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Aqua-Hot Hydronic Heating System Shop Manual 09/04

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15549 East Highway 52 Fort Lupton, Colorado 80621 1-800-685-4298 Fax: 303-857-9000

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Содержание Aqua-Hot AHE-100-04S

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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