AHE-100-02S SERVICE MANUAL © 2011 Aqua-Hot Heating Systems Inc.
© 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
Table of Contents Section 1: Introduction to the Aqua-Hot AHE-100-02S Introduction ............................................................................................................... ..Page 6-7 Danger, Warning, Caution, and Note Box Definitions................................................... ...Page 6 Section 2: Aqua-Hot Hydronic Heating System Overview Technical Information ................................................................................................... ...Page 8 I.D.
Table of Contents Section 6: Diesel-Burner Overview ................................................................................................................ Page 33-38 I.D. Plate ...................................................................................................................... Page 33 Diesel-Burner Overview ......................................................................................... Page 33-34 Diesel-Burner Operational Flow Chart .....................................
This Page Left Blank Intentionally © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 1: INTRODUCTION This service and parts manual is designed to aid trained and qualified service technicians with the process of troubleshooting and servicing the Aqua-Hot AHE-100-02S Hydronic heating system. The Aqua-Hot AHE-100-02S heating system features a 12 Volt-DC powered diesel-burner and a 120 Volt-AC, 1650 Watt electric heating element.
SECTION 1: INTRODUCTION Engine Preheat System: The engine preheat system is responsible for heating the motor home’s engine block in order to make it easier to start-up when cool weather conditions exist. When the engine preheat system is activated via the interior switch, the motor home’s engine coolant is circulated through a dedicated copper coil in the Aqua-Hot’s boiler tank, where heat from the antifreeze and water heating solution is transferred to the motor home’s engine coolant.
SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Figure 1 Aqua-Hot AHE-100-02S Technical Specifications Diesel-Burner, Heat Input (Firing Rate) ................................................................................................................................................ 50,000 BTU/hr Diesel-Burner, Fuel Consumption (Continuous Operation) ......................................................................................................................0.
SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Figure 2 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Figure 3 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Heat Source is selected “Diesel Burner” Switch Turned On “Electric Element” Switch Turned On Diesel-Burner heat source selected by Diesel-Burner Switch Electric Heating Element heat source selected by Electric Element Switch Diesel-Burner fires into the Combustion Chamber, which heats the antifreeze and water heating solution in the Boiler Tank Electric Heating Element activates, which heats the antifreeze and water heating solution in the Boiler tank Boiler T
SECTION 3: INTERIOR SWITCH PANEL NOTE: The Interior switches are supplied by the OEM. Electric Element Switch: NOTE: If a 12 VDC switch is used to activate the 120 VAC heating element, there will be a relay, which the 12 VDC switch will activate to allow 120VAC power to be supplied to the 120VAC heating element.
SECTION 4: EXHAUST SYSTEM REQUIREMENTS Because the Aqua-Hot’s exhaust is hot and must be kept away from any heat-sensitive material, the exhaust system should be checked to ensure that it continues to meet the following requirements: The exhaust must not be directed downward as a fire could result when parked in dry, grassy areas.
SECTION 5: AQUA-HOT COMPONENTS Figure 6 190 º F Diesel Burner Control Thermostat Thermostats 2. Control Thermostat: Diesel Burner The Diesel Burner control thermostat is installed onto the Aqua-Hot’s boiler tank and monitors the temperature of the antifreeze and water heating solution to determine when it is at operating temperature and when it requires heat. The Aqua-Hot’s Diesel Burner is considered to be at operating temperature between 175°F and 200°F.
SECTION 5: AQUA-HOT COMPONENTS Control Thermostat Replacement Procedure: Note: If a screw longer than 1/4” is used to secure the FAILURE TO DISCONNECT ALL POWER SUPLIES AND/OR TO thermostat in place, it may cause the thermostat mounting bracket to be pushed away from the boiler tank, and may result in overheating. ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY. 5.
SECTION 5: AQUA-HOT COMPONENTS Figure 8 198 º F Electric Element Control Thermostat Thermostats 1. Disconnect all power supplies. Control Thermostat: Electric Element 2. Remove the thermostat access cover. The Electric Element control thermostat is installed onto the Aqua-Hot’s boiler tank and monitors the temperature of the antifreeze and water heating solution to determine when it is at operating temperature and when it requires heat.
SECTION 5: AQUA-HOT COMPONENTS Control Thermostat Replacement Procedure: Note: If a screw longer than 1/4” is used to secure the FAILURE TO DISCONNECT ALL POWER SUPLIES AND/OR TO thermostat in place, it may cause the thermostat mounting bracket to be pushed away from the boiler tank, and may result in overheating. ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY. 1.
SECTION 5: AQUA-HOT COMPONENTS AC High-Limit Thermostat: The AC high-limit thermostat serves as a safety measure in the event that the electric heating element continues to operate after the maximum operating temperature is reached. The high-limit thermostat allows the current for the heating element to pass through it until the boiler tank reaches a temperature of 230°F.
SECTION 5: AQUA-HOT COMPONENTS Replacement Procedure: DC High-Limit Thermostat: The DC high-limit thermostat serve as a safety measure in the event that the diesel-burner continues to operate after the maximum operating temperature is reached. The high-limit thermostat allow the current for the diesel-burner to pass through it until the boiler tank reaches a temperature of 230°F.
SECTION 5: AQUA-HOT COMPONENTS Figure 12 Valves Check Valve: With the circulation pump operating, tap on the check valve and wait five minutes to evaluate if interior heat is now present. Check valves are installed into the zone outlet ports for each heating loop to ensure that the antifreeze and water heating solution only flows in one direction. If the heating solution attempts to backflow into the boiler tank, the check valve closes to prevent that from happening.
SECTION 5: AQUA-HOT COMPONENTS Replacement Procedure: (continued) 2. 3. Shut off both the return and the supply ball valves coming out of the aqua hot’s boiler tank.. Zone Ball Valve Disconnect the interior heating zone line from the defective check valve.. Figure 13 NOTE: When the interior heating zone line is disconnected from the check valve, approximately 2 quarts of antifreeze will leak out of the interior heating zone line. 4.
SECTION 5: AQUA-HOT COMPONENTS Tempering Valve: The tempering valve for the Aqua-Hot mixes the heated domestic water from the boiler tank with cold domestic water at a preset ratio to reduce the risk of scalding. Troubleshoot the tempering valve if the following condition has occurred: NOTE: Prior to trouble shooting the tempering valve, it is recommended to review the Lack of Hot Water TroubleShooting guide in section 9.
SECTION 5: AQUA-HOT COMPONENTS Tempering Valve: Figure 14 Thermostat and Bonnet Assembly Spring O-Ring Thermostat Tempering Valve © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 5: AQUA-HOT COMPONENTS Pumps Circulation Pumps A, B, and C: The Zone circulation pump first draw the heated antifreeze and water heating solution from the Aqua-Hot’s boiler tank, then propel it through the hydronic heating system’s interior heat plumbing. Replacement Procedure: FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY. 1.
SECTION 5: AQUA-HOT COMPONENTS 11. Install the replacement pump onto the Aqua Hot, and t tighten down the union previously loosened. Be sure to review the wiring schematic in appendix A for proper pump wiring. 12. Re-Install the check valve onto the Aqua-Hot zone circulation pump. The arrow on the check valve must point away from the circulation pump. 15. Refill the Aqua-Hot boiler tank with the antifreeze and water heating solution. 13.
SECTION 5: AQUA-HOT COMPONENTS Stir Pump / Circulation Pump B: The stir pump circulates the antifreeze and water heating solution within the Aqua-Hot boiler tank in order to ensure even-heating of the solution. To accomplish this, the stir pump draws the solution from the supply port of the tank and deposits it back into the return port of the tank, after circulation through heating loop number 2.
SECTION 5: AQUA-HOT COMPONENTS Pumps Engine Preheat Pump: The Engine Preheat circulation pump draws the cold antifreeze and water heating solution from the motor home’s engine and then propels it through the Engine Preheat Heat exchanger, located inside the boiler tank. Replacement Procedure: FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY. 1.
SECTION 5: AQUA-HOT COMPONENTS 12. Reinstall the bulk head fitting. Be sure to use a back up wrench on the pump stand to ensure the pump is properly positioned while tightening down the bulk head fitting. 16. Remove the hose pinch off pliers previously used to pinch off the hose. 17. Test for proper operation 13. Using a 3/4” and a 1 1/8 wrench tighten down the union. 14. Reconnect the hose barb fitting and hose to the engine preheat pump bulk head fitting. 15.
SECTION 5: AQUA-HOT COMPONENTS Zone Relay: Zone Pumps Interior Heat Exchanger Fans/ The Zone relay is an electrical device where the DC circuit from the Interior Room Thermostat determines whether the DC power is permitted to flow to the circulation pump and the heat exchanger fans. This allows the Interior Room Thermostat to switch both the fans and circulation pump on. Troubleshoot the Zone relay if either of the following conditions have occurred: The Interior fans fail to operate.
SECTION 5: AQUA-HOT COMPONENTS Bedroom Zone Bathroom Zone Living room Zone Terminal Strip Figure 19 Fuse Block A B C D E F Relay Socket Relay Relay Clip © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 5: AQUA-HOT COMPONENTS Electrical - AC 3. Electric Heating Element: A. Remove the AC access cover. The electric heating element uses AC power as an alternate power source for heating the Aqua-Hot’s boiler tank. Troubleshoot the electric heating element if the following condition has occurred: B. Using an AC voltmeter, verify that 110 volts of AC power are present. 4. There is a lack of hot domestic water and interior heat when the electric element is selected as the heating source. 1. 2.
SECTION 5: AQUA-HOT COMPONENTS 2. Drain the antifreeze and water heating solution from the Aqua-Hot’s boiler tank using the drain valve. 3. Remove the Electric Element access cover. 4. Remove the two wires secured to the defective electric heating element by releasing the screw terminals. Using a 1-1/2 inch socket, remove the defective electric heating element from the Aqua-Hot boiler tank. 10. Test for proper operation 5. 6. 7.
SECTION 6: DIESEL-BURNER OVERVIEW Diesel-Burner Overview The Aqua-Hot’s diesel-burner is a device that ignites a mixture of diesel fuel and air within a controlled setting to serve as a heat source. The flame is established in a combustion chamber within the Aqua-Hot’s boiler tank, and the heat from the flame is transferred to the antifreeze and water heating solution where it can be used for each system of the Aqua-Hot - domestic hot water, interior heat, and engine preheat.
SECTION 6: DIESEL-BURNER OVERVIEW Figure 23 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 6: DIESEL-BURNER OVERVIEW Operational Flow-Chart Operation sequence once the Aqua-Hot’s Diesel switch is turned ON NOTE: The Diesel switch’s indicator light will illuminate anytime the Diesel Burner switch is in the ON position The Motor (#2), which turns the Combustion Air Blower (#5) and drives the Fuel Pump (#14), will begin to operate. NOTE: If the Aqua-Hot’s coolant temperature is approximately 200°F (+/5°F) or higher, the Motor (#2) will not operate.
SECTION 6: DIESEL-BURNER OVERVIEW Diesel-Burner Operations: The following sequence illustrates how the Diesel-Burner operates once it is activated. Also, if diesel-burner malfunctions are experienced, use this sequence of operating events as a diagnostic tool to determine at what point in the dieselburner’s operation the malfunction is occurring. Use the “KEY” provided to understand each symbol shown.
SECTION 6: DIESEL-BURNER OVERVIEW Figure 25 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 6: DIESEL-BURNER OVERVIEW Figure 26 The Diesel-Burner will continue to produce heat in this manner until it is switched off either manually or by the VDC Control Thermostat, which occurs when the coolant temperature in the Aqua Hot’s Boiler Tank Reaches 200 (+/- 5) degrees Fahrenheit.
SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Instructions for Detaching the Diesel Burner WARNING! Be sure to move the Diesel-Burner switch on the Interior Switch Panel to the OFF position and disconnect the Diesel-Burner’s power supply before detaching the Diesel-Burner from the Aqua-Hot. Failure to turn off the Diesel-Burner and disconnect power could result in serious bodily injury.
SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Step 3: Disconnect the Diesel Burner’s Controller Figure 29 B-Plug C-Plug 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Step 4: Remove the Diesel Burner from the Aqua-Hot Figure 30a Figure 30b 1. The Diesel-Burner is secured to the Aqua-Hot with two nuts that can be loosened, and swung out of the way by using a 10mm socket wrench with a 10 inch long extension. Figure 30c 2. Carefully pull the Diesel-Burner away from the Aqua-Hot 4 to 5 inches before rotating the burner, and then remove. © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Step 5: Disconnect the Diesel Burner’s Thermostat Wires From the Aqua-Hot Figure 31b Figure 31a Thermostat Access Cover Wire Access Slot 1. Using a Phillips head Screw Driver loosen the screws securing the thermostat access cover in place, and remove the thermostat access cover. 1. Disconnect the thermostat wires by firmly pulling on the pink connectors. Remove the wires from the wire access slot.
SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Reattaching the Diesel Burner to the Aqua-Hot CAUTION! When reattaching the diesel-burner be sure to properly align the diesel-burner before tightening the eye-bolt nuts. Also, visually inspect all of the rubber grommets on the top and bottom of the diesel-burner’s cast-aluminum blower casing to ensure they are in place. DO NOT over tighten the eye-bolt nuts. Torque specifications are: approx. 20-40 in. lbs.
SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Step 3: Plug in the diesel-burner’s controller and mount 3. Locate the Diesel-Burner’s Controller and connect both plugs. Figure 35 NOTE: The Diesel Burner’s Controller might have to be mounted onto the side of the diesel burner, before the plugs are inserted into the control unit, otherwise it might not be possible to mount the control unit. Step 4: Reinstall the Access Cover Figure 36 1. Reinstall the Aqua-Hot’s access cover . 2.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING 1. 2. Is the indicator light illuminated? Turn the Control Switch ON. NO 3. 4. 5. 1. 2. Yes Remove the AquaHot’s Access cover. Check the AquaHot fuse (F) for continuity. Replace if necessary. 1. NOTE: The Indicator light will illuminate for only 30 seconds if fuse (F) is blown (open circuit) 3. Attempt heater restart NO Is the Diesel Burner’s “MOTOR” operating? 2. Yes 3.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING 1. 2. Turn the Control Switch Off. Remove the fuel-line from the AquaHot’s “Diesel Fuel Return” and place a short piece of fuel line in its place. Put the opposite end of the fuel line in a container. Place the probes of a DC Multi meter into plug locations, B-1(+) and B-2(-), of the Diesel Burner’s “Control Unit”. Also, measure the voltage across B-2 (-) and B-4 (+) Turn the Control Switch ON. Observe the fuel flow.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Does a spark appear across the Ignition Electrodes? Within 15 seconds, after turning ON the Control Switch, disconnect one of the two wires from the “Flame Detection Photocell”. A spark should now appear across the “Ignition Electrodes”. NO Does a spark appear across the Ignition Electrodes? Yes Yes 1. 2. Remove shop rag from the “Flame Detection Photocell, exposing it to a light source. The spark should disappear.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING 1. 2. 3. Does the spark reappear? Yes To prevent a HIGH VOLTAGE shock and or a fire hazard, be sure to remove both “Ignition Electrodes” (tape the ends and separate the wires) or connect a jumper wire across the Electrodes. NO 1. 2. 3. 4. Turn the Control Switch Off. Replace the “Control Unit”. Reconnect “Fuel Solenoid Valve” wire. Reattach “Diesel Burner Head” and attempt heater restart.. 1. 2. 3. 4. 5. 6. Turn the Control Switch OFF.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING 1. 2. 3. 4. 5. 6. Check “Fuel Solenoid Valve” wires for continuity. Replace wires if necessary. Replace “Control Unit” if wires indicate continuity. Retest fuel flow (without Fuel Nozzle) Install “Fuel Nozzle”. Retest Fuel Nozzle spray pattern (fine mist of fuel present?). Reattach “Diesel Burner Head” and attempt heater restart. 1. 2. 3. 4. 5. Turn the Control Switch OFF. Replace “Fuel Nozzle”.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Diesel-Burner Motor: The motor drives the combustion air blower and the fuel pump. In order to perform the following procedures, it may be necessary to detach the dieselburner head. NOTE: Before testing the diesel burner motor it is recommended to ensure that the ground post on the Aqua-Hot is securely tightened. Turn the diesel switch ON and verify both the diesel burner switch (B1) and the diesel burner motor (B4) have 12VDC.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Diesel-Burner Motor (continued) - RPM Test: 1. Disconnect the ignition cables from the ignition electrodes. 7. Connect the motor’s wires directly to a 12 volt DC power supply. 2. Remove the four ignition coil screws that secure the ignition coil to the protection cap. 8. Turn the power supply ON and use a phototachometer to test for a proper RPM reading. 3.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Motor Replacement Procedure: Be sure to move the Diesel-Burner switch on the Interior Switch Panel to the OFF position and disconnect the Diesel-Burner’s power supply before detaching the Diesel-Burner from the Aqua-Hot. Failure to turn off the Diesel-Burner and disconnect power could result in serious bodily injury. 5.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Figure 39 Motor Replacement Procedure: (continued) © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Flame Sensor: The flame sensor is a photo resistive device which supplies the diesel-burner’s controller with a DC voltage signal when it detects a flame. When the flame sensor senses the light of the flame, it will shut the ignition coil off, and send a signal to the diesel burner controller indicating that everything is working properly. If the flame sensor does not sense the flame, it will shut the diesel burner down in a default after 20 seconds.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Flame Sensor Replacement Procedure: 1. In order to perform the following procedures it is necessary to detach diesel-burner head. Be sure to review the detaching/attaching instructions in section 7. 2. Remove the screw that fastens the flame sensor to the photo disc and detach the sensor’s green and blue wires from the C-plug harness’ green and violet wires, and remove flame sensor. 3.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Ignition Electrodes The diesel-burner’s ignition coil produces a high voltage ignition spark across the ignition electrodes, which ignites the incoming air/fuel mixture. Cleaning and Maintenance: 1. Polish away any carbon deposits that may have baked onto the metal tips of the ignition electrodes with a course sponge. 2. If the ignition electrode’s electrical insulator is cracked or damaged, the ignition electrode must be replaced.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Ignition Electrodes 2. Replacement Procedure: (continued) 5. Insert the new electrode into the orange electrode boot, and snap into place. Pull firmly on the electrode to make sure the retaining clip has secured the electrode in place. Remove both the ignition cables from the ignition electrodes, or connect a jumper wire (with alligator clips) across the metal tips of the electrodes.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Fuel Nozzle: 2. 5. Remove the B-plug from the diesel-burner controller. 6. If the cone shaped spray pattern did not appear, fol low the troubleshooting guides for the following components and verify they are operating properly: A. Fuel Solenoid B. Fuel pump C. D.C. High Limit thermostats NOTE: An adjustment of the ignition electrodes may be necessary after replacing the fuel nozzle.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING stand approximately 1/2”. Remove the fuel solenoid shaft from the nozzle manifold using a 16mm wrench.. Discard the shaft and valve kit, as replacements are provided with the new fuel solenoid assembly. Fuel Solenoid: The fuel solenoid allows the flow of diesel fuel to the diesel-burner’s fuel nozzle. NOTE: If a long after-smoking condition exists during the diesel-burner’s purge cycle, the fuel solenoid valve kit may need to be replaced.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Fuel Pump: The fuel pump draws diesel fuel from the vehicle’s fuel tank and creates a preset pressure of 145 PSI, which is required for proper fuel atomization. Reference the illustration below for a basic overview and understanding of how the fuel pump functions. 7. If fuel does flow through the fuel pump when ran off an external source inspect the following in the motor home: A. Check the motor home fuel tank for fuel.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Fuel Pump Replacement Procedure: NOTE: To perform the following procedure it will be necessary to remove the diesel burner. Follow the section on detaching and reattaching the diesel burner, section 7 of this manual. 1. 2. 3. 4. 5. 6. Locate and disconnect the C-Plug harness wires that connect to the flame sensor and the fuel solenoid. Also, disconnect the ignition cables from the ignition electrodes.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Fuel Pump: (continued) Figure 47 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Bearings: 5. Remove the three hex head screws that secure the motor and motor flange to the blower housing. Re move the motor and flange assembly along with the clutch halves. Disconnect the motor’s black (+) and brown (-) wires from the C-plug harness’ wires. 6. Remove the four blower housing screws that secure the blower housing to the blower casing. Remove the blower housing so that the combustion air blower is exposed. 7.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING 3. Remove the four nozzle stand plate screws that secure the nozzle stand plate in place. Remove the nozzle stand plate by pulling on the nozzle stand until the plate releases from the cast-aluminum blower casing. NOTE: It is recommended to mark the internal components of the diesel burner prior to disassembling of the burner. Make a mark between the motor flange and the blower housing, and also between the blower housing and the blower casing.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING 12. Place a feeler gauge between the combustion air blower and the flat surface of the blower casing. Slowly tighten (or loosen) the retaining nut, holding the combustion air blower, until a .003-.005 gap is achieved. Remove feeler gauge. 13. Spin the combustion air blower to ensure a friction free rotation.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Ignition Coil: The ignition coil produces a high voltage ignition spark (approx. 8000 volts), which is released across the metal tips of the ignition electrodes during the initial diesel-burner start-up. Use extreme care when testing the ignition coil, as a High Voltage Shock may result. NOTE: In order to perform the following procedures it is necessary to detach and reattach the diesel-burner head.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Ignition Coil: 2. NOTE: In order to perform the following procedures it is necessary to detach and reattach the diesel-burner head. Be sure to review the section for detaching and reattaching the diesel burner.. Replacement Procedure: 1. Disconnect the ignition cables from the ignition electrodes. Remove the four ignition coil screws that secure the ignition coil to the protection cap.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Diesel-Burner Controller: The diesel-burner controller operates all the components of the diesel-burner head and safely shuts the heater OFF in the event of an overheat, flameout, and low voltage condition. It also receives dieselburner operation status signals from the flame sensor, VDC control thermostat, and VDC high-limit thermostat. Component Test: VDC/VAC Control Thermostat Circuit Test: Locate the diesel-burner controller’s B-plug and Cplug.
SECTION 8: DIESEL-BURNER COMPONENTS/TROUBLE SHOOTING Be sure to remove the jumper wire that was used to make the connection from the C-1 location to the C-7 location. Failure to do so will result in an overheating condition during normal operation. Replacement Procedure: 1. Remove both the B-plug and the C-plug from the diesel-burner controller. Gently pry away each side of the diesel-burner controller bracket from the diesel-burner controller’s locking posts with a flat-head screw driver.
SECTION 9: GENERAL TROUBLESHOOTING IF THE AQUA-HOT IS BLACK SMOKING: 1. Things to check before opening up heater 1. Low Voltage - Fire up generator/plug coach into shore power 2. Damaged or Restricted exhaust pipe - Inspect exhaust pipe for damage 2. Access cover must be removed to check the following: 1. 2. 3. 4. Air Intake Closed off - on the bottom of the burner is the air adjustment, set at the half way point. Broken Protection Cap - Check cap for cracks or missing pieces.
SECTION 9: GENERAL TROUBLESHOOTING IF THE AQUA-HOT IS BLUE/WHITE SMOKING: 1. If The Heater Smokes on Start up/Shut down. a. Fuel solenoid - plunger worn out - plastic/metal in the way of plunger - fuel solenoid intermittent. b. Nozzle Tower - cracked - poorly machined c. Short cycling - control t-stat bad - someone turned heater off/on repeatedly d.
SECTION 9: GENERAL TROUBLESHOOTING IF ONE OF THE AQUA-HOT HEATING ZONES WILL NOT GET HOT: 1. General Problems A. Diesel/Electric not operating (antifreeze cold) B. Heater is Not up to operating Temperature (antifreeze is cold) C. Interior Zone Thermostat Not calling for heat D. Zone Circulation Pump Not Operating E. Heat Exchanger Fans Not Operating 2. If Fans and Pumps are Running A. Stuck Check Valve B. Kinked Line C.
SECTION 9: GENERAL TROUBLESHOOTING IF THERE IS A LACK OF DOMESTIC HOT WATER: 1: General information 1. The heater is only rated for water flow of 1.5 GPM 2. The heater is only rated for a 55*F temperature Rise on the cold water coming into the unit 3. The diesel burner must be on for continuous hot water, the electric element is for limited use only. 2: Things to test for a lack of hot water problem. 1. Aqua-Hot Heater Bypassed 2. Outside Water Faucet is left on. 3. Washing Machine Valve has gone bad 4.
SECTION 9: GENERAL TROUBLESHOOTING IF THERE IS ANTIFREEZE LEAKING: NOTE: To find an antifreeze leak, the system must be Hot (up to operating temperature) Or pressurized to 17 PSI. Inspect the following components on the Aqua-Hot Heating System for Leaks: 1. On the Front-Side of Aqua-Hot 1. Electric element 2. Circulation/Stir pump c. Copper plumbing d. Tank ports - It might be necessary to cut away some of the insulation around the tank ports to locate the leak. e. Pump 6. Burn Chamber Leak a.
SECTION 9: GENERAL TROUBLESHOOTING IF THERE IS ANTIFREEZE LEAKING: (CONTINUED) 2. On the Top-Side of Aqua-Hot 1. Expansion Tank Connection a. Cracked expansion tank tubing b. Radiator Cap c. Filler neck/Filler neck solder joing 2. Supply/Return Ports A. Defective fitting B. Leaking fitting Note: If no leaks are found on the Aqua-Hot, it is possible that there is a leak within the motor home. Check all Heat exchangers, connections, and tubing for leaks.
APPENDIX A: WIRING DIAGRAM © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX A: WIRING DIAGRAM © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX B: BLEEDING THE INTERIOR A. Place a bucket underneath the coach, where the Aqua-Hot’s Drain Valve is located. NOTE: Be sure to check that the drain valve is completely closed. HEATING ZONE CIRCULATION PUMP I. Close the Drain Valve. J. Close the pump manifold valve. K. Repeat steps B-J for all three zone pumps (i.e. Bedroom, Bathroom, and Living Room). B. Remove the Aqua-Hot’s Radiator Cap and pour 15 gallons of a 50/50 solution of water and antifreeze, reference figure B1. C.
APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP Living room Supply Living room Return 13 lb Radiator Cap Bathroom Supply Bathroom Return Bedroom Supply Bedroom Return Figure B1 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX B: BLEEDING Figure B2 THE INTERIOR HEATING ZONE CIRCULATION PUMP Return Ball Valve Supply Ball Valve Drain Valve © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP Using an Air Blower to pressurize the Boiler Tank Expansion Tank Tubing 13 lb Radiator Cap Air Blower Figure B3 NOTE: If too much air pressure is applied to the boiler tank, it will leak out around the radiator cap’s rubber seal. © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP Using a Coolant System Tester to pressurize the Boiler Tank Coolant System Tester Pressurize System up to 15 psi Figure B4 © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure NOTE: A fuel pressure gauge is used to properly check the fuel pump’s pressure setting. The fuel pump is preset to 145 PSI. Perform the following procedures to check for a proper fuel pressure setting. NOTE: In order to perform the following procedure it is necessary to detach and reattach the diesel-burner head. Be sure to review the detaching/attaching instructions. Step 1: Remove the diesel-burner Figure C1 1.
APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Figure C3 2. Using a 5/8” and a 3/4” wrench install the fuel pressure gauge. WARNING! A spark will appear across the ignition electrodes for a brief moment after the diesel burner has been activated. DO NOT attempt to make any fuel pressure adjustments until the spark has disappeared. Failure to do so may result in serious bodily injury.
APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 1: Follow the directions for Checking the Fuel Pressure in this section. Figure C5 1. Remove the Diesel Burner and install the Fuel Pressure Gauge . WARNING! A spark will appear across the ignition electrodes for a brief moment after the diesel burner has been activated. DO NOT attempt to make any fuel pressure adjustments until the spark has disappeared. Failure to do so may result in serious bodily injury.
APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 2: Adjust the Fuel pressure to 145 PSI. Figure C7 1. Once the fuel solenoid has been activated, and the fuel pressure gauge is registering a pressure, the fuel pressure can be adjusted. To increase the fuel pressure turn the pressure adjustment screw clockwise, and to reduce the fuel pressure, turn the pressure adjustment screw counter clockwise.
APPENDIX D: EXTREME COLD WEATHER OPERATION Diesel-Burner When storing the Motorhome: Not winterizing the AquaHot when freezing temperatures are present will result in serious damage to the Aqua-Hot’s Domestic Water Heating System. Also, be sure to use an FDA approved, “GRAS” rated antifreeze for winterization. 1. If the Diesel burner Fails to operate: NOTE: The Aqua-Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized. A.
APPENDIX D: EXTREME COLD WEATHER OPERATION If there is a lack of interior Heat: Note: The 120 Volt-AC Electric Heating Element is the Aqua-Hot’s secondary heat source for heating both the interior and/or 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). If the ambient temperature is ex- 1. Is the Diesel Burner activated? 2. Is the Diesel Burner operating Properly? 3.
APPENDIX E: AQUA-HOT MAINTENANCE Monthly Maintenance: Annual Maintenance: Check the antifreeze and water heating solution to ensure that it is at the proper level by visually checking the solution level in the expansion tank. The level of the antifreeze and water heating solution within the expansion tank should only be checked when the Aqua-Hot is at maximum operating temperature. If additional antifreeze and water heating solution is required, fill the expansion tank to the “HOT” level mark.
APPENDIX E: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Procedure: Note: Before performing an annual maintenance, it is recommended to test run the Diesel-Burner. While testing inspect exhaust for smoke. Step 1: Test Run the Diesel Burner 1. Turn the Diesel-Burner Switch to the on position. 2. After the Diesel-Burner has ignited, inspect the exhaust for smoke. 3. Shut the Diesel-Burner off, and wait for unit to completely shut off. NOTE: The diesel-burner can either be shut off by: 1.
APPENDIX E: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Procedure: Step 4: Remove The Diesel Burner Figure E4a 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. Figure E4b Figure E4c 3. The Diesel-Burner is secured to the Aqua-Hot with two nuts that can be loosened, and swung out of the way by using a 10mm socket wrench with a 10 inch long extension. © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX E: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Procedure: Step 5: Remove The Diesel Burner (continued) Figure E5 Thermostats Diode Wire 4. Carefully pull the Diesel-Burner away from the Aqua-Hot 4 to 5 inches before rotating the burner, and then remove. NOTE: To remove the diesel burner, it may be necessary to disconnect the wires from the control and hi limit thermostats It may also be necessary to disconnect the Diode Wire.
APPENDIX E: AQUA-HOT MAINTENANCE Step 6: Clean and Inspect the Combustion Chamber and Heat Transfer Tabs. Use caution when handling the combustion chamber, it may be extremely hot, and serious burns could result from touching a hot combustion chamber. Heat Transfer Tabs Figure E6a Figure E6b 1. Remove the combustion chamber by pulling it straight out, approximately 16 inches. 2. Once the combustion chamber has been removed.
APPENDIX E: AQUA-HOT MAINTENANCE Step 6: Clean and Inspect the Combustion Chamber and Heat Transfer Tabs. Figure E6c Seam on stainless steel tube Back side of air swirler Outer ring that the photo disc seats against 3. Inspect the combustion chamber for damage or signs of warping. 1. Inspect the combustion chamber for cracks appearing along the seam of the stainless steel tube. A. If the crack is over 1” in length, the combustion chamber must be replaced. 2.
APPENDIX E: AQUA-HOT MAINTENANCE Step 7: Reinstall the Combustion Chamber CAUTION! Failure to reinstall the combustion chamber will result in serious damage to the diesel burner. Figure E7 Seam on stainless steel tube 1. Reinstall the combustion chamber into the Aqua-Hot. Please note: the seam on the stainless steel tube must be in the “up” position. Failure to do so could result in premature failure of the combustion chamber. © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX E: AQUA-HOT MAINTENANCE Step 8: Inspect Diesel-Burner Figure E8 Electrode Fuel Nozzle Fuel Pump Grommet Photo Disc Ear Flame Sensor Inspect the following: 1. Electrodes - damaged - improperly adjusted 2. Fuel Pump - leaks 3. Photo disc - warped - bent 4. Harness & Ignition Coil Wires - crack or bare wires - Hard or brittle wires 5. Flame Sensor - cracked - overheated (purple color) - melted wires - dirty 6. Rubber Grommets - hard/brittle - rubber has been cut out - right/left 7.
APPENDIX E: AQUA-HOT MAINTENANCE Step 9: Clean Ignition Electrodes and Flame Sensor Metal Tips Figure E9 Flame Sensor 1. Ignition electrodes A. Polish away any carbon deposits that may have baked onto the metal tips of the ignition electrodes with a course sponge. 2. Flame Sensor A. For light dirt, dust, and/or carbon deposits, simply wipe off the flame sensor with a soft cloth. B.
APPENDIX E: AQUA-HOT MAINTENANCE Step 10: Replace The Fuel Nozzle Figure E10 1. Use a 3/4 in. wrench to hold the fuel nozzle manifold hex, while loosening the fuel nozzle with a 5/8 in. wrench and remove. NOTE: Be sure to use care when handling the new fuel nozzle. Oils and/or small dust or dirt particles from your hands may plug the nozzle’s small orifice. A partially plugged orifice will restrict fuel flow, which will affect the combustion process of the diesel-burner. 2.
APPENDIX E: AQUA-HOT MAINTENANCE Step 11: Adjust Ignition Electrodes Figure E11 1. Using a 10mm socket, slightly loosen the retaining clamp bolt. 2. Place the electrode adjustment gauge on the nozzle manifold hex and insert the metal tips of the ignition electrodes into the appropriate notches of the electrode adjustment gauge. 3. Using a 10 mm socket, tighten the retaining clamp bolt. NOTE: Be sure not to over-tighten the retaining clamp bolt when readjusting the ignition electrodes.
APPENDIX E: AQUA-HOT MAINTENANCE Step 12: Inspect Photo Disc Figure E12 Photo Disc 1. If the photo disc is not free floating, the electrode clamp bolt has been over-tightened, and has bent the electrode clamp. Using a 10mm socket remove the electrode clamp, and re-straighten. -Lay the clamp’s beveled side down on a solid flat surface and align the thick end of the punch at dead center. Tap the punch lightly until the retaining clamp returns to proper form.
APPENDIX E: AQUA-HOT MAINTENANCE Step 14: Plug in the diesel-burner’s controller and mount Figure E14a 1. Locate the Diesel-Burner’s Controller and connect both plugs. NOTE: The Diesel Burner’s Controller might have to be mounted onto the side of the diesel burner, before the plugs are inserted into the control unit, otherwise it might not be possible to mount the control unit. © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
APPENDIX E: AQUA-HOT MAINTENANCE Step 15: Re-Install the Aqua-Hot Access Cover 1. Reinstall the Aqua-Hot’s access cover . 2. Securely tighten the screws securing the access cover in place. Step 16: Test for Normal Operation A. Turn the Diesel-Burner switch on, and let the diesel burner run for a complete cycle, until it shuts off on it’s own.. B. After the Diesel-Burner has shut off, turn on the interior heat/run hot water, until the Diesel Burner cycles back on.
APPENDIX F: WINTERIZATION PROCCESS Not winterizing the Aqua-Hot when freezing temperatures are present will result in serious damage to the Aqua-Hot’s Domestic Water Heating System. Also, be sure to use an FDA approved, “GRAS” rated antifreeze for winterization. NOTE: The Aqua-Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized. 5.
© 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
© 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev.
AHE-100-02S SERVICE MANUAL 15549 East Highway 52 | Fort Lupton, CO 80621 Toll free: 800.685.4298 | phone: 303.659.8221 | fax:303.857.7881 www.aquahot.
