Vehicle Systems Aqua-Hot AHE-100-04S Shop Manual Download

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Aqua-Hot Hydronic Heating System Shop Manual 09/04

SECTION 5: DIESEL-BURNER

Component

Overview

5.1

Component Overview

Diesel-Burner Controller

10.

Heat Exchanger

Motor

11.

Combustion Chamber

Ignition Coil

12.

Exhaust Port

Clutch

13.

Flame Sensor

Combustion Air Blower

14.

Fuel Pump

Fuel Solenoid Valve

15.

Fuel Tubes (Supply / Return)

Electrode Boots

16.

Combustion Air Intake Port,

Ignition Electrodes

with Adjustable Shutter

Fuel Nozzle

Figure

Page 9

Summary of Contents for Aqua-Hot AHE-100-04S

Page 1: ...Aqua Hot Hydronic Heating System Shop Manual 09 04 Shop Manual Model Numbers AHE 100 04S 12 VDC AHE 120 04X 12 VDC AHE 130 04X 12 VDC...

Page 2: ...Indicator Light 4 8 Pump 1 Indicator Light 4 9 Pump 2 Indicator Light 4 10 Pump 3 Indicator Light 4 11 Low Battery Voltage Fault Indicator Light 4 12 Low Temp Cutoff Status Indicator Light 4 13 Diesel...

Page 3: ...t Figure 12 Diesel Burner Motor RPM Test Figure 13 Diesel Burner Motor Replacement Figure 14 Diesel Burner Motor Replacement continued Figure 15 Diesel Burner Flame Sensor Components Figure 16 Diesel...

Page 4: ...alve Electric Heating Element Access Cover Fill Radiator Cap VAC Access Cover VAC Service Input Thermostat Access Cover Marking Plates Hour Meter Heating Zones Status 5 4 3 2 1 Electric Heating Elemen...

Page 5: ...r MUST BE supplied from outside the vehicle CAUTION This appliance operates on both AC and DC Electrical Power The AC Powered Electrical Heating Element can be wired using flexible nonmetallic cable R...

Page 6: ...e Heating System reference Figures 1 and 2 for Marking Plate information and view the Model number AHE 100 04S This model features a single 120 VAC 1650 Watt Electric Heating Element NOTE Reference Ap...

Page 7: ...Battery Voltage Fault This reset can be accomplished by turning OFF the Diesel switch for approximately 30 seconds then turning the switch back ON reference Section 4 4 and 4 11 3 3 Electric Switch N...

Page 8: ...ua Hot s Boiler Tank The 120 VAC 2000 Watt Electric Heating Element will heat the Aqua Hot System to the maximum operating temperature 190 F 5 degrees in approximately 1 2 hours High The process of mo...

Page 9: ...These five indicator lights separately will illuminate GREEN whenever a Zone Thermo stat for a particular zone is calling for heat reference Figure 5 The GREEN indicator lights also indicate that VDC...

Page 10: ...Aqua Hot s VDC VAC Control Thermostat will automatically activate the Diesel Burner and or the 120 VAC Electric Heating Element only if the Diesel and or the Electric switch is in the ON position In...

Page 11: ...ed to the VDC battery system reference Section 4 4 for reset instructions 4 12 Low Temp Cutoff Status Indicator Light NOTE This indicator light circuitry is not utilized on these Aqua Hot models 4 13...

Page 12: ...er Controller 10 Heat Exchanger 2 Motor 11 Combustion Chamber 3 Ignition Coil 12 Exhaust Port 4 Clutch 13 Flame Sensor 5 Combustion Air Blower 14 Fuel Pump 6 Fuel Solenoid Valve 15 Fuel Tubes Supply R...

Page 13: ...re reaches the preset temperature of approximately 190 5 degrees Fahrenheit A NOTE If process A occurs the Low Temp Cutoff Status Aqua Hot Heating Status and Diesel Burner Status lights on the Electro...

Page 14: ...e After approximately 10 25 seconds the Fuel Solenoid Valve opens and fuel is released into the Fuel Nozzle then sprayed into the Combustion Chamber Fuel Pump Fuel Solenoid Valve Fuel Nozzle Combustio...

Page 15: ...mixture is then ignited creating combustion Ignition Electrodes Ignition Coil Combustion The combustion s flame is detected by the Flame Sensor and the Ignition Coil is then automatically switched off...

Page 16: ...s 190 5 degrees Fahrenheit 5 Cool Exhaust Gases 6 NOTE Whenever the Diesel Burner is switched off by the VDC VAC Control Thermostat it will automatically be reactivated once the Aqua Hot Boiler Tank s...

Page 17: ...ysteme GmbH MADE IN GERMANY HEIZGERAT Typ Spannung El Leistung Warmestrom Brennstoff zul Betriebsuberdruck Prufzeichen Fabriknummer Inbetriebnahmejahr 2001 2002 2003 DBW 2010 75 12 V 60W 13 2 kW Diese...

Page 18: ...2 B 1 On Off Switch Circuit with Low Voltage Protection Yellow Wire to JP 4 Pin 7 B 3 B 4 B 6 C 1 C 8 C 7 C 6 C 4 C 2 C 5 B 6 Indicator Light Circuit Green Wire to JP 4 Pin 1 C 5 Ground Circuit Brown...

Page 19: ...Diesel Burner operates 3 minute prime cycle only but does not ignite TS3 The Aqua Hot s Diesel Burner ignites after several starting attempts TS4 The Aqua Hot s Exhaust System sputters TS5 The Aqua Ho...

Page 20: ...may result I Check the coolant level in the Aqua Hot s Expansion Tank and the Boiler Tank if necessary A If coolant level is satisfactory Continue troubleshooting If coolant level is low Add coolant...

Page 21: ...tatus light illuminate A If YES The VDC VAC Control Thermostat continued on next page SECTION 7 TROUBLESHOOTING Section 7 1 continued Section 7 1 continued A If YES Check the JP 3 Plug for loose wire...

Page 22: ...sel Burner fails to operate Q4 Is the Diesel Burner s Motor operating Quick Check Listen at the heater for the Diesel Burner s Motor to operate or check for output air at the heater s exhaust pipe A I...

Page 23: ...d Failure to do so could result in additional overheating incidents II Turn the Diesel switch ON and allow the Aqua Hot to reach operating temperature i e until the Diesel Burner cycles OFF Locate bot...

Page 24: ...oller s Component Test A If the Controller is not functioning properly The Controller must be replaced reference Section 8 11 for replacement instructions If the Controller is functioning properly Con...

Page 25: ...onent Test A If the Fuel Pump is not functioning properly The Fuel Pump must be replaced reference Section 8 8 for replace ment instructions If the Fuel Pump is functioning properly Reference NOTE 7 2...

Page 26: ...ition Electrodes are in poor condition The Ignition Electrodes must be replaced reference Section 8 5 for replacement instructions If the Ignition Electrodes are not properly adjusted Adjust the Ignit...

Page 27: ...and ensure that the fuel line is com pletely submersed in the fuel then turn the Diesel switch ON Are air bubbles visible in the container of fuel when the Diesel Burner is operating A If air bubbles...

Page 28: ...rly I In order to determine if the Controller is functioning properly reference Section 8 11 and perform the Controller s Component Test A If the Controller is not functioning properly The Controller...

Page 29: ...sputtering from the Aqua Hot s exhaust system A If constant sputtering exists Continue troubleshooting NOTE 7 4 B Inspect the clear bowl of the Fuel Filter for water If water exists be sure to purge...

Page 30: ...both fuel lines at the filter head prior to any fitting removal If fittings are removed and reinstalled be sure to remove both clamps prior to attempting a heater restart Failure to do so could resul...

Page 31: ...s Fuel Pressure Adjustment Check A If the Fuel Pump is not producing the correct pressure Adjust the fuel pressure to 145 psi If the Fuel Pump is producing the correct pressure Continue troubleshootin...

Page 32: ...erefore be sure to perform the inspections listed below until the air leak has been detected 1 Inspect the fuel system supply side from the vehicle s fuel tank to the Diesel Burner Inspect the fuel sy...

Page 33: ...r to perform the following checks it is necessary to locate the Aqua Hot s Electronic Controller and Switch Panel reference Illustration 7 6 1 Q1 Is the Electronic Controller s Low Battery Voltage Fau...

Page 34: ...ad NOTE 7 6 B If after testing and correcting the battery system the Low Battery Voltage Fault indicator light continues to illuminate and or if the Low Voltage Reset button will not reset the Elec tr...

Page 35: ...Gas Analyzer will be required reference Illustration 7 6 3 Also reference Section 11 for the Bacharach Fyrite CO Analyzer s part number information if necessary I When using the Bacharach Fyrite CO An...

Page 36: ...altitude area be sure to properly adjust the Diesel Burner so that it operates within the 10 5 11 5 CO range NOTES 7 6 F If the proper CO value cannot be obtained perform each of the following inspect...

Page 37: ...or operation Is the Circulation Pump operating rotating A If YES Check the particular Heating Loop s plumbing system for kinks and or any other types of flow restrictions If NO Perform each of the fol...

Page 38: ...perly installed with the Pin Jumper covering both pins in order to provide continuity A If YES Continue troubleshooting If NO Reseat the Pin Jumper on both pins NOTE If reseating the Pin Jumper does n...

Page 39: ...hot water performance A If YES Continue troubleshooting If NO Adjust the antifreeze and water heating solution accordingly until the proper concentration is obtained Q3 Is the shower s flow rate i e...

Page 40: ...56 degrees Hot water causes a third degree burn in one second 149 degrees Hot water causes a third degree burn in two seconds 133 degrees Hot water causes a third degree burn quickly 115 120 degrees G...

Page 41: ...Appendix A Does the Electronic Controller s Electric Heating Element Status light illuminate continued in next column A If YES Check for loose wire connections at the Electric switch and at the JP 2...

Page 42: ...be sure to use extreme caution when performing each check as 120 VAC power will be present at each of the electrical components Failure to do so may result in serious bodily injury i e an electrical s...

Page 43: ...sistance After turning the Engine Preheat switch ON TS11 The Aqua Hot s Engine Preheat System does not preheat the engine NOTE 7 11 A The Diesel or Electric switch must be activated along with the Eng...

Page 44: ...800 685 4298 for assistance If NO Locate the Electronic Controller s JP 2 Plug and check for DC voltage at the Preheat O pin reference Appendix A NOTE 7 11 B Be sure to utilize the JP7 GND stud as a g...

Page 45: ...chnical Support Department at 1 800 685 4298 for assistance Annually WARNING Before cleaning or servicing disconnect all power supplies To keep the Aqua Hot running smoothly it is ideal to have the Di...

Page 46: ...proximately 4 5 inches Please note that you may have to lift the Diesel Burner Head slightly while pulling it away from the Aqua Hot 3 Rotate the Diesel Burner Head upward until all internal component...

Page 47: ...tions NOTE The functionality of each component can be determined by completing the manual checks as listed in the Component Test or the compo nents can be tested by using a Controller Tester Reference...

Page 48: ...rown wires from the C Plug Harnesses Black and Brown wires reference Figures 12 and 13 Connect the Motor s wires directly to a 12 Volt DC power supply reference Figure 12 Turn the power supply ON and...

Page 49: ...reinstalling the Motor Worn Bearings can cause lower than normal RPM readings and premature Motor wear To properly test for worn Bearings reference Section 8 9 for the Bearings Function Test B The Mo...

Page 50: ...9 04 SECTION 8 DIESEL BURNER SERVICE MAINTENANCE AND REPAIR INFORMATION Motor continued Figure 13 Figure 14 Ignition Coil Mounting Screws Housing Casting Casting Clutch Halves Black Wire to Diesel Bur...

Page 51: ...acing a shop rag over the Flame Sensor s glass surface to simulate a no flame condition then remove the rag and expose to a light source to simulate a flame condition If the Flame Sensor is operating...

Page 52: ...tal tips of the Ignition Electrodes with a Scotch Brite pad or similar reference Figure 16 If the Ignition Electrode s electrical insulator reference Figure 16 is cracked and or damaged the Ignition E...

Page 53: ...ghtly until the Retaining Clamp returns to proper form i e flat 4 Remove the Electrode Adjustment Gauge and reattach to the Diesel Burner Head Replacement Procedure 1 Disconnect the Ignition Cables fr...

Page 54: ...r to activate the Diesel Burner After approximately 20 seconds the Fuel Solenoid will click and a fine mist of fuel should appear from the Fuel Nozzle in a cone shaped spray pattern Remove the B Plug...

Page 55: ...nition of the Diesel Burner and serious bodily injury 4 Turn ON the Diesel switch reference Figure 4 for 5 seconds then turn it OFF This will activate the Diesel Burner s prime cycle will operate the...

Page 56: ...on Cleaning Tips Maintenance N A Adjustment Procedure N A Replacement Procedure 1 Disconnect the Ignition Cables from the Ignition Electrodes and loosen the Retaining Clamp Bolt reference Figure 16 2...

Page 57: ...e in place with the Retaining Clip Connect the C Plug Harness Violet and Brown wires to the Fuel Solenoid Valve s and Electrical Terminals reference Figure 18 9 Perform the Ignition Electrodes Adjustm...

Page 58: ...Section 8 2 for detaching and reattaching instructions Component Test Clamp off and remove the Aqua Hot s Fuel Return and Fuel Supply Lines reference Figure 1 Attach a short piece of fuel line to bot...

Page 59: ...crews Pump Mounting Screw Fuel Pressure Regulator Ignition Electrodes Photo Disc Retaining Clip Flame Sensor Retaining Clamp Fuel Nozzle Manifold Plate Screw 2 Fuel Nozzle Manifold Plate Screw 1 Fuel...

Page 60: ...rn the Diesel switch ON reference Figure 4 A pressure will register on the Fuel Pressure Gauge once the Fuel Solenoid opens after approximately 10 25 seconds 3 If the Fuel Pressure Gauge registers a 1...

Page 61: ...DIESEL BURNER SERVICE MAINTENANCE AND REPAIR INFORMATION Fuel Pump continued Fuel Pump increase decrease 60 80 100 120 140 160 180 200 40 20 0 psi T F O R C H S A MADE IN U S A Fuel Pressure Gauge Fig...

Page 62: ...Remove the Fuel Nozzle Manifold Plate by pulling on the Fuel Nozzle Manifold until the plate releases from the cast aluminum Blower Casting reference Figures 13 and 19 5 Remove the two Fuel Mounting S...

Page 63: ...lectrodes then remove the fuel line clamps from both the Fuel Return Line and the Fuel Supply Line reference Figure 19 9 Reinstall the Photo Disc and secure it in place with the Retaining Clip referen...

Page 64: ...s section Component Test N A Cleaning Tips Maintenance N A Adjustment Procedure N A Replacement Procedure 1 Clamp off and remove the Fuel Supply Line and Fuel Return Line from the Diesel Burner Head r...

Page 65: ...Side A and Side B of the Blower Casting reference Figure 23 Push all the contents of the Bearing Kit out of the Blower Casting s bore bearing cavity Discard the Retaining Nut steel Drive Gear Snap Rin...

Page 66: ...and on the Combustion Air Blower s shaft Attach the Motor and flange assembly with the recessed edge of the Motor Flange in line with the Wiring Access Slot of the Blower Casting to the Blower Housin...

Page 67: ...nued Blower Housing Screws Blower Housing Combustion Air Blower w shaft Blower Casing O Ring Blower Casting Rubber Grommets Dished Surface Washer Dished Surface Washer Flat Washer Snap Ring Bearing Sp...

Page 68: ...wn wires from the C Plug Harness Yellow and Brown wires Connect the Ignition Coil wires directly to a 12 Volt DC power supply i e Black wire to lead and Brown wire to lead Turn the power supply ON and...

Page 69: ...on If one of the conditions below does not exist please contact the Technical Support Department at 1 800 685 4298 for additional assistance Condition 1 A battery voltage level of between 11 5 and 14...

Page 70: ...09 04 COM V 5 2 1 B 2 Battery Circuit Brown Wire to JP 4 Pin 4 B 4 Battery Circuit Red Wire to JP 4 Pin 3 B Plug B 1 B 2 B 3 B 4 B 6 Figure 26 Diesel Burner Controller continued SECTION 8 DIESEL BURNE...

Page 71: ...Figures 4 and 8 If a voltage reading does not register on the voltmeter the Controller must be replaced If voltage is present proceed to the next circuit test VDC High Limit Thermostat Circuit Test Lo...

Page 72: ...ocking posts with a flat head screwdriver Once the locking posts have been released pull on the Controller to remove it from the Diesel Burner Head 2 Slide the new Controller into the Controller Mount...

Page 73: ...nual 09 04 SECTION 8 DIESEL BURNER SERVICE MAINTENANCE AND REPAIR INFORMATION Diesel Burner Controller continued 7 11 Diesel Burner Controller Figure 27 Bracket Slot Locking Post Diesel Burner Control...

Page 74: ...is conditional upon proper use of the Heater by the end user This warranty does not apply to damage or failure of the AQUA HOT Heater or the vehicle into which it was installed due to improper instal...

Page 75: ...roller Diesel Burner 12 VDC Coil Ignition 12 VDC Motor Combustion Air Fuel Pump 12 VDC Valve Fuel Solenoid 12 VDC Valve Fuel Solenoid Kit Electrode Ignition Sensor Flame Disc Photo Pump Fuel Kit Nozzl...

Page 76: ...0 280 WPE 600 190 Gauge Adjustment Electrode Tester Controller Gauge Fuel Pressure Gas Analyzer CO Order Grainger Part 6T153 from a Grainger Industrial Supply Store near you or visit the Grainger webs...

Page 77: ...Aqua Hot Hydronic Heating System Shop Manual 09 04 Wiring Diagrams Appendix A...

Page 78: ...2 BLUE Circ Pump 3 Circ Pump 2 Circ Pump 1 1 1 JP 4 JP 3 JP 2 JP 1 OPTIONAL 14 BLK WHT WHT RED BLK BLU BLU RED BLK VIO VIO BLK RED ORG ORG BLK RED 1 2 4 6 1 2 4 6 1 2 6 4 TO 12VDC POWER SUPPLY I E BAT...

Page 79: ...rc Pump 2 Circ Pump 1 1 1 JP 4 JP 3 JP 2 OPTIONAL 14 BLK L2 TO 120 VAC G L1 N 2 BLK 5 RED 4 RED ELECTRIC HI LOW BLU BLU YEL ORG VIO BRN WHT GRN YEL GRN RED BLK ORG ORG RED BLK VIO VIO BLK RED BLU BLU...

Page 80: ...C D V 2 1 2 P M U P N O I T A L U C R I C C D V 2 1 1 P M U P N O I T A L U C R I C P M U P C D V 2 1 X O B N O I T C N U J N A F 5 N A F 5 O M R E H T 5 I M R E H T 5 N A F 4 N A F 4 0 M R E H T 4 I...

Page 81: ...Aqua Hot Hydronic Heating System Shop Manual 09 04 Illustrations Appendix B...

Page 82: ...Shop Manual 09 04 APPENDIX B RESETTING THE HIGH LIMIT THERMOSTAT VDC High Lim it Therm ostat To RESET Simply press the Red button on the Thermostat VAC High Lim it Therm ostat To RESET Simply press th...

Page 83: ...Heat Exchanger Fresh Water Tank Heat Exchanger Living Room Exchanger Living Room Heat Exchanger Kitchen Heat Exchanger Circulation Pump 1 Circulation Pump 2 Circulation Pump 3 Heating Zone 1 Heating Z...

Page 84: ...Kitchen Heat Exchanger Bathroom Heat Exchanger Bedroom Heat Exchanger Engine Engine Preheating Fresh Water Tank Heat Exchanger Heating Loop 2 Bathroom and Fresh Water Tank Bay Heating Loop 1 Bedroom A...

Page 85: ...a Hot Hydronic Heating System Shop Manual 09 04 www vehiclesys com 15549 East Highway 52 Fort Lupton Colorado 80621 1 800 685 4298 Fax 303 857 9000 Copyright 2004 Vehicle Systems Inc All rights reserv...

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