Vehicle Systems Aqua-Hot AHE-100-02S Shop Manual Download

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Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Shop Manual

Model Numbers

AHE-100-02S - 12 VDC

AHE-200-02S - 24 VDC

Summary of Contents for Aqua-Hot AHE-100-02S

Page 1: ...Aqua Hot Hydronic Heating System Shop Manual REV A 03 02 Shop Manual Model Numbers AHE 100 02S 12 VDC AHE 200 02S 24 VDC...

Page 2: ...l Burner Identification Plate 4 Diesel Burner Wiring Information 4 1 Control Unit Wiring 5 Diesel Burner Service Maintenance and Repair Information 5 1 General Maintenance 5 2 Detaching the Diesel Bur...

Page 3: ...ater Inlet Domestic Water Engine Coolant Return Diesel Fuel Supply Diesel Fuel Return Diesel Burner Control Unit Mixer Valve Electric Heating Element Access Panel Zone Relay C Zone Relay A Zone Relay...

Page 4: ...ecreational vehicles and in marine applications Complies with the requirements of UL 307A and USCG CFR33 12 VDC 110 VAC 1650 W Fuel Diesel 1 or 2 Firing rate 50 000 btu hr patent No 5 025 985 and 5 06...

Page 5: ...at Control Switch Indicator Light Engine Preheat Switch Brown Living Room A Zone Cozy Heat Exchanger Bathroom B Zone Cozy Heat Exchanger Bedroom C Zone Cozy Heat Exchanger T STAT Fresh Water Tank Bay...

Page 6: ...und COMMON White Wire to White ROMEX Wire GROUND Green Wire to ROMEX Copper Wire 120 VAC 1650 Watt Electric Heating Element 120 VAC POWER SUPPLY Black ROMEX Wire to LOAD Black Wire Orange Wire VDC Con...

Page 7: ...ir Fan 14 Fuel Pump 6 Fuel Solenoid Valve 15 Fuel Ports Supply Return 7 Electrode Holder 16 Combustion Air Port Intake 8 Ignition Electrodes with Adjustable Shutter 9 Fuel Nozzle 3 1 Diesel Burner Com...

Page 8: ...Diesel Burner is operational anytime the operator activates the Diesel Burner Control Switch to the ON position The Diesel Burner will then automatically maintain the temperature of the coolant witho...

Page 9: ...Diesel Burner I D Plate Figure 6 Fabrikschild Duplikat gultig nur zusammen mit Original Thermosysteme GmbH MADE IN GERMANY HEIZGERAT Typ Spannung El Leistung Warmestrom Brennstoff zul Betriebsuberdru...

Page 10: ...ed Indicator Light Green To Ignition Coil Yellow From Normally Closed VDC Control Thermostat White Flame Detector Green For All Heater Components Brown C Plug B Plug 4 1 Control Unit Wiring S S S S Se...

Page 11: ...tion Chamber if necessary see Figure 8 This simple tune up will keep your Aqua Hot running smoothly throughout the year This annual tune up will also allow service personnel to inspect for wear and te...

Page 12: ...e Bolts out of the way 2 With both hands carefully pull the Diesel Burner away from the Aqua Hot approximately 4 5 inches Please note that you may have to lift the head slightly while pulling it away...

Page 13: ...ection Photocell 5 3 Flame Detection Photocell Ignition Electrodes 5 4 Ignition Electrodes Note Electrode Adjustment Gauge is located on the outside surface of the Diesel Burner on the lefthand side F...

Page 14: ...M vice M vice M vice M vice Maintenance and R aintenance and R aintenance and R aintenance and R aintenance and Repair I epair I epair I epair I epair Infor nfor nfor nfor nformation mation mation mat...

Page 15: ...Maintenance and R aintenance and R aintenance and R aintenance and R aintenance and Repair I epair I epair I epair I epair Infor nfor nfor nfor nformation mation mation mation mation Figure 14 Page 1...

Page 16: ...across the Thermostat Is there continuity across the Thermostat 1 Replace the Thermostat 2 Attempt heater restart 1 Remove the Aqua Hot s ACCESS COVER 2 Remove the THERMOSTAT ACCESS PANEL see Figure 1...

Page 17: ...estart 1 Check the Control Switch s A wire connections B fuse E for continuity see Figure 3 2 Check DC power supply wires and connections see Figure 3 3 Reattach DIESEL FUEL RETURN line see Figure 1 4...

Page 18: ...OL UNIT 1 see Figure 7 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 8 see Figure 11 Does a spark disappear after th...

Page 19: ...e Control Switch OFF 2 Remove FUEL NOZZLE 9 see Figure 12 3 Turn the Control Switch ON After approx 20 seconds fuel should flow freely from the fuel nozzle port Does the Solenoid Valve operate properl...

Page 20: ...ttach DIESEL BURNER HEAD see Figure 9 and attempt heater restart 1 Turn the Control Switch OFF 2 Replace FUEL NOZZLE 9 see Figure 12 3 Retest Fuel Nozzle spray pattern fine mist of fuel present 4 Reco...

Page 21: ...or for six months 180 days whichever is greater 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 installation assembl...

Page 22: ...300 AH HH WH 56 WPX 274 313 Electrode Ignition DBW 2010 AH HH WH 59 WPX 638 78A Sensor Flame DBW 2010 300 AH HH WH 61 WPX 887 71A Photo Disc DBW 2010 AH HH WH 62 WPX 886 41A Nozzle Fuel 35 GPH DBW 20...

Page 23: ...PE 600 190 Gauge Kit Fuel Pressure DBW 2010 300 AH HH WH 140 Tester CO 2 DBW 2010 300 AH HH WH Order item 140 from a Grainger Industrial Supply Store near you or visit the Grainger website at www grai...

Page 24: ...Heating Specialists Manufacturers and Distributors Manufacturers and Distributors Manufacturers and Distributors Manufacturers and Distributors Manufacturers and Distributors 15549 East Highway 52 For...