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Aqua-Hot 400D - User Manual

Aqua-Hot 400D
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INSTALLATION MANUAL
© 2011 Aqua-Hot Heating Systems Inc.

Table of Contents

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Summary

Section 1: Aqua-Hot Hydronic Heating System

Section 2: Aqua-Hot Installation

Installing the Mounting Tray and the Aqua-Hot

Procedure for mounting the Aqua-Hot unit and its tray.

Installing the Expansion Tank

Procedure for mounting and connecting the expansion tank.

Pressure Testing the Aqua-Hot Tank

Cautionary advice for pressure testing the Aqua-Hot tank.

Section 3: Hydronic Heating System

Heat Exchanger Locations and Clearances

Guidelines for placing heat exchangers for optimal heat distribution.

Mounting Requirements

Requirements for ventilation and mounting heat exchangers.

Mounting the Heat Exchangers

Instructions on cutting openings and securing heat exchangers.

Wiring the Heat Exchangers

Procedures for connecting wires to heat exchangers.

Plumbing Requirements

Guidelines for routing and sizing plumbing lines for heat exchangers.

Plumbing the Hydronic Heating System

Steps for connecting plumbing lines to heat exchangers.

Section 4: Thermostats

Fresh Water Tank Thermostat

Selecting location, mounting, and wiring the fresh water tank thermostat.

Room Thermostat

Selecting location, mounting, and wiring room thermostats.

Section 5: Domestic Water System

Domestic Water System Requirements

Requirements for the domestic water system, including accumulator tanks.

Domestic Water System Plumbing

Procedure for plumbing the domestic water system.

Section 6: Switch Panel

Switch Panel Location

Selecting an accessible location for the switch panel.

Switch Panel Mounting

Instructions for cutting opening and mounting the switch panel.

Switch Panel Wiring

Procedures for wiring the switch panel to the controller.

Section 7: Fuel System

Fuel Filter Location

Guidelines for mounting the fuel filter for easy access.

Fuel System Requirements

Specifications for the diesel fuel supply and lines.

Fuel System Installation

Steps for installing the fuel lines and filter.

Section 8: Exhaust System

Exhaust System Requirements

Requirements for exhaust exit, pipe type, and length.

Installing the Exhaust System

Procedures for routing and securing the exhaust pipe.

Section 9: Electronic Controller Wiring

Electronic Controller Wiring

Overview of controller connections and polarity.

Wiring Harness Connection

Steps to connect the wiring harness to the controller.

Connecting the 12 Volt-DC Power

Procedure for connecting the DC power supply.

Connecting the 120 Volt-AC Power

Procedure for connecting the AC power supply.

Section 10: Purging the Systems

Purging the Hydronic Heating System

Filling and bleeding the hydronic heating system with solution.

Purging the System by Grounding the Zone Thermostat Connection

Method to purge heating loops using pump grounding.

Purging the Domestic Water System

Procedure for bleeding air from the domestic water system.

Section 11: Initial Start-Up

Activating the Aqua-Hot

Steps to safely activate the Aqua-Hot system after installation.

Appendix A: Wiring Diagram

Appendix B: Wire Gauge Information

Appendix C: Electronic Controller Features

Secondary 12 Volt-DC Battery Connection

Feature for secondary DC battery connection for safety.

Terminals Strips with Screw-Type Fasteners

Description of terminal strips and screw-type fasteners.

Appendix D: Antifreeze Types

RV & Marine Antifreeze

Information on why RV/Marine antifreeze is not suitable for the system.

Automotive Antifreeze;Coolant

Information on why automotive antifreeze is not suitable.

Appendix E: Antifreeze Mixture Water Quality Recommendations

Appendix F: Antifreeze Terms and Mixture Ratio

Propylene Glycol Based Antifreeze Solution

Details on selecting the right PPG solution for protection.

Freeze Point and Burst Point

Explanation of freeze point and burst point for antifreeze.

Boiling Point

Explanation of the boiling point's effect on system efficiency.

Rust and Anti-Corrosive Inhibitors

Function of inhibitors in protecting system components.

Summary

Overview of antifreeze functions: freeze, boil-over, anti-corrosion.

Appendix G: Measuring Propylene Glycol Using a Refractometer

Calibrate the Refractometer

Procedure for calibrating the refractometer.

Aqua-Hot 400D Specifications

General IconGeneral
Fuel TypeDiesel
Heating Power40, 000 BTU/hr
BTU/hr Output (Heating)40, 000 BTU/hr
AC Electrical Input120V AC, 60Hz
DC Electrical Input12V DC
Dimensions12.5"

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