OWNER`S MANUAL - Aqua-Hot

OWNER`S MANUAL - Aqua-Hot
© 2007 Aqua-Hot Heating Systems Inc.
Owner’s Manual
TABLE OF CONTENTS
Limited Warranty Statement
Introduction
Introduction to the Aqua-Hot Hydronic Heating System. . . . . . . . . . . . . . . . . . . . . . . . Page 2
Operating Instructions
Activating the Aqua-Hot Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zone Thermostat Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Domestic Hot Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Engine Preheat System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aqua-Hot Operational Flow-Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 5
Page 5
Page 5
Page 5
Page 7
Maintenance
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
Winterization
Domestic Hot Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
De-Winterizing the Domestic Hot Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
Troubleshooting
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Electronic Controller Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Diesel-Burner Blinking Fault Indicator Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
Appendices
Appendix A: Antifreeze Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 1
Appendix B: Antifreeze Mixture Water Quality Recommendations. . . . . . . . . . . . . . . B 1
Appendix C: Antifreeze Terms and Mixture Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . C 1
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
2-YEAR LIMITED WARRANTY
AQUA-HOT® HYDRONIC HEATING SYSTEM
AHE-525-D
Aqua-Hot Heating Systems Inc. warrants the Aqua-Hot Heater to be free from defects in material and
workmanship under normal use and service for a period of two years on both parts and labor commencing
upon the original date of registration of the vehicle. Replacement parts are warranted for the remainder of
the Heater’s standard warranty coverage or for six months, whichever is greater.
The intent of this warranty is to protect the Heater’s end-user from such defects, which would occur in
the manufacturing of the product. Thus, problems due to improper specifications, improper installations,
improper use, the use of accessory parts or parts not authorized by Aqua-Hot Heating Systems Inc., repair by
unauthorized persons, and damage or abuse of the Heater are specifically excluded from warranty coverage.
For additional information or to obtain a warranty repair authorization, please contact the Aqua-Hot Heating
Systems Technical Support Department at 1-800-685-4298 (8:00 AM to 5:00 PM Mountain Standard Time)
or visit www.aqua-hot.com.
INTRODUCTION
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.
The Aqua-Hot Heating System is a Hydronic Heating System
(heating with hot water) that provides interior zone heating
where and when it is needed, as well as a continuous,
on-demand supply of domestic hot water. Both heating
features are accomplished by a 12 Volt-DC powered DieselBurner and a 120 Volt-AC powered Electric Heating Element. These two heating sources maintain the temperature of the Aqua-Hot’s antifreeze and water heating solution. In addition,
the Aqua-Hot has been designed to preheat the vehicle’s
engine prior to starting. This preheat feature provides an easy
engine start-up whenever cool weather conditions are present. Be sure to reference Figures 1-A through 1-C for a complete
component overview.
NOTE: This Aqua-Hot product utilizes a propylene glycol
based antifreeze and water heating solution. This
propylene glycol based solution is a Boiler type
Figure 1-A
antifreeze that is “Generally Recognized as Safe”
(GRAS) by the FDA. For additional information regarding this “GRAS” antifreeze product, please
reference Appendix A, contact the Aqua-Hot Heating
Systems Technical Support Department at 1-800-685-4298, or visit the web site at www.aqua-hot.com.
Danger, Warning, Caution, and Note Boxes:
Danger, Warning, Caution, and Note boxes appear throughout
this manual as a means of alerting the operator to important
information.
Indicates that personal injury is likely or imminent.
Indicates that serious damage to the heater will occur and
personal injury is possible as well.
Indicates that damage to the heater is possible.
NOTE: Indicates information that requires special attention
by the operator.
Engine Preheat Inlet
Engine Preheat Outlet
Engine Preheat
Circulation Pump
Access Panel
Pump 2 Zone Outlet
Pump 1 Zone Outlet
Access Cover
Zones 1 and 2
Return Ports
Air Release Valve
Expansion Tank
Connection
Product I.D.
Label
120 Volt-AC
Connection
Domestic Cold
Water Inlet
Domestic Hot
Water Outlet
Diesel Fuel Inlet
Diesel Fuel Outlet
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page Introduction
1
2
3
4
Figure 1-B
5
9
1 - Electric Heating Element HighLimit 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
8 -Circulation Pump - Zone 2
9 - Boiler Tank Stir Pump
6
7
Expansion Tank
Connection
Interlock Switch
Diesel-Burner HighLimit Thermostats
Expansion Tank
Diesel-Burner
Controller
Diesel-Burner
Motor
Diesel-Burner
Figure 1-C
System Drain
Mounting Tray
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page INTRODUCTION
Product I.D. Label
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 window
or 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 for
the 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 inches
Top - 0 inches
Sides - 0 inches
Install in strict compliance with local codes, NFPA 1192, and the manufacturer’s instructions.
Figure 2
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page OPERATING INSTRUCTIONS
Zone Thermostat Operation
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.
Interior Room Thermostat:
Simply adjust each Interior Room Thermostat to the desired
temperature. Then, whenever an Interior Room Thermostat
“calls-for-heat,” the Aqua-Hot’s Circulation Pump and Interior Heat Exchanger Fans will be activated. These
devices, together, will supply warmth and comfort to each
interior heating zone. The Aqua-Hot must be at operating
temperature before zones will function. Please contact the
specific motorhome manufacturer for the exact location of the
Interior Room Thermostats.
Fresh Water Tank Thermostat:
DO NOT operate the Diesel-Burner and/or the Electric Heating Element without the antifreeze and water heating solution
in the Aqua-Hot’s Boiler Tank. Failure to do so will cause
serious damage to the Heater.
Activating the Aqua-Hot Heating System:
Diesel-Burner:
Turn the Diesel-Burner switch ON; reference Figure 3. This procedure will activate the Diesel-Burner and the indicator
light located adjacent to the Diesel-Burner switch. Allow 1020 minutes for the Aqua-Hot System to reach operating temperature. Please note that the Diesel-Burner is the primary
heat source for heating both the interior and the domestic hot
water (such as when cool ambient temperatures exist and/or
when there is a high demand for domestic hot water).
Electric Heating Element:
Turn the Electric Element switch ON; reference Figure 3. This procedure will activate the 120 Volt-AC Electric Heating Element and the indicator light located adjacent to the Electric
Element switch. Allow 1-2 hours for the Aqua-Hot System to
reach operating temperature.
NOTE: The motorhome must be connected to shore power,
or the generator must be running, in order to activate
the Electric Heating Element.
Also, please note that the Electric Heating Element is a secondary heat source for heating both the interior and the
domestic hot water during low heating demand situations
(such as when moderate ambient temperatures exist and/or
when there is a low demand for domestic hot water).
NOTE: Both the Diesel-Burner and the Electric Heating Element are thermostatically controlled. Either, or
both, heating sources will automatically maintain the
temperature of the Aqua-Hot’s antifreeze and water
heating solution between approximately 160ºF and
190˚F (±5). Therefore, to heat the motorhome/domestic hot water, simply choose the desired heat
source(s) and leave the switch(s) (i.e., Diesel-Burner
and/or Electric Element) ON.
Simply adjust the Fresh Water Tank Thermostat for bay
heating to approximately 40ºF. This will prevent freezing of
the domestic water storage system. Please contact the specific
motorhome manufacturer for the exact location of the Fresh
Water Tank Thermostat.
Using the Domestic Hot Water System
When the Aqua-Hot is at operating temperature, the domestic
water is automatically heated as it is being used. Because
the Aqua-Hot does not store any hot water, simply open any
hot water faucet and a continuous supply of hot water will
be present within a few seconds. This hot water feature is
continuous and is accomplished by the Aqua-Hot’s Domestic
Hot Water Heating System. Please note that the Diesel-Burner switch must be ON in order to obtain a continuous supply of
hot water (e.g., during showers); be sure to also activate the
Electric Element switch for maximum hot water capacity.
NOTE: The Aqua-Hot’s “Domestic Water Priority System” disables the interior zone heating fans, zone
circulation pumps, and the engine preheat pump
whenever domestic hot water is being used on a continuous basis (e.g., during showers). Once the demand for continuous domestic hot water ceases,
the Aqua-Hot will enable the fans and pumps to
operate and provide heat to the Heating Zones. Please note that the Electronic Controller’s Low
Temp Cutoff Status indicator light will illuminate
GREEN whenever the Aqua-Hot is able to provide
interior zone heating; reference Figure 7.
Using the Engine Preheat System
When the Aqua-Hot is at operating temperature, and the
Diesel-Burner and/or the Electric Element switch is ON, follow these simple instructions:
1. Turn the Aqua-Hot’s Engine Preheat switch ON;
reference Figure 3. This will activate the Engine Preheat Circulation Pump and circulate the engine’s coolant
through the Engine Preheat System. This feature will
adequately warm the engine for easy start-ups when cool
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page OPERATING INSTRUCTIONS
temperatures exist.
NOTE: Allow approximately 1 to 2 hours of engine preheating run time. The preheat duration will be
shortest when the Diesel-Burner switch is ON.
2. Turn OFF the Aqua-Hot’s Engine Preheat switch
whenever engine preheating is not desired.
NOTE: The Aqua-Hot’s Engine Preheating System acts as
a supplemental heating source, in addition to the
Diesel-Burner and the Electric Heating Element. While traveling, the engine’s heated coolant will
automatically pass through the Engine Preheat
System, transferring heat into the Aqua-Hot’s Boiler
Tank. This design feature reduces the total operating
hours of the Diesel-Burner and the Electric Heating
Element. The Engine Preheat switch does not need
to be on for this supplemental heating system to
function.
Figure 3
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page OPERATING INSTRUCTIONS
Aqua-Hot Operational Flow-Chart
Heating Zone Thermostat
calls for heat.
Engine Preheat switch on the Interior
Switch Panel is activated.
A hot water faucet (e.g., kitchen sink,
shower, etc.) is opened.
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 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.
Continuous hot water is supplied to the
faucet.
The cooled antifreeze and water heating
solution is returned to the Boiler Tank to be
reheated.
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.
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page MAINTENANCE
When the Aqua-Hot is at maximum operating
temperature, the coolant will be very HOT! If the AquaHot’s Heating System is accessed, scalding by hot vapor or
coolant could result!
Expansion Tank; reference Figure 4. Please note that the coolant
level should be checked only when the Aqua-Hot is at maximum
operating temperature (i.e., immediately after the Diesel-Burner
cycles off). When the Aqua-Hot is at maximum operating
temperature, the antifreeze and water heating solution should be at
the level marked “HOT” on the Expansion Tank.
Before cleaning or servicing, disconnect all power supplies!
Replenishing the Antifreeze Solution
DO NOT operate the Diesel-Burner and/or the Electric
Heating Element without the antifreeze and water heating
solution in the Aqua-Hot’s Boiler Tank. Failure to do so will
cause serious damage to the Heater.
Propylene Glycol that is “Generally Recognized As Safe” by
the FDA must be utilized for the antifreeze and water heating
solution.
NOTE: For additional information regarding this propylene
glycol-based, boiler-type antifreeze that has been
“Generally Recognized As Safe” by the FDA, please
reference Appendix A, contact the Aqua-Hot Heating
Systems Technical Support Department at
1-800-685-4298, or visit the web site at www.aqua-hot.com.
Maintenance Schedule
Biannual Maintenance:
Check the Aqua-Hot’s antifreeze and water heating solution to
ensure that it is at the proper level. This can be accomplished
by visually checking the coolant level in the Aqua-Hot’s
If the antifreeze and water heating solution needs replenishing, remove the Expansion Tank’s cap and fill the Expansion Tank to
the “HOT” level mark. When refilling, open the Air Release Valve
located on the Expansion Tank Connection to release air pockets;
reference Figure 1-A. Hold the valve open until all air is released. If necessary, refill the Expansion Tank again. Be sure the valve is
closed when finished by hand tightening. Reference Appendices A
through C to determine the correct ratio of antifreeze to water, the
proper type of antifreeze, and the water quality recommendations
for the Aqua-Hot Hydronic Heating System’s antifreeze and water
heating solution.
Annual Maintenance:
To keep the Aqua-Hot running smoothly, it is ideal to have the
Diesel-Burner tuned-up annually. A tune-up should consist
of a new Fuel Nozzle and Fuel Filter; reference Figure 5. To
ensure maximum Diesel-Burner performance, always use the
recommended Fuel Nozzle and Fuel Filter when replacing these
parts. Reference the Aqua-Hot’s Service and Parts Manual for
spare parts information and detailed replacement instructions,
contact the Aqua-Hot Heating Systems Technical Support
Department at 1-800-685-4298 for assistance or to locate the
nearest Aqua-Hot Service Center, or visit the website at www.
aqua-hot.com.
Figure 4
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page MAINTENANCE
Figure 5
Part Number: FLX-013-150
Part Number: FLE-120-100
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page WINTERIZATION
of FDA-approved RV Antifreeze.
5. Open and close all interior and exterior water faucets,
one at a time, until only pure RV Antifreeze is present. Perform this procedure for both the hot and cold faucets.
Not winterizing the Aqua-Hot when freezing temperatures
exist will result in serious damage to the Aqua-Hot’s
Domestic Water Heating System. Be sure to fill the Aqua-Hot
Domestic Water line with FDA-approved RV antifreeze when
winterizing.
6. Remove the hose and reconnect the domestic water
demand pump’s suction line to the fresh water storage
tank.
NOTE: The Aqua-Hot can still be used for interior zone
heating even if the domestic hot water system has
been drained and winterized.
7. Disconnect all electrical power supplies to the Aqua-Hot
during storage.
Domestic Water System
De-Winterizing the Domestic Hot Water Heating System:
The Aqua-Hot’s Domestic Water Heating System must be
completely drained of domestic water any time the heater is
stored where freezing temperatures may be experienced.
For de-winterization, completely fill the fresh water storage
tank. Open and close all interior and exterior water faucets,
one at a time, until only clear water is present/visible. Reference Figure 6.
Winterizing the Domestic Water Heating System:
Please follow these instructions when winterizing the
Aqua-Hot’s Domestic Hot Water Heating System; reference
Figure 6.
1. Completely drain the fresh water storage tank.
If disinfecting the potable water system after de-winterizing,
be sure to follow RVIA’s “Instructions for Disinfection of
Potable Water Systems on Recreation Vehicles.” These
instructions can be obtained by contacting the Recreational
Vehicle Industry Association at (703) 620-6003, visiting them
online at www.rvia.com, or writing to them at the following
address:
2. Disconnect the domestic water demand pump’s suction
line from the fresh water storage tank.
3. Attach an adequate piece of hose onto the suction side of
the domestic water demand pump.
Recreation Vehicle Industry Association
1896 Preston White Drive
P.O. Box 2999
Reston, VA 20195-0999
4. Place the opposite end of the hose into an adequate supply
Arrows indicate directional flow of
domestic water
To Hot Water Faucets
Domestic
Hot Water
OUTLET
Domestic
Cold Water
INLET
Fresh
Water Storage
Tank
Figure 6
To Cold Water
Faucets
Demand
Pump
RV
Antifreeze
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.
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page 10
TROUBLESHOOTING
General Information
Should the Aqua-Hot Hydronic Heating System fail to
operate, complete the following checks:
1) Check the Interior Switch Panel for a blinking indicator
light on the Diesel-Burner switch; reference Figure
3. If the indicator light is blinking, count the number
of consecutive flashes, record the number, and contact
the Aqua-Hot Heating Systems Technical Support
Department at 1-800-685-4298.
2) Check the Aqua-Hot’s Electronic Controller for any RED
lights, which indicate a fault condition. Reference Figure
7 and the Electronic Controller Diagnosis section to
identify these fault conditions.
2) Verify that the Aqua-Hot’s access cover is securely
installed. The Aqua-Hot Hydronic Heating System will
not operate if the access cover is not completely installed.
3) Ensure that the vehicle’s fuel tank contains a sufficient
level of fuel.
4) Ensure that the Aqua-Hot’s boiler tank has an adequate
supply of antifreeze and water heating solution by
checking the level at the Expansion Tank. If the level is
low, reference the “Maintenance” section of this manual
for refilling instructions.
If the Aqua-Hot Heating System’s failure to operate is not
resolved with the aforementioned checks, please contact the
Aqua-Hot Heating Systems Technical Support Department at
1-800-685-4298 for additional assistance or visit the web site
at www.aqua-hot.com.
Electronic Controller Diagnosis
Low Tank-Level Cutoff Indicator Light:
This indicator light will illuminate RED when either the 120
Volt-AC Electric Heating Element and/or Diesel-Burner have
automatically shut down due to a low antifreeze and water
heating solution level inside the Aqua-Hot’s Boiler Tank. This
fault will automatically reset when the low-level condition is
corrected.
Low Battery Voltage Fault Indicator Light:
This indicator light will illuminate RED and the Diesel-Burner
will shut down whenever the 12 Volt-DC voltage level falls
below 10.5 volts, which is too low for the Aqua-Hot to operate
properly. This fault must be manually reset after the voltage
level has been restored to the 12 Volt-DC battery system;
reference the Low Voltage information below.
Low Voltage Fault Indicator Light and Reset Button:
The Aqua-Hot’s Electronic Controller must be manually reset
whenever the Low Battery Voltage Fault indicator light has
been activated. The Electronic Controller can be reset either
by turning OFF the Diesel-Burner switch on the Heater’s
Interior Switch Panel for approximately 30 seconds, then
turning the switch back ON or by pressing the “Low Voltage
Reset” button located on the Electronic Controller (use a thin,
straight, nonmetallic object to access the reset button through
the small hole in the faceplate).
Overload Fault Indicator Light:
This indicator light will illuminate RED whenever one of the
following conditions have occurred:
A. The Aqua-Hot is off due to an electrical overload (i.e.,
short) in the main 12 Volt-DC power supply circuitry.
B. The Aqua-Hot is off due to a combination of high
electrical 12 Volt-DC power loads and a high surface
temperature of the Electronic Controller.
The Aqua-Hot will automatically restart once the electrical
overload (i.e., short) and/or high-heat condition is corrected.
Heating Zones Status Indicator Lights:
These five indicator lights (separately) will illuminate
GREEN whenever a Zone Thermostat is calling for heat. The
GREEN indicator lights also indicate that 12 Volt-DC power
is being supplied to the particular interior heating zone’s Heat
Exchangers (i.e., fan motors). A short in either a heating
zone’s Interior Room Thermostat or a heating zone’s Heat
Exchanger circuit will cause a heating zone’s indicator light to
illuminate RED.
NOTE: The Low Temp Cutoff Light must be illuminated and
the heater must be up to operating temperature for zone heat to be supplied.
Pumps #1, #2, and #3 Indicator Lights:
These indicator lights (separately) will illuminate GREEN
whenever a Circulation Pump is operating. If any of the three
indicator lights illuminate RED, it indicates that an electrical
overload condition (i.e., short) has occurred in the particular
component’s circuitry.
NOTE: Zone Circulation Pumps #1 and #2 are activated
whenever a Zone Thermostat calls for heat. The
Circulation Pump #3/Boiler Tank Stir Pump is
activated whenever the Domestic Water is being
used on a continuous basis or the heater is not up to
operating temperature.
Engine Preheat Pump Indicator Light:
This indicator light will illuminate GREEN whenever the Engine Preheat Circulation Pump is operating. Please note
that this light will only be active if the Engine Preheat switch
is ON in conjunction with either the Diesel-Burner and/or the
Electric Element switch. If this indicator light illuminates
RED, it indicates an electrical overload condition (i.e., short)
has occurred in this particular component’s circuitry.
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page 11
TROUBLESHOOTING
NOTE: The Aqua-Hot must be up to operating temperature
and the Low Temp Cutoff Light must be illuminated
for the engine preheat feature to function.
Heating Status Indicator Light:
This indicator light will illuminate GREEN whenever the
Aqua-Hot’s VDC/VAC Control Thermostat calls for the
Diesel-Burner and/or Electric Element to heat the antifreeze
and water heating solution in the Aqua-Hot’s Boiler Tank. When this indicator light is off, no heat is being supplied
to the Aqua-Hot’s Boiler Tank by either of these two heat
sources.
NOTE: The Aqua-Hot’s VDC/VAC Control Thermostat will
automatically activate the Diesel-Burner and/or the
Electric Heating Element only if the Diesel-Burner
and/or Electric Element switch is in the ON position. Therefore, to heat the motorhome/domestic hot water,
simply choose the desired heat source(s) and leave
the switch(s) (i.e., Diesel-Burner and/or Electric
Element) ON.
Electric Heating Element Status Indicator Light:
This indicator light will illuminate GREEN whenever the Aqua-Hot’s Electric Heating Element is operating and
providing heat to the Aqua-Hot’s Boiler Tank. Please note that
this light will only be active if the Electric Element switch is
in the ON position. If this indicator light illuminates RED,
it indicates that an electrical overload condition (i.e., short)
has occurred in the Electric Heating Element’s 12 Volt-DC
powered circuitry.
Diesel-Burner Blinking Fault Indicator Light
The Interior Switch Panel incorporates a self-diagnostic
Blinking Fault Indicator Light that uses a series of blinking
lights to indicate a component failure during the DieselBurner’s operation.
Each series of blinks are active for 0.5 seconds “ON” and 0.5
seconds “OFF” with a three-second interval between each
Fault Series. This sequence will repeat continuously until the
Diesel-Burner switch is moved to the “OFF” position, the
12 Volt-DC power is disconnected from the Diesel-Burner’s
Controller, or the Aqua-Hot’s access cover is removed.
Should a Diesel-Burner malfunction occur, the Aqua-Hot
Hydronic Heating System will cease operation and will
activate the appropriate Indicator Light Blinking Fault
Sequence. Count the number of flashes, record the number,
and contact the Aqua-Hot Heating Systems Technical Support
Department at 1-800-685-4298.
Figure 7
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
Page 12
APPENDIX A
Antifreeze Types
Appendix A: Antifreeze Types
The following information addresses the necessary usage
of a propylene glycol based “boiler” type antifreeze in the
Aqua-Hot. 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 should be utilized.
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. Please note, however, that RV & Marine antifreeze
can be utilized to winterize the Aqua-Hot’s Domestic Hot
Water Heating System.
Because of the significant impact various types of antifreeze
can have on a Hydronic Heating System, including the level
of safety provided, it has been recognized that there is 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:
These types 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 “Generally
Recognized as Safe” (GRAS) 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.
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
Automotive Antifreeze/Coolant:
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
A
APPENDIX B
Antifreeze Mixture Water
Quality Recommendations
Appendix B: Antifreeze Mixture Water Quality Recommendations
In order to ensure maximum performance and longevity of
an Aqua-Hot Heating System’s Boiler Tank and associated
components, it has been determined that there is a need to use
distilled, de-ionized, or soft water in combination with concentrated propylene glycol for the Aqua-Hot’s antifreeze and
water heating solution. Please note that this is only necessary
when mixing concentrated propylene glycol antifreeze with
water; suppliers of pre-mixed antifreeze are responsible for the
use of high-quality (distilled, de-ionized, or soft) water when
preparing their antifreeze for sale.
Hard water possesses a high-level of calcium and magnesium
ions, which deplete the propylene glycol antifreeze’s corrosion inhibitors. This, in turn, causes the antifreeze and water
heating solution to begin turning acidic, which can corrode the
Aqua-Hot’s Boiler Tank and associated components prematurely. Therefore, concentrated propylene glycol should be
diluted with distilled, de-ionized, or soft water which is 80
ppm or less in total hardness. The local water agency should
have up-to-date water quality reports which should indicated if
the local tap water is within this guideline.
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
B
APPENDIX C
Antifreeze Terms
and Mixture Ratio
APPENDIX C: Antifreeze Terms and Mixture Ratio
The following information addresses the process of selecting
an antifreeze and water mixture ratio that provides adequate
Freeze, Boiling, and Rust/Anti-Corrosive protection. A 50/50 mixture ratio is recommended, which will result in a freeze
point of approximately -28ºF and a boil point of approximately 222ºF.
is expelled rather than utilized for the function of the heating
system. Therefore, a higher boiling point is desired in order
to combat the loss of efficiency, which allows the antifreeze to
transport the heat created from the internal process throughout
the motorhome where it can be utilized productively rather
than dissipating due to its change from a liquid to a gas.
The following information should be utilized for the purpose
of clarifying some terms commonly associated with antifreeze.
Rust and Anti-Corrosive Inhibitors:
Freeze Point and Burst Point:
Antifreeze lowers the freezing point of any liquid, to which it
has been added, by preventing the formation of ice crystals;
however, as the ambient temperature continues to decline,
the water in the solution will attempt to attain a solid state. The point in which the water begins to solidify is termed the
“Freeze Point.” Although the water in the solution has begun
to freeze, producing a “slushy” consistency, the antifreeze in
the solution will continue to combat the normal expansion
of the solution as it freezes. The point in which the solution
can begin to expand, due to colder temperatures, is called the
“Burst Point.” Once the solution reaches the burst point, the
potential is present for ruptured pipes to exist. The burst point
of the antifreeze and water heating solution is dependent upon
the brand of propylene glycol employed.
Boiling Point:
The Aqua-Hot utilizes the antifreeze and water heating solution as a transportation means for the heat produced from the
internal processes. The antifreeze absorbs the heat created
until its boiling point is reached; it is at this point that the
liquid turns to a gas and is expelled to prevent the Heating
System from overheating. Each time the boiling point is
reached, a loss of efficiency occurs because the heat produced
Another major function of antifreeze is to provide protection
to the internal metal components of the Aqua-Hot Hydronic
Heating System from corrosion and rust. Antifreeze is able
to perform this function by the addition of rust- and anti-corrosive inhibitors, which are designed specifically to activate in
a water solution.
Summary:
Antifreeze has three basic functions: freeze protection, boilover protection, and anti-corrosion and rust protection. Antifreeze is also primarily responsible for heat transfer;
however, antifreeze itself does not possess acceptable heat
transfer characteristics. Therefore, as water is an excellent
heat conductor, it is added to the mixture. A 50/50 solution 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 from providing adequate
domestic hot water and interior heating. Additionally, if the
antifreeze and water heating solution contains over 70 percent
antifreeze, the freezing point is actually raised, resulting in
less freeze protection. Please reference the attached graphical
representation regarding the percentage of antifreeze to water
and how it directly affects the solution’s freezing point.
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
C
Percentage of Propylene Glycol
in Solution
APPENDIX C: ANTIFREEZE TERMS AND MIXTURE RATIO
60%
50%
40%
30%
20%
10%
-7
-28
-60
-40
-20
8
0
10
19
20
26
30
Freezing Point Temperature
(In Degrees Fahrenheit)
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
C
OWNER’S SERVICE LOG:
Date
Service Performed
Service Center
15549 East Highway 52 • Fort Lupton, Colorado 80621
1.800.685.4298 • Fax: 303.857.9000 • www.aqua-hot.com
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