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

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Model Numbers
AHE-100-04S - 12 VDC
AHE-120-04X - 12 VDC
AHE-130-04X - 12 VDC
®
Aqua-Hot
Hydronic Heating System Shop Manual 09/04

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

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

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Section 1 General Heater Information Page Component Overview Marking Plate Section 2 Model Differentiation Aqua-Hot Model Differentiation Section 3 Switch Panel Interior Switch Panel Diesel Switch Electric Switch Engine Preheat Switch Section 4 Electronic Controller Electronic Controller Electric Heating Element Status Indicator Light Heating Zones Status Indicator Lights Low Voltage Reset...
  • Page 3 TABLE OF CONTENTS Section 8 Diesel-Burner Service, Maintenance, and Repair Information Page Fuel Solenoid Valve Fuel Pump Bearings 8.10 Ignition Coil 8.11 Diesel-Burner Controller Section 9 Warranty Information Warranty Information Section 10 Spare Parts List Section 11 Special Tools Referenced Illustrations Figure 1: Aqua-Hot Hydronic Heating System and Inclusive Components Figure 2:...

  • Page 4: Component Overview

    SECTION 1: GENERAL HEATER INFORMATION Component Component Overview Overview ELECTRONIC CONTROLLER ������ ��� Motor Coach Heating Specialists Low Tank-Level Switch Panel Cutoff Electric Heating Low Voltage Heating Status Element Status Reset �� ������� ������� Engine Preheat Pump Pump #1 Heating Zones Status Diesel Electric...

  • Page 5: Marking Plate

    SECTION 1: GENERAL HEATER INFORMATION Marking Marking Plate Plate By Vehicle Systems, Inc. Ft. Lupton, CO 80621 Model Number AHE-100 12 VDC / 184 Watts Model Number Diesel-Burner / DC Power Serial Number 04-637 120 VAC, 60 Hz / 1.65 kW...

  • Page 6: Model Differentiation

    Aqua-Hot Model Differentiation Models Vehicle Systems, Inc. manufactures three individual models of the Aqua-Hot Hydronic Heating System. The varying factor between these three models is the number of Electric Heating Elements featured, as well as the voltage employed by each Electric Heating Element.

  • Page 7: Switch Panel

    SECTION 3: SWITCH PANEL Switch Panel Interior Switch Panel The Interior Switch Panel serves as an interior means of controlling the separate heating sources of the Aqua-Hot, as well as activating the “Engine Preheat” system, when necessary. The AHE-120-04X and AHE-130-04X dual element Heating Systems feature a “High/Low”...

  • Page 8: Engine Preheat Switch

    SECTION 3: SWITCH PANEL Switch Panel, continued High: The process of moving the “High/Low” switch to the “High” position, in conjunction with the activation of the “Electric” switch, allows both the 120 VAC/1650 Watt and the 240 VAC/4500 Watt Electric Heating Elements to supply heat to the Aqua-Hot’s Boiler Tank. The 120 VAC/1650 Watt and 240 VAC/4500 Watt Electric Heating Elements will heat the Aqua-Hot System to the maximum operating temperature (190°F (+/- 5 degrees)) in approximately 0.5-1 hour.

  • Page 9: Electronic Controller

    SECTION 4: ELECTRONIC CONTROLLER Electronic Electronic Controller Controller ELECTRONIC CONTROLLER Low Tank-Level Cutoff Electric Heating Low Voltage Heating Status Element Status Reset Engine Preheat Pump Pump #1 Heating Zones Status Pump #2 Pump #3 Low Battery Voltage Fault Diesel-Burner Status Low Temp Cutoff Status Overload Fault...

  • Page 10: Low Voltage Reset

    SECTION 4: ELECTRONIC CONTROLLER Electronic Low Voltage Reset Controller, The Aqua-Hot’s Electronic Controller must be manually reset whenever the Low Battery continued Voltage fault indicator light has been activated; reference Figure 5. The Electronic Controller can be manually reset either by depressing the “Low Voltage Reset” button located on the Electronic Controller (use a thin, straight object to access the reset button through the small hole in the faceplate) or by turning OFF the “Diesel”...

  • Page 11: Pump #3 Indicator Light

    SECTION 4: ELECTRONIC CONTROLLER Electronic 4.10 Pump #3 Indicator Light Controller, This indicator light will illuminate GREEN whenever Circulation Pump #3 is operating; continued reference Figures 1 and 5. Please note that this light will only be active if the Aqua-Hot is at normal operating temperature (i.e., between 160°F and 190°F) and Heating Zone #1 is calling for heat;...

  • Page 12: Diesel-Burner

    SECTION 5: DIESEL-BURNER Component Component Overview Overview 1. Diesel-Burner Controller Heat Exchanger 2. Motor Combustion Chamber 3. Ignition Coil Exhaust Port 4. Clutch Flame Sensor 5. Combustion Air Blower Fuel Pump 6. Fuel Solenoid Valve Fuel Tubes (Supply / Return) 7.

  • Page 13: Operational Flow-Chart

    SECTION 5: DIESEL-BURNER Operational Operational Flow-Chart Flow-Chart Once the heater switches OFF, Operation sequence once the Simultaneously, the Ignition thermostatically or manually, Aqua-Hot’s Diesel switch is Coil (#3) produces a high the Fuel Solenoid Valve (#6) turned ON. voltage spark across the closes, which interrupts the Ignition Electrodes (#8), NOTE:...

  • Page 14: Operational Sequence

    SECTION 5: DIESEL-BURNER Operational Operational Sequence Sequence The following sequence illustrates how the Aqua-Hot’s Diesel-Burner operates once it is activated. Also, if Diesel-Burner malfunctions are experienced, use the following sequence of operating events as a diagnostic tool to determine the point in the Diesel-Burner’s operation that the malfunction occurs.
  • Page 15 SECTION 5: DIESEL-BURNER Operational Operational Sequence Sequence, continued Diesel Fuel Spray Exhaust Gases Combustion Air The particular component begins to operate. The component is currently operating. Diesel-Burner Operation, continued The Ignition Coil produces a high voltage spark, which is transferred across the Ignition Electrodes.
  • Page 16 SECTION 5: DIESEL-BURNER Operational Operational Sequence Sequence, continued Diesel Fuel Spray Combustion Air The particular component begins to operate. The component is currently operating. Diesel-Burner Operation, continued The Diesel-Burner will continue to produce heat in this manner until it is switched off either manually or by the VDC / VAC Control Thermostat, which occurs when the coolant temperature in the Aqua- Hot’s Boiler Tank reaches 190 (+/- 5) degrees Fahrenheit.

  • Page 17: Identification Plate

    SECTION 5: DIESEL-BURNER I.D. Plate Identification Plate Fabrikschild-Duplikat To be shipped with gultig nur zusammen mit Original Original Heater Thermosysteme GmbH MADE IN GERMANY DBW 2010.75 Model Type HEIZGERAT Typ Spannung / El. Leistung 12 V / 60W Voltage / Wattage 13,2 kW Warmestrom Brennstoff...

  • Page 18: Diesel-Burner Wiring

    SECTION 6: DIESEL-BURNER WIRING Controller Diesel-Burner Controller Wiring NOTE: Reference Figure 3 for all "JP" Plug and Pin locations on the Electronic Controller C-1 ( + ) VDC / VAC Control Thermostat Circuit (Orange Wire) to JP-4 (Pin 5). C-2 ( + ) Motor Circuit (Black Wire) to Diesel-Burner.

  • Page 19: Troubleshooting

    However, if additional assistance is needed, please feel free to contact Vehicle Systems’ Technical Support Department at 1-800-685-4298 or E-mail the issue to Vehicle Systems’ Technical Support Department by going to www.vehiclesys.com and clicking on “Technical Support.”...

  • Page 20: After Turning The "Diesel" Switch On

    SECTION 7: TROUBLESHOOTING Section 7.1 Section 7.1, Illustration 7.1-1 continued After turning the “Diesel” switch ON: TS1 : The Aqua-Hot’s Diesel-Burner fails to operate. NOTE (7.1-A): In order to perform the following ��� ���������� ������ checks, it is necessary to locate the Aqua-Hot’s Electronic Controller and Switch Panel;...
  • Page 21 SECTION 7: TROUBLESHOOTING Section 7.1, Section 7.1, continued continued A: If YES: inspect battery wiring for damage Check the JP-3 Plug for loose and/or loose connections, and wire connections and/or harness ensure that all of the Aqua-Hot’s damage electrical motors are operating normally when under load.
  • Page 22 SECTION 7: TROUBLESHOOTING Section 7.1, Section 7.1, Illustration 7.1-2 continued continued must be replaced; reference Appendix A. Please contact the Technical Support Department at 1-800-685-4298 for assistance. If NO: The Electronic Controller must be replaced. Please contact the Technical Support Department at 1-800-685-4298 for assistance.
  • Page 23 SECTION 7: TROUBLESHOOTING Section 7.1, Section 7.2, continued continued Turn the “Diesel” switch ON and allow the NOTE (7.1-D): If the Aqua-Hot still does not Aqua-Hot to reach operating temperature (i.e., until the Diesel-Burner cycles OFF). operate after performing all of the listed checks, contact the Technical Support Department at Locate both the VDC High-Limit Thermostat 1-800-685-4298 for additional assistance.
  • Page 24 SECTION 7: TROUBLESHOOTING Section 7.2, Section 7.2, Illustration 7.2-1 continued continued Q3 : Is the Diesel-Burner’s Fuel Solenoid Valve functioning properly? In order to determine if the Fuel Solenoid Valve is functioning properly, reference Section 8.7 and perform the Fuel Solenoid Valve’s “Component Test.”...

  • Page 25: Ts3 - The Aqua-Hot's Diesel-Burner Ignites After Several Starting Attempts

    SECTION 7: TROUBLESHOOTING Section 7.2, Section 7.2, continued continued In order to determine if the Ignition Elec- trodes are in good condition and properly adjusted, reference Section 8.5. NOTE (7.2-D): If the Aqua-Hot still does not ignite after performing all of the listed checks, contact A: If the Ignition Electrodes are in poor the Technical Support Department at 1-800-685- condition:...
  • Page 26 SECTION 7: TROUBLESHOOTING Section 7.3, Section 7.3, Illustration 7.3-1 continued continued Q2 : Is the Diesel-Burner’s Flame Sensor functioning properly? In order to determine if the Flame Sensor is functioning properly, reference Section 8.4 and perform the Flame Sensor’s “Compo- nent Test.”...
  • Page 27 SECTION 7: TROUBLESHOOTING Section 7.3, Section 7.3, Illustration 7.3-2 continued continued Q5 : Is the Diesel-Burner’s Fuel Supply System functioning properly? Fuel Filter Quick Check: With the Diesel-Burner ignited, listen for constant sputtering from the Aqua-Hot’s exhaust system. A: If constant sputtering exists: Continue troubleshooting.
  • Page 28 SECTION 7: TROUBLESHOOTING Section 7.3, Section 7.3, Illustration 7.3-3 continued continued NOTE (7.3-C): Be sure to check that each fitting at If the Ignition Coil is functioning properly: the Fuel Filter Head contains thread sealant. A Reference “NOTE (7.3-D).” fitting without thread sealant could result in an air leak.

  • Page 29: Ts4: The Aqua-Hot's Exhaust System Sputters

    SECTION 7: TROUBLESHOOTING Section 7.4 Section 7.4, Illustration 7.4-1 continued After turning the “Diesel” switch ON: TS4: The Aqua-Hot’s exhaust system sputters. Fuel Filter NOTE (7.4-A): Before advancing to the following procedures, be sure to check that the vehicle’s fuel tank has a sufficient level of fuel.
  • Page 30 SECTION 7: TROUBLESHOOTING Section 7.4, Section 7.4, Illustration 7.4-2 continued continued A: If air bubbles are not visible: Reference “NOTE (7.4-D).” If air bubbles are visible: Fuel Filter You will need to inspect the fuel system (supply side) for air leaks. Therefore, be sure to perform the inspections listed below until the air leak has been detected:...

  • Page 31: Ts5: The Aqua-Hot's Exhaust System Produces White Smoke After Ignition

    SECTION 7: TROUBLESHOOTING Section 7.5 Section 7.5, Illustration 7.5-1 continued After turning the “Diesel” switch ON: TS5: The Aqua-Hot’s exhaust system produces white smoke after ignition. Q1 : Is the Diesel-Burner’s Fuel Nozzle function- ing properly? In order to determine if the Fuel Nozzle is functioning properly, reference Section 8.6 and perform the Fuel Nozzle’s “Component Test.”...
  • Page 32 SECTION 7: TROUBLESHOOTING Section 7.5, Section 7.5, Illustration 7.5-2 continued continued A: If constant white smoke exists: Continue troubleshooting. Fuel Filter NOTE (7.5-B): Inspect the clear bowl of the Fuel Filter for water. If water exists, be sure to purge the Aqua-Hot’s entire fuel system prior to replacing the Fuel Filter.

  • Page 33: Ts6: The Aqua-Hot's Exhaust System Produces Black Smoke After Ignition

    SECTION 7: TROUBLESHOOTING Section 7.5, Section 7.6, Illustration 7.6-1 continued continued 2. Once the potential air leak has been discovered and corrected, reattach the Aqua-Hot’s Fuel Return Line ELECTRONIC CONTROLLER and attempt heater restart. Hydro-Hot Aqua-Hot Does the Aqua-Hot’s exhaust system still sputter? If the exhaust system is still sputtering: Continue performing the air leak...
  • Page 34 SECTION 7: TROUBLESHOOTING Section 7.6, Section 7.6, Illustration 7.6-1 continued continued Reset the Low Voltage Reset (button) on the Electronic Controller (this can be accom- plished either by using a thin, straight object to access the reset button through the small hole in the Faceplate or by turning OFF the “Diesel”...
  • Page 35 SECTION 7: TROUBLESHOOTING Section 7.6, Section 7.6, Illustration 7.6-3 continued continued If the Fuel Nozzle is functioning properly: Continue troubleshooting. Q3 : Is the Diesel-Burner’s Motor operating at the proper RPM speed? In order to determine if the Motor is operat- #3 - Plunger #4 - Rubber Ball ing properly, reference Section 8.3 and...
  • Page 36 SECTION 7: TROUBLESHOOTING Section 7.6, Section 7.6, continued continued 3. Pump the rubber ball 18 times. NOTES (7.6-F): If the proper CO value cannot be 4. Release the suction hose from obtained, perform each of the following inspections, the CO Analyzer’s plunger. as necessary, until the cause has been detected: 5.
  • Page 37 SECTION 7: TROUBLESHOOTING Section 7.7 Section 7.7, continued After turning the “Diesel” switch ON: Observe the DC voltage on the voltmeter. TS7: The Aqua-Hot is at operating temperature, but an Interior and/or Fresh Water Tank Heating Does a nominal 12 Volt-DC Zone is not producing heat.
  • Page 38 SECTION 7: TROUBLESHOOTING Section 7.8 Section 7.8, Illustration 7.8-1 continued After turning the “Diesel” switch ON: ELECTRONIC CONTROLLER TS8: The Aqua-Hot is at operating temperature; �������� � however, the Interior and/or Fresh Water Low Tank-Level Tank Heat Exchanger fans are not Cutoff Electric Heating Low Voltage...

  • Page 39: System Is Not Producing Hot Water

    SECTION 7: TROUBLESHOOTING Section 7.9 Section 7.9, continued After turning the “Diesel” switch ON: NOTE (7.9-B): Domestic hot water flow rates exceeding 1.5 Gallons per Minute (GPM) can TS9: The Aqua-Hot is at operating temperature, contribute to poor domestic hot water performance. but the domestic hot water system is not However, this is directly dependent upon the producing hot water.
  • Page 40 SECTION 7: TROUBLESHOOTING Section 7.9, continued The chart below is a graphical representation of how the Aqua-Hot’s Domestic Hot Water System theoretically performs under varying incoming domestic cold water temperatures. Because each Aqua- Hot has a performance tolerance, this graphic should be used as a general guideline and not as actual domestic hot water performance data.

  • Page 41: After Turning The Electric Switch On

    SECTION 7: TROUBLESHOOTING Section 7.10 Section 7.10, continued After turning the “Electric” switch ON: A: If YES: Check for loose wire connections TS10: The Aqua-Hot’s 120 VAC Electric Heating at the “Electric” switch and at the Element does not operate (i.e., lack of hot JP-2 Plug’s Electric (O) and Electric (I) pins.
  • Page 42 SECTION 7: TROUBLESHOOTING Section 7.10, Section 7.10, continued continued Turn the “Diesel” switch ON and allow the NOTE (7.10-E): The Temperature of the Aqua-Hot’s Boiler Tank must be below 160°F prior to performing Aqua-Hot to reach maximum operating temperature (i.e., until the Diesel-Burner this test.

  • Page 43: After Turning The Engine Preheat Switch On

    SECTION 7: TROUBLESHOOTING Section 7.10, Section 7.11 continued After turning the “Engine Preheat” switch ON: Q4 : Is the 120 VAC Electric Heating Element functioning properly? TS11: The Aqua-Hot’s Engine Preheat System does not preheat the engine. WARNING: The following checks need to be performed with the NOTE (7.11-A): The “Diesel”...
  • Page 44 SECTION 7: TROUBLESHOOTING Section 7.11, continued Does the Electronic Controller’s Engine Preheat Pump light now illuminate? A: If YES: Check for loose wire connections at the “Engine Preheat” switch and at the JP-2 Plug’s Preheat (O) and Preheat (I) pins; reference Appendix A.

  • Page 45: Diesel-Burner Service, Maintenance, And Repair Information

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION General General Recommended Maintenance Recommended Monthly Maintenance Check the Aqua-Hot’s water and antifreeze solution to ensure that it is at the proper level. Do this by visually checking the coolant level in the Aqua-Hot’s Expansion Tank; refer- ence Figure 1.

  • Page 46: Detaching And Reattaching The Diesel-Burner Head

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Detaching and Detaching and Reattaching the Diesel-Burner Head Reattaching the Diesel-Burner Grommets Head Eye-Bolts Diesel-Burner and Nuts Head Blower Casting Diesel Diesel Fuel Supply Fuel Return Figure 10 WARNING: Be sure to turn the “Diesel” switch OFF and disconnect the B-Plug Harness from the Diesel-Burner’s Controller prior to detaching the Diesel-Burner Head;...

  • Page 47: Motor

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Motor Motor Function: The Motor drives the Combustion Air Blower and the Fuel Pump. NOTE: In order to perform the following procedures, it may be necessary to detach and reattach the Diesel-Burner Head. Therefore, be sure to reference Section 8.2 for detaching and reattaching instructions.
  • Page 48 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Motor, continued Adjustment Procedure: N/A RPM Test: Disconnect the Ignition Cables from the Ignition Electrodes; reference Figure 16. Remove the four Ignition Coil Screws, which secure the Ignition Coil to the Protection Housing;...
  • Page 49 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Motor, continued Replacement Procedure: Remove the four Ignition Coil Mounting Screws, which secure the Ignition Coil to the Protection Housing; reference Figure 13. Lift the Ignition Coil to disconnect its wires from the C-Plug Harness wires prior to removing. Remove the Protection Housing from the Diesel-Burner to expose the Motor and Clutch Halves;...
  • Page 50 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Motor, continued Ignition Coil Housing Mounting Screws Casting Figure 13 Casting Motor Figure 14 Clutch Halves Black Wire Brown Wire (to Diesel-Burner) (to Diesel-Burner) Page 47 ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...

  • Page 51: Flame Sensor

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Flame Flame Sensor Sensor Function: The Flame Sensor is a photoresistive device, which supplies the Diesel-Burner’s Controller with a DC voltage signal when it detects a flame (i.e., a light source). NOTE: The functionality of each component can be determined by completing the manual checks, as listed under the “Component Test”...

  • Page 52: Ignition Electrodes

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Flame Figure 15 Sensor, continued Flame Sensor Green Wire Photo Disc Green Wire (to Diesel-Burner) NOTE: This screw is used to fasten the Flame Sensor to Photo Disc . Remove Blue when replacing the Flame Wire Sensor.
  • Page 53 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Ignition Electrodes, into the appropriate notches of the Electrode Adjustment Gauge as continued illustrated in Figure 16. Tighten the Retaining Clamp Bolt. NOTE: Be sure not to overtighten the Retaining Clamp Bolt when readjusting the Ignition Electrodes.

  • Page 54: Fuel Nozzle

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Fuel Nozzle Nozzle Function: The Fuel Nozzle is simply a fuel atomizer. It reduces the diesel fuel into a fine spray, which is mixed with incoming combustion air and ignited within the Combus- tion Chamber.

  • Page 55: Aqua-Hot ® Hydronic Heating System Shop Manual

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Nozzle, WARNING: Be sure to reattach the Diesel-Burner Head prior to switching the continued heater ON. Failure to do so may result in ignition of the Diesel- Burner and serious bodily injury. Turn ON the “Diesel”...

  • Page 56: Fuel Solenoid Valve

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Fuel Solenoid Valve Solenoid Function: The Fuel Solenoid Valve allows the flow of diesel fuel to the Diesel-Burner’s Valve Fuel Nozzle. NOTE: In order to perform the following procedures, it is necessary to detach and reattach the Diesel-Burner Head.
  • Page 57 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Solenoid Valve, Fit the Fuel Nozzle Manifold Plate inside the cast-aluminum Blower Casting and continued secure in place with the four Fuel Nozzle Manifold Plate Screws. Reinstall the Photo Disc and secure in place with the Retaining Clip. Connect the C-Plug Harness’...

  • Page 58: Fuel Pump

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump Fuel Pump Function: The Fuel Pump draws diesel fuel from the vehicle’s fuel tank and creates a preset pressure of 145 psi (required for proper fuel atomization). Reference the illustra- tion below for a basic overview and understanding of how the Fuel Pump operates.
  • Page 59 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued Ignition Cable (1) Fuel Nozzle Manifold Retaining Plate Screw (1) Clamp Retaining Clip Ignition Electrodes Photo Disc Flame Sensor Supply Banjo Bolt Fuel Pump Fuel Supply Fuel Tube Line Fuel Nozzle Manifold Return Plate Screw (2)
  • Page 60 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued Fuel Pressure Function Test: NOTES: A: A Fuel Pressure Gauge (reference Section 11 for special tools information) is used to properly check the Fuel Pump’s pressure setting; reference Figure 21. The Fuel Pump is preset to 145 psi (the pressure required for proper fuel atomization at the Fuel Nozzle).
  • Page 61 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued 80 100 120 Fuel Pressure Gauge Figure 20 increase Fuel Pump decrease Pressure Regulator Screw (Adjustment) Figure 21 Page 58 ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 62 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued Replacement Procedure: Locate and disconnect the C-Plug Harness wires, which connect to the Flame Sensor and the Fuel Solenoid Valve; reference Figures 3, 15, and 18. Also, disconnect the Ignition Cables from the Ignition Electrodes; reference Figures 16 and 19.
  • Page 63 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued and secure in place with the four Fuel Nozzle Manifold Plate Screws. Install the new Grommets on both Fuel Tubes (Supply and Return) and secure the tubes to the Fuel Pump with the new Banjo Bolts and Gasket Rings;...

  • Page 64: Bearings

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Bearings Bearings Function: The Bearings support the Combustion Air Blower’s shaft and allows the blower to turn smoothly. NOTE: The functionality of each component can be determined by completing the manual checks, as listed under the “Component Test” area for each individual component, or the components can be tested by using a “Controller Tester.”...
  • Page 65 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Bearings, continued NOTE: Inspect the Clutch Halves for cracks and ensure that the flat portion in each shaft hole is free of wear and tear. Too much play on the shaft produces a loud clacking noise. If any cracks or wear are detected, the Clutch Half must be replaced.
  • Page 66 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Bearings, continued through the Bearing Kit assembly until the threaded portion appears on Side-A of the Blower Casting; reference Figure 23. Place the new thick flat Washer and steel Drive Gear on the threaded end of the Combustion Air Blower’s shaft.
  • Page 67 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Bearings, continued Side-B Side-A Blower Casting Blower Housing Rubber Grommets Blower Casing Blower Housing Combustion Air O-Ring Blower w/shaft Screws Dished Surface Washer Dished Wave Snap Surface Retaining Washer Ring Washer Flat Drive Bearing Washer...

  • Page 68: Ignition Coil

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Ignition Coil 8.10 Ignition Coil Function: The Ignition Coil produces a high voltage ignition spark (approximately 8000 volts), which is released across the metal tips of the Ignition Electrodes during the initial Diesel-Burner start-up.

  • Page 69: Diesel-Burner Controller

    SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Diesel-Burner 8.11 Diesel-Burner Controller Controller Function: The Controller operates all the components of the Diesel-Burner Head and safely shuts the heater OFF in the event of an overheat, flameout, or low voltage condi- tion.
  • Page 70 SECTION 8: DIESEL-BURNER, MAINTENANCE, AND REPAIR INFORMATION Diesel-Burner Controller, continued B-2 ( - ) Battery Circuit (Brown Wire) to JP-4 (Pin 4) COM (-) B-Plug B-1 B-2 B-3 B-4 ( + ) Battery Circuit (Red Wire) to JP-4 (Pin 3) Figure 26 Page 67 ®...
  • Page 71 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Diesel-Burner Controller, NOTE: If, after performing the following circuit tests, the Controller is deter- continued mined to be defective and must be replaced, reference the Controller’s “Replacement Procedure” in this section. Reference Section 10 for spare parts information.
  • Page 72 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Diesel-Burner Controller, Cleaning Tips/Maintenance: N/A continued Adjustment Procedure: N/A Replacement Procedure: Remove both the B-Plug and C-Plug from the Controller; reference Figure 8. Gently pry away each side of the Controller Mounting Bracket from the Controller’s locking posts with a flat-head screwdriver.
  • Page 73 SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Diesel-Burner 7.11 Diesel-Burner Controller Controller, continued Bracket Slot Locking Post Diesel-Burner Controller Controller Mounting Bracket Figure 27 Page 70 ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...

  • Page 74: Warranty Information

    AQUA-HOT Heater, or the vehicle into which it was installed, due to improper installation, assembly, maintenance, abuse, neglect, accident, or the use of parts no supplied by Vehicle Systems, Inc. Vehicle Systems is not responsible for incidental or consequential damages.

  • Page 75: Section 10 Spare Parts List

    SECTION 10: SPARE PARTS LIST Control Unit 1 2 3 WPX-287-962 Controller, Diesel-Burner, 12 VDC WPX-101-838 Coil, Ignition, 12 VDC WPX-425-060 Motor, Combustion Air/Fuel Pump, 12 VDC WPX-322-083 Valve, Fuel Solenoid, 12 VDC WPX-386-650 Valve, Fuel Solenoid, Kit WPX-274-313 Electrode, Ignition WPX-638-78A Sensor, Flame WPX-887-71A...

  • Page 76: Section 11 Special Tools

    SECTION 11: SPECIAL TOOLS 80 100 120 WPX-310-646 Gauge, Adjustment, Electrode WPX-440-280 Tester, Controller WPE-600-190 Gauge, Fuel Pressure **************** Gas Analyzer, CO � Order Grainger Part # 6T153 from a Grainger Industrial Supply Store near you or visit the Grainger website at www.grainger.com.

  • Page 77: Wiring Diagrams

    Appendix A Wiring Diagrams ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 78 APPENDIX A WIRING INFORMATION (AHE-100-04S) �� ��� ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 79 WIRING INFORMATION (AHE-120-04X) APPENDIX A �� ��� �� ��� 7 BLK ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 80 WIRING INFORMATION (AHE-130-04X) APPENDIX A 12 VDC 12 VDC 7 BLK ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 81 Appendix B Illustrations ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 82 APPENDIX B: RESETTING THE HIGH-LIMIT THERMOSTAT To RESET: Simply press the Red button on the Thermostat. To RESET: Simply press the Red button on the Thermostat. ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 83 APPENDIX B: HYDRONIC HEATING SYSTEM OVERVIEW Heating Loop #1 Heating Zone #1 Heating Loop #2 Heating Zone #3 Heating Zone #2 Heating Loop #3 Heating Zone #5 Return Plumbing Lines Supply Plumbing Lines Circulation Pump #1 Circulation Pump #2 Circulation Pump #3 ®...
  • Page 84 ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...
  • Page 85 �������������������������������������������������������������� 15549 East Highway 52 Fort Lupton, Colorado 80621 1-800-685-4298 Fax: 303-857-9000 © Copyright 2004 Vehicle Systems, Inc. All rights reserved. www.vehiclesys.com ����������� ® Aqua-Hot Hydronic Heating System Shop Manual 09/04...

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