owner`s manual - Aqua-Hot
®
OWNER’S MANUAL
Model Number
HHE-200-08E - 12 VDC.
HHE-500-08M - 12 VDC.
OWNER’S INFORMATION
Owner’s Name:
Address:
CUT HERE AND MAIL IN
City:
State:
Zip Code:
Telephone:
E-mail Address:
Motorhome Model:
Date of Purchase (Motorhome):
Hydro-Hot Model No. (reference Figure 1 “Marking Plate”):
Hydro-Hot Serial No. (reference Figure 1 “Marking Plate”):
Please Mail To:
Vehicle Systems’ Warranty Department
15549 East Highway 52
Ft. Lupton, CO 80621
Vehicle Systems, Inc.
Warranty Department
15549 East Highway 52
Ft. Lupton, CO 80621
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
TABLE OF CONTENTS
Section 1
Overview
1.0
Section 2
Operating Instructions
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Section 3
Maintenance Schedule ........................................................................... 13
Winterization
4.1
Section 5
Activating the Hydro-Hot Heating System ........................................ 4
Zone Thermostat(s) Operation ............................................................... 6
Using the Domestic Hot Water System ............................................... 6
Using the Engine Preheat System ......................................................... 7
Diesel-Burner Component Overview .................................................. 9
Diesel-Burner Operational Flow-Chart .............................................. 10
Precautions.................................................................................................. 12
Maintenance
3.1
Section 4
Hydro-Hot Overview.................................................................................. 1
Domestic Hot Water System ................................................................. 15
Troubleshooting
5.1
5.2
General Information................................................................................. 17
Electronic Controller Diagnostic.......................................................... 18
SECTION 1: OVERVIEW
Hydro-Hot
Overview
1.0 Activating the Hydro-Hot Heating System
The Hydro-Hot Heating System is an on-board Hydronic Heating System (heating
with hot water) that provides a continuous, on-demand supply of domestic hot
water, as well as interior zone heating where and when it is needed. Both heating features are accomplished by a unique VDC-Powered Diesel-Fired Burner and
a VAC-Powered Electric Heating Element (120 VAC). These two heating sources
maintain the temperature of the Hydro-Hot’s solution of water and antifreeze. In
addition, the Hydro-Hot has been designed to preheat the vehicle’s engine prior to
starting (HHE-200 Model Only). This preheat feature provides an easy engine startup whenever cool weather conditions are present. Be sure to review Figure 1A and
1B for complete component overview.
NOTE: This Hydro-Hot product utilizes a Propylene Glycol (P.G.) based water
and antifreeze solution. This P.G. based solution is a Boiler type antifreeze,
which is Generally Recognized as Safe (“GRAS”) by the FDA. For additional information regarding this GRAS antifreeze product, please contact us at 1-800685-4298 or visit our website at www.vehiclesys.com.
Page 1
©
Hydro-Hot Motor Coach Heating System Owner’s Manual 08/03
SECTION 1: OVERVIEW
Hydro-Hot
Overview,
continued
Figure 1A
Page 2
SECTION 1: OVERVIEW
Hydro-Hot
Overview,
continued
Figure 1B
Page 3
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
SECTION 2: OPERATING INSTRUCTIONS
Heat
Sources
Please read the complete Owner’s Manual prior to operating your Hydro-Hot
Heating System. Also, be sure to fill out and mail in your Owner’s Information Card
located at the front of this manual.
2.1 Activating the Hydro-Hot Heating System
Diesel-Burner
Turn the Diesel switch ON, reference Figure 2. This procedure will activate the
Diesel-Burner and the indicator light located on the Diesel switch. Allow 10-20
minutes for the Hydro-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 switch ON, reference Figure 2. This procedure will activate
the 120 VAC Electric Heating Element and the indicator light located on the
Electric switch. Allow 1-2 hours for the Hydro-Hot System to reach operating
temperature.
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 tempera-tures exist and/
or when there is a low demand for domestic hot water).
NOTE: Both the Diesel-Burner and the Electric Heating Element are ther-
Page 4
SECTION 2: OPERATING INSTRUCTIONS
Heat
Sources,
continued
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 Hydro-Hot’s water and antifreeze solution
between approximately 160-190 (+/- 5) degrees Fahrenheit. So to heat your
motorhome / domestic hot water, simply choose the desired heat source(s)
and leave the switch(s) (i.e. Diesel and/or Electric) ON.
Page 5
©
Hydro-Hot Motor Coach Heating System Owner’s Manual 08/03
SECTION 2: OPERATING INSTRUCTIONS
Comfort
Control
2.2 Zone Thermostat(s) Operation
Interior Room Thermostats
Simply adjust each Interior Room Thermostat to the desired temperature. Then
whenever an Interior Room Thermostat “calls-for-heat”, the Hydro-Hot’s Circulation Pump(s) and Interior Heat Exchanger Fans will be activated. These devices
together will supply warmth and comfort to each interior heating zone. Please
contact your specific motorhome manufacturer for the exact location of the
Interior Room Thermostat(s).
Fresh Water Tank Thermostat
Simply adjust the Thermostat (i.e. Bay Heating) to approximately 40 degrees
Fahrenheit. This will prevent freezing of the domestic water storage system.
Please contact your specific motorhome manufacturer for the exact location of
the Fresh Water Tank Thermostat.
Hot Water
2.3 Using the Domestic Hot Water System
When the Hydro-Hot is at operating temperature, the domestic water is
automatically heated as it is being used. Because the Hydro-Hot does not
store any hot water, simply open any hot water faucet and a continuous
supply of domestic hot water will be present within a few seconds. This
hot water feature is continuous and is accomplished by the Hydro-Hot’s
Domestic Hot Water Heating System. Please note that the Diesel
switch must be ON to get an unlimited supply of hot water (i.e. during
showers).
Page 6
SECTION 2: OPERATING INSTRUCTIONS
Hot Water,
continued
Engine
Preheat
NOTE: The Hydro-Hot’s “Domestic Water Priority System” disables
the interior Zone Heating Fans, Zone Circulation Pumps, and the
Engine Preheat Pump (if applicable) whenever domestic hot water is
being used on a continuous basis (i.e. during showers). Once the
demand for continuous domestic hot water ceases the Hydro-Hot
will enable the Fans and Pumps to operate and provide heat to the
Heating Zones. Please note that the Electronic Controller’s Low
Temperature Cuttoff Status indicator light will illuminate GREEN
whenever the Hydro-Hot is able to provide zone heating, reference
Figure 5.
2.4 Using the Engine Preheat System
Engine Preheat (HHE-200 Model Only)
When the Hydro-Hot is at operating temperature, and the Diesel-Burner
and/or the 120 VAC Electric Heating Element switch is ON, follow these simple
instructions:
A. Turn the Hydro-Hot’s Engine Preheat switch ON, reference Figure 2.
This procedure 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 on
cool mornings.
Page 7
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
SECTION 2: OPERATING INSTRUCTIONS
Engine
Preheat,
continued
NOTE: Allow approximately 1 to 2 hours of engine preheating run time. Preheat duration will be shortest when the Diesel switch is ON.
B. Turn OFF the Aqua-Hot’s Engine Preheat switch whenever engine
preheating is not desired.
NOTE: The Hydro-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 / Motoraide System, transferring heat into the Hydro-Hot’s
Boiler Tank. This design feature reduces the total operating hours of the Diesel-Burner and the Electric Heating Element.
Figure 2
Page 8
SECTION 2: OPERATING INSTRUCTIONS
DieselBurner
Component
Overview
2.5 Diesel-Burner Component Overview
1.
2.
3.
4.
5.
Control Unit
Motor
Ignition Coil
Clutch
Combustion Air Blower
6.
7.
8.
9.
10.
Fuel Solenoid
Electrode Holder
Ignition Electrodes
Fuel Nozzle
Heat Exchanger
11.
12.
13.
14.
15.
16.
Combustion Chamber
Exhaust Port
Flame Sensor
Fuel Pump
Fuel Ports (Supply / Return)
Combustion Air Intake Port,
with Adjustable Shutter
Figure 3
Page 9
©
Hydro-Hot Motor Coach Heating System Owner’s Manual 08/03
SECTION 2: OPERATING INSTRUCTIONS
DieselBurner
Operational
Flow-Chart
2.6 Diesel-Burner Operational Flow-Chart
~ Reference Figure 3 for all numbers indicated inside parenthesis. (e.g. #8).
Page 10
SECTION 2: OPERATING INSTRUCTIONS
DieselBurner
Operational
Flow-Chart,
continued
2.6 Diesel-Burner Operational Flow-Chart, continued
Page 11
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
SECTION 2: OPERATING INSTRUCTIONS
Important
Information
2.7 Precautions
WARNINGS:
• The Hydro-Hot’s Exhaust is HOT!
• DO NOT park in areas where dry conditions exist underneath the vehicle, as a fire may result (i.e. in a dry grassy field for example).
• DO NOT operate the Hydro-Hot’s Diesel-Fired Burner inside an enclosed
building.
• The Heater should be switched OFF when refueling.
CAUTION: DO NOT operate the Diesel-Burner and/or the Electric Heating Element without the water and antifreeze solution in the Hydro-Hot’s Boiler Tank.
Failure to do so will cause serious damage to the Heater.
Page 12
SECTION 3: MAINTENANCE
Upkeep
3.1 Maintenance Schedule
Monthly
Check the Hydro-Hot’s solution of water and antifreeze to ensure that it is at
the proper level. Do this by visually checking the coolant level in the Hydro-Hot’s Expansion Tank, reference Figure 1A. Please note that the coolant
level should be checked only when the Hydro-Hot is at maximum operating
temperature (i.e. when the Diesel-Burner cycles OFF), “HOT.”
WARNING: When the Hydro-Hot is at maximum operating temperature (HOT),
DO NOT loosen the Radiator Cap. If removed, scalding by hot vapor or coolant
could result.
NOTE: This Hydro-Hot product utilizes a Propylene Glycol (P.G.) based water
and antifreeze solution. This P.G. based solution is a Boiler type antifreeze,
which is Generally Recognized as Safe (“GRAS”) by the FDA. For additional
information regarding this GRAS antifreeze product, please contact us at 1-800685-4298 or visit our website at www.vehiclesys.com.
If the coolant needs replenishing, fill the Hydro-Hot’s Expansion Tank to the
FULL HOT level mark. Be sure to use a 50/50 mixture of water and (P.G.) antifreeze.
Page 13
©
Hydro-Hot Motor Coach Heating System Owner’s Manual 08/03
SECTION 3: MAINTENANCE
Upkeep,
continued
Annually
WARNING: Before cleaning or servicing, disconnect all power supplies.
To keep your Hydro-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,
along with a thorough cleaning of the Combustion Chamber, if necessary (reference Figure 4). To ensure maximum Diesel-Burner performance, always use the
recommended Fuel Nozzle (i.e. 0.35 GPH) and Fuel Filter (i.e. 10 Micron) when
replacing these parts. Reference the Hydro-Hot “Parts Manual” for spare parts
information. If detailed replacement instructions are needed, please reference
the Hydro-Hot “Shop Manual” for your specific model of Hydro-Hot, or contact our
Technical Department at 1-800-685-4298 for the nearest Hydro-Hot Service Center.
CAUTION: DO NOT operate the Diesel-Burner and/or the Electric Heating Element
without the water and antifreeze solution in the Hydro-Hot’s Boiler Tank. Failure to do
so will cause serious damage to the Heater.
Figure 4
Page 14
SECTION 4: WINTERIZATION
Storage
4.1 Domestic Hot Water System
The Hydro-Hot’s Domestic Hot Water Heating System must be completely drained
of domestic water any time the heater is stored where freezing temperatures may
be experienced.
CAUTION: Not winterizing your Hydro-Hot, when freezing temperatures are
present, will result in serious damage to the Hydro-Hot’s Domestic Hot Water
Heating System.
NOTE: The Hydro-Hot can still be used for interior zone heating even if the
domestic hot water system has been drained and winterized.
Please follow the instructions listed below when winterizing the Hydro-Hot’s
Domestic Hot Water Heating System:
A. Completely drain the fresh water storage tank.
NOTE: If your motorhome is equipped with appliances that use fresh water (i.e.
ice makers, water purifiers, etc.) follow the manufacturer’s recommendation for
winterization.
B. Disconnect the domestic water demand pump’s suction line from the fresh
water storage tank.
Page 15
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
SECTION 4: WINTERIZATION
Storage,
continued
C. Attach an adequate piece of hose onto the suction side of the domestic water
demand pump.
D. Place the opposite end of the hose into an adequate supply of FDA approved
RV-Antifreeze.
E. Open / 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.
F.
Remove the hose and reconnect the domestic water demand pump’s suction
line to the fresh water storage tank.
G. Disconnect all electrical power supplies to the Hydro-Hot during storage.
NOTE: For de-winterization, completely fill the fresh water storage tank. Open
/ close all interior and exterior water faucets, one at a time, until only clear
water is present / visible.
CAUTION: If you’re disinfecting your potable water system, after de-winterizing, be sure to follow RVIA’s “Instruction for Disinfection of Potable Water
Systems on Recreation Vehicles.” These instructions can be found in the ANSI
A119.2 Handbook for Recreational Vehicle Standards. To receive a copy of this
RVIA Standard, write to: Recreation Vehicle Industry Association, 1896 Preston
White Drive, P.O. Box 2999, Reston, VA 20195-0999, or visit the RVIA website at
www.rvia.com.
Page 16
SECTION 5: TROUBLESHOOTING
General
Information
5.1 General Information
If the Hydro-Hot’s Diesel switch “Indicator Light” does not illuminate, and the
Diesel-Burner is not functioning, locate the Electronic Controller (Figure 5) and
check the following:
A. Check the Hydro-Hot’s Electronic Controller for any RED lights indicating a
fault condition. Reference Figure 5 and the Electronic Controller Troubleshooting section to identify these fault conditions.
B. Check for loose wire connections on the Electronic Controller’s Plug terminals.
When checking for loose plug terminals, remove the Electronic Controller
Faceplate by unscrewing the four cover screws.
C. Remove the Hydro-Hot’s Access Cover and check for loose plug connectors on
the Diesel-Burner’s Control Unit (located on the under side), see Figure 1A.
D. Check to ensure that the vehicle’s fuel tank has a sufficient level of fuel.
E. If your Hydro-Hot still fails to operate, please contact our Technical Support
Department at 1-800-685-4298 for additional troubleshooting assistance or
visit our website at www.hydro-hot.com.
Page 17
©
Hydro-Hot Motor Coach Heating System Owner’s Manual 08/03
SECTION 5:
Electronic
Controller
TROUBLESHOOTING
5.2 Electronic Controller Diagnostic
Figure 5
Page 18
SECTION 5:
Electronic
Controller,
continued
TROUBLESHOOTING
Low Tank-Level Cutoff Indicator Light:
This indicator light will illuminate RED when either the 120 VAC Electric Heating
Element and/or Diesel-Burner have automatically shutdown due to a low water and
antifreeze solution level inside the Hydro-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 whenever the VDC voltage level is too low
for the Hydro-Hot to operate properly. This fault must be manually reset after the
voltage level has been restored to the VDC battery system, see Low Voltage Reset
below.
Low Voltage Reset (Button):
The Hydro-Hot’s Electronic Controller must be manually reset whenever the Low
Battery Voltage Fault indicator light has been activated. To reset the Electronic
Controller, simply depress 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).
Overload Fault Indicator Light:
This indicator light will illuminate RED whenever one of the following conditions
have occurred:
1. The Hydro-Hot is off due to an electrical overload (i.e. short) in the main VDC
power supply circuitry.
2. The Hydro-Hot is off due to a combination of high electrical VDC power loads
and a high surface temperature of the Electronic Controller.
Page 19
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
SECTION 5:
Electronic
Controller,
continued
TROUBLESHOOTING
The Hydro-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, for each particular zone, is calling for heat. The GREEN indicator lights
also indicate that VDC power is being supplied to the particular interior heating
zone’s Heat Exchangers (i.e. fan motors). If any of the five indicator lights illuminate RED, it indicates that an electrical overload condition (i.e. short) has occurred
in a particular heating zone’s circuitry.
NOTE: A short in either a heating zone’s Interior Room Thermostat or heating
zone’s Heat Exchanger circuit, will cause the indicator light to illuminate RED.
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: The Zone Circulation Pumps #1 and #2 are activated whenever a Zone
Thermostat calls for heat. Pump #3 / Stir Pump is activated whenever the Domestic Water is being used on a continuous basis.
Page 20
SECTION 5:
Electronic
Controller,
continued
TROUBLESHOOTING
Engine Preheat Pump Indicator Light: (HHE-200 Model Only)
This indicator light will illuminate GREEN whenever the Engine Preheat 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 and/or the Electric switch. If this
indicator light illuminates RED, it indicates an electrical overload condition (i.e.
short) has occurred in this particular component’s circuitry.
Heating Status Indicator Light:
This indicator light will illuminate GREEN whenever the Hydro-Hot’s VDC / VAC
Control Thermostat is calling for heat, allowing the water and antifreeze solution
in the Hydro-Hot’s Boiler Tank to be heated by either the Diesel-Burner and/or the
Electric Heating Element. When this indicator light is off, no heat is being supplied
to the Hydro-Hot’s Boiler Tank.
NOTE: The Hydro-Hot’s VDC / VAC Control Thermostat will automatically
activate the Diesel-Burner and/or the Electric Heating Element, only if the
Diesel and/or Electric switch is in the ON position. So to heat your motorhome
/ domestic hot water, simply choose the desired heat source(s) and leave the
switch(s) (i.e. Diesel and/or Electric) ON.
Page 21
©
Hydro-Hot Motor Coach Heating System Owner’s Manual 08/03
SECTION 5:
Electronic
Controller,
continued
TROUBLESHOOTING
Electric Heating Element Status Indicator Light:
This indicator light will illuminate GREEN whenever the Hydro-Hot’s Electric Heating Element is operating and providing heat to the Hydro-Hot’s Boiler Tank. Please
note that this light will only be active if the Electric switch is in the ON position. If
this indicator light illuminates RED, it indicates an electrical overload condition (i.e.
short) has occurred in the Electric Heating Element’s VDC powered circuitry.
Page 22
WARRANTY INFORMATION
- FOR HYDRO-HOT MODELS Vehicle Systems Inc. warrants the HYDRO-HOT Heater to be free from defects in material and workmanship under normal use and service for a period of two (2) years on both parts and labor commencing upon
the original date of registration of the vehicle. The warranty period may not however, exceed 36 months
from the orignal date of delivery by Vehicle Systems, Inc. Replacement parts are warranted for the remainder of the Heater’s standard warranty period or for six months (180 days), whichever is greater.
This warranty is conditional upon proper use of the Heater by the end-user. This warranty does not apply
to damage or failure of the HYDRO-HOT Heater, or the vehicle into which it was installed, due to improper
installation, assembly, maintenance, abuse, neglect, accident, or the use of parts not supplied by Vehicle
Systems Inc. Vehicle Systems is not responsible for incidental or consequential damages.
The intent of this warranty is to protect the end-user of the heating system from such defects, which
would occur in the manufacture of the product. The warranty is not intended to protect the end-user
from problems, which are outside the ability of Vehicle Systems’ control.
To obtain warranty repair authorization or for additional product information, please contact our Technical
Support Department at 1-800-685-4298 (8 AM to 5 PM Mountain Standard Time).
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
OWNER’S SERVICE LOG:
Date
(Continued)
Date
Service Performed
Service Center
OWNER’S SERVICE LOG:
Service Performed
Hydro-Hot © Motor Coach Heating System Owner’s Manual 08/03
Service Center
Motor Coach Heating Specialists • Manufacturers and Distributors
15549 East Highway 52 • Fort Lupton, Colorado 80621 • 1-800-685-4298 • Fax: 303-857-9000
© Copyright 2003 Vehicle Systems, Inc. All rights reserved
www.vehiclesys.com
LTE-VHS-224
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