Owner s anual - Aqua-Hot€¦ · 2-YEAR LIMITED WARRANTY AQUA-HOT® HYDRONIC HEATING SYSTEM...
Transcript of Owner s anual - Aqua-Hot€¦ · 2-YEAR LIMITED WARRANTY AQUA-HOT® HYDRONIC HEATING SYSTEM...
Owner’s Manual© 2007 Aqua-Hot Heating Systems Inc.
© 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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage �
INTRODUCTION
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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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage 5
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 .
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage �
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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage 7
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.
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage �
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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage �
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. APage 10
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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage 11
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 .
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. APage 12
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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. 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 .
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Antifreeze Mixture Water Quality Recommendations
APPENDIX B
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
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
© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
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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© 2007 Aqua-Hot® 525-D Hydronic Heating System Owner’s Manual Rev. A
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:
15549 East Highway 52 • Fort Lupton, Colorado 806211.800.685.4298 • Fax: 303.857.9000 • www.aqua-hot.com