeding the Fresh Water System.

1. Ensure that the Domestic Water Pump has 12 Volt-DC power, then activate the Domestic Water Pump by opening all water faucets separately.

2. Once the Domestic Water System is completely bled, check for leaks.



Pressure the Aqua-Hot Heating System 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 connectionsat each Heat Exchanger using

a soapy water solution, and watch for bubbles to appear, which indicates an air leak.Figure 33



Bleeding the EnginePreheat System

3.28 Bleeding the Engine Preheat System

1. Ensure that the Engine’s Coolant System has been completely refilled.

2. Start and run the Engine until it reaches normal operating temperatures.

3. Turn the Engine OFF.

4. Check the engine coolant level and top off, if necessary.

5. Turn ON the “Preheat” switch located on the Switch Panel. During this procedure, check for leaks in the Engine Preheat plumbing system and connections.

6. Move the “Preheat” switch to the OFF position by pressing it in a downward motion.

3.29 Connecting 120 Volt-AC Power to the Aqua-Hot

WARNING: Do not activate the Aqua-Hot’s Electric Heating Element until the antifreeze and water heating solution has been added to the Aqua-Hot’s Heat Tank and the heating system has 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 Equipment must comply with Article 551, Part A and other Sections of NFPA 70, “National Electrical Code.”

1. For Aqua-Hot Model AHE-100-04S:

Run one 12-2 ROMEX wire, with Ground, from an over-current protected (20 Amp Circuit Breaker required) 120 Volt-AC power supply to the Aqua-Hot’s VAC Service Input; reference Figure 34A.

For Aqua-Hot Model AHE-130-04X:

Run two 12-2 ROMEX wires, with Ground, from two over-current protected (25-Amp Circuit Breaker required) 120 Volt-AC power supplies to the Aqua-Hot’s VAC Service Input; reference Figure 34B.

2. Insert the wire(s) through the Aqua-Hot’s ROMEX Clamp and connect the 120 Volt-AC Power supply to the Aqua-Hot’s Electric Heating Element wires as illustrated in Figure 34A for the AHE-100-04S Model or Figure 34B for the AHE-130-04X Model.

VAC PowerInstallation

!



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Activatingthe Aqua-Hot

3.30 Initial Activation of the Aqua-Hot

1. Move the Aqua-Hot’s “Diesel” switch to the ON position. Do this by pressing the switch in an upward motion.

NOTE: Activate the “Diesel” switch for approximately five seconds ONLY and then switch it OFF. This procedure will purge the Diesel-Burner’s fuel system by allowing the Heater’s Fuel-Pump to operate for approximately three minutes during its normal shutdown/purge cycle. After the three minute purge cycle has ended, repeat this procedure once more.

2. Move the Aqua-Hot’s “Diesel” switch to the ON position and leave it on. This procedure will activate the Diesel-Burner and the Indicator Light circuit of the switch.

NOTES:

A. It will take approximately 30 seconds before the Diesel-Burner will ignite and exhaust can be heard exiting the heater.

B. Allow approximately 10-20 minutes for the Aqua-Hot to reach normal operating temperature (approximately 195°F).

3. Because the number and voltage of the Electric 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 employed. Follow the Electric Element activation instructions below.

AHE-100-04S

Move the Aqua-Hot’s “Electric” switch to the ON position. This will supply 120 Volt-AC Power to the Aqua-Hot’s Electric Heating Element.

AHE-130-04X

Move the Aqua-Hot’s “Electric” switch to the ON position and move the “High/Low” switch to the “High” position. This will supply 120 Volt-AC power to both Electric Heating Elements.

NOTE: Both the 12 Volt-DC powered Diesel-Burner and all Electrical Heating Elements are thermostatically controlled. Either or both heating sources will automatically maintain the temperature of the Aqua-Hot’s antifreeze and water heating solution.

4. Once the Aqua-Hot has reached its normal operating temperature of approximately 195°F, switch ON each Interior and Fresh Water Tank Thermostat to their maximum temperature settings. This procedure will activate all Interior and Fresh Water Tank Heat Exchangers in each particular heating zone.

5. The Aqua-Hot is now ready for normal operation and use.


Wiring Diagrams

APPENDIX A

A1Aqua-Hot™ Hydronic Heating System Installation Manual 07/05

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+

#4 F

AN

-

#4 T

HE

RM

-0

#4 T

HE

RM

-I

#3 F

AN

+

#3 F

AN

-

#3 T

HE

RM

-O

#3 T

HE

RM

-I

#2 F

AN

+

#2 F

AN

-

#2 T

HE

RM

-O

#2 T

HE

RM

-I

#1 F

AN

+

#1 F

AN

-

#1 T

HE

RM

-O

#1 T

HE

RM

-I

DIE

SE

L-O

DIE

SE

L-I

ELE

CT

RIC

-O

ELE

CT

RIC

-I

PR

EH

EA

T-O

PR

EH

EA

T-I

IND

-LT

(+)

B3

IND

-LT

(-)

B6

LLC

O-I

LLC

O-O

TS

TAT-

I

TS

TAT-

O

AC

RE

L -

AC

RE

L +

LTC

O-I

LTC

O-O

EP

PU

MP

-

EP

PU

MP

+

PU

MP

1 -

PU

MP

1 +

PU

MP

2 -

PU

MP

2 +

PU

MP

3 -

PU

MP

3 +

B1

+

C7-

I

C1-

O

B2

-

B4

+

B3

+

B6

-

12 V

DC

1 0

8 6 4 2

12 B

LU11

ORG

1-B

LK

BLK

3-W

HT

3-W

HT

BLK

BLK

GRN

APPENDIX A Wiring Information (AHE-100-04S)


EN I

GN

E TA

EH

ER

P

YZO

C OT

SR

EG

NA

HC

XE TA

EH

.X

AM

S TT AW 42

CD

V2 1

CD

V21

CD

V2 1

MO

ORDE B

E #

1N

OZ G

N ITAEH

LA

NO ITP

O

GN IT

AE HE

#4

NO Z

RETA

W H SERF K

NA T

E #

3N

OZ G

NITA EH

M

OORH T

A BE

#2

NO Z

GNI T

AEH

/M

OOR

GN I

V ILNEH

C TIKE

#5

NO Z

GNI T

AEH

C IR T

CE L

EL

ES

E ID

-+ +

TAE

HE

RP

ENI

GN

E

+ -

YZO

C OT

SR

EG

NA

HC

XE TA

EH

.X

AM

STT AW 42

CD

V 21

+ +- -

YZO

C OT

SR

EG

NA

HC

XE TA

EH

.X

AM

STT AW 4 2

YZO

C OT

SR

EG

NA

HC

XE TA

EH

.X

AM

ST TAW 42

-+

LEY 7TH

W 6G R

O 5NR B 4DER 3

N RG 1

CD

V 21

-+

DERKL B

ULB

2C

4C

NRB

NRG

5C

6C

LEY8

C

K LB

DER 61DER 51

K LB 31UL B 21GR

O 11

N RB 8DER 7TH

W 6OI

V 5NR

G 4NRB 3K LB 2DE R 1

DER 5

GRO 11ULB 21

TH

W - 3

KLB -1

NRG

THW 3

E U LB 2

Circ. Pump 3 Circ. Pump 2 Circ. Pump 1

1 1JP 4JP 3

JP 2JP 1

) LANOI TPO(

K LB 4 1

2L

TO 120 VAC

N G

+ - -+

1 L N

K LB 2

DER 5

DE R 4

C IR T

CEL

E

WOL / I

H

UL BU LB LEY

GRO

O IV

NRB

THW

NRG

LEYNR

G

DE RK LBG R

OGR

O

DE RKLBOI

VOI

V

KLBDER

U LBULB

KLBDER

THW

THW

THW-3

12 VDC

LEN

AP H

CTIWS

CD

V21R

O TO

M

CD

V213 P

MUP N

OI TALU

CRIC

CD

V212 P

MUP N

OI TAL U

CRIC

CD

V211 P

M UP N

O ITALU

CR IC

PM UP

CD

V 21

XO

B N

OI TC

NUJ

MA

RG

AID

GNI

RIW

+ N

AF 5 #

- N

AF 5#

O-M

RE

HT 5#

I-M

RE

HT 5#

+ N

AF 4#

- N

AF 4 #

0-M

RE

HT 4#

I-M

RE

HT 4#

+ N

AF 3#

- N

AF 3#

O-M

RE

HT 3#

I-M

RE

HT 3#

+ N

AF 2#

- N

AF 2#

O-M

RE

HT 2#

I-M

RE

HT 2#

+ N

AF 1#

- N

AF 1 #

O -M

RE

HT 1#

I-M

RE

HT 1#

O-LE

SEI

D

I-LE

SEI

D

O-C I

RT

CEL

E

I -CI

RT

CE L

E

O-TA

EH

ER

P

I-TA

EH

ER

P

)+( TL-

DNI

3B

)-( TL-

DNI

6B

I-O

CLL

O-O

CLL

I-TAT

ST

O- TAT

ST

- LE

R C

A

+ LE

R C

AI-

OCTL

O-O

CT L

-P

MU

PP

E

+P

MU

PP

E

- 1P

MU

P

+ 1P

MU

P

- 2P

MU

P

+ 2P

MU

P

- 3P

MU

P

+ 3P

MU

P

+ 1B

I-7C

O-1C

- 2B

+ 4B

+ 3B

- 6B

CD

V 21 OT

YLPPUS R EW

OP Y RETT

AB ,.E. I()S

NOIT

CEN

NO

C

8PJ N I 4

B5PJ V21+

7PJ D

NG

EVL

AV

D IO

N ELO S L EU F

GN

D

THE

RM

OS

TAT

THE

RM

OS

TAT

THE

RM

OS

TAT

THE

RM

OS

TAT

FLO

ATS

WIT

CH

VAC

/VD

C C

ON

TRO

LTH

ER

MO

STA

T

12 VDC

VAC

RE

LAY

VAC

RE

LAY

N.C

.

VAC

HIG

H L

IMIT

N.C

.

VAC

HIG

H L

IMIT

ELE

CTR

IC H

EAT

ING

ELE

ME

NT

120V

AC

,200

0W

ELE

CTR

IC H

EAT

ING

ELE

ME

NT

120V

AC

,200

0W

GND

M

M M M

HO

UR

ME

TER

M N.C

.

VD

C H

IGH

LIM

IT

FLA

ME

SEN

SOR

IGN

ITIO

N C

OIL

12 V

DC

B-P

LUG

C-P

LUG

DIE

SE

L-B

UR

NE

RC

ON

TRO

LLE

R12

VD

C

K LB 21 0

8 6 4 2

1 0

8 6 4 2

RIG

HT

LEFT

7 BLK

62

41

- +

62

41

- +

62

41

- +

62

41

- +

APPENDIX A Wiring Information (AHE-130-04X)


ENGINE PREHEAT

TO COZY HEAT EXCHANGERS24 WATTS MAX.

12VDC

12VDC

12VDC

BEDROOMHEATING ZONE #1

OPTIONAL HEATING ZONE #4

FRESH WATER TANK HEATING ZONE #3

BATHROOM HEATING ZONE #2

LIVING ROOM/KITCHENHEATING ZONE #5

ELECTRIC DIESEL

-+

+

-

+

+

-


12VDC

+

+

-

-


TO COZY HEAT EXCHANGERS24 WATTS MAX. -

+

Circ

. Pum

p 3

Circ

. Pum

p 2

Circ

. Pum

p 1

1

1

JP 4

JP 3

JP 2

JP 1

(OPTIONAL)

WHTWHT

REDBLK

BLUBLU

REDBLK

VIOVIOBLKRED

ORGORGBLKRED

1

2

4

6

1

2

4

6

1

26

4+

--

+

��

��

��

��

��

TO 12VDCPOWER SUPPLY(I.E., BATTERY CONNECTIONS)

SWITCH PANEL

BLUBLU

YELORG

VIOBRN

GRN

WHT JP8B4 IN

JP5+12V

JP7GND

#5 FAN +

#5 FAN -

#5 THERM-O

#5 THERM-I

#4 FAN +

#4 FAN -

#4 THERM-0

#4 THERM-I

#3 FAN +

#3 FAN -

#3 THERM-O

#3 THERM-I

#2 FAN +

#2 FAN -

#2 THERM-O

#2 THERM-I

#1 FAN +

#1 FAN -

#1 THERM-O

#1 THERM-I

DIESEL-O

DIESEL-I

ELECTRIC-O

ELECTRIC-I

PREHEAT-O

PREHEAT-IIND-LT (+) B3IND-LT (-) B6

LLCO-ILLCO-O

TSTAT-I

TSTAT-O

AC REL -

AC REL +

LTCO-I

LTCO-O

EPPUMP-

EPPUMP+

PUMP1 -

PUMP1 +

PUMP2 -

PUMP2 +

PUMP3 -

PUMP3 +

B1 +

C7-I

C1-O

B2 -

B4 +

B3 +

B6 -

APPENDIX A Enlarged View of Switch Panel and Heating Zone Wiring (AHE-100-04S)


ENIGNE TAEHERP

YZOC OTSREGNAHCXE TAEH

.XAM STTAW 42

CDV21

CDV21

CDV21

MOORDEBE #1NOZ GNITAEH

LANOITPO GNITAEH

E #4NOZ

RETAW HSERF KNAT

E #3NOZ GNITAEH

MOORHTABE #2NOZ GNITAEH

CIRTCELE LESEID

-

++

+

-


.XAM STTAW 42

CDV21

+

+

-

-


.XAM STTAW 42


.XAM STTAW 42 -

+

Circ

. Pum

p 3

Circ

. Pum

p 2

Circ

. Pum

p 1

1

1

JP 4

JP 3

JP 2

JP 1

) LA

NOIT

PO(

CIRTCELE WOL / IH

ULBULB

LEYGRO

OIVNRB

THWNRG

LEYNRG

DERKLBGROGRO

DERKLBOIVOIV

KLBDER

ULBULB

KLBDER

THWTHW

LENAP HCTIWS

+ NAF 5#

- NAF 5#

O-MREHT 5#

I-MREHT 5#

+ NAF 4#

- NAF 4#

0-MREHT 4#

I-MREHT 4#

+ NAF 3#

- NAF 3#

O-MREHT 3#

I-MREHT 3#

+ NAF 2#

- NAF 2#

O-MREHT 2#

I-MREHT 2#

+ NAF 1#

- NAF 1#

O-MREHT 1#

I-MREHT 1#

O-LESEID

I-LESEID

O-CIRTCELE

I-CIRTCELE

O-TAEHERP

I-TAEHERP

)+( TL-DNI3B

)-( TL-DNI6B

I-OCLL

O-OCLL

I-TATSTO-TATST

- LER CA

+ LER CAI-OCTL

O-OCTL

-PMUPPE

+PMUPPE

- 1PMUP

+ 1PMUP

- 2PMUP

+ 2PMUP

- 3PMUP

+ 3PMUP

+ 1B

I-7C

O-1C

- 2B

+ 4B

+ 3B

- 6B

CDV21 OT YLPPUS REWOP

YRETTAB ,.E.I()SNOITCENNOC

8PJ NI 4B

5PJ V21+

7PJ DNG

GND

THERMOSTAT

THERMOSTAT

THERMOSTAT

THERMOSTAT

6 2

4 1

-

+

6 2

4 1

-

+

6 2

4 1

-

+

6 2

4 1

-

+

To the 1-Way Plugs

/MOOR GNIVILNEHCTIK

E #5NOZ GNITAEH

APPENDIX A Enlarged View of Switch Panel and Heating Zone Wiring (AHE-130-04X)

Wire GaugeInformation

APPENDIX B

B1Aqua-Hot™ Hydronic Heating System Installation Manual 07/05

A M E R I C A N B O AT A N D YA C H T C O U N C I L R E C O M M E N D AT I O N S

C O N D U C T O R S S I Z E S F O R 3 % D R O P I N V O LTA G E

L e n g t h o f C o n d u c t o r f r o m S o u r c e o f C u r r e n t t o D e v i c e a n d b a c k t o S o u r c e F e e tTOTAL

CURRENTON CIRCUIT

IN AMPS. 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

5 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6

10 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2

15 12 10 10 8 8 6 6 6 4 4 2 2 2 2 2 1 1 1 1

20 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0

25 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0

30 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0

40 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 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 4/0

100 4 2 2 1 0 2/0 3/0 4/0

5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8

10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6

15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2

20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2

25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 1

30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 1

40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0

50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 2/0

60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0

70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 4/0

80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0

90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0

100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0

12 Volts - 3% Drop Wire Sizes (gage) - Based on Minimum CM Area

24 Volts - 3% Drop Wire Sizes (gage) - Based on mInimum CM Area

APPENDIX B Wire Gauge Chart

AHE-100-04S, 120-04X, and 130-04X Installation Manual 11-16-04 · 2017-04-10 · Aqua-Hot™...

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Transcript of AHE-100-04S, 120-04X, and 130-04X Installation Manual 11-16-04 · 2017-04-10 · Aqua-Hot™...