Airxcel Aqua-Hot 100 Series Service Manual

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100

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AHE-125-DN1

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Page 1 Service Manual Series AHE-125-DN1...
Page 2: Table Of Contents
Introduction Contents Caution Notes Caution Notes ................2 As you read this information, take particular note of the NOTICE, CAUTION, WARNING, and DANGER symbols when they appear. Introduction ..................3 This information is important for safe and efﬁ cient use of the Maintenance Schedule ..............6 Aqua-Hot system.
Page 3: Introduction
Introduction System Overview The Aqua-Hot 125DN Series is a Hydronic Heating System heating loop and to heat exchangers to evenly warm the coach. that can provide heat and hot water on demand using a built-in Water is heated on-demand by going into a heat exchanger electric heating element and an external diesel burner.
Page 4 Introduction Important Notes: Heat Priority Option: • A qualiﬁ ed installer or service technician must perform equipment installation or service. Contact Aqua-Hot for The Aqua-Hot comes equipped with the three-way valve Factory Authorized Service Centers or Certiﬁ ed Technicians (sometimes known as the summer/winter valve). This controls located near you at www.aquahot.com/service-help, or call the ﬂ...
Page 5 Introduction Introduction to this Document Welcome to the Aqua-Hot 125DN Service Manual. This manual will serve as a guide for diagnosing and repairing the Aqua-Hot, how to perform standard maintenance, and guide If the information in this manual is not followed you through troubleshooting procedures to repair the Aqua-Hot.
Page 6: Maintenance Schedule
Maintenance Schedule Introduction Maintenance Schedule Monthly Maintenance Check the Aqua-Hot’s antifreeze and distilled water heating solution to ensure that it is at the proper level. This can be accomplished by visually checking the coolant level in the Aqua- Hot’s expansion bottle; reference Figure 63 on page 34. DO NOT operate the diesel burner and/or electric heating Please note that the coolant level should be checked ONLY element without antifreeze and distilled water heating...
Page 7: System Features
System Features Figure 6 System Speciﬁ cations Electric Element Power Consumption ........1500 W (maximum) Voltage ................120V AC DC Power Consumption ............84W (maximum) Zone Heat Circulation Pumps ...................1 Power Consumption (max) ............. 21W Voltage ................12V DC Heating Zones Maximum ..................3 Domestic Water Heating Maximum .................
Page 8: Component Cut-Aways
Component Cut-Aways Basic Components Aqua-Hot 125D 1. Tempering Valve 2. Fluid Circulation Pump 3. Aqua-Hot Controller 4. Antifreeze and Water Heating Solution Tank 5. AC Electric Element Figure 7 6. AC Activation Relay Plate-to-plate Heat Exchanger 8. Three-Way Valve 9. Zone Air-Bleed Valve 10.
Page 9 Component Cut-Aways Basic Components Aqua-Hot Diesel Burner 1. Combustion Air Fan 2. Fluid Outlet 3. Fluid Inlet 4. Combustion Chamber 5. Circulation Pump 6. Exhaust Gas Temperature Sensor Exhaust Outlet 8. Air Inlet 9. Control Unit 10. Burner Motor 11. Fuel Inlet 12.
Page 10: Operational Flowchart
Operational Flowchart Operational Flow Chart A heat source is selected from Interior Switch Panel External Diesel Burner Electric Element Electric Heating Element The diesel burner will will activate, providing begin providing heat to the heat to the antifreeze and antifreeze and water heating water heating solution solution present within the within the boiler tank...
Page 11: Operating The Lcd
Operating the LCD Operating the LCD above) as well as a button to turn the zone on or off If the zone temperature is set, but this item Introduction: is not set to ON, the zone heat exchanger will not activate. This document will outline the basic operating instructions for the Aqua-Hot LCD Screen.
Page 12 Operating the LCD LOW: While in LOW mode, the electric element will work to maintain a tank temperature of 170°F (76°C), with a minimum tank temperature of 165° F (74°C). HIGH: While set to HIGH, the electric element will work to maintain a tank temperature of 180°F (82°C), with a minimum tank temperature of 165°...
Page 13: Aqua-Hot Controller
Controller The Aqua-Hot Controller System Voltage: System voltage faults indicate that there is a problem with the coach-side power supply Introduction: which powers the Aqua-Hot. The Aqua-Hot can only operate within a The Aqua-Hot 125DN operates on a controller platform voltage range of 11V DC to 16V DC.
Page 14 Controller necessary to utilize the DIAG screens, which will be explained Electric: next. The Electric section indicates the controller’s current handling status of the AC electric relay. This status indicates that the controller is attempting to activate the element relay only. This does NOT indicate whether the electric element is in working order or not.
Page 15 Controller LTCO Status: The LTCO status indicates the sensor reading from the Low-Temperature Cutoff Thermostat, which is the device that governs whether to provide heat or hot water. LLCO Status: LLCO status relays the current sensor reading of the Low-Level Cutoff sensor within the overﬂ...
Page 16 Controller Testing Functionality: One of the new features of this control system is the ability to independently activate speciﬁ c elements within the Aqua-Hot for testing purposes. Figure 23 Heating sub-systems can be activated independent of their control circuits and other control sensors as a means of testing functionality.
Page 17 Controller Three-Way Valve (E): 8. Discard defective controller. The ﬁ nal element on this screen is not directly 9. Plate new controller onto the mounting plate. related to the heating subsystems of the • Ensure the controller is properly oriented - reference Aqua-Hot.
Page 18: Fluid Level Sensor
Fluid Level Sensor Fluid Level Sensor Troubleshooting Procedure: Locate the ﬂ uid level Introduction: sensor (Figure 25) The ﬂ uid level sensor monitors the current ﬂ uid level within the Aqua-Hot. This device is intended as a fail-safe measure Using a multi-meter, test which will disengage the Aqua-Hot if the ﬂ...
Page 19 Fluid Level Sensor Before continuing to the replacement procedure, Expansion Bottle can be ensure that the unit has cooled to ambient temperature, found mounted to the all power sources have been disconnected, and the side of the Aqua-Hot unit unit is completely shut off. Replacement Procedure: In order to replace the ﬂ...
Page 20: High-Limit Thermostats
High-Limit Thermostats High-Limit Thermostats Troubleshooting Procedure: Locate the high-limit Introduction: thermostat which is suspected of failure The Aqua-Hot is equipped with three resettable High-Limit Thermostats. These thermostats are in place to prevent the heater from operating beyond its safe operational threshold. These thermostats are resettable and easily replaceable.
Page 21 High-Limit Thermostats Replacement Procedure: If it has been determined that one, or multiple high-limit thermostats need to be replaced, they can be easily replaced by following the directions below. 1. Disconnect all sources of AC and DC power from the Aqua- Hot (if the AC high-limit thermostat is the issue, the AC access cover will need to be removed - see Figure 32).
Page 22: Low-Temperature Cutoff Thermostat
Low-Temp Cutoff Thermostat Low-Temperature Cutoff Thermostat Locate the Aqua-Hot LCD screen. Navigate to INPUTS FROM AQUA-HOT. Introduction: Locate the LTCO at the The Low-Temperature Cutoff Thermostat (LTCO) is installed unit, and using a multi- to measure the incoming domestic water temperature. Using meter, test for continuity Turn on a hot water faucet that reading, the Aqua-Hot controller is able to determine...
Page 23: Three-Way Valve
Three-Way Valve Three-Way Valve Continue trouble- Continue trouble- shooting here shooting here Introduction: The three-way valve (aka the summer/winter valve) is Grab the hoses Leave the probes of the responsible for changing the ﬂ ow of coolant either through the highlighted green below.
Page 24 Three-Way Valve • There may be residual ﬂ uid that exits the ﬁ ttings - use towels or other clean up items as necessary. 9. Carefully remove the Three-Way Valve from the last ¾” heater hose on the right of the valve. •...
Page 25: Tempering Valve
Tempering Valve Tempering Valve Testing Procedure: Introduction: Follow the testing procedure to the right in order to diagnose the tempering valve. Troubleshoot the tempering valve if the The tempering valve of the Aqua-Hot mixes the hot domestic following conditions have occurred: water from the interior of the Aqua-Hot with cold incoming •...
Page 26 Tempering Valve Replacement Procedure: any other components in the Aqua-Hot. 9. Remove the assembly from the Aqua-Hot. 1. Shut off the external domestic water connection, and open a hot water faucet valve within the coach to relieve the 10. Remove all three ﬁ ttings from the tempering valve as shown water pressure.
Page 27: Fluid Circulation Pump
Fluid Circulation Pump Power cycle the Aqua-Hot Fluid Circulation Pump to clear any current faults. Introduction: Locate the Aqua-Hot LCD The ﬂ uid circulation pump operates to provide ﬂ uid circulation screen. Navigate to the to either the interior heating zone or the antifreeze boiler tank TESTING page (Figure 46a).
Page 28 Fluid Circulation Pump Replacement Procedure: 1. Drain coolant from system. Pour into a bucket to be reused later. 2. Remove the top and side panels from the Aqua-Hot. Save Circulation Pump the screws and washers to be reused later. 3. Place a paper towel into the Aqua-Hot unit on the bottom of the cabinet.
Page 29: Ac Electric System
Fluid Circulation Pump AC Electric System AC Electric System Locate the Aqua-Hot LCD Introduction: screen. Navigate to the The AC Electric system of the Aqua-Hot 125DN unit functions to TESTING page (Figure 51) provide heat to the Aqua-Hot boiler tank. This is done with an electric element and an electric relay.
Page 30 Fluid Circulation Pump AC Electric System Replacement Procedure: 1. Ensure that the Aqua-Hot has been completely shut down and all power sources have been disconnected. Be sure the boiler tank is completely cooled. 2. Using hose pinch-off pliers, clamp off the heating zone inlet Failure to disconnect all power supplies and/or allow and outlet ports.
Page 31: Ac Relay
Fluid Circulation Pump AC Relay AC Relay Replacement Procedure: 1. Ensure that the Aqua-Hot has been completely shut down and all power sources have been disconnected. Be sure the Introduction: boiler tank is completely cooled. The AC Relay is an electrical device where the DC circuit from 2.
Page 32: Ets Module
ETS Module ETS Module Using a meat thermometer, measure the temperature of the tank face. Record Introduction: this temperature on a piece of paper. The ETS (Engine Temperature Sensor) Module is a brass thermistor that continually measures the temperature of the ﬂ...
Page 33 ETS Module Replacement Procedure: 8. Reconnect the disconnected wires from the harness. If the ETS Module has been diagnosed and a replacement 9. Reconnect the TO HEAT SOURCE hose to the Aqua-Hot and must be made, follow the instructions below. remove the hose clamp.
Page 34: High Altitude Replacement
High Altitude Replacement ETS Module Figure 63 1. Fuel Line Coupler Fuel Lines Requirements 2. High Altitude Bypass 3. Fuel Pump • Parts needed: 4. Fuel Filter • PLX-125-HA1, High Altitude Kit 5. Fuel Line • Potential other parts needed: 6.
Page 35 High Altitude Replacement ETS Module Fuel Line to Coupler Hose A Clamp B Bubble Figure 64 NOTE: The fuel lines must be secured and supported properly to avoid air traps or bubbles. Avoid unnecessary dips or bends, the line should not run downward from the fuel pump. High Altitude Bypass Orientation BEST - 0°...
Page 36 High Altitude Replacement ETS Module Burner Bottom View Fuel Line Connection Figure 66 Fuel Filter 0 - 90° Fuel Line Connection Ø 5 Figure 68 Figure 67 p. 36 ©Aqua-Hot® 125DN Service Manual...
Page 37 High Altitude Replacement ETS Module Fuel Purge Procedure: • Ground goes to Pin #1 The fuel lines should be automatically primed with the ﬁ rst • Power goes to Pin #2 operation of the burner. It may need to be power cycled a few •...
Page 38 High Altitude Replacement ETS Module The ﬁ rst operation of the burner with the Aqua-Hot may not light up perfectly. This is normal and may take a couple tries to get the fuel lines purged of air before a successful start-up. NOTE: Make sure to perform the fuel line purge procedure Failure to follow instructions on the fuel delivery system can on Page 37 prior to starting this start up of the burner.
Page 39: General Troubleshooting
General Troubleshooting Lack of Interior Heat or Hot Water Fill Cap Upper Fitting Introduction: A lack of interior heat or hot water when provided with Hot Fluid Line adequate heat from either the electric element and/or the diesel burner can be attributed to an overheat thermostat, the Aqua-Hot controller, the three-way valve, or the ﬂ...
Page 40: Winterization
Winterizing the Aqua-Hot General Troubleshooting Winterizing the Aqua-Hot The Aqua-Hot’s domestic water heating system must be completely drained of domestic water at any time the heater is stored where freezing temperatures may be experienced. winterizing Aqua-Hot when freezing Please follow these instructions when winterizing the Aqua- temperatures are present will result in serious Hot domestic water heating system.
Page 41: Burner Troubleshooting
General Troubleshooting Burner Troubleshooting External Diesel Burner Troubleshooting This section will cover any issues with the external diesel burner. The diesel burner is the primary heat source to the 125DN. The troubleshooting procedures listed below are arranged in order of repair complexity. Do not replace parts without correctly determining the failure.
Page 42 General Troubleshooting Burner Troubleshooting General Failure Symptoms of the Burner This section will cover the typical failures of the diesel burner. Refer to the table more fails and their remedies. Failure Symptom Possible Cause Remedy Burner switches off auto- No combustion after start or automatic Switch off burner and switch back on.
Page 43: Appendix A: System Schematics
System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. ©Aqua-Hot® 125DN Service Manual p. 43...
Page 49: Appendix B: Parts
System Schematics Parts ELE-014-711 ELX-THM-309 (white) or ELX-THM-310 (black) Thermistor, Tank Temperature Sensor Thermistor ELE-102-211 ELE-102-201 Burner DC Harness Aqua-Hot AC Harness ELE-400-900 ELE-HLT-425 Harness, Buehler C20 Pump VAC High Limit 215°F Thermostat w/ Spade Connectors ©Aqua-Hot® 125DN Service Manual p.
Page 50 System Schematics Parts ELE-HLT-426 ELE-LTC-200 VAC High Limit Thermostat 215°F w/ Leads Low-Temperature Cutoff Thermostat w/ Spade Terminals ELE-PCB-100 ELX-2E7-102 Controller, Aqua-Hot PCB 125DN Element, 1” NPSM, 120 VAC, 1500W, Heating EXE-103-0EX MSX-907-162 Heat Exchanger, Cozy III Refractometer p. 50 ©Aqua-Hot®...
Page 51 System Schematics Parts PLE-063-200 PLX-100-900 3 Qt. Expansion Tank w/Internal Fluid Level Sensor, 5/8” Barb Fluid Circulation Pump PLX-111-125 PLX-125-3WV Pressure Relief Valve, 125 PSI Kit, Three-Way Motorized Valve, ½” NPT PLX-362-100 PLX-CTB-290 Tempering Valve Clamp, Hose, Constant Tension, 1-1/16” ©Aqua-Hot®...
Page 52 System Schematics Parts ELX-232-948 SME-102-080 AC Relay Cover, AC Element Cover for 125DN & 100DE PLE-125-FL1 PLX-125-HA1 Kit, Fuel Line, 125DN Kit, High Altitude Assembly, 125DN p. 52 ©Aqua-Hot® 125DN Service Manual...
Page 53: Appendix C: Measuring Antifreeze
Appendix Measuring Antifreeze Using a Refractometer Calibration Screw Prism Assembly Daylight Plate Assembly Eye Piece Properly Apply Antifreeze to the Prism Assembly Use the guide below to properly apply the ethylene glycol mixture to the prism assembly of the refractometer. Once that is complete, peer through the eyeglass of the refractometer to continue to the next step.
Page 54 Service Manual SERIES Aqua-Hot Heating Systems, LLC 7501 Miller Drive, Frederick, CO 80504 Visit us online at www.aquahot.com Call us at 574-AIR-XCEL (574-247-9235). ©2021 Aqua-Hot Heating Systems, LLC. Printed in the USA...

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Airxcel Aqua-Hot 100 Series Service Manual

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