Aqua-Hot AHE-600-D03 Service Manual
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Aqua-Hot AHE-600-D03 Service Manual

Hydronic heating system
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AHE-600-D03
AHE-675-D03
SERVICE MANUAL
© 2012 Aqua-Hot Heating Systems Inc.

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  • Page 1 AHE-600-D03 AHE-675-D03 SERVICE MANUAL © 2012 Aqua-Hot Heating Systems Inc.
  • Page 2 — Page 2 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 3: Table Of Contents

    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 ....................Page 8 Section 2: Aqua-Hot Hydronic Heating System Overview Technical Information…………………………………………………………………….Page 9 I.D.
  • Page 4 Motor ........................Page 65-68 Flame Sensor ......................Page 69-70 Ignition Electrodes ....................Page 71-72 Fuel Nozzle ......................Page 72-73 Fuel Solenoid ......................Page 74 — Page 4 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 5 If the Aqua-Hot is Black Smoking ………………………………………………………..Page 85 If the Aqua-Hot is Blue/White Smoking ..............Page 86 If one of the Aqua-Hot’s Heating Zones will not get hot .......... Page 87 If there is a lack of domestic continuous hot water ..........Page 87-88 If there is antifreeze leaking ...................

  • Page 6: Section 1: Introduction To The Aqua-Hot 600 Series Introduction

    In order for the diesel-burner to pendent interior zone heating, and engine preheating. Be be considered as a heating source by the Aqua-Hot, it must sure to reference Figures 3 through 5 for a complete compo- have an adequate fuel supply, receive power from the elec- nent overview.
  • Page 7 The interior heating system is responsible for providing heat to the motor home’s interior in order to maintain the temper- NOTE: The Aqua-hot 600D is equipped with 2 - 2000 watt ature at a comfortable level. 120 Volt A.C. electric heating elements. The Aqua-Hot 675D is equipped with 1 - 2000 watt 120 Volt A.C.

  • Page 8: Model Differentiation

    Electric Heating Elements featured. In order to determine which of the following Aqua-Hot models has been employed, locate the Marking Plate on the Heating System (reference Figure 2 For Marking Plate information) and view the Model number.

  • Page 9: Section 2: Aqua-Hot Hydronic Heating System Overview Technical Information

    RVIA Standards, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive, P.O. Box 2999, Reston, VA 22090-0999, call them at (703) 620-6003, or visit them online at www.rvia.org. — Page 9 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 10: Label Sample

    2: A 600 S ECTION ERIES VERVIEW Each Aqua-Hot heating system possesses an I.D. label on the heater, to what standard it has been tested, and important unit itself. This I.D. label details the specifications of the safety notices. Figure 2...

  • Page 11: Component Overview

    Zone 3 Circulation Pump Zone 2 Circulation Domestic Water Pump Access panel Engine Pre- heat Pump Diesel Burn- Drain Valve Diesel Burner Controller — Page 11 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 12 Wiring Harness Port Product ID Label Zone 1, 2 and 3 Domestic Water Outlet Ports Inlet/Outlet Ports Engine Preheat Inlet/Outlet Ports Diesel Fuel Inlet/Outlet Ports — Page 12 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 13 ERIES VERVIEW Thermostat Access Panel Figure 5 Control Thermostat Fluid Level Sensor D.C. High Limit Thermostats (2) A.C. High Limit Thermostat A.C. Relay — Page 13 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 14: Aqua-Hot Operational Flow-Chart

    Zone calling for Heat Exchangers in Aqua-hot’s internal En- heat the Zone calling for gine Preheat System heat — Page 14 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 15: Antifreeze & Water Heating Solution

    Aqua-Hot Heating of chemical inhibitors. Due to their potentially hazardous Systems Inc. recommends CAMCO’s Boiler Antifreeze properties, they should never be used in the Aqua-Hot’s -100°. Hydronic Heating System. Antifreeze Types:...
  • Page 16 70 percent antifreeze, the freezing point is ac- tually raised, resulting in less freeze protection. The Aqua-Hot utilizes the antifreeze and water heating solu- tion as a transportation means for the heat produced from the internal processes. The antifreeze absorbs the heat created until its boiling point is reached;...

  • Page 17: Diesel-Burner Switch

    The interior switch panel is used to control the two potential Engine Preheat Switch: heating sources for the Aqua-Hot’s boiler tank, as well as to control the engine preheat feature. When a switch is activat- The engine preheat switch activates the engine preheat ed, the indicator light on the switch will illuminate.

  • Page 18: High/Low Switch (Electric Element)

    120 VAC/2000 Watt Electric Heating Ele- Element to supply heat to the Aqua-hot’s Boiler tank. The ment to supply heat to the Aqua-hot’s Boiler tank. The 120 120 VAC/2000 Watt Electric heating Element will heat the VAC/2000 Watt Electric heating Element will heat the Aqua Aqua-Hot System to the maximum operating temperature -Hot System to the maximum operating temperature(190°F...

  • Page 19: Pin Label

    ECTION NTERIOR WITCH ANEL For Heaters Manufactured Before January 2011 Figure 8a For Heaters Manufactured Between January 2011 thru August 2011 Figure 8b — Page 19 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 20 Electronic Controller Pin# 4 To “Electric-I” Pin# 2 To “Preheat-O” Pin# 9 To Chassis Ground Pin# 4 To “Preheat-I” Pin# 9 To Chassis Ground — Page 20 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 21: Section 4: Exhaust System Requirements Exhaust System Requirements

    XHAUST YSTEM EQUIREMENTS  Because the Aqua-Hot’s exhaust is hot and must be kept The exhaust must be able to freely exit away from the away from any heat-sensitive material, the exhaust system vehicle without any obstructions. should be checked to ensure that it continues to meet the following requirements: ...

  • Page 22: Interlock Switch

    Remove the defective Interlock Switch from the Aqua- Hot. The Interlock Switch is a safety device designed to ensure that the Aqua-Hot’s access cover is securely installed before Install the replacement Interlock Switch onto the allowing the diesel-burner to operate.

  • Page 23: Fluid Level Sensor

    Ensure that the Aqua-Hot has been completely shut down and that all power sources have been disconnect- Verify that the Aqua-Hot’s boiler tank is full of the anti- ed. Also, because this replacement procedure will in- freeze and water heating solution.

  • Page 24: Control Thermostat

    B. Disconnect the control thermostat’s wires from their perature and when it requires heat. The Aqua-Hot is consid- connections, and, using an ohmmeter, check for ered to be at operating temperature between 158°F and continuity.
  • Page 25 CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Screw the replacement control thermostat into the port Ensure that the Aqua-Hot has been completely shut on the Aqua-Hot’s boiler tank and tighten securely with down and that all power sources have been disconnect- a 7/8 socket.

  • Page 26: High Limit Thermostat (Right)

    215°F. Should this temperature be reached, the high-limit thermostat blocks the current to the element, Ensure that the Aqua-Hot has been completely shut down which prevents it from continuing to provide heat to the boil- and that all power supplies have been disconnected.

  • Page 27: High Limit Thermostat (Left)

    CAUSE SERIOUS DAMAGE OR PERSONAL INJURY high-limit thermostat blocks the current to the element, which prevents it from continuing to provide heat to the boil- Ensure that the Aqua-Hot has been completely shut down er tank. and that all power supplies have been disconnected.
  • Page 28 NOTE: Bypassing the high-limit thermostats is for testing only and must not be used for the Aqua-Hot’s normal Remove the Thermostat Access Panel functioning. Remove the two wires from the defective high-limit Disconnect the DC high-limit thermostats’...

  • Page 29: Check Valves

    Troubleshooting: Verify that the heating zone is operating properly by Check the Aqua-Hot’s antifreeze and water heating solu- checking the following: tion’s ratio of water to propylene glycol. The mixture ratio should be approximately 50/50.
  • Page 30 11. Refill the Aqua-Hot’s boiler tank with the antifreeze and Remove the hose from the defective check valve. water heating solution. Unscrew the defective check valve from the Aqua-Hot’s boiler tank.

  • Page 31: Tempering Valve

    OMPONENTS Tempering Valve: Remove both the Domestic Water access panel and the The tempering valve for the Aqua-Hot mixes the heated do- Thermostat Access Panel. mestic water from the boiler tank with cold domestic water at a preset ratio to reduce the risk of scalding.
  • Page 32 5: A ECTION OMPONENTS Figure 17 Mixer Valve Assembly Hot Water Outlet Port Cold Water inlet Port — Page 32 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 33: Circulation Pumps 1, 2

    Circulation Pumps #1, #2 and #3: The circulation pumps first draw the heated antifreeze and If the indicator light illuminates green, complete the water heating solution from the Aqua-Hot’s boiler tank, then following: propel it through the Hydronic heating system’s interior heat plumbing.
  • Page 34 Using constant tension pliers, loosen and slide back the 10. Refill the Aqua-Hot’s boiler tank with the antifreeze and constant tension clamps securing the hoses to the circu- water heating solution. lation pump.

  • Page 35: Engine Preheat Pump

    600 Series Aqua-Hot. ter, check the wires on the wiring harness for 12 volts of DC power.
  • Page 36 CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Reconnect the wires on the replacement pump to the wire Ensure that the Aqua-Hot has been completely shut down harness on the heater by uniting the red quick-disconnect and that all power sources have been disconnected. Also, terminals.

  • Page 37: Electric Heating Element: Right

    If the boiler tank is above 158°F, the Aqua-Hot is at operating temperature and requires no heat. Troubleshooting: 3. Verify the Electronic Controller is sending 12 Volt DC to NOTE: For continuous domestic hot water to be present, the A.C.
  • Page 38 Reinstall the Electric Element access cover. A. Disconnect all power supplies. Refill the Aqua-Hot’s boiler tank with the antifreeze and water heating solution. B. Remove the Electric Element access cover. C. Remove all wires from the electric heating element.

  • Page 39: Electric Heating Element: Left

     There is a lack of hot domestic water and interior heat If the boiler tank is above 158°F, the Aqua-Hot is at when the electric element is selected as the heating operating temperature and requires no heat.
  • Page 40 TO ALLOW THE HEATER TO COOL BEFORE SERVICING Aqua-hot 675 will have 240 VAC present at the terminal COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY block for the left electric element.
  • Page 41 5: A ECTION OMPONENTS Figure 21 Left Electric Right Electric Element Element — Page 41 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 42: Relay (Right)

    COULD CAUSE SERIUOS DAMAGE OR PERSONAL INJURY Disconnect the AC power source to the motor home Ensure that the Aqua-Hot has been completely shut (unplugging from shore power or shutting off the gener- down and that all power sources have been disconnect- ator).
  • Page 43 (pins 6 and 8), and remove the AC wires from the relay. There are two different Models in the Aqua-Hot 600 Series. The Aqua-Hot 600 has 2-2000 Watt 120 VAC electric heat- E. Using an ohmmeter, check the relay AC pins (6 and ing elements.

  • Page 44: Relay (Left)

    AC relay. Secure the Thermostat Access cover in place Figure 21 Left A.C. Right A.C. Relay Relay — Page 44 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 45: Section 6: Electronic Controller General Facts

    Electronic Controller Overview The electronic controller is an electronic circuit board that Aqua-Hot unit. Indicator lights on the front panel will illu- controls the electrical functions of the Aqua-Hot heating minate red if there is a short circuit, overload, or fault condi- system.

  • Page 46: Secondary 12 Volt Dc Battery Connection

    Secondary 12 Volt-DC Battery Connection: The electronic controller is equipped with two 12 Volt-DC ensure that the Aqua-Hot will be protected in the event that power source connections, which allow for a secondary 12 the primary power is interrupted while the diesel-burner is Volt-DC battery connection.

  • Page 47: Low Voltage Reset Feature

    Low-Voltage Reset Feature: button on the electronic controller (use a thin, straight, non- Whenever the Aqua-Hot’s DC power is interrupted, for long- metallic object to access the button through the faceplate) or er than 5 minutes, the “low battery voltage fault” red indica- by turning off the diesel-burner switch on the interior switch tor light on the electronic controller will illuminate.

  • Page 48: Replacement Procedure

    AILURE TO DISCONNECT ALL POWER SUPPLIES AND Ensure that the pin jumpers are properly configured for TO ALLOW THE HEATER TO COOL BEFORE SERVICING an Aqua-Hot 600; reference information in this section COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY for proper pin-jumper configuration. Reference Figure...

  • Page 49: Electric Heating Element Status Indicator Light

    The Low Temp Cutoff thermostat does not function on the Aqua-Hot 600 series. Therefore the Low-Temp Cutoff ther- If the light is off and the electric element switch on the interi-...

  • Page 50: Engine Preheat Pump Indicator Light

    Pump #2 is also the Stir Pump, and will be activated anytime the Diesel-Burner is operating, and heating up the antifreeze solution. — Page 50 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 51: Overload Fault Indicator Light

    Aqua-Hot. Under normal operating conditions, this indicator light is off. This light illuminates red when the Aqua-Hot is shut down due to excessive DC voltage (over 14.8 Volts) and/or the electronic controller has overheated.

  • Page 52: Section 8: Diesel-Burner Overview

    IESEL URNER Diesel-Burner Overview The Aqua-Hot’s diesel-burner is a device that ignites a mix- from the flame is transferred to the antifreeze and water heat- ture of diesel fuel and air within a controlled setting to serve ing solution where it can be used for each system of the Aq- as a heat source.

  • Page 53: Diesel-Burner Overview

    8: D ECTION IESEL URNER Figure 29 — Page 53 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 54: Diesel-Burner Operational Flow Chart

    The Motor (#2), which turns the unassisted. Combustion Air Blower (#5) NOTE: and drives the Fuel Pump (#14), When the Aqua-Hot’s Diesel Burn- will begin to operate. er is switched OFF by the VDC/ The combustion process will con- NOTE:...

  • Page 55: Diesel-Burner Operational Overview

    Use the tions are experienced, use this sequence of operating events “KEY” provided to understand each symbol shown. Figure 30 — Page 55 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 56 8: D ECTION IESEL URNER Figure 31 — Page 56 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 57 8: D ECTION IESEL URNER Figure 32 — Page 57 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 58: Detaching The Diesel-Burner

    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 procedure. Step 1: Turn Off the Diesel Switch Figure 33 1.
  • Page 59 Step 3: Disconnect the Diesel Burner’s Controller Figure 35 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. Step 4: Disconnect the fuel lines from the Aqua-Hot Figure 36a Figure 36b 1. Locate where the fuel lines on the diesel burner 2.

  • Page 60: Reattaching The Diesel-Burner

    Step 5: Remove the Diesel Burner from the Aqua-Hot Figure 37b Figure 37a 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 extension.
  • Page 61 Step 1: Reattaching the Diesel Burner to the Aqua-Hot Figure 38a 1. The Diesel-Burner is secured to the Aqua-Hot with two eye-bolt nuts that can be swung into place, after the diesel burner has been properly aligned and set in place.
  • Page 62 7/16 inch wrench, tighten down both the supply and return fuel fittings. CAUTION! Be sure to remove the clamps, off of the Fuel Supply and Return lines at the ports on top of the Aqua-Hot prior to starting the diesel burner, or serious damage will occur to the diesel-burner’s fuel pump.
  • Page 63 Step 4: Reinstall the Access Cover NOTE: The access cover must be installed prior to operation as a safety switch exists, which will prevent the Aqua-Hot from operating whenever the access cover is not properly installed. Figure 41b Figure 41a 1.

  • Page 64: Diesel-Burner Component Overview

    10: D ECTION IESEL URNER OMPONENTS Figure 42 — Page 64 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 65: Motor

    Webasto burner controller. burner head. Verify the Electronic Controller is sending power NOTE: The Aqua-hot 600 Series is equipped with a 20A to the diesel burner motor. Fast Blow Fuse, located on the red #20 wire, between the electronic controller and the diesel burner controller’s B- Plug, which is the diesel burner motor power wire.
  • Page 66 Disconnect the motor’s black (+) and brown (-) wires from the C-plug harnesses black (+) and brown (-) wires. Figure 44 — Page 66 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 67 Diesel-Burner’s power supply before de- and the combustion air blower shaft. Attach the mo- taching the Diesel-Burner from the Aqua-Hot. Fail- tor and flange assembly, with the recessed edge of ure to turn off the Diesel-Burner and disconnect the motor flange in-line with the wiring access slot of power could result in serious bodily injury.
  • Page 68 10: D ECTION IESEL URNER OMPONENTS Motor Replacement Procedure: (continued) — Page 68 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 69: Flame Sensor

    Once the diesel burner has been removed, Locate and detach the flame sensor’s green and blue wires from the C-plug harness wires. Figure 46 Flame Sensor Green Wire Blue Wire — Page 69 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 70 C-plug harness’ green and vio- burner, in section 9 of this manual. let wires, and remove flame sensor. Figure 47 — Page 70 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 71: Ignition Electrodes

    If it is missing, electrodes into the appropriate notches of the elec- replace the electrode boot. trode adjustment gauge. Figure 48 — Page 71 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 72: Fuel Nozzle

    Fuel Nozzle Component Test: 1. Follow the directions for detaching the diesel burner, Figure 49 in section 9, of this manual. — Page 72 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 73 A partially plugged orifice will restrict fuel flow, which will affect the combustion process of the diesel-burner. Figure 50 — Page 73 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 74: Fuel Solenoid

    Using an 8mm wrench, remove the lock nut and flat washer from the end of the fuel solenoid shaft and then pull the fuel solenoid away from the nozzle — Page 74 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 75: Fuel Pump

    145 PSI, A. Check the motor home fuel tank for fuel. If the which is required for proper fuel atomization. Ref- fuel level is below 1/4 the Aqua-Hot diesel erence the illustration below for a basic overview burner will not operate.
  • Page 76 Do not adjust the fuel pressure regulator of the NOTE: burner in section 9 of this manual. new fuel pump, as it has been factory preset. — Page 76 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 77 10: D ECTION IESEL URNER OMPONENTS Fuel Pump: (continued) Figure 53 — Page 77 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 78: Bearings

    C-plug harness wires, prior to removing. Remove the protection cap from the diesel-burner so that the motor and clutch halves are exposed. Figure 54 — Page 78 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 79 — Page 79 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 80 Figure 56 — Page 80 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 81: Ignition Coil

    4. Ensure the electrode boots are not broken inside the igni- (-) wires from the C-plug harness’ yellow (+) and tion coil wires. brown (-) wires. Figure 57 — Page 81 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 82 Follow the instructions for reattaching the diesel burner and test for proper operation. Disconnect the ignition cables, on the defective ignition coil, from the ignition electrodes. Figure 58 — Page 82 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 83: Controller

    2-way male plug to the 6-way female plug. The diesel circuit test. -burner will not ignite during normal operation if the VDC high-limit thermostat is left disconnected. — Page 83 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 84 C-plug and B-plug ports facing downward. Failure to do so, will result in moisture collecting in the ports and potential damage to the diesel-burner controller’s internal circuitry. Figure 60 — Page 84 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 85: Section 11: Troubleshooting If The Aqua-Hot Is Black Smoking

    Is the Photo Disc bent or tight. A. The photo disc must be free floating. If it is bound up, it will not seat against the combustion chamber. — Page 85 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 86: If The Aqua-Hot Is Blue/White Smoking

    — Page 86 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 87: If One Of The Aqua-Hot's Heating Zones Will Not Get Hot

    (i.e. shower, sink, etc.) hot water faucets will only produce warm water. — Page 87 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 88: If There Is Antifreeze Leaking

    The copper pipes come out of the boiler to 15 PSI. tank and are possible leak points Inspect the following components on the Aqua-Hot G. Burn Chamber Leak Heating System for Leaks : i. If Antifreeze is running out of the tip of 1.
  • Page 89 A: W AHE-600-D03 M 2011 PPENDIX IRING IAGRAM ANUFACTURED BEFORE ANUARY — Page 89 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 90 AHE-600-D03 M 2011 2011 PPENDIX IRING IAGRAM ANUFACTURED ETWEEN ANUARY THRU UGUST — Page 90 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 91 A: W AHE-600-D03 M 09/01/2011 PPENDIX IRING IAGRAM ANUFACTURED FTER — Page 91 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 92: Appendix A: Wiring Diagram

    A: W AHE-675-D03 M 2011 PPENDIX IRING IAGRAM ANUFACTURED EFORE ANUARY — Page 92 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 93 AHE-675-D03 M 2011 2011 PPENDIX IRING IAGRAM ANUFACTURED ETWEEN ANUARY THRU UGUST — Page 93 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 94 A: W AHE-675-D03 M 2011 PPENDIX IRING IAGRAM ANUFACTURED AFTER ANUARY — Page 94 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 95 NFORMATION Because all Aqua-Hot heating systems are designed to operate only when there is an adequate supply of DC (Direct Current) voltage, it is imperative that the proper wire gauge be determined and used for the DC power supply and ground wires. This bulletin address- es how to determine the DC amperage draw of the heating system, including heat exchangers, then, how to determine the proper wire gauge based upon those findings for a specific application.

  • Page 96: Appendix B: Wire Gauge Chart

    PPENDIX AUGE NFORMATION For example, an Aqua-Hot 600-D with six Aqua-Hot Cozy heat exchangers has a total amperage draw of 23.38 amps . Determining the Proper Wire Gauge: 1. Measure the total length of the wire required for the distance between the vehicle’s battery and the elec- tronic controller for Aqua-Hot models 450-DE, 450-DM, 525-D, 600-D, and 675-D and the heater itself for the Aqua-Hot 375-D model.
  • Page 97 Step 2: Install fuel line bypass fittings onto the diesel burner. Figure C2 1/4” Fuel Tube unions 1. Locate the 1/4 “ fuel tube unions on the bottom side of diesel burner. — Page 97 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...

  • Page 98: Appendix C: Fuel Pressure Check And Adjustment

    NOTE: It may be possible to install rubber fuel lines over the Steel fuel pipes, instead of disconnecting them and using a fuel bypass fitting. — Page 98 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 99 1. Using a 5/8” and a 3/4” wrench remove the fuel nozzle. Figure C6 2. Using a 5/8” and a 3/4” wrench install the fuel pressure gauge. — Page 99 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 100 2. Turn the diesel burner switch to the on position. A pressure will register on the fuel pressure gauge once the fuel solenoid opens (after approx. 10-20 seconds. — Page 100 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 101 2. Turn the diesel burner switch to the on position. A pressure will register on the fuel pressure gauge once the fuel solenoid opens (after approx. 10-20 seconds. — Page 101 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 102 NOTE: If the fuel pressure cannot be adjusted refer to the fuel pump section in section 10 of this manual for troubleshooting tips. — Page 102 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 103 B. Is the Diesel Fuel liquid or Jelled? C. Are the electrodes properly adjusted? NOTE: The Aqua-Hot can continue to be used for interior zone heating once the domestic water heating system D. When was the last time an Annual Service has been drained and winterized.

  • Page 104: Appendix D: Extreme Cold Weather Operation

    If there is a lack of interior Heat: 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 hot water during low heat- ing demand situations (such as when moderate ambient temperatures exist and/or when there is a low demand for domestic hot water).

  • Page 105: Appendix E: Aqua-Hot Annual Maintenance

    TO ALLOW THE HEATER TO COOL BEFORE SERVICING water heating solution within the expansion tank should only COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY be checked when the Aqua-Hot is at maximum operating temperature. To keep the Aqua-Hot running smoothly, it is recommended to have the diesel-burner tuned up annually.
  • Page 106 2. Using hose pinch off pliers, clamp off both fuel lines going to the fuel filter. Reference Thermostat figure E2. Figure E3 Connector Figure E2 Diesel Burner Controller Plugs — Page 106 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 107 AINTENANCE Aqua-Hot Maintenance Procedure: Step 4: Remove The Diesel Burner 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. Figure E4b Figure E4a...
  • Page 108 Diesel Burner’s white Thermostat Plug 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 thermo- stats from the diesel-burner’s white thermostat plug.
  • Page 109 Failure to do so will mately 16 inches. reduce the Aqua-Hot’s heat transfer capabilities. NOTE: If the heat transfer tabs are excessively sooty, it may be necessary to vacuum the soot out of the heat transfer tabs.
  • Page 110 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. — Page 110 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 111 Combustion Chamber Gasket Air Swirler 1. Reinstall the Combustion Chamber Assembly and the Air Swirler into the Aqua-Hot. Please note: It will be necessary to replace the combustion chamber gasket, anytime the combustion chamber is removed. — Page 111 —...
  • Page 112 Broken or cracked “Ears” Harness & Ignition Coil Wires - due to over tightening of eyebolts. - crack or bare wires - Hard or brittle wires — Page 112 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 113 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. — Page 113 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 114 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. — Page 114 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 115 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. 4. Remove the electrode adjustment gauge. — Page 115 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 116 NOTE: When reinstalling the diesel burner be careful not to damage the photo disc or bend the electrodes. Also, be careful to not pinch any wires between the burner and the Aqua-Hot Tank. 1. Align the Diesel-Burner with the Aqua-Hot, using the alignment tabs welded on the Aqua-Hot.
  • Page 117 CAUTION! Be sure to remove the clamps, off of the Fuel Supply and Return lines at the ports on top of the Aqua-Hot prior to start- ing the diesel burner, or serious damage will occur to the diesel-burner’s fuel pump.
  • Page 118 Step 14: Re-Install the Aqua-Hot Access Cover NOTE: The access cover must be installed prior to operation as a safety switch exists, which will prevent the Aqua-Hot from operating whenever the access cover is not properly installed. Figure E17a Figure E17b 1.

  • Page 119: Appendix F: Winterization

    F: W PPENDIX INTERIZATION Figure F1 — Page 119 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 120 — Page 120 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 121 — Page 121 — ® © March 2012 Aqua-Hot 600 Series Hydronic Heating System Service Manual—Rev. C...
  • Page 122 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.com...

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600 seriesAhe-675-d03

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