owner s anual - aqua-hot€¦ · 2-year limited warranty aqua-hot® hydronic heating system...

© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A

TABLE OF CONTENTS

Limited Warranty Statement

Introduction IntroductiontotheAqua-HotHydronicHeatingSystem . . . . . . . . . . . . . . . . . . . . . . . .Page2

Operating Instructions ActivatingtheAqua-HotHeatingSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page5 ZoneThermostatOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page5 UsingtheDomesticHotWaterSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page5 UsingtheEnginePreheatSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page5 Aqua-HotOperationalFlow-Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page7

Maintenance MaintenanceSchedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page8

Winterization DomesticHotWaterSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page10 De-WinterizingtheDomesticHotWaterSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page10

Troubleshooting GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page11 ElectronicControllerDiagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page11 Diesel-BurnerBlinkingFaultIndicatorLight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page12

Appendices AppendixA:AntifreezeTypes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 AppendixB:AntifreezeMixtureWaterQualityRecommendations . . . . . . . . . . . . . . .B1 AppendixC:AntifreezeTermsandMixtureRatio . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1

2-YEAR LIMITED WARRANTYAQUA-HOT® HYDRONIC HEATING SYSTEM

AHE-525-D

Aqua-HotHeatingSystemsInc .warrantstheAqua-HotHeatertobefreefromdefectsinmaterialandworkmanshipundernormaluseandserviceforaperiodoftwoyearsonbothpartsandlaborcommencingupontheoriginaldateofregistrationofthevehicle .ReplacementpartsarewarrantedfortheremainderoftheHeater’sstandardwarrantycoverageorforsixmonths,whicheverisgreater .

TheintentofthiswarrantyistoprotecttheHeater’send-userfromsuchdefects,whichwouldoccurinthe manufacturing of the product. Thus, problems due to improper specifications, improper installations, improperuse,theuseofaccessorypartsorpartsnotauthorizedbyAqua-HotHeatingSystemsInc .,repairbyunauthorized persons, and damage or abuse of the Heater are specifically excluded from warranty coverage.

Foradditionalinformationortoobtainawarrantyrepairauthorization,pleasecontacttheAqua-HotHeatingSystemsTechnicalSupportDepartmentat1-800-685-4298(8:00AMto5:00PMMountainStandardTime)orvisitwww .aqua-hot .com .

© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage 2

This manual should be maintained in legible condition and kept in a safe, easily accessible

place for future reference.

Please read the complete Owner’s Manual prior to operating the Aqua-Hot Hydronic Heating

System. Also, be sure to fill out and mail in the “Warranty Registration” card located at the

front of this manual.

TheAqua-HotHeatingSystemisaHydronicHeatingSystem(heatingwithhotwater)thatprovidesinteriorzoneheatingwhereandwhenitisneeded,aswellasacontinuous,on-demandsupplyofdomestichotwater .Bothheatingfeaturesareaccomplishedbya12Volt-DCpoweredDiesel-Burneranda120Volt-ACpoweredElectricHeatingElement .

ThesetwoheatingsourcesmaintainthetemperatureoftheAqua-Hot’santifreezeandwaterheatingsolution .Inaddition,theAqua-Hothasbeendesignedtopreheatthevehicle’senginepriortostarting .Thispreheatfeatureprovidesaneasyenginestart-upwhenevercoolweatherconditionsarepresent .BesuretoreferenceFigures1-Athrough1-Cforacompletecomponentoverview .

NOTE: ThisAqua-Hotproductutilizesapropyleneglycolbasedantifreezeandwaterheatingsolution .ThispropyleneglycolbasedsolutionisaBoilertype

antifreezethatis“GenerallyRecognizedasSafe”(GRAS)bytheFDA .Foradditionalinformationregardingthis“GRAS”antifreezeproduct,pleasereferenceAppendixA,contacttheAqua-HotHeatingSystemsTechnicalSupportDepartmentat1-800-685-4298,orvisitthewebsiteatwww.aqua-hot.com .

Danger, Warning, Caution, and Note Boxes:

Danger,Warning,Caution,andNoteboxesappearthroughoutthismanualasameansofalertingtheoperatortoimportantinformation .

Indicates that personal injury is likely or imminent.

Indicatesthatseriousdamagetotheheaterwilloccurandpersonalinjuryispossibleaswell .

Indicatesthatdamagetotheheaterispossible .

NOTE: Indicatesinformationthatrequiresspecialattentionbytheoperator .

INTRODUCTION

Figure 1-A

Access Cover

Pump 1 Zone Outlet

Pump 2 Zone Outlet

Engine Preheat InletEngine Preheat Outlet

Zones 1 and 2 Return Ports

Air Release Valve

Product I.D. Label

Diesel Fuel Inlet

Diesel Fuel Outlet

Expansion Tank Connection

Domestic Hot Water Outlet

Domestic Cold Water Inlet

120 Volt-AC Connection

engine preheat circulation pump access panel

© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage �

INTRODUCTION

2 3 451

9

8

7

6

1 - ElEctric HEating ElEmEnt HigH-limit tHErmostat

2 - Fluid lEvEl switcH

3 - diEsEl-BurnEr HigH-limit tHErmostats

4 - vdc/vac control tHErmostat

5 - low-tEmp cut-oFF tHErmostat

6 - circulation pump - ZonE 1

7 - ElEctric HEating ElEmEnt

8 - circulation pump - ZonE 2

9 - BoilEr tank stir pump

Figure 1-B

diEsEl-BurnEr

diEsEl-BurnEr controllEr

diEsEl-BurnEr motor

diEsEl-BurnEr HigH-limit tHErmostats

mounting tray

systEm drain

intErlock switcH

Expansion tank

Expansion tank connEction

Figure 1-C


INTRODUCTION

3069328

Direct Vent Appliance

For installation only in a compartment that is completely closed off from living quarters and accessible only from the outdoors.

The Exhaust System MUST NOT terminate beneath the vehicle or under an openable windowor vent.

Combustion Air MUST BE supplied from outside the vehicle.

CAUTION: THIS APPLIANCE OPERATES ON BOTH AC AND DC POWER.

USE COPPER CONDUCTORS ONLY!

Use a 25-Amp fuse for over-current protection for the DC power supply.

Use a circuit breaker that cuts power at 20-Amps maximum for over-current protection forthe 120-VAC power supply.

Mount the Heater near a bay/storage door so that the Access Cover can be easily removed for service.

WARNING: DO NOT OPERATE APPLIANCE WITH ACCESS COVERS REMOVED.

Minimum Heater Clearances:Front - Open Access

Back - 0 inchesTop - 0 inches

Sides - 0 inches

Install in strict compliance with local codes, NFPA 1192, and the manufacturer’s instructions.

Product I.D. Label

Figure 2


OPERATING INSTRUCTIONSZone Thermostat Operation

Interior Room Thermostat:

SimplyadjusteachInteriorRoomThermostattothedesiredtemperature .Then,wheneveranInteriorRoomThermostat“calls-for-heat,”theAqua-Hot’sCirculationPumpandInteriorHeatExchangerFanswillbeactivated .Thesedevices,together,willsupplywarmthandcomforttoeachinteriorheatingzone .TheAqua-Hotmustbeatoperatingtemperaturebeforezoneswillfunction .Pleasecontactthespecific motorhome manufacturer for the exact location of the InteriorRoomThermostats .

Fresh Water Tank Thermostat:

SimplyadjusttheFreshWaterTankThermostatforbayheatingtoapproximately40ºF .Thiswillpreventfreezingofthe domestic water storage system. Please contact the specific motorhomemanufacturerfortheexactlocationoftheFreshWaterTankThermostat .

Using the Domestic Hot Water System

WhentheAqua-Hotisatoperatingtemperature,thedomesticwaterisautomaticallyheatedasitisbeingused .BecausetheAqua-Hotdoesnotstoreanyhotwater,simplyopenanyhotwaterfaucetandacontinuoussupplyofhotwaterwillbepresentwithinafewseconds .ThishotwaterfeatureiscontinuousandisaccomplishedbytheAqua-Hot’sDomesticHotWaterHeatingSystem .PleasenotethattheDiesel-BurnerswitchmustbeONinordertoobtainacontinuoussupplyofhotwater(e .g .,duringshowers);besuretoalsoactivatetheElectricElementswitchformaximumhotwatercapacity .

NOTE: TheAqua-Hot’s“DomesticWaterPrioritySystem”disablestheinteriorzoneheatingfans,zonecirculationpumps,andtheenginepreheatpumpwheneverdomestichotwaterisbeingusedonacontinuousbasis(e .g .,duringshowers) .Oncethedemandforcontinuousdomestichotwaterceases,theAqua-HotwillenablethefansandpumpstooperateandprovideheattotheHeatingZones .PleasenotethattheElectronicController’sLowTempCutoffStatusindicatorlightwillilluminateGREENwhenevertheAqua-Hotisabletoprovideinteriorzoneheating;referenceFigure7 .

Using the Engine Preheat System

WhentheAqua-Hotisatoperatingtemperature,andtheDiesel-Burnerand/ortheElectricElementswitchisON,fol-lowthesesimpleinstructions:

1. TurntheAqua-Hot’sEnginePreheatswitchON; referenceFigure3 .ThiswillactivatetheEnginePre-

heatCirculationPumpandcirculatetheengine’scoolantthroughtheEnginePreheatSystem .Thisfeaturewilladequatelywarmtheengineforeasystart-upswhencool

The Aqua-Hot’s Exhaust is HOT!

DO NOT park in areas where dry conditions exist underneath the vehicle, as a fire may result (e.g., in a dry, grassy field)!

DO NOT operate the Aqua-Hot’s Diesel-Burner inside an enclosed building!

The Heater must be switched OFF when refueling.

DO NOT operatetheDiesel-Burnerand/ortheElectricHeat-ingElementwithouttheantifreezeandwaterheatingsolutionintheAqua-Hot’sBoilerTank .Failuretodosowillcauseserious damagetotheHeater .

Activating the Aqua-Hot Heating System:

Diesel-Burner:

TurntheDiesel-BurnerswitchON;referenceFigure3 .ThisprocedurewillactivatetheDiesel-BurnerandtheindicatorlightlocatedadjacenttotheDiesel-Burnerswitch .Allow10-20minutesfortheAqua-HotSystemtoreachoperatingtem-perature .PleasenotethattheDiesel-Burneristheprimary heat sourceforheatingboththeinteriorandthedomestichotwater(suchaswhencoolambienttemperaturesexistand/orwhenthereisahighdemandfordomestichotwater) .

Electric Heating Element:

TurntheElectricElementswitchON;referenceFigure3 .Thisprocedurewillactivatethe120Volt-ACElectricHeatingElementandtheindicatorlightlocatedadjacenttotheElectricElementswitch .Allow1-2hoursfortheAqua-HotSystemtoreachoperatingtemperature .

NOTE: Themotorhomemustbeconnectedtoshorepower,orthegeneratormustberunning,inordertoactivatetheElectricHeatingElement .

Also,pleasenotethattheElectricHeatingElementisasecondary heat sourceforheatingboththeinteriorandthedomestichotwaterduringlowheatingdemandsituations(suchaswhenmoderateambienttemperaturesexistand/orwhenthereisalowdemandfordomestichotwater) .

NOTE: BoththeDiesel-BurnerandtheElectricHeatingElementarethermostaticallycontrolled .Either,orboth,heatingsourceswillautomaticallymaintainthetemperatureoftheAqua-Hot’santifreezeandwaterheatingsolutionbetweenapproximately160ºFand190˚F (±5). Therefore, to heat the motorhome/do-mestichotwater,simplychoosethedesiredheatsource(s)andleavetheswitch(s)(i .e .,Diesel-Burnerand/orElectricElement)ON .


OPERATING INSTRUCTIONStemperaturesexist .

NOTE: Allowapproximately1to2hoursofenginepreheatingruntime .ThepreheatdurationwillbeshortestwhentheDiesel-BurnerswitchisON .

2. TurnOFFtheAqua-Hot’sEnginePreheatswitch wheneverenginepreheatingisnotdesired .

NOTE: TheAqua-Hot’sEnginePreheatingSystemactsasasupplemental heating source,inadditiontotheDiesel-BurnerandtheElectricHeatingElement .Whiletraveling,theengine’sheatedcoolantwillautomaticallypassthroughtheEnginePreheatSystem,transferringheatintotheAqua-Hot’sBoilerTank .ThisdesignfeaturereducesthetotaloperatinghoursoftheDiesel-BurnerandtheElectricHeatingElement .TheEnginePreheatswitchdoesnotneedtobeonforthissupplementalheatingsystemtofunction .

Figure 3


OPERATING INSTRUCTIONS

Aqua-Hot Operational Flow-Chart

Heating Zone Thermostatcalls for heat.

The heated antifreeze and water heating solution flows through the Hydronic Heating

System transferring heat to the heat exchanger, which is, in turn, transferred to

the surrounding zone.

The cooled antifreeze and water heating solution is returned to the Boiler Tank to be

reheated.

Engine Preheat switch on the Interior Switch Panel is activated.

The engine’s coolant is circulated through the Aqua-Hot’s internal Engine Preheat

System where the heat from the Boiler Tank is transferred to the engine’s coolant.

The antifreeze and water heating solution within the Boiler Tank is reheated, as needed, and continues warming the

engine’s coolant as it circulates through the Aqua-Hot’s internal Engine Preheat

System.

A hot water faucet (e.g., kitchen sink, shower, etc.) is opened.

Continuous hot water is supplied to the faucet.


MAINTENANCE

When the Aqua-Hot is at maximum operating temperature, the coolant will be very HOT! If the Aqua-

Hot’s Heating System is accessed, scalding by hot vapor or coolant could result!

Before cleaning or servicing, disconnect all power supplies!

DO NOT operatetheDiesel-Burnerand/ortheElectricHeatingElementwithouttheantifreezeandwaterheating

solutionintheAqua-Hot’sBoilerTank .Failuretodosowillcauseserious damagetotheHeater .

PropyleneGlycolthatis“GenerallyRecognizedAsSafe”bytheFDAmust beutilizedfortheantifreezeandwaterheating

solution .

NOTE: Foradditionalinformationregardingthispropyleneglycol-based,boiler-typeantifreezethathasbeen“GenerallyRecognizedAsSafe”bytheFDA,pleasereferenceAppendixA,contacttheAqua-HotHeatingSystemsTechnicalSupportDepartmentat

1-800-685-4298,orvisitthewebsiteatwww.aqua-hot.com .

Maintenance Schedule

Biannual Maintenance:

ChecktheAqua-Hot’santifreezeandwaterheatingsolutiontoensurethatitisattheproperlevel .ThiscanbeaccomplishedbyvisuallycheckingthecoolantlevelintheAqua-Hot’s

ExpansionTank;referenceFigure4 .PleasenotethatthecoolantlevelshouldbecheckedonlywhentheAqua-Hotisatmaximumoperatingtemperature(i .e .,immediatelyaftertheDiesel-Burnercyclesoff) .WhentheAqua-Hotisatmaximumoperatingtemperature,theantifreezeandwaterheatingsolutionshouldbeatthelevelmarked“HOT”ontheExpansionTank .

Replenishing the Antifreeze Solution

Iftheantifreezeandwaterheatingsolutionneedsreplenishing,remove the Expansion Tank’s cap and fill the Expansion Tank to the “HOT” level mark. When refilling, open the Air Release Valve locatedontheExpansionTankConnectiontoreleaseairpockets;referenceFigure1-A .Holdthevalveopenuntilallairisreleased .If necessary, refill the Expansion Tank again. Be sure the valve is closed when finished by hand tightening. Reference Appendices A throughCtodeterminethecorrectratioofantifreezetowater,thepropertypeofantifreeze,andthewaterqualityrecommendationsfortheAqua-HotHydronicHeatingSystem’santifreezeandwaterheatingsolution .

Annual Maintenance:

TokeeptheAqua-Hotrunningsmoothly,itisidealtohavetheDiesel-Burnertuned-upannually .Atune-upshouldconsistofanewFuelNozzleandFuelFilter;referenceFigure5 .ToensuremaximumDiesel-Burnerperformance,alwaysusetherecommendedFuelNozzleandFuelFilterwhenreplacingtheseparts .ReferencetheAqua-Hot’sServiceandPartsManualforsparepartsinformationanddetailedreplacementinstructions,contacttheAqua-HotHeatingSystemsTechnicalSupportDepartmentat1-800-685-4298forassistanceortolocatethenearestAqua-HotServiceCenter,orvisitthewebsiteatwww .aqua-hot .com .

Figure 4


MAINTENANCE

Figure 5

Part Number: FLX-013-150

Part Number: FLE-120-100


WINTERIZATION

NotwinterizingtheAqua-Hotwhenfreezingtemperaturesexistwill result in serious damage totheAqua-Hot’s

Domestic Water Heating System. Be sure to fill the Aqua-Hot DomesticWaterlinewithFDA-approvedRVantifreezewhen

winterizing .

NOTE: TheAqua-Hotcanstillbeusedforinteriorzoneheatingevenifthedomestichotwatersystemhasbeendrainedandwinterized .

Domestic Water System

TheAqua-Hot’sDomesticWaterHeatingSystemmustbecompletelydrainedofdomesticwateranytimetheheaterisstoredwherefreezingtemperaturesmaybeexperienced .

Winterizing the Domestic Water Heating System:

PleasefollowtheseinstructionswhenwinterizingtheAqua-Hot’sDomesticHotWaterHeatingSystem;referenceFigure6 .1. Completelydrainthefreshwaterstoragetank .

2. Disconnectthedomesticwaterdemandpump’ssuctionlinefromthefreshwaterstoragetank .

3. Attachanadequatepieceofhoseontothesuctionsideofthedomesticwaterdemandpump .

4. Placetheoppositeendofthehoseintoanadequatesupply

ofFDA-approvedRVAntifreeze .

5. Openandcloseallinteriorandexteriorwaterfaucets,oneatatime,untilonlypureRVAntifreezeispresent .Performthisprocedureforboththehotandcoldfaucets .

6. Removethehoseandreconnectthedomesticwaterdemandpump’ssuctionlinetothefreshwaterstoragetank .

7. DisconnectallelectricalpowersuppliestotheAqua-Hotduringstorage .

De-Winterizing the Domestic Hot Water Heating System:

For de-winterization, completely fill the fresh water storage tank .Openandcloseallinteriorandexteriorwaterfaucets,oneatatime,untilonlyclearwaterispresent/visible .ReferenceFigure6 .

Ifdisinfectingthepotablewatersystemafterde-winterizing,besuretofollowRVIA’s“Instructions for Disinfection of Potable Water Systems on Recreation Vehicles .”TheseinstructionscanbeobtainedbycontactingtheRecreationalVehicleIndustryAssociationat(703) 620-6003,visitingthemonlineatwww.rvia.com,orwritingtothematthefollowingaddress:

Recreation Vehicle Industry Association1896 Preston White DriveP.O. Box 2999Reston, VA 20195-0999

To Hot Water Faucets

DomesticHot WaterOUTLET

FreshWater Storage

Tank DemandPump

DomesticCold Water

INLET

Arrows indicate directional flow ofdomestic water

To Cold WaterFaucets

RVAntifreeze

Remove the hose from the Fresh Water Storage Tank and attach an adequate piece of hose onto the suction side of the demand pump. Place this hose into a container of RV Antifreeze and allow this to pump through the Domestic Water System until the faucets run pure antifreeze.

Figure 6


TROUBLESHOOTING

General Information

ShouldtheAqua-HotHydronicHeatingSystemfailtooperate,completethefollowingchecks:

1) ChecktheInteriorSwitchPanelforablinkingindicatorlightontheDiesel-Burnerswitch;referenceFigure3 .Iftheindicatorlightisblinking,countthenumberof consecutive flashes, record the number, and contact theAqua-HotHeatingSystemsTechnicalSupportDepartmentat1-800-685-4298 .

2) ChecktheAqua-Hot’sElectronicControllerforanyREDlights,whichindicateafaultcondition .ReferenceFigure7andtheElectronic Controller Diagnosissectiontoidentifythesefaultconditions .

2) VerifythattheAqua-Hot’saccesscoverissecurelyinstalled .TheAqua-HotHydronicHeatingSystemwillnotoperateiftheaccesscoverisnotcompletelyinstalled .

3) Ensure that the vehicle’s fuel tank contains a sufficient leveloffuel .

4) EnsurethattheAqua-Hot’sboilertankhasanadequatesupplyofantifreezeandwaterheatingsolutionbycheckingthelevelattheExpansionTank .Ifthelevelislow,referencethe“Maintenance”sectionofthismanualfor refilling instructions.

IftheAqua-HotHeatingSystem’sfailuretooperateisnotresolvedwiththeaforementionedchecks,pleasecontacttheAqua-HotHeatingSystemsTechnicalSupportDepartmentat1-800-685-4298foradditionalassistanceorvisitthewebsiteatwww.aqua-hot.com .

Electronic Controller Diagnosis

Low Tank-Level Cutoff Indicator Light:

ThisindicatorlightwillilluminateREDwheneitherthe120Volt-ACElectricHeatingElementand/orDiesel-BurnerhaveautomaticallyshutdownduetoalowantifreezeandwaterheatingsolutionlevelinsidetheAqua-Hot’sBoilerTank .Thisfaultwillautomaticallyresetwhenthelow-levelconditioniscorrected .

Low Battery Voltage Fault Indicator Light:

ThisindicatorlightwillilluminateREDandtheDiesel-Burnerwillshutdownwheneverthe12Volt-DCvoltagelevelfallsbelow10 .5volts,whichistoolowfortheAqua-Hottooperateproperly .Thisfaultmustbemanuallyresetafterthevoltagelevelhasbeenrestoredtothe12Volt-DCbatterysystem;referencetheLow Voltageinformationbelow .

Low Voltage Fault Indicator Light and Reset Button:

TheAqua-Hot’sElectronicControllermustbemanuallyresetwhenevertheLowBatteryVoltageFaultindicatorlighthasbeenactivated .TheElectronicControllercanbereseteitherbyturningOFFtheDiesel-BurnerswitchontheHeater’s

InteriorSwitchPanelforapproximately30seconds,thenturningtheswitchbackON orbypressingthe“LowVoltageReset”buttonlocatedontheElectronicController(useathin,straight,nonmetallicobjecttoaccesstheresetbuttonthroughthesmallholeinthefaceplate) .

Overload Fault Indicator Light:

ThisindicatorlightwillilluminateREDwheneveroneofthefollowingconditionshaveoccurred:

A. TheAqua-Hotisoffduetoanelectricaloverload(i .e .,short)inthemain12Volt-DCpowersupplycircuitry .

B. TheAqua-Hotisoffduetoacombinationofhigh electrical12Volt-DCpowerloadsandahighsurface temperatureoftheElectronicController .

TheAqua-Hotwillautomaticallyrestartoncetheelectricaloverload(i .e .,short)and/orhigh-heatconditioniscorrected .

Heating Zones Status Indicator Lights:

These five indicator lights (separately) will illuminate GREENwheneveraZoneThermostatiscallingforheat .TheGREENindicatorlightsalsoindicatethat12Volt-DCpowerisbeingsuppliedtotheparticularinteriorheatingzone’sHeatExchangers(i .e .,fanmotors) .Ashortineitheraheatingzone’sInteriorRoomThermostatoraheatingzone’sHeatExchangercircuitwillcauseaheatingzone’sindicatorlighttoilluminateRED .

NOTE: TheLowTempCutoffLightmustbeilluminatedandtheheatermustbeuptooperatingtemperatureforzoneheattobesupplied .

Pumps #1, #2, and #3 Indicator Lights:

Theseindicatorlights(separately)willilluminateGREENwheneveraCirculationPumpisoperating .IfanyofthethreeindicatorlightsilluminateRED,itindicatesthatanelectricaloverloadcondition(i .e .,short)hasoccurredintheparticularcomponent’scircuitry .

NOTE: ZoneCirculationPumps#1and#2areactivatedwheneveraZoneThermostatcallsforheat .The

CirculationPump#3/BoilerTankStirPumpis activatedwhenevertheDomesticWaterisbeing

usedonacontinuousbasisortheheaterisnotuptooperatingtemperature .

Engine Preheat Pump Indicator Light:

ThisindicatorlightwillilluminateGREENwhenevertheEnginePreheatCirculationPumpisoperating .PleasenotethatthislightwillonlybeactiveiftheEnginePreheatswitchisONinconjunctionwitheithertheDiesel-Burnerand/ortheElectricElementswitch .IfthisindicatorlightilluminatesRED,itindicatesanelectricaloverloadcondition(i .e .,short)hasoccurredinthisparticularcomponent’scircuitry .


NOTE: TheAqua-HotmustbeuptooperatingtemperatureandtheLow Temp Cutoff Lightmustbeilluminatedfortheenginepreheatfeaturetofunction .

Heating Status Indicator Light:

ThisindicatorlightwillilluminateGREENwhenevertheAqua-Hot’sVDC/VACControlThermostatcallsfortheDiesel-Burnerand/orElectricElementtoheattheantifreezeandwaterheatingsolutionintheAqua-Hot’sBoilerTank .Whenthisindicatorlightisoff,noheatisbeingsuppliedtotheAqua-Hot’sBoilerTankbyeitherofthesetwoheatsources .

NOTE: TheAqua-Hot’sVDC/VACControlThermostatwillautomaticallyactivatetheDiesel-Burnerand/ortheElectricHeatingElementonlyiftheDiesel-Burnerand/orElectricElementswitchisintheONposition .Therefore,toheatthemotorhome/domestichotwater,simplychoosethedesiredheatsource(s)andleavetheswitch(s)(i .e .,Diesel-Burnerand/orElectricElement)ON .

Electric Heating Element Status Indicator Light:

ThisindicatorlightwillilluminateGREENwhenevertheAqua-Hot’sElectricHeatingElementisoperatingand

TROUBLESHOOTINGprovidingheattotheAqua-Hot’sBoilerTank .PleasenotethatthislightwillonlybeactiveiftheElectricElementswitchisintheONposition .IfthisindicatorlightilluminatesRED,itindicatesthatanelectricaloverloadcondition(i .e .,short)hasoccurredintheElectricHeatingElement’s12 Volt-DC poweredcircuitry .

Diesel-Burner Blinking Fault Indicator Light

TheInteriorSwitchPanelincorporatesaself-diagnosticBlinkingFaultIndicatorLightthatusesaseriesofblinkinglightstoindicateacomponentfailureduringtheDiesel-Burner’soperation .

Eachseriesofblinksareactivefor0 .5seconds“ON”and0 .5seconds“OFF”withathree-secondintervalbetweeneachFaultSeries .ThissequencewillrepeatcontinuouslyuntiltheDiesel-Burnerswitchismovedtothe“OFF”position,the12Volt-DCpowerisdisconnectedfromtheDiesel-Burner’sController,ortheAqua-Hot’saccesscoverisremoved .

ShouldaDiesel-Burnermalfunctionoccur,theAqua-HotHydronicHeatingSystemwillceaseoperationandwillactivatetheappropriateIndicatorLightBlinkingFaultSequence. Count the number of flashes,recordthenumber,andcontacttheAqua-HotHeatingSystemsTechnicalSupportDepartmentat1-800-685-4298 .

Figure 7

Antifreeze Types

APPENDIX A


APPENDIX A: ANTIFREEZE TyPES

Thefollowinginformationaddressesthenecessaryusageofapropyleneglycolbased“boiler”typeantifreezeintheAqua-Hot .Propyleneglycolisasaferalternativetothemoretoxicethyleneglycolantifreeze;however,asmandatedbyIAPMO(InternationalAssociationofPlumbingandMechani-cal Officials), only those propylene glycol based “boiler” type antifreezesdeemed“GenerallyRecognizedasSafe”(GRAS)bytheFDAshouldbeutilized .

Because of the significant impact various types of antifreeze canhaveonaHydronicHeatingSystem,includingthelevelofsafetyprovided,ithasbeenrecognizedthatthereisaneedtoprovideanexplanationregardingtwoadditionalprominenttypesofantifreeze/coolantavailable .Thefollowinginformationshouldbeutilizedasaneducationalmeansofensuringthatthepropertypeofpropyleneglycolbasedantifreezeisselected:

RV & Marine Antifreeze:

Thesetypesofpropyleneglycolbasedantifreezeproductsare formulated specifically for “winterizing” applications only .AlthoughRV&Marineantifreezeisoften“GenerallyRecognizedasSafe”bytheFDA,itshouldneverbeused

intheAqua-Hot’sHydronicHeatingSystem .Thistypeofantifreezeisnotformulatedtotransferheat,whichisessentialtotheHeatingSystem’sfunctionalityanddoesnotcontainrustinhibitors .Pleasenote,however,thatRV&MarineantifreezecanbeutilizedtowinterizetheAqua-Hot’sDomesticHotWaterHeatingSystem .

Automotive Antifreeze/Coolant:

Thesetypesofpropyleneglycolbasedantifreezeproductsareformulated specifically to protect automotive engines against corrosion,freezingtemperatures,andoverheating .Theyalsohaveexcellentheattransferandthermalconductivitycharacteristics .Althoughthesetypesofantifreezeproductsareconsideredlesstoxicandsaferthanethyleneglycolforpeople,pets,andtheenvironment,theyarenot“GenerallyRecognizedasSafe”(GRAS)ratedbytheFDA .Therefore,theymustbemarkedwitha“harmfulifswallowed”warning .Thisadditionalwarningisrequiredbecausethesetypesofantifreezeproductscontainhighlevelsofchemicalrustinhibitors .Duetotheirpotentiallyhazardousproperties,theyshouldneverbeusedintheAqua-Hot’sHydronicHeat-ingSystem .

A 1

Antifreeze Mixture Water Quality Recommendations

APPENDIX B


APPENDIX B: ANTIFREEZE MIXTURE WATER QUALITy RECOMMENDATIONS

InordertoensuremaximumperformanceandlongevityofanAqua-HotHeatingSystem’sBoilerTankandassociatedcomponents,ithasbeendeterminedthatthereisaneedtousedistilled,de-ionized,orsoftwaterincombinationwithcon-centratedpropyleneglycolfortheAqua-Hot’santifreezeandwaterheatingsolution .Pleasenotethatthisisonlynecessarywhenmixingconcentratedpropyleneglycolantifreezewithwater;suppliersofpre-mixedantifreezeareresponsiblefortheuseofhigh-quality(distilled,de-ionized,orsoft)waterwhenpreparingtheirantifreezeforsale .

Hardwaterpossessesahigh-levelofcalciumandmagnesiumions,whichdepletethepropyleneglycolantifreeze’scorro-sioninhibitors .This,inturn,causestheantifreezeandwaterheatingsolutiontobeginturningacidic,whichcancorrodetheAqua-Hot’sBoilerTankandassociatedcomponentsprema-turely .Therefore,concentratedpropyleneglycolshouldbedilutedwithdistilled,de-ionized,orsoftwaterwhichis80ppmorlessintotalhardness .Thelocalwateragencyshouldhaveup-to-datewaterqualityreportswhichshouldindicatedifthelocaltapwateriswithinthisguideline .

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Antifreeze Terms and Mixture Ratio

APPENDIX C


APPENDIX C: ANTIFREEZE TERMS AND MIXTURE RATIOThefollowinginformationaddressestheprocessofselectinganantifreezeandwatermixtureratiothatprovidesadequateFreeze,Boiling,andRust/Anti-Corrosiveprotection .A50/50mixtureratioisrecommended,whichwillresultinafreezepointofapproximately-28ºFandaboilpointofapproximately222ºF .

Thefollowinginformationshouldbeutilizedforthepurposeofclarifyingsometermscommonlyassociatedwithantifreeze .

Freeze Point and Burst Point:

Antifreezelowersthefreezingpointofanyliquid,towhichithasbeenadded,bypreventingtheformationoficecrystals;however,astheambienttemperaturecontinuestodecline,thewaterinthesolutionwillattempttoattainasolidstate .Thepointinwhichthewaterbeginstosolidifyistermedthe“FreezePoint .”Althoughthewaterinthesolutionhasbeguntofreeze,producinga“slushy”consistency,theantifreezeinthesolutionwillcontinuetocombatthenormalexpansionofthesolutionasitfreezes .Thepointinwhichthesolutioncanbegintoexpand,duetocoldertemperatures,iscalledthe“BurstPoint .”Oncethesolutionreachestheburstpoint,thepotentialispresentforrupturedpipestoexist .Theburstpointoftheantifreezeandwaterheatingsolutionisdependentuponthebrandofpropyleneglycolemployed .

Boiling Point:

TheAqua-Hotutilizestheantifreezeandwaterheatingsolu-tionasatransportationmeansfortheheatproducedfromtheinternalprocesses .Theantifreezeabsorbstheheatcreateduntilitsboilingpointisreached;itisatthispointthattheliquidturnstoagasandisexpelledtopreventtheHeatingSystemfromoverheating .Eachtimetheboilingpointisreached, a loss of efficiency occurs because the heat produced

isexpelledratherthanutilizedforthefunctionoftheheatingsystem .Therefore,ahigherboilingpointisdesiredinorderto combat the loss of efficiency, which allows the antifreeze to transporttheheatcreatedfromtheinternalprocessthroughoutthemotorhomewhereitcanbeutilizedproductivelyratherthandissipatingduetoitschangefromaliquidtoagas . Rust and Anti-Corrosive Inhibitors:

AnothermajorfunctionofantifreezeistoprovideprotectiontotheinternalmetalcomponentsoftheAqua-HotHydronicHeatingSystemfromcorrosionandrust .Antifreezeisabletoperformthisfunctionbytheadditionofrust-andanti-cor-rosive inhibitors, which are designed specifically to activate in awatersolution .

Summary:

Antifreezehasthreebasicfunctions:freezeprotection,boil-overprotection,andanti-corrosionandrustprotection .Antifreezeisalsoprimarilyresponsibleforheattransfer;however,antifreezeitselfdoesnotpossessacceptableheattransfercharacteristics .Therefore,aswaterisanexcellentheatconductor,itisaddedtothemixture .A50/50solutionofpropyleneglycolantifreezeandwaterisrecommendedtoprovidethebestperformancecombinationoftheaforementionedfunctions .Ifexcesspropyleneglycolexistswithinanantifreezeandwaterheatingsolution,thewater’sheatabsorptionpropertiesarecompromised,whichcouldultimatelyinhibittheAqua-Hotfromprovidingadequatedomestichotwaterandinteriorheating .Additionally,iftheantifreezeandwaterheatingsolutioncontainsover70percentantifreeze,thefreezingpointisactuallyraised,resultinginlessfreezeprotection .Pleasereferencetheattachedgraphicalrepresentationregardingthepercentageofantifreezetowaterandhowitdirectlyaffectsthesolution’sfreezingpoint .

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APPENDIX C: ANTIFREEZE TERMS AND MIXTURE RATIO

100-20-40-60 20 30

10%

20%

30%

40%

50%

60%

Freezing Point Temperature

(In Degrees Fahrenheit)

locylG enelyporP fo egatnecreP

noituloS ni

-28 -7 8 19 26

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Date Service Performed Service Center

OWNER’S SERVICE LOG:

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