AHE-600-D01 AHE-675-D01 SERVICE MANUAL © 2013 Aqua-Hot Heating Systems Inc.
Table of Contents Section 1: Introduction to the Aqua-Hot 600 Series Introduction ............................................................................................................ Page 6-8 Danger, Warning, Caution, and Note Box Definitions............................................. Page 6 Model Differentiation ..............................................................................................
Section 6: Electronic Controller General Facts ........................................................................................................... Page 44 Secondary 12 Volt DC battery Connection ............................................................... Page 45 Terminal Strips with Screw-Type Fasteners ............................................................. Page 45 Low Voltage Reset Feature ......................................................................................
Section 10: Diesel-Burner Components and Repair Information (continued) Fuel Pump .............................................................................................................. Page 79-81 Bearings ................................................................................................................. Page 82-84 Ignition Coil ............................................................................................................ Page 85-86 Controller .............................
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 600 series Hydronic heating system. The Aqua-Hot 600 heating system features a 12 Volt-DC powered diesel-burner and two AC powered electric heating element.
SECTION 1: INTRODUCTION When the engine preheat system is activated via the interior switch panel, 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. The heated engine coolant is then transported back to the engine where it transfers the heat to the engine to gradually warm it.
SECTION 1: INTRODUCTION TO THE AQUA-HOT 600 SERIES Aqua-Hot Model Differentiation (600 series) Aqua-Hot Heating Systems, Inc. Manufactures two individual models of the Aqua-Hot 600 series Hydronic Heating Systems. The varying factor between these two models is the output of the Electric Heating Elements featured.
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Figure 1 Diesel Burner, Heat Input (Firing Rate) ..................................................................................................................................... 56,000 BTU/hr Diesel Burner, Fuel Consumption (Continuous Operation) .......................................................................................................... 0.40 gal/hr Heater, Voltage/Maximum Power Consumption .........................................................
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Each Aqua-Hot heating system possesses an I.D. label on the unit itself. This I.D. label details the specifications of the heater, to what standard it has been tested, and important safety notices. Figure 2 Use a 25 1 inch 3 inches 3 inches © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Figure 3 Thermostat Access Panel Return Manifold 13 LB Radiator Cap AC Wiring Ports VAC Wiring Access Panel Zone 1 Circulation Pump Zone 2 Circulation Pump Zone 3 Circulation Pump I.D. Label Engine Preheat Pump Domestic Water Tempering Valve Diesel Burner © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Figure 4 Engine Preheat Inlet Port Engine Preheat outlet Port Diesel Fuel Inlet Port Diesel Fuel Outlet Port Hot Water Outlet Port Cold Water Inlet Port © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Figure 5 Thermostat Access Panel Fluid Level Sensor Control Thermostat High Limit Thermostats A.C. Relay © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Heat Source is selected from the Interior Switch Panel Chart 1 “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
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Antifreeze and Water Heating Solution: As the antifreeze type and mixture ratio is essential to the Aqua-Hot’s performance and ability to comply with regulations, the following information is being supplied to understand various types of antifreeze, the quality of water necessary, and the mixture ratio. Aqua-Hot Heating Systems Inc. recommends CAMCO’s Boiler Antifreeze -100°. tivity characteristics.
SECTION 2: AQUA-HOT 600 SERIES OVERVIEW Freeze Point and Burst Point: Summary: Antifreeze lowers the freezing point of any liquid, to which it has been added, by preventing the formation of ice crystals; however, as the ambient temperature continues to decline, the water in the solution will attempt to attain a solid state. The point in which the water begins to solidify is termed the “Freeze Point.
SECTION 3: INTERIOR SWITCH PANEL The interior switch panel is used to control the two potential heating sources for the Aqua-Hot’s boiler tank, as well as to control the engine preheat feature. When a switch is activated, the indicator light on the switch will illuminate.
SECTION 3: INTERIOR SWITCH PANEL AHE-600-D01 - Electric Element (s) AHE-675-D01- Electric Element (s) Function: The “Electric switch, in conjunction with the “High/Low” switch, activates the Aqua-Hot’s Electric Heating Element (s), thereby illuminating the indicator light on the switch; reference Figure 7.
SECTION 3: INTERIOR SWITCH PANEL Figure 8a Original Switch - Obsolete © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 3: INTERIOR SWITCH PANEL—MANUFACTURED AFTER 09/01/2011 Replacement Switch Figure Figure8b 8b For Heaters Manufactured After 09/01/2011 Electric High/ Low 10 9 Pin # 2 Pin# 4 Pin # 6 Pin# 9 Switch 10 9 Engine Preheat Switch 10 9 Diesel Burner Switch 10 2 2 2 2 4 4 4 4 Jumper Wire Switch Pin 2# 1 Pin# Electric Element Switch Jumper Wire Electronic Controller To To Harness Harness Yellow Yellow Wire Wire # 38 #38 To Harness Green Wire # 39 To Harness Green Wire To #39Harness
SECTION 4: AQUA-HOT COMPONENTS This section details various components of the Aqua-Hot that may require troubleshooting and/or replacement in the event of a malfunction. The diesel-burner and its components are detailed in Section 9 of this manual. If the “Low Tank-Level Cutoff” indicator light on the electronic controller extinguishes when the jumper wire is installed, inspect the wire harness for damaged or severed wires.
SECTION 4: AQUA-HOT COMPONENTS 7. Connect the replacement Fluid Level Sensor’s wires in the same configuration as the removed Fluid Level Sensors wires. 8. Refill the Aqua-Hot’s Boiler tank with the proper water/ antifreeze mixture. 9. Test for proper operation. Figure 9 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 4: AQUA-HOT COMPONENTS Thermostats Control Thermostat: NOTE: The diesel-burner and/or electric element switch must be in the on position, for the “Heating Status” indicator light on the electronic controller to illuminate. If the “Heating Status” indicator light on the electronic controller does not illuminate with the jumper wire installed, follow the instructions in this manual to replace the electronic controller.
SECTION 4: AQUA-HOT COMPONENTS 6. Screw the replacement control thermostat into the port on the Aqua-Hot’s boiler tank and tighten securely with a 7/8 socket. 7. Connect the replacement control thermostat’s wires in the same configuration as the removed control thermostat’s wires. 8. Refill the Aqua-Hot’s boiler tank with the antifreeze and water heating solution. 9. Test the Aqua-Hot for normal operation.
SECTION 4: AQUA-HOT COMPONENTS AC High-Limit Thermostat : Right Electric Element NOTE: If the high-limit thermostat has tripped, troubleshoot the control thermostat, and verify the boiler tank is full of the antifreeze-water solution. 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.
SECTION 4: AQUA-HOT COMPONENTS AC High-Limit Thermostat: Left Electric Element NOTE: If the high-limit thermostat has tripped, , troubleshoot the control thermostat, and verify the boiler tank is full of the antifreeze-water solution. 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.
SECTION 4: AQUA-HOT COMPONENTS DC High-Limit Thermostat: The DC high-limit thermostat serves 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 allows the current for the diesel-burner to pass through it until the boiler tank reaches a temperature of 220°F.
SECTION 4: AQUA-HOT COMPONENTS Figure 13 220 °F D.C. High Limit Thermostat Webasto Thermostat Plug Valves Check Valve: 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 4: AQUA-HOT COMPONENTS Replacement Procedure: 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. FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD 7. Remove the hose barb fitting from the defective check valve. 8. Clean the hose barb fitting and then wrap the hose barb fitting’s pipe threads with Teflon tape. 9.
SECTION 4: 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: There is a lack of hot domestic water. 2. Drain the water pressure by opening the faucets and allowing the water to drain. 3. Remove the Diesel Burner from the Aqua Hot. 4.
SECTION 4: AQUA-HOT COMPONENTS Figure 15 Mixer Valve Assembly Hot Water Outlet Port Cold Water inlet Port © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 4: AQUA-HOT COMPONENTS Pumps Circulation Pumps #1, #2 and #3: The circulation pumps 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. Troubleshoot the circulation pumps if the following condition has occurred: B. With the jumper wire installed, check the indicator light corresponding to the pump not operating. If the indicator light illuminates green, complete the following: A.
SECTION 4: AQUA-HOT COMPONENTS Replacement Procedure: FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR 5. Remove the hoses from the defective circulation pump. 6. Release the pump from the mounting bracket by pulling on each Nylatch plunger, then remove the defective pump from the Aqua-Hot. 7. Slide the hoses back onto the replacement pump and set the constant tension clamps back into place. 8.
SECTION 4: AQUA-HOT COMPONENTS Pumps Engine Preheat Pump: A. Verify that the low temperature cutoff light and the diesel burner/electric heating element status lights are illuminated on the electronic controller. 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. B.
SECTION 4: AQUA-HOT COMPONENTS The Engine Preheat Pump indicator light illuminates red on the electronic controller. 3. Disconnect the defective engine preheat pump’s wires by separating the quick-disconnect terminals. 4. Using constant tension pliers, loosen and slide back the constant tension clamps securing the hoses to the engine preheat pump. 5. Remove the hoses from the defective engine preheat pump. 6.
SECTION 4: AQUA-HOT COMPONENTS If the “Electric Heating Element Status” indicator light illuminates on the electronic controller with the jumper wire installed, check the Electric Element Switch, on the interior switch panel for functionality. Electrical - AC Electric Heating Element: Right If the “Electric Heating Element Status” indicator light does not illuminate on the electronic controller with the jumper wire installed, follow the instructions in this manual to replace the electronic controller.
SECTION 4: AQUA-HOT COMPONENTS 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 involve the boiler tank and the potential for hot coolant, be sure the heater has adequately cooled. 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. E.
SECTION 4: AQUA-HOT COMPONENTS Electrical - AC If the “Electric Heating Element Status” indicator light illuminates on the electronic controller with the jumper wire installed, check the Electric Element Switch, on the interior switch panel for functionality. Electric Heating Element: Left There are two different Models in the Aqua-Hot 600 Series. The Aqua-Hot 600 has 2-2000 Watt 120 VAC electric heating elements.
SECTION 4: AQUA-HOT COMPONENTS NOTE: The Aqua Hot 600 will have 120 VAC present at the wires for the left electric element, while the Aqua-hot 675 will have 240 VAC present at the wires for the left electric element. Replacement Procedure: FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING D. Using an amp-meter, verify that amps are present at the element’s wires.
SECTION 4: AQUA-HOT COMPONENTS Figure 19 Left Electric Element Right Electric Element © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 4: AQUA-HOT COMPONENTS AC Relay: Right A. Locate the AC wires connected to the AC relay (pins 2 and 4), and remove the AC wires from the relay. The AC relay is an electrical device where the DC circuit from the electronic controller determines whether the AC power is permitted to flow to the electric heating element.
SECTION 4: AQUA-HOT COMPONENTS C. Locate the Left AC relay and check pin #1 for 12VDC +. AC Relay: Left The AC relay is an electrical device where the DC circuit from the electronic controller determines whether the AC power is permitted to flow to the electric heating element. This allows the electronic controller to switch the electric heating element on and off in conjunction with the interior switch panel and control thermostat even though the electric heating element is on a separate circuit.
SECTION 4: AQUA-HOT COMPONENTS AC Relay: Left (Continued) 7. Using the wiring diagram in Appendix A, connect the wires previously removed to the replacement AC relay. 8. Secure the Thermostat Access cover in place Figure 20 Left A.C. Relay Right A.C. Relay © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 5: ELECTRONIC CONTROLLER Electronic Controller Overview The electronic controller is an electronic circuit board that controls the electrical functions of the Aqua-Hot heating system. All wiring for the switch panel is connected to the electronic controller, as well as the wiring circuitry from the Aqua-Hot unit. Indicator lights on the front panel will illuminate red if there is a short circuit, overload, or fault condition within the system.
SECTION 5: ELECTRONIC CONTROLLER Electronic Controller Features Secondary 12 Volt-DC Battery Connection: The electronic controller is equipped with two 12 Volt-DC power source connections, which allow for a secondary 12 Volt-DC battery connection. This 12 Volt-DC battery connection is a product-safety feature that should be utilized whenever the Aqua-Hot’s main 12 Volt-DC power supply is connected to a battery disconnect switch.
SECTION 5: ELECTRONIC CONTROLLER Low-Voltage Reset Feature: Whenever the Aqua-Hot’s DC power is interrupted, for longer than 5 minutes, the “low battery voltage fault” red indicator light on the electronic controller will illuminate.
SECTION 5: ELECTRONIC CONTROLLER Replacement Procedure: FAILURE TO DISCONNECT ALL POWER SUPPLIES AND/OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING 6. Snap the replacement electronic controller into the mounting bracket. 7. Ensure that the pin jumpers are properly configured for an Aqua-Hot 600; reference information in this section for proper pin-jumper configuration. Reference Figure 25. 8.
SECTION 6: ELECTRONIC CONTROLLER INDICATOR LIGHTS Electric Heating Element Status NOTE: The Electric Heating Element Status indicator light does not indicate AC Voltage at the Electric element. It only indicates the status of the “DC” Side of the Electric element, i.e. interior switch, electronic control board, relay. This indicator light shows the status of the electric heating element by illuminating green for on, red for fault, or by turning off when the electric element switch is turned off.
SECTION 6: ELECTRONIC CONTROLLER INDICATOR LIGHTS Engine Preheat Pump This indicator light shows the status of the Engine Preheat Pump by illuminating green for on, red for fault, or by turning off when the Engine Preheat Pump is not operating. The system is functioning properly if the motor home’s interior thermostat is calling for heat, the circulation pump is active, and the indicator light is green.
SECTION 6: ELECTRONIC CONTROLLER INDICATOR LIGHTS Diesel-Burner Status (continued) If the indicator light turns red, there is either a short in the wiring or the diesel-burner is in need of servicing. When checking the wiring, be sure to verify that the diesel-burner controller’s harness connectors are completely locked together. Also verify the Photo Eye Wires have not been pinched. Reference section 9 of this manual for additional dieselburner information.
SECTION 7: DIESEL-BURNER 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 7: DIESEL-BURNER Figure 28 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 7: DIESEL-BURNER 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 190°F (+/5°F) or higher, the Motor (#2) will not operate.
SECTION 7: DIESEL-BURNER 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. Figure 29 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 7: DIESEL-BURNER Figure 30 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 7: DIESEL-BURNER Figure 31 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 8: 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 8: DETACHING AND REATTACHING THE DIESEL BURNER Step 3: Disconnect the Diesel Burner’s Controller Figure 34 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. Step 4: Disconnect the Diesel Burner from the Aqua-Hot Figure 35 Eye Bolt Eye Bolt 1. The Diesel-Burner is secured to the Aqua-Hot with two Eye Bolt Nuts that can be loosened, and swung out of the way by using a 10mm socket wrench with a 10 inch long extension.
SECTION 8: DETACHING AND REATTACHING THE DIESEL BURNER Step 5: Remove the Diesel Burner & Fuel Lines from the Aqua-Hot Figure 36 1. Locate where the fuel lines on the diesel burner connect to the Aqua-Hot Bulkhead fittings. Figure 37 2. Using an 11/16 wrench, loosen the nuts securing each fuel line to the Aqua-Hot. Thermostat Access Panel Figure 38 2. Carefully pull the Diesel-Burner away from the Aqua-Hot 4 to 5 inches before rotating the burner, and then remove.
SECTION 8: 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 castaluminum 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 8: DETACHING AND REATTACHING THE DIESEL BURNER Step 2: Reattach the fuel lines to the Aqua-Hot. Figure 42 Figure 43 1. Align the fuel lines on the diesel burner with the fittings on the Aqua-Hot, and using a 11/16 inch wrench, tighten down both the supply and return fuel fittings. WARNING!!! If the fuel lines are connected backwards serious damage may occur to the burner’s fuel pump, and the fuel pump will start to leak Diesel Fuel out of the shaft seal.
SECTION 8: DETACHING AND REATTACHING THE DIESEL BURNER Step 4: Reinstall the Access Cover Figure 45 1. Reinstall the Aqua-Hot’s access cover . 2. Securely tighten the screws securing the access cover in place. © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 9: DIESEL-BURNER COMPONENTS - TROUBLESHOOTING FLOW CHART Is the indicator light illuminated? Turn the Burner Control Switch ON. Using a Jumper Wire, Jumper the Diesel (I) and the Diesel (o) Terminals together, on the JP2 plug on the Electronic Controller. If the Diesel burner Status Light Illuminates Green the problem is in the motor Home, Either a loose wire, bad switch, etc.
SECTION 9: DIESEL-BURNER COMPONENTS - TROUBLESHOOTING FLOW CHART 5. Using a digital volt meter, Check both the C7 (I) and the C1(O) Terminals for 12 VDC, on the JP4 plug, on the Electronic Controller. If either wire does not have 12 VDC the Electronic Controller will need to be replaced. Is there continuity across the thermostat? Check the Diesel Burner’s “VDC Control Thermostat” for continuity.
SECTION 9: DIESEL-BURNER COMPONENTS - TROUBLESHOOTING FLOW CHART Yes 1. Check the voltage level of the DC-multi meter. NOTE: Voltage level should be within 0.5 volts of the system’s DC batter voltage. Does the DC multi meter indicate acceptable system voltage? Yes 1. 2. 3. Inspect the “Flame Detection Photocell” for dust and/or sooty carbon deposits. Clean if necessary. Completely cover the “Flame Detection Photocell” with a shop rag. Turn the Control Switch ON. After approx.
SECTION 9: DIESEL-BURNER COMPONENTS - TROUBLESHOOTING FLOW CHART 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 9: DIESEL-BURNER COMPONENTS - TROUBLESHOOTING FLOW CHART 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 9: DIESEL-BURNER COMPONENTS - TROUBLESHOOTING FLOW CHART 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 9: DIESEL-BURNER COMPONENTS 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. Component Test: 1. Locate the diesel-burner controller’s C-Plug and insert the probes of a DC voltmeter into the C-2 (+) and the C5 (-) locations. 2. Verify the Electronic Controller is sending power to the diesel burner motor. A.
SECTION 9: DIESEL-BURNER COMPONENTS Diesel-Burner Motor (continued) RPM Test: 1. 2. Disconnect the ignition cables from the ignition electrodes. Remove the four ignition coil screws that secure the ignition coil to the protection cap. 3. Lift the ignition coil and disconnect its wires from the C-Plug harness wires prior to removing. 4. Remove the protection cap from the diesel-burner so that the motor and clutch halves are exposed.
SECTION 9: DIESEL-BURNER COMPONENTS 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. 1. 2. 3. Follow the directions for detaching the diesel burner in section 8.
SECTION 9: DIESEL-BURNER COMPONENTS Figure 48 Motor Replacement Procedure: (continued) © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS 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 8. 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 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS 2. Fuel Nozzle: 6. Remove the B-plug from the diesel-burner controller. 7. 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 9: DIESEL-BURNER COMPONENTS 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. 3.
SECTION 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS 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 9 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. Remove the retaining clip that secures the photo disc in place.
SECTION 9: DIESEL-BURNER COMPONENTS Fuel Pump: (continued) Figure 56 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 9: DIESEL-BURNER COMPONENTS 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. Spin the combustion air blower by hand.
SECTION 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS 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 9: DIESEL-BURNER COMPONENTS Ignition Coil: 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.. 3. Connect the new ignition coil cables, to the ignition electrodes. 4. Connect the new ignition coil’s black (+) and brown (-) wires to the C-plug harness’ yellow (+) and brown (-) wires.
SECTION 9: DIESEL-BURNER COMPONENTS 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.
SECTION 9: DIESEL-BURNER COMPONENTS NOTE: If the Control Box is replaced and the Ignition Coils still will not operate, it is possible the Electronic Controller is defective. Figure 62 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.
SECTION 10: TROUBLE SHOOTING 1. Black Smoke 1. Is the heater experiencing a low voltage condition. 8. A. Fire up the generator or plug the coach into shore power. 2. A. Remove the Combustion Chamber and inspect for signs of damage. Inspect the aluminum for signs of warping, or melted aluminum. Is the Exhaust Pipe Damaged or Restricted? 9. A. Inspect the exhaust pipe for damage, or excessive bends. NOTE: The Access cover will need to be removed to check the following. 3.
SECTION 10: TROUBLE SHOOTING 2. Blue/White Smoke 1. If the heater is smoking blue/white smoke during the start up or shut down cycle: A. Is the Fuel Solenoid functioning properly i. Test the fuel solenoid and make sure it engages as soon as power is put to it. Any delay in the fuel solenoid may cause blue/ white smoke. ii. Remove the fuel solenoid and inspect the plunger for any damage or debris that may interfere with the fuel shutting down. B. Is the Nozzle Tower Damaged? i.
SECTION 10: 3. Lack of Interior Heat A. Is the Diesel Burner /Electric Heating Element working properly? B. Is the Heater up to operating temperature? TROUBLE SHOOTING F. If the Heat Exchanger Fans, and the Zone Circulation Pumps are operating check for the following: i. Stuck Check Valve ii. Inspect for a Kinked plumbing line. iii.Is there a Lack of antifreeze in the boiler tank. C. Is the Interior Room Thermostat Calling for heat? D. Is the Zone Circulation Pump operating? E.
TROUBLE SHOOTING Figure 65 SECTION 10: © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
SECTION 10: 4. Lack of Domestic Hot Water 1. Things to keep in mind when trouble shooting a heater for a lack of hot water. A. The Diesel Burner must be on for continuous hot water B. The Heater is only rated for a water flow of 1.5GPM. C. The heater is only rated for a 55°F Temperature rise on the cold water coming in. 2. Check the following if there is a lack of domestic hot water: TROUBLE SHOOTING C. Has the Internal Washing Machine Valve gone bad? i.
SECTION 10: TROUBLE SHOOTING 1. On the Front-Side of the Aqua-Hot: A. Fluid Level Sensor B. Control Thermostat C. Drain Valve Assembly D. Electric Heating Element (s). i. One electric element is located on the left of the diesel burner, and the diesel burner will need to be removed to be able to inspect it. E. Circulation Pump (s). i. When checking the circulation pumps be sure to inspect the plumbing for the hoses, the tank ports, and the circulation pump. F. Combustion “Burn” Chamber leak i.
SECTION 10: TROUBLE SHOOTING 2. On the Top of the Aqua-Hot: A. Radiator Cap i. Bad seal ii. Loose B. Expansion Tank Tubing i. Cracked ii. Loose C. Filler Neck i. Bent ii. Broken nipple iii. Bad solder joint D. Supply and Return interior zone heat ports. i. Tubing/hose ii. Brass fittings C B D A Figure 67 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
AHE-600-D01 APPENDIX A: WIRING DIAGRAM FOR AHE-600-D01 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
AHE-675-D01 APPENDIX A: WIRING DIAGRAM FOR AHE-675-D01 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
APPENDIX B: 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 B1 1.
APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 3: Installing the fuel pressure gauge Figure B3 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. Step 2: Adjust The Fuel Pressure to 145 PSI 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: 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. NOTE: The Aqua-Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized. 1. If the Diesel burner Fails to operate: A.
APPENDIX C: EXTREME COLD WEATHER OPERATION If there is a lack of interior Heat: Note: The 120/240 Volt-AC Electric Heating Ele- ment (s) 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 extremely cold the Diesel-Burner must be utilized. 1. Is the Diesel Burner activated? 2.
APPENDIX D: 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 D: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Procedure: Note: Before performing an annual maintenance, it is recommended to test run the DieselBurner. 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. Step 3: Run the Diesel Burner 1.
APPENDIX D: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Procedure: Step 4: Remove The Diesel Burner Figure D4a 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. Failure to do so may result in the Diesel burner igniting. Figure D4b Figure D4c 3. The Diesel-Burner is secured to the Aqua-Hot with two 10mm nuts that can be loosened, and swung out of the way by using a 10mm socket wrench with a 10 inch long extension.
APPENDIX D: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Procedure: Step 4: Remove The Diesel Burner (continued) Figure D4d 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 control and hi limit thermostats from the diesel-burner’s white thermostat plug. © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
APPENDIX D: AQUA-HOT MAINTENANCE Step 5: 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. Figure D5a 1. Remove the combustion chamber by pulling it straight out, approximately 16 inches. Figure D5b 2. Once the combustion chamber has been re moved. Use a long handled wire brush, and brush the heat transfer tabs, to loosen soot deposits.
APPENDIX D: AQUA-HOT MAINTENANCE Step 5: Clean and Inspect the Combustion Chamber and Heat Transfer Tabs (continued) Figure D5c Figure D5d 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. Remove and 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.
APPENDIX D: AQUA-HOT MAINTENANCE Step 6: Reinstall the Combustion Chamber CAUTION! Failure to reinstall the combustion chamber will result in serious damage to the diesel burner. Figure D6 1. Reinstall the Combustion Chamber into the Aqua-Hot. Be sure to install the combustion chamber Seam in the 12:00 position. Failure to do so, may cause a crack to appear along the seam. © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
APPENDIX D: HYDRO-HOT MAINTENANCE Step 7: Inspect Diesel-Burner Figure D7 Electrode Fuel Nozzle Fuel Pump Grommet Photo Disc Flame Sensor Ear 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 D: AQUA-HOT MAINTENANCE Step 8: Clean Ignition Electrodes and Flame Sensor Electrode Tips Figure D8 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 D: AQUA-HOT MAINTENANCE Step 9: Replace The Fuel Nozzle Figure D9 NOTE: It is recommended to check fuel pressure any time the fuel nozzle is replace. 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.
APPENDIX D: AQUA-HOT MAINTENANCE Step 10: Adjust Ignition Electrodes Figure D10 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 D: AQUA-HOT MAINTENANCE Figure D11 Figure D12 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
APPENDIX D: AQUA-HOT MAINTENANCE Step 11: Inspect Photo Disc Figure D13 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 D: AQUA-HOT MAINTENANCE Step 14: Plug in the diesel-burner’s controller and mount Figure D15a Figure D15b 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. © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
APPENDIX E: AQUA-HOT MAINTENANCE Step 14: Re-Install the Aqua-Hot Access Cover Figure D16 1. Reinstall the Aqua-Hot’s access cover . 2. Securely tighten the five screws securing the access cover in place. Step 15: 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 Figure F1 © January 2013 Aqua-Hot® 600-D01 Series Hydronic Heating System Service Manual - Rev.
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.
