Aqua-Hot AHE-100-02S Service Manual
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Aqua-Hot AHE-100-02S Service Manual

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AHE-100-02S
SERVICE MANUAL
© 2011 Aqua-Hot Heating Systems Inc.

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

  • Page 1 AHE-100-02S SERVICE MANUAL © 2011 Aqua-Hot Heating Systems Inc.
  • Page 2 — Page 2 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 3: Table Of Contents

    Table of Contents Section 1: Introduction to the Aqua-Hot AHE-100-02S Introduction ....................... ..Page 6-7 Danger, Warning, Caution, and Note Box Definitions ............Page 6 Section 2: Aqua-Hot Hydronic Heating System Overview Technical Information ......................Page 8 I.D. Label Sample ......................Page 9 Component Overview ....................Page 9-10...
  • Page 4 If the Aqua-Hot is Black Smoking ................. Page 70 If the Aqua-Hot is Blue/White Smoking ................ Page 71 If one of the Aqua-Hot’s Heating Zones will not get hot ..........Page 72 If there is a lack of domestic continuous hot water ............Page 73 If there is antifreeze leaking ...................
  • Page 5 This Page Left Blank Intentionally — Page 5 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 6: Section 1: Introduction To The Aqua-Hot Ahe-100-02S Introduction

    In order for the diesel- zone heating, and engine preheating. Be sure to reference burner to be considered as a heating source by the Aqua-Hot, Figures 3 for a complete component overview. it must have an adequate fuel supply, receive power from the...
  • Page 7 Until the thermostat signals that where it transfers the heat to the engine to gradually warm it. heat is no longer required, the Aqua-Hot will continue to send the heated antifreeze and water solution through the Additionally, the Aqua-Hot includes a motor-aide feature, loop, which returns the cooled solution to the Aqua-Hot’s...

  • Page 8: 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 8 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 9: Label Sample

    2: A AHE-100-02S O ECTION VERVIEW Figure 2 — Page 9 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 10 2: A AHE-100-02S O ECTION VERVIEW Figure 3 — Page 10 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 11: Aqua-Hot Operational Flow-Chart

    Zone calling for Heat Exchangers in through the Aqua- heat the Zone calling for hot’s internal Engine heat Preheat System — Page 11 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 12: Diesel-Burner Switch

    The engine preheat switch does not need to be activated for the motor-aide fea- ture to work and should be shut off when traveling. Figure 4 — Page 12 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 13: 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 14: Control Thermostat: Diesel Burner

    The Diesel Burner control thermostat is installed onto the ature by checking with a digital thermometer. Aqua-Hot’s boiler tank and monitors the temperature of the antifreeze and water heating solution to determine when it is B. Disconnect the control thermostat’s wires from their at operating temperature and when it requires heat.
  • Page 15 Using a 1/4” nut driver, unscrew the two screws secur- ing the control thermostat to the Aqua-Hot’s boiler tank thermostat mounting bracket. Install the replacement control thermostat into the ther- mostat mounting bracket and secure with the two screws previously removed.

  • Page 16: Control Thermostat: Electric Element

    Verify that the boiler tank’s temperature is below 230°F. The Electric Element control thermostat is installed onto the Aqua-Hot’s boiler tank and monitors the temperature of the Locate the AC control thermostat and remove its wires, antifreeze and water heating solution to determine when it is by loosening and removing the screws securing the at operating temperature and when it requires heat.
  • Page 17 Using a 1/4” nut driver, unscrew the two screws secur- ing the control thermostat to the Aqua-Hot’s boiler tank thermostat mounting bracket. Install the replacement control thermostat into the ther- mostat mounting bracket and secure with the two screws previously removed.

  • Page 18: High Limit Thermostat

    The electric heating element fails to operate. Using a 1/4” nut driver, unscrew the two screws secur- Troubleshooting: ing the thermostat to the Aqua-Hot’s boiler tank thermo- stat mounting bracket. Disconnect all power supplies. Install the replacement thermostat into the thermostat Remove the thermostat access cover.

  • Page 19: High Limit Thermostat

    NOTE: Bypassing the high-limit thermostats is for testing only and must not be used for the Aqua-Hot’s nor- Note: If a screw longer than 1/4” is used to secure the mal functioning.

  • Page 20: Check Valves

    Check the Aqua-Hot’s antifreeze and water heating solu- tion’s ratio of water to antifreeze. The mixture ratio Troubleshoot the check valves if the following condition has should be approximately 50/50.
  • Page 21 Reconnect the interior heating zone fitting and line to the replacement check valve. Refill the Aqua-Hot boiler tank with the antifreeze and water heating solution. Test for proper operation NOTE: The Aqua Hot zone circulation pump is not a self priming pump.

  • Page 22: Tempering Valve

    OMPONENTS Tempering Valve: Follow the instructions for removing the diesel burner.. The tempering valve for the Aqua-Hot mixes the heated do- Using Channel Lock Pliers, remove the Thermostat and mestic water from the boiler tank with cold domestic water at Bonnet Assembly.
  • Page 23 5: A ECTION OMPONENTS Tempering Valve: Figure 14 Thermostat and Bonnet Assembly Spring Thermostat O-Ring Tempering Valve — Page 23 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 24: Circulation Pumps C, B & A

    The Zone circulation pump first draw the heated antifreeze COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY and water heating solution from the Aqua-Hot’s boiler tank, then propel it through the hydronic heating system’s interior Ensure that the Aqua-Hot has been completely shut heat plumbing.
  • Page 25 Be sure to review the wiring schematic in appendix A tighten down the union previously loosened. for proper pump wiring. 12. Re-Install the check valve onto the Aqua-Hot zone cir- 15. Refill the Aqua-Hot boiler tank with the antifreeze and culation pump. The arrow on the check valve must water heating solution.

  • Page 26: Stir Pump

    The stir pump circulates the antifreeze and water heating solution within the Aqua-Hot boiler tank in order to ensure If voltage is present and the pump still fails to oper- even-heating of the solution. To accomplish this, the stir...

  • Page 27: Engine Preheat Pump

    Engine Preheat Heat Ensure that the Aqua-Hot has been completely shut exchanger, located inside the boiler tank. down and that all power sources have been disconnect- ed.
  • Page 28 A for proper pump wiring. Figure 17 Union Pump Bulkhead Pump Pump Fitting Bulkhead Stand Stand Locking nut fitting — Page 28 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 29: Interior Zone Relay - Interior Heat Exchanger Fans/Zone Pumps

    If the zone works with the inte- rior room thermostat bypassed the problem is located in the motor home, not within the heating system. Figure 18 — Page 29 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 30 5: A ECTION OMPONENTS Bedroom Zone Bathroom Zone Figure 19 Terminal Strip Living room Zone Fuse Block A B C Relay Socket Relay Relay Clip — Page 30 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 31: Electric Heating Element

    COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY ment. Ensure that the Aqua-Hot has been completely shut If the boiler tank is above 210°F, the Aqua-Hot is at down and that all power sources have been disconnect- operating temperature and requires no heat.
  • Page 32 Reinstall the Electric Element access cover. Remove the two wires secured to the defective electric heating element by releasing the screw terminals. Refill the Aqua-Hot’s boiler tank with the antifreeze and water heating solution. Using a 1-1/2 inch socket, remove the defective electric heating element from the Aqua-Hot boiler tank.

  • Page 33: Section 6: Diesel-Burner Overview

    URNER VERVIEW 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 34 6: D ECTION IESEL URNER VERVIEW Figure 23 — Page 34 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 35: Diesel-Burner Operational Flow Chart

    Combustion Chamber (#11) through the Fuel Nozzle the Aqua-Hot Boiler Tank without additional involvement from the (#9) operator. — Page 35 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 36: Diesel-Burner Operational Overview

    NOTE: The Motor and Combus- tion Air Blower will begin to oper- ate only if the VDC Control Ther- mostat is closed and calling for heat — Page 36 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 37 6: D ECTION IESEL URNER VERVIEW Figure 25 — Page 37 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 38 200 (+/- 5) degrees Fahrenheit. NOTE: Whenever the Diesel-Burner is switched off by the VDC Con- trol Thermostat, it will automatically be reactivated once the Aqua-Hot Boiler Tank’s coolant reaches the preset termperature of approximately 175 (+/-) 5 degrees Fahrenheit.

  • Page 39: 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 replacement procedure. Step 1: Turn Off the Diesel Switch Figure 27 1.
  • Page 40 ETACHING AND EATTACHING THE IESEL URNER Step 3: Disconnect the Diesel Burner’s Controller Figure 29 B-Plug C-Plug 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. — Page 40 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 41 Step 4: Remove the Diesel Burner from the Aqua-Hot Figure 30a Figure 30b 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 exten- sion.
  • Page 42 7: D ECTION ETACHING AND EATTACHING THE IESEL URNER Step 5: Disconnect the Diesel Burner’s Thermostat Wires From the Aqua-Hot Figure 31b Figure 31a Thermostat Access Cover Wire Access Slot 1. Using a Phillips head Screw Driver loosen the screws 1.
  • Page 43 Use extreme caution when tightening down the eye-bolt nuts, over tightening of the eye- bolt nuts can cause the aluminum blower casing to crack. (Torque Specifications = Approximately 20-40 in. lbs.) — Page 43 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 44 Step 4: Reinstall the Access Cover Figure 36 1. Reinstall the Aqua-Hot’s access cover . 2. Securely tighten the screws securing the access cover in place. — Page 44 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 45 Replace the Thermostat. below 175ºF when checking across the 2. Attempt Heater Restart the “VDC Control Thermo- thermostat? stat” for continuity. 2. Attempt Heater Restart — Page 45 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 46 Head” is detached. An open flame can result and cause seri- ous personal injury. To prevent a fire hazard, be ure to disconnect one of the “Fuel Solenoid Valve” wires. — Page 46 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 47 Photocell wires, “Fuel Solenoid approx. 15 seconds and then switch Valve” wire and C-plug. off. Reattach “Diesel Burner Head” and attempt heater restart. — Page 47 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 48 VDC Power (+) and properly (click)? port? ground (-) to the Solenoid Valve electrical terminals. “Fuel Solenoid Valve” should click when VDC power is applied. — Page 48 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 49: Troubleshooting Flow Chart

    End of Troubleshooting Flow Chart. For additional troubleshooting information please contact: Aqua Hot Heating System’s Service Department at 303-659-8221 Mon-Fri 7:00 a.m. - 4:00 p.m. — Page 49 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 50: Motor

    NOTE: Before testing the diesel burner motor it is recom- for loose or damaged wire connections. If the C-Plug mended to ensure that the ground post on the Aqua-Hot is harness and connections are in good condition, but the securely tightened.
  • Page 51 Figure 38 Disconnect the motor’s black (+) and brown (-) wires from the C-plug harnesses black (+) and brown (-) wires. — Page 51 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 52 Follow the directions for reattaching the diesel parts together. burner in section ? NOTE: The new blower motor may come mounted to a new 11. Test for proper operation motor flange. — Page 52 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 53 8: D ECTION IESEL URNER OMPONENTS ROUBLE HOOTING Motor Replacement Procedure: (continued) — Page 53 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 54: Flame Sensor

    C-plug harness wires. Figure 40 Flame Sensor Green Wire Blue Wire — Page 54 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 55 Follow the directions for reattaching the diesel blue wires from the C-plug harness’ green and vio- burner, in section 9 of this manual. let wires, and remove flame sensor. Figure 41 — Page 55 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 56: Ignition Electrodes

    If it is missing, replace the electrode boot. Figure 42 — Page 56 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 57: Fuel Nozzle

    Be sure to review section 7 for detaching and reattaching instructions. Fuel Nozzle Component Test: 1. Follow the directions for detaching the diesel burner, in section 7, of this manual. — Page 57 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 58 A partially plugged orifice will restrict fuel flow, which will affect the combustion process of the diesel-burner. Figure 44 — Page 58 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 59: 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 59 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 60: 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 61 7 of this manual. NOTE: Do not adjust the fuel pressure regulator of the new fuel pump, as it has been factory preset. — Page 61 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 62 8: D ECTION IESEL URNER OMPONENTS ROUBLE HOOTING Fuel Pump: (continued) Figure 47 — Page 62 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 63: 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 48 — Page 63 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 64 Discard the retaining nut, steel drive gear, snap rings, bear- ings, spacer tube, and washers, as replacements are provided in the new bearing kit. — Page 64 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 65 Figure 50 — Page 65 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 66: 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 51 — Page 66 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 67 Follow the instructions for reattaching the diesel Lift the ignition coil and disconnect its wires from burner and test for proper operation. the C-plug harness wires, prior to removing. Figure 52 — Page 67 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 68: Controller

    If voltage is present, proceed to the next stat’s wires to the thermostat. The diesel-burner circuit test. will not ignite during normal operation if the VDC high-limit thermostat is left disconnected. — Page 68 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 69 Failure to do so, will result in moisture collecting in the ports and potential damage to the diesel-burner controller’s internal circuitry. Figure 53a Figure 53b — Page 69 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 70: If The Aqua-Hot Is Black Smoking

    Impeller Fan Not Gapped Properly The impeller needs to be gapped at 3-5 thousands or tighten fan down until it rubs, back it off ¼ turn. — Page 70 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 71: If The Aqua-Hot Is Blue/White Smoking

    Fuel Pump Intermittent Ignition Coil - If the coil doesn’t turn on, the fuel sprays for 20 seconds, before the photo eye shuts the fuel off. — Page 71 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 72: If One Of The Aqua-Hot's Heating Zones Will Not Get Hot

    D. Zone Circulation Pump Not Operating E. Heat Exchanger Fans Not Operating 2. If Fans and Pumps are Running A. Stuck Check Valve B. Kinked Line No Antifreeze in system — Page 72 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 73: If There Is A Lack Of Domestic Continuous Hot Water

    Must be 1.5 GPM or Less. 7. Mixer Valve is stuck (knob does not turn freely) 8. Copper Coil is not bonded properly to the outside of the boiler tank. — Page 73 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 74 NOTE: To find an antifreeze leak, the system must be Hot (up to operating temperature) Or pressurized to 17 PSI. Inspect the following components on the Aqua-Hot Heating System for Leaks: 1. On the Front-Side of Aqua-Hot - 1. Electric element 2.

  • Page 75: If There Is Antifreeze Leaking

    2. Supply/Return Ports A. Defective fitting B. Leaking fitting Note: If no leaks are found on the Aqua-Hot, it is possible that there is a leak within the motor home. Check all Heat exchangers, connections, and tubing for leaks. — Page 75 —...

  • Page 76: Appendix A: Wiring Diagram

    A: W PPENDIX IRING IAGRAM — Page 76 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 77 A: W PPENDIX IRING IAGRAM — Page 77 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 78: Appendix B: Bleeding The Interior Heating Zone Circulation Pump

    Depending on the plumbing lines diameter and total length it may be necessary to repeat B-J several times C. Place the radiator cap back onto the Aqua-Hot and tight- before any of the solution appears. Be sure to close both the drain valve and the pump manifold valve each time that the boiler tank is refilled D.
  • Page 79 PPENDIX LEEDING THE INTERIOR EATING IRCULATION Living room Supply Living room Return 13 lb Radiator Bathroom Supply Bathroom Return Bedroom Supply Bedroom Return Figure B1 — Page 79 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 80 B: B PPENDIX LEEDING THE INTERIOR EATING IRCULATION Return Ball Supply Ball Valve Valve Figure B2 Drain Valve — Page 80 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 81 Blower Figure B3 NOTE: If too much air pressure is applied to the boiler tank, it will leak out around the radiator cap’s rubber seal. — Page 81 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 82 LEEDING THE INTERIOR EATING IRCULATION Using a Coolant System Tester to pressurize the Boiler Tank Coolant System Tester Pressurize System up to 15 psi Figure B4 — Page 82 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 83 1. Refer to the section on detaching/reattaching the diesel burner, to detach the diesel burner. Step 2: Installing the fuel pressure gauge Figure C2 1. Using a 5/8” and a 3/4” wrench remove the fuel nozzle. — Page 83 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 84 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 84 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 85 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 85 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 86: Appendix C: Fuel Pressure Check And Adjustment

    NOTE: If the fuel pressure cannot be adjusted refer to the fuel pump section in section 8 Of this manu- al for troubleshooting tips. — Page 86 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 87 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 88: 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 89: 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 90 2. Using hose pinch off pliers, clamp off both fuel lines going to the fuel filter. Reference Thermostat figure ??. Figure E3 Connector Figure E2 Diesel Burner Controller Plugs — Page 90 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 91 Figure E4c Figure E4b 3. 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 91 —...
  • Page 92 Thermostats Diode Wire 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 wires from the control and hi limit thermostats It may also be necessary to disconnect the Diode Wire.
  • Page 93 If there is a minimal amount of soot, it may be left in the heat transfer tabs, and will be evacuated out the exhaust pipe, upon start up of diesel burner. — Page 93 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 94 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 94 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 95 Seam on stainless steel tube 1. Reinstall the combustion chamber into the Aqua-Hot. Please note: the seam on the stainless steel tube must be in the “up” position. Failure to do so could result in premature failure of the combustion chamber.
  • Page 96 Broken or cracked “Ears” Harness & Ignition Coil Wires - due to over tightening of eyebolts. - crack or bare wires - Hard or brittle wires — Page 96 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 97 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 97 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 98 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 98 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 99 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 99 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 100 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 101 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. — Page 101 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 102 B. After the Diesel-Burner has shut off, turn on the interior heat/run hot water, until the Diesel Burner cycles back on. When the diesel burner cycles back on, check the exhaust for signs of smoke. — Page 102 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...

  • Page 103: Appendix F: Winterization Process

    Not winterizing the Aqua-Hot when freezing temperatures this procedure for both the hot and cold faucets. are present will result in serious damage to the Aqua-Hot’s Domestic Water Heating System. Also, be sure to use an Turn off Demand Water pump and remove the hose and re- FDA approved, “GRAS”...
  • Page 104 — Page 104 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 105 — Page 105 — ® © 2011 Aqua-Hot AHE-100-02S Hydronic Heating System Service Manual—Rev. B...
  • Page 106 AHE-100-02S 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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