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© 2011 Aqua-Hot

®

AHE-100-02S Hydronic Heating System Service Manual—Rev. B

Ignition Coil:

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.
Lift  the  ignition  coil  and  disconnect  its  wires  from
the C-plug harness wires, prior to removing.

2. Connect the new ignition coil’s black (+) and brown

(-)  wires  to  the  C-plug  harness’  yellow  (+)  and
brown (-) wires.  Attach the ignition coil to the pro-
tection  cap  with  the  four  ignition  coil  screws,  then
reconnect  the  ignition  cables  to  the  ignition  elec-
trodes.

3. Follow the instructions for reattaching the diesel

burner and test for proper operation.

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..

NOTE: If the new ignition coil does not function, check
wire connections and ensure they are properly connected.

Figure 52

S

ECTION

8: D

IESEL

-B

URNER

C

OMPONENTS

/T

ROUBLE

S

HOOTING

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Summary of Contents for AHE-100-02S

Page 1: ...SERVICE MANUAL 2011 Aqua Hot Heating Systems Inc AHE 100 02S ...

Page 2: ... Page 2 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B ...

Page 3: ... Diesel Burner Switch Page 12 Electric Element Switch Page 12 Engine Preheat Switch Page 12 Section 4 Exhaust System Requirements Exhaust System Requirements Page 13 Section 5 Aqua Hot Components Control Thermostat Diesel Burner Page 14 15 Control Thermostat Electric Element Page 16 17 A C High Limit Thermostat Page 18 D C High Limit Thermostat Page 19 Check Valves Page 20 21 Tempering Valve Page ...

Page 4: ...56 57 Fuel Nozzle Page 57 58 Fuel Solenoid Page 59 Fuel Pump Page 60 62 Bearings Page 63 65 Ignition Coil Page 66 67 Controller Page 68 69 Section 9 General Troubleshooting If the Aqua Hot is Black Smoking Page 70 If the Aqua Hot is Blue White Smoking Page 71 If one of the Aqua Hot s Heating Zones will not get hot Page 72 If there is a lack of domestic continuous hot water Page 73 If there is anti...

Page 5: ... Page 5 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B This Page Left Blank Intentionally ...

Page 6: ...ian Understanding the Aqua Hot AHE 100 02S Major Systems The basis for the Aqua Hot heating system s functionality is the antifreeze and water heating solution which is comprised of water that is distilled de ionized or soft as well as anti freeze Through this solution s ability to maintain and trans fer heat the Aqua Hot s three major systems the domestic water system engine preheat system and in...

Page 7: ...a particular area it sends a signal to the Aqua Hot s corresponding zone relay The Zone Relay responds by activating the circulation pump for that zone which sends the heated antifreeze and water heat ing solution through the Heating Loop corresponding to the zone requesting heat The fans on the heat exchangers in the zone calling for heat are also activated therefore as the heat ed solution flows...

Page 8: ...m of 3 plus Engine Preheat Domestic Water Heating Capacity continuous on demand Antifreeze Type Used Ethylene Glycol Dimensions 18 5 H x 18 5 W x 36 75 L Dry Weight approximately 200lbs NOTE All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Association s RVIA ANSI NFPA 1192 Handbook for Recreational Vehicle Standards To receive a copy of this h...

Page 9: ... Page 9 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B SECTION 2 AQUA HOT AHE 100 02S OVERVIEW Figure 2 ...

Page 10: ... Page 10 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B SECTION 2 AQUA HOT AHE 100 02S OVERVIEW Figure 3 ...

Page 11: ...e Zone calling for heat Heat Exchanger fans activate The Circulation Pump activates for the Zone which called for heat The heated antifreeze and water heating solution is trans ported throughout the plumbing lines the that zone Heat is transferred to the Engine Preheat System The engine s coolant is circulated through the Aqua hot s inter nal Engine Preheat System where the heat from the Boiler Ta...

Page 12: ...ught to operating temperature by the electric heating element in approximately 1 to 2 hours The electric element alone will not be able to provide continu ous hot water Engine Preheat Switch The engine preheat switch activates the engine preheat pump which draws the motor home s engine coolant through the boiler tank to heat it before returning it to the engine block to transfer the heat there The...

Page 13: ... could result when parked in dry grassy areas The exhaust must not terminate underneath the vehicle underneath an open able window or vent in the awning area of the motor home if applicable or near slide out areas The exhaust must be able to freely exit away from the vehicle without any obstructions 1 3 4 2 standard automotive type exhaust piping should be used with a maximum of two 90 degree pipe...

Page 14: ...witch pan el on If the Diesel Burner comes on and runs but there is still a lack of hot water verify that the control thermostat is operating within the proper operating temperature range A Using a digital temperature sensor place the probe on the tank next to the thermostat The proper operating temperature for the diesel burner is 175 F 200 F 2 If the Diesel Burner Does not come on and run A Veri...

Page 15: ...minals 3 Using a 1 4 nut driver unscrew the two screws secur ing the control thermostat to the Aqua Hot s boiler tank thermostat mounting bracket 4 Install the replacement control thermostat into the ther mostat mounting bracket and secure with the two screws previously removed 5 Inspect the quick connectors on the thermostat wires Replace if necessary Re Connect the control thermo stat s wires or...

Page 16: ...sconnect all power supplies 2 Remove the thermostat access cover 3 Verify that the boiler tank s temperature is below 230 F 4 Locate the AC control thermostat and remove its wires by loosening and removing the screws securing the wires in place 5 Using an ohmmeter check the thermostat for continuity If continuity is not present follow the instructions in this section to replace the AC control ther...

Page 17: ...wires to the terminals 3 Using a 1 4 nut driver unscrew the two screws secur ing the control thermostat to the Aqua Hot s boiler tank thermostat mounting bracket 4 Install the replacement control thermostat into the ther mostat mounting bracket and secure with the two screws previously removed 5 Inspect the wires going to the control thermostat Re place if necessary Re Connect the control thermost...

Page 18: ...he instructions in this section to replace the AC high limit thermostat 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 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the b...

Page 19: ...following follow the instructions in this section to replace the high limit thermostat Replacement Procedure FAILURE TO DISCONNECT ALL POWER SUPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnected Also because this replacement procedure will i...

Page 20: ...ve the check valve was stuck closed and no further action is necessary 3 Check the Aqua Hot s antifreeze and water heating solu tion s ratio of water to antifreeze The mixture ratio should be approximately 50 50 If the solution is com prised fully of antifreeze 100 the check valves will continue to stick NOTE Storing the motor home for an extended period of time can cause the check valves to stick...

Page 21: ...heck valve must point away from the circulation pump 6 Reconnect the interior heating zone fitting and line to the replacement check valve 7 Refill the Aqua Hot boiler tank with the antifreeze and water heating solution 8 Test for proper operation 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 interi...

Page 22: ...R PERSONAL INJURY 1 Turn the motor home s water pump off 2 Drain the water pressure by opening the faucets and al lowing the water to drain 3 Follow the instructions for removing the diesel burner 4 Using Channel Lock Pliers remove the Thermostat and Bonnet Assembly 5 Once the thermostat and bonnet assembly has been re moved replace the o ring stainless steel spring and thermostat 6 Re Install the...

Page 23: ...ge 23 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B SECTION 5 AQUA HOT COMPONENTS Tempering Valve Thermostat Tempering Valve Thermostat and Bonnet Assembly Spring O Ring Figure 14 ...

Page 24: ... will in volve the potential for hot coolant be sure the heater is adequately cooled 2 Shut off both the return and the supply ball valves com ing out of the aqua hot boiler tank 3 Disconnect the interior heating zone line from the check valve 4 Unscrew the check valve from the Aqua Hot zone circulation pump 5 Disconnect the defective circulation pump s wires by removing the protective loom and cu...

Page 25: ...he check valve 14 Reconnect the wires on the replacement pump to the wire harness on the heater by using a red butt connector Be sure to review the wiring schematic in appendix A for proper pump wiring 15 Refill the Aqua Hot boiler tank with the antifreeze and water heating solution NOTE The Aqua Hot zone circulation pump is not a self priming pump If the circulation pump gets an air pocket it wil...

Page 26: ...he diesel burner Controller C 2 pin and hooks up to the B Zone Relay Pin 6 terminal i Verify the Diode Wire is connected and the screw for Pin 6 on the B Zone relay is tight If diesel burner motor is running and no voltage is present at Pin 6 on the B Zone Relay replace the diode wire If voltage is present at Pin 6 on the B Zone Relay continue C Using a Volt Meter check the 2 zone pump for voltage...

Page 27: ... Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the potential for hot coolant be sure both the heat er and motor home engine are adequately cooled 3 Using hose pinch off pliers clamp both hoses attached to the engine preheat loop closed 4 Remove the Hose and hose barb fitting attached to the engine preheat ...

Page 28: ... wire harness on the heater by using a red butt connector Be sure to review the wiring schematic in appendix A for proper pump wiring 16 Remove the hose pinch off pliers previously used to pinch off the hose 17 Test for proper operation NOTE The Aqua Hot Engine Preheat pump is not a self priming pump If the pump gets an air pocket it will be necessary to bleed the air out of the pump To bleed the ...

Page 29: ...the Fuse block and using a volt meter check for 12VDC on the C Pumps D Fans Fuse If no power is present check the fuse 4 On the Right Hand side of the Zone relay check pins A 7 and 9 for 12 VDC If no power is present Inspect the wires and verify the C and D fuses are good 5 On the Zone Relay check pin B for ground If there is not a ground present verify that the room thermostat is calling for heat...

Page 30: ...qua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B SECTION 5 AQUA HOT COMPONENTS Terminal Strip Fuse Block A B C D E F Relay Socket Relay Relay Clip Bedroom Zone Bathroom Zone Living room Zone Figure 19 ...

Page 31: ...C power is present at the Aqua Hot Check The following A Using a digital Clamp On amp meter verify that 11 2 to 13 amps are present the element s wires If the Electric Element wires show a 11 2 13 amp draw the electric element is working properly 5 Check the electric heating element for functionality by completing the following A Disconnect all power supplies B Remove all wires from the electric h...

Page 32: ...ove the defective electric heating element from the Aqua Hot boiler tank 6 Install the replacement 1650 watt electric heating ele ment into the boiler tank ensuring that the up lettering on the element is installed in the up position 7 Connect the wires removed from the defective electric heating element to the replacement electric heating ele ment and tighten the screw terminals 8 Reinstall the E...

Page 33: ...and engine pre heat SECTION 6 DIESEL BURNER OVERVIEW Diesel Burner Overview The Aqua Hot s diesel burner is a device that ignites a mix ture 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 Figure 21 Figure 22 Controller Diode Wire Ignition Coil Electrode Adjustment Gauge Fue...

Page 34: ... Page 34 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B SECTION 6 DIESEL BURNER OVERVIEW Figure 23 ...

Page 35: ...ocess will con tinue to operate in this manner until one of the following occurs A The VDC Control Thermostat which senses cool ant temperature reaches the pre set temperature of approximately 200 5 F B the Aqua Hot Diesel Burner Switch is turned OFF NOTE If process B occurs the Diesel Burner switch s Indicator Light on the Switch Panel will go OFF Once the heater switches OFF thermostatically or ...

Page 36: ...it is activated Also if diesel burner malfunc tions are experienced use this sequence of operating events as a diagnostic tool to determine at what point in the diesel burner s operation the malfunction is occurring Use the KEY provided to understand each symbol shown Figure 24 NOTE The Motor and Combus tion Air Blower will begin to oper ate only if the VDC Control Ther mostat is closed and callin...

Page 37: ... Page 37 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B SECTION 6 DIESEL BURNER OVERVIEW Figure 25 ...

Page 38: ... switched off either manually or by the VDC Control Thermostat which oc curs when the coolant temperature in the Aqua Hot s Boiler Tank Reaches 200 5 degrees Fahrenheit NOTE Whenever the Diesel Burner is switched off by the VDC Con trol Thermostat it will automatically be reactivated once the Aqua Hot Boiler Tank s coolant reaches the preset termperature of approximately 175 5 degrees Fahrenheit ...

Page 39: ...urner from the Aqua Hot Failure to turn off the Diesel Burner and disconnect power could result in serious bodily injury CAUTION Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to beginning this replacement procedure Step 1 Turn Off the Diesel Switch 1 Move the Interior Switch Panel s Diesel Burner switch to the OFF position 1 Remove the Aqua Hot s a...

Page 40: ...Hydronic Heating System Service Manual Rev B SECTION 7 DETACHING AND REATTACHING THE DIESEL BURNER 1 Locate the Diesel Burner s Controller and disconnect both plugs Step 3 Disconnect the Diesel Burner s Controller Figure 29 B Plug C Plug ...

Page 41: ...he Diesel Burner from the Aqua Hot 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 exten sion 2 Carefully pull the Diesel Burner away from the Aqua Hot 4 to 5 inches before rotating the burner and then remove Figure 30a Figure 30b Figure 30c ...

Page 42: ... remove the thermostat access cover Thermostat Access Cover 1 Disconnect the thermostat wires by firmly pulling on the pink connectors Remove the wires from the wire access slot Wire Access Slot 1 Using Pliers loosen the constant tension clamps securing the fuel lines to the diesel burner and slide away from the burner 2 Remove the fuel lines from the diesel burner NOTE Before Disconnecting the fu...

Page 43: ... 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 An improper alignment and or over tightening of the eye bolt nuts can cause damage to the diesel burner s cast aluminum blower casing CAUTION 1 Install the fuel...

Page 44: ...sel 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 3 Plug in the diesel burner s controller and mount Figure 35 Step 4 Reinstall the Access Cover 1 Reinstall the Aqua Hot s access cover 2 Securely tighten the screws securing the access cover in plac...

Page 45: ... for conti nuity NOTE This thermostat protects against overheating temperatures Yes 1 Remove the Aqua Hot s Access cover 2 Check the Aqua Hot fuse F for continuity Replace if necessary NOTE The Indicator light will illuminate for only 30 seconds if fuse F is blown open circuit 3 Attempt heater restart NO Check the Diesel Burner s VDC Control Thermo stat for continuity Is there continuity across th...

Page 46: ... DC batter voltage Does the DC multi meter indicate ac ceptable system voltage 1 Check the Control Switch s A Wire connections B Fuse E for continuity 2 Check DC power supply wires and connections 3 Reattach Diesel Fuel Return line 4 Attempt heater restart NO NO Yes 1 Inspect eh Flame Detection Photocell for dust and or sooty carbon deposits Clean if necessary 2 Completely cover the Flame Detectio...

Page 47: ... Control Unit Apply DC power to C 8 plug yellow wire and ground to C 5 plug brown wire A spark should now appear across the Ignition electrodes NO NO Yes Yes Does a spark disappear after the Photocell is exposed to NO Does the Photocell operate Properly Does the Ignition Coil operate Properly 1 Replace the Flame Detection Photocell 2 Reconnect Fuel Solenoid Valve 3 Reattach Diesel Burner Head and ...

Page 48: ...O Yes 1 Replace Fuel Solenoid Valve 2 Retest fuel flow without Fuel Nozzle 3 Install Fuel Nozzle 4 Retest Fuel Nozzle spray pattern fine mist of fuel present 5 Reconnect Ignition wires to Ignition Elec trodes or remove jumper wire 6 Reattach Diesel Burner Head and attempt heater restart 1 Turn the Control Switch Off 2 Reconnect ignition wires to Ignition Electrodes or re move jumper wire 3 Reattac...

Page 49: ...l Nozzle 3 Retest Fuel Nozzle spray pattern fine mist of fuel present 4 Reconnect ignition wires to Ignition Electrodes or remove jumper wires 5 Reattach Diesel Burner Head and attempt heater restart NOTE If an improper fuel spray is still observed a normal spray pattern should be observed as a coned shaped mist the Diesel Burner s Fuel Pump should be calibrated for the proper fuel pressure settin...

Page 50: ...ess for loose or damaged wire connections If the C Plug harness and connections are in good condition but the motor is not operating the motor must be replaced If there is no 12 Volts D C present on the C 2 pin The diesel burner controller will need to be replaced NOTE If the B1 Terminal does not have power verify that the E Fuse is good and that the diesel burner switch is send ing power to the d...

Page 51: ...ug harnesses black and brown wires 7 Connect the motor s wires directly to a 12 volt DC power supply 8 Turn the power supply ON and use a photo tachometer to test for a proper RPM reading 9 At approximately 12 volts DC the RPM reading should be 4500 RPM s 300 RPM s If the motor s RPM reading is not within the above specs the motor must be replaced NOTE Test the diesel burner s bearings prior to re...

Page 52: ... hex head screws 7 Connect the black and the brown wires of the new motor to the C Plug harness yellow and brown wires Feed the C plug harness yellow and brown wires back through wiring access hole in the protection cap 8 Reinstall the protection cap Reconnect the black and brown wires 9 Reinstall the ignition coil and secure to the protec tion cap with the four ignition coil screws 10 Follow the ...

Page 53: ... Page 53 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B Motor Replacement Procedure continued Figure 39 SECTION 8 DIESEL BURNER COMPONENTS TROUBLE SHOOTING ...

Page 54: ...flame sensor s glass surface to simulate a no flame condition and then remove the rag and expose to a light source to simulate a flame condition 5 If the flame sensor is operating properly the ohm meter should register high resistance over 100K Ω when the glass surface is covered and less than 200 Ω when exposed to a light source 6 If these resistance numbers cannot be obtained ver ify the flame s...

Page 55: ...r to the photo disc and detach the sensor s green and blue wires from the C plug harness green and vio let wires and remove flame sensor 3 Slide the tab of the new flame sensor into the pro vided slot in the photo disc and secure in place with the screw Connect the flame sensor s green wire to the green C plug harness wire and the blue wire to the C plug harness violet wire 4 Follow the directions...

Page 56: ... 1 Using a 10mm socket loosen and remove the re taining clamp bolt and the retaining clamp 2 Slide the electrode out of the photo disc 3 To remove the electrode hold onto the orange elec trode boot and pull firmly on the electrode 4 Once the electrode has been removed Inspect inside the orange electrode boot for the retaining clip which holds the electrode in place If it is missing replace the ele...

Page 57: ...imply a fuel atomizer It reduces the diesel fuel into a fine spray which is mixed with incoming combustion air and is ignited within the combustion chamber Fuel Nozzle Component Test 1 Follow the directions for detaching the diesel burner in section 7 of this manual 2 Remove both the ignition cables from the ignition electrodes or connect a jumper wire with alligator clips across the metal tips of...

Page 58: ... loosen it a 1 4 turn and then firmly re tighten This will establish a seated fit and avoid any leaks 3 After replacing the fuel nozzle reattach the diesel burner head 4 Turn ON the diesel switch for 5 seconds then turn it OFF This will activate the diesel burner s prime cycle and flush the fuel system of any poten tial contaminants Perform this procedure twice 5 Test for normal operation NOTE Be ...

Page 59: ... sole noid shaft from the nozzle manifold using a 16mm wrench Discard the shaft and valve kit as replace ments are provided with the new fuel solenoid as sembly 3 Insert the contents of the new fuel solenoid valve kit into the new fuel solenoid shaft Slide the new fuel solenoid onto the fuel solenoid shaft Thread the new fuel solenoid shaft with fuel solenoid to the fuel nozzle manifold and tighte...

Page 60: ...he fuel level is below 1 4 the Aqua Hot diesel burner will not operate B Inspect the supply fuel line for kinks which would prohibit fuel flow C Inspect the supply fuel line for cuts which would cause the diesel burner to suck air D Inspect the fuel filter to make sure all fittings are tight including hose clamps Also make sure the fuel filter is tight E Inspect the Aqua Hot for loose or cracked f...

Page 61: ...nd plate inside the cast aluminum blower casing and secure in place with the four noz zle stand plate screws Install the grommets on the fuel return and supply banjo pipes and secure the pipes to the fuel pump with the new banjo bolts and gasket rings 8 Reconnect the C plug harness violet and brown wires to the fuel solenoid s and electrical terminals 9 Insert both the ignition cables into the rub...

Page 62: ... Page 62 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B Fuel Pump continued Figure 47 SECTION 8 DIESEL BURNER COMPONENTS TROUBLE SHOOTING ...

Page 63: ...o 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 Spin the combustion air blower by hand Placing one of the clutch halves ...

Page 64: ...9 Install a new snap ring into side A of the blower casing Once the snap ring is in place insert the remaining contents of the new bearing kit into side B of the blower casing starting with the wave washer Secure the bearing kit assembly in place with the remaining snap ring 10 Inspect the combustion air blower for warping and or damage If warping or damage is visible the combustion air blower mus...

Page 65: ... ignition coil to the C plug harness yellow and brown wires Rein stall the ignition coil and secure to the protection cap with the four ignition coil screws Reconnect the ignition cables to the ignition electrodes 16 Fit the nozzle stand plate inside the cast aluminum blower casing and secure in place with the four noz zle stand plate screws Reattach the fuel supply and return lines to the diesel ...

Page 66: ...ire to lead and brown wire to lead 4 Turn the power supply ON and watch for a spark to appear across the metal tips of the ignition elec trodes If a spark does not appear the ignition coil must be replaced 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 Befo...

Page 67: ...ug harness yellow and brown wires Attach the ignition coil to the pro tection cap with the four ignition coil screws then reconnect the ignition cables to the ignition elec trodes 3 Follow the instructions for reattaching the diesel burner and test for proper operation NOTE In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review ...

Page 68: ...cuit test VDC VAC Control Thermostat Circuit Test Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the C 1 and B 2 locations and turn the diesel switch ON If a voltage reading does not register on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test VDC High Limit Thermostat Circuit Test L...

Page 69: ...sts with a flat head screw driver Once the locking posts have been released pull on the diesel burner controller to re move it from the diesel burner head 2 Slide the new diesel burner controller into the diesel burner controller bracket Push down on the diesel burner controller until the locking posts snap into the bracket slots 3 Reconnect the B plug and the C plug NOTE Be sure to install the di...

Page 70: ...esel Burner must be removed to check the following 1 Photo Disc Bent or Tight The photo disc must be loose so it will seal on the combustion chamber properly 2 Combustion Chamber Warped Melted Inspect for signs of warping melted aluminum 3 Bad Nozzle If nozzle is spraying poorly it must be replaced 4 Fuel Pressure not at 145 PSI Check fuel pressure with fuel pressure gauge 4 Diesel Burner must be ...

Page 71: ...er off on repeatedly d Return Fuel Check Valve heaters manufactured before 2001 2 If The Heater Smokes During The Burn Cycle a Electrodes out of adjustment b Air in the fuel system c Bad nozzle d Fuel pressure e Fuel Pump f Intermittent Ignition Coil If the coil doesn t turn on the fuel sprays for 20 seconds before the photo eye shuts the fuel off SECTION 9 GENERAL TROUBLESHOOTING IF THE AQUA HOT ...

Page 72: ... 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 No Antifreeze in system SECTION 9 GENERAL TROUBLESHOOTING IF ONE OF THE AQUA HOT HEATING ZONES WILL NOT GET HOT ...

Page 73: ...ly 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 Antifreeze Concentration is incorrect a 30 50 antifreeze concentration 5 Operating Range of the heater I E Control Thermostat is incorrect a 175 F 210 F 6 Water Flow is too fast a Must be 1 5 GPM or Less 7 Mixer Valve is stuck knob does not turn fr...

Page 74: ...e tank ports to locate the leak e Pump 6 Burn Chamber Leak a If Antifreeze is running out of the tip of the exhaust pipe remove the burner and combustion chamber and inspect inside the burn chamber for leaks 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 followi...

Page 75: ...n 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 ...

Page 76: ... Page 76 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B APPENDIX A WIRING DIAGRAM ...

Page 77: ... Page 77 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B APPENDIX A WIRING DIAGRAM ...

Page 78: ... Close the pump manifold valve K Repeat steps B J for all three zone pumps i e Bedroom Bathroom and Living Room L Once all air had been bled from the system be sure that both the return manifold valve lower located on the left side of the diesel burner and the pump manifold valve upper are completely opened Reference Figure B2 M Once all air has been bled from the system be sure to connect and cla...

Page 79: ...Hydronic Heating System Service Manual Rev B APPENDIX B BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP Bedroom Return Bedroom Supply Bathroom Return Bathroom Supply Living room Return Living room Supply 13 lb Radiator Cap Figure B1 ...

Page 80: ... Page 80 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B APPENDIX B BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP Supply Ball Valve Return Ball Valve Drain Valve Figure B2 ...

Page 81: ...NDIX B BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP Air Blower Expansion Tank Tubing 13 lb Radiator Cap Using an Air Blower to pressurize the Boiler Tank NOTE If too much air pressure is applied to the boiler tank it will leak out around the radiator cap s rubber seal Figure B3 ...

Page 82: ...2S Hydronic Heating System Service Manual Rev B Coolant System Tester Pressurize System up to 15 psi Using a Coolant System Tester to pressurize the Boiler Tank Figure B4 APPENDIX B BLEEDING THE INTERIOR HEATING ZONE CIRCULATION PUMP ...

Page 83: ...or 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 Instructions for Checking Fuel Pressure NOTE Step 1 Remove the diesel burner 1 Refer to the section on detaching reattaching the diesel burner to detach the diesel burner Figure C1 Step 2 Installing t...

Page 84: ...trodes 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 In some installations it may be necessary to shine a light on the flame sensor to simulate a flame condition to shot of the ignition coil 2 Turn the diesel burner switch to the on position A pr...

Page 85: ... 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 In some installations it may be necessary to shine a light on the flame sensor to simulate a flame condition to shot of the ignition coil 2 Turn the diesel burner switch to th...

Page 86: ... 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 clock wise and to reduce the fuel pressure turn the pressure adjustment screw counter clockwise NOTE If the fuel pressure cannot be adjusted refer to the fuel pump section in section 8 Of this manu al for troubles...

Page 87: ... and or the domestic hot water during low heating de mand situations such as when moderate ambient temperatures exist and or when there is a low demand for domestic hot wa ter If the 120 Volt AC Electric Heating Element is not providing enough heat turn the Diesel Burner on in conjunction with the 120 Volt AC Electric Heating Element NOTE The Aqua Hot can continue to be used for interior zone heat...

Page 88: ...ere at least 5 heat exchangers installed in the Interior of the motor home B Are there cold air returns installed for every heat exchanger Reference Figure D2 C Are the heat exchangers mounted as close to the hot air outlet grill as possible Reference Figure D2 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 ho...

Page 89: ...he fuel nozzle Oils and or small dust or dirt particles from the hands may plug the nozzle s small orifice A par tially plugged orifice will restrict fuel flow which will affect the combustion process of the diesel burner APPENDIX E AQUA HOT MAINTENANCE Monthly Maintenance Check the antifreeze and water heating solution to ensure that it is at the proper level by visually checking the solution lev...

Page 90: ...rge the old fuel out of the nozzle holder to prevent contami nation of the replacement nozzle 3 Shut the Diesel Burner off and wait for unit to completely shut off Note Before performing an annual maintenance it is recommended to test run the Diesel Burner While testing inspect exhaust for smoke NOTE It is recommended that the replacement fuel filter be filled with clean diesel fuel prior to insta...

Page 91: ...t Maintenance Procedure Step 4 Remove The Diesel Burner 1 Locate the Diesel Burner s Controller and disconnect both plugs 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 Figure E4a Figure E4b Figure E4c ...

Page 92: ...from the Aqua Hot 4 to 5 inches before rotating the burner and then remove Step 5 Remove The Diesel Burner continued Aqua Hot Maintenance Procedure 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 Figure E5 Diode Wire Thermostats ...

Page 93: ...esult from touching a hot combustion chamber 2 Once the combustion chamber has been removed Use a long handled wire brush and brush the heat trans fer tabs to loosen soot deposits Failure to do so will reduce the Aqua Hot s heat transfer capabilities Heat Transfer Tabs NOTE If the heat transfer tabs are excessively sooty it may be necessary to vacuum the soot out of the heat transfer tabs If there...

Page 94: ... combustion chamber must be replaced 2 Inspect the aluminum Air Swirler for signs of warping If any part of the air swirler is warped the combustion chamber must be replace A Inspect the outer ring that the photo disc seats against for signs of warping B Inspect the back side of the Air Swirler for signs of warping between screws Step 6 Clean and Inspect the Combustion Chamber and Heat Transfer Ta...

Page 95: ...er CAUTION Failure to reinstall the combustion chamber will result in serious damage to the diesel burner 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 Figure E7 ...

Page 96: ...zzle 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 Broken or cracked Ears due to over tightening of eyebolts Photo Disc Figure E8 ...

Page 97: ...olish 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 Should heavy carbon deposits be present completely remove the flame sensor from the photo disc and clean with brake cleaner Metal Tips Flame Sensor Figure E9 ...

Page 98: ...ict fuel flow which will affect the combustion process of the diesel burner Be sure to reattach the diesel burner head prior to switching the heater ON Failure to do so may result in ignition of the diesel burner and serious bodily injury 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 2 When replacing the fuel nozzle be su...

Page 99: ...ing clamp bolt 4 Remove the electrode adjustment gauge NOTE Be sure not to over tighten the retaining clamp bolt when readjusting the ignition electrodes Over tightening the retaining clamp bolt will bend the retaining clamp and prevent the photo disc from floating freely Not allowing the photo disc to float freely will cause poor combustion and result in a smoky exhaust A bent retaining clamp can...

Page 100: ...clamp returns to proper form Step 13 Re Install Diesel Burner 1 Align the Diesel Burner with the Aqua Hot using the alignment tabs welded on the Aqua Hot 2 Swing the Eye Bolts around the Ears on the diesel burner and securely tighten using a 10mm socket with a 10 inch long extension NOTE When reinstalling the diesel burner be careful not to damage the photo disc or bend the electrodes Also be care...

Page 101: ...in the diesel burner s controller and mount 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 Figure E14a ...

Page 102: ...curely 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 When the diesel burner cycles back on check the exhaust for signs of s...

Page 103: ...o an adequate supply of FDA approved GRAS RV Antifreeze and turn on the demand water pump 5 Open and close all interior and exterior water faucets one at a time until only pure RV Antifreeze is present Perform this procedure for both the hot and cold faucets 6 Turn off Demand Water pump and remove the hose and re connect the domestic water demand pump s suction line to the fresh water storage tank...

Page 104: ... Page 104 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B ...

Page 105: ... Page 105 2011 Aqua Hot AHE 100 02S Hydronic Heating System Service Manual Rev B ...

Page 106: ...15549 East Highway 52 Fort Lupton CO 80621 Toll free 800 685 4298 phone 303 659 8221 fax 303 857 7881 www aquahot com SERVICE MANUAL AHE 100 02S ...

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