Fluid-Level Sensor - Aqua-Hot 400 Series Service Manual

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Service manual (106 pages)

Installation manual (63 pages)

Use and care manual (25 pages)

Table Of Contents

Table of Contents

Fluid-Level Sensor: Serial #: A400-130001 - A400-130104

The fluid-level sensor monitors the level of antifreeze and

water heating solution within the Aqua-Hot's boiler tank to

ensure that an adequate volume exists.

Troubleshoot the fluid-level sensor if one of the following

condition has occurred:



The Propane-burner and/or Electric heating element

fails to operate.



The Aqua-Hot fails to operate and the "Low Tank-Level

Cutoff" indicator light on the electronic controller is illu-

minated red.

Troubleshooting:

1. Verify that the Aqua-Hot's boiler tank is full of the anti-

freeze and water heating solution.

2. Verify that the wire connector is securely plugged into

the fluid-level sensor and secured with the attached

clip.

3. Verify that the fluid-level sensor's wires are securely

installed in the terminal strip on the wire harness, as

well as tightly fastened to the electronic controller.

4. Verify the functionality of the fluid-level sensor by com-

pleting the following:

The fluid-level sensor requires power to operate and pos-

sesses a third wire for power (#17), which advances from

the sensor to join the red #1 wire on the "PUMP 3+" termi-

nal on the electronic controller's JP3 plug. Therefore, if

pump #3 light is red, the Low Tank Level Cutoff light will

illuminate red as well.



Remove the faceplate from the electronic controller.



Install a jumper wire on the JP3 plug, between pins 15

and 16 (between "LWCO-I" and "LWCO-O") on the elec-

tronic controller in order to bypass the fluid-level sensor.

If the "Low-Tank Level Cutoff" indicator light on the electron-

ic controller extinguishes when the jumper wire is installed,

inspect the wire harness for damaged or severed wires. If no

wires are found to be damaged or severed, follow the in-

structions in this section to replace the fluid-level sensor.

If however the "Low Tank-Level Cutoff" indictor light contin-

ues to illuminate once the jumper wire is installed, follow the

instructions in this manual to replace the electronic control-

ler.

Replacement Procedure:

Failure to disconnect all power supplies and/or to allow the

heater to cool before servicing could cause serious damage

or personal injury.

1. Ensure that the Aqua-Hot has been completely shut

down and that all power sources have been disconnect-

ed. Also, because this replacement will involve the boil-

er tank and the potential for hot coolant, be sure the

heater has cooled.

2. Drain the antifreeze and water heating solution from

the Aqua-Hot's boiler tank using the drain valve.

3. Disconnect the fluid-level sensor's wires by releasing

the clip securing the plug to the sensor and pulling the

plug away from the sensor.

4. Using a 7/8" wrench, unscrew the fluid-level sensor

from the Aqua-hot's boiler tank. It may be necessary to

use a 7/8" Crow's Foot wrench.

5. Add a liquid thread sealant (such as Loctite

threads of the replacement fluid-level sensor.

6. Screw the replacement fluid-level sensor into the port

on the Aqua-Hot's boiler tank and tighten with a

wrench.

7. Plug the fluid-level sensor's wires into the replacement

sensor and secure with the clip.

8. Refill the Aqua-Hot's boiler tank with the antifreeze and

water heating solution.

9. Test for proper operation.

Figure 9