Aqua-Hot 200 Series Service Manual

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200

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AHE-250-P01

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Page 1 Service Manual Series AHE-250-P01...
Page 2: Table Of Contents
Maintenance Schedule ..............6 Aqua-Hot system. System Features ................7 NOTICE signals a situation where potential damage to the Component Cut-Away ..............8 Aqua-Hot could occur. Operational Flowchart..............9 Relay Control Board ..............10 Interior Switch Panel ..............12 Exhaust System Requirements ..........13 Interlock Switch ................14 Fluid Level Sensor ..............15...
Page 3: Introduction
Welcome to the Aqua-Hot 250P Service Manual. This manual based) Heating Systems that can provide heat and tank-less, will serve as a guide for diagnosing and repairing the Aqua-Hot, continuous hot water in one small, easy to install package. how to perform standard maintenance, and guide you through troubleshooting procedures to repair the Aqua-Hot.
Page 4 NOTE: Should any additional assistance be needed, please contact the Technical Support Department at 574-AIR-XCEL • DO NOT connect the 12-volt DC power to the Aqua-Hot if the (574-247-9235). vehicle requires welding. • At maximum operating temperature, the coolant will be very hot and scalding.
Page 6: Maintenance Schedule
When the Aqua-Hot is at maximum operating temperature, the an overheat condition until the unit has been serviced by a coolant is very hot. If the Aqua-Hot heating system is accessed, qualiﬁ ed technician. Failure to do so could result in damage scalding by hot vapor or coolant may occur.
Page 7: System Features
NOTE: This product label is attached to the side of the listed in the Recreational Vehicle Industry Association’s Aqua-Hot, and provides a ready reference to speciﬁ cations, (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle test standards, and important safety notices.
Page 8: Component Cut-Away
DO 15. Boiler Tank NOT remove these panels. Doing so risks irreparable damage to the Aqua-Hot. Only remove the service panel for service. 16. Domestic Hot-Water Coil 17. Interlock Switch 18.
Page 9: Operational Flowchart
Hot water ﬂ ows from the water The heating zone faucet fans activate The cooled antifreeze Heat is transferred to the is returned to the boiler vehicle interior via the heat tank to be reheated. exchangers ©Aqua-Hot® 250 Series Propane Service Manual p. 9...
Page 10: Relay Control Board
Fuse Functions, Locations, and Ratings: There are three fast-blow fuses included with this relay The relay control board at use in your Aqua-Hot 250 Propane board and may need to be replaced if they cease to function. Series is designed to function in conjunction with the Fenwal The cradles for these fuses are labeled FH1, FH2, and FH3 and Burner Control Card to allow the heater to operate.
Page 11 When this light is on, it indicates that there is either a demand for hot water, or the Aqua-Hot is not yet up to operating temperature. ©Aqua-Hot®...
Page 12: Interior Switch Panel
The interior switch panel is used to control the two heating the boiler tank if the need arises. A cold boiler tank can expect sources for the Aqua-Hot’s boiler tank. When a switch is to be brought to operating temperature by the electric heating activated, the indicator light on the switch will illuminate.
Page 13: Exhaust System Requirements
• Use standard two-inch automotive-type exhaust piping and avoid bends if possible. The Aqua-Hot’s exhaust is hot and must be kept away from any heat-sensitive material. Therefore, the exhaust system should • The 3-inch and 4-inch black pipe nipple and the exhaust...
Page 14: Interlock Switch
Monday through Friday, 7am to 4pm Mountain Standard Time. 2. Release the interlock switch from the Aqua-Hot cabinet by pushing in on the locking tabs and pulling the NOTE: Before attempting to troubleshoot any Aqua-Hot interlock switch.
Page 15: Fluid Level Sensor
The ﬂ uid expansion bottle is ﬁ lled to at least the “COLD” the Aqua-Hot. This device is intended as a fail-safe measure mark. which will disengage the Aqua-Hot if the ﬂ uid ever drops below a set threshold. The ﬂ uid level sensor is located on the expansion •...
Page 16 Fluid Level 9. Crimp the new faston connectors to the new ﬂ uid level Sensor sensor. 10. Connect these wires to their receptacles on the Aqua-Hot Lower Fitting to harness. Fluid Return Hose 11. Reconnect the overﬂ ow hose to the upper ﬁ tting.
Page 17: Control Thermostat
Take the temperature and when it requires heat. The Aqua-Hot is reading within 12 inches from the painted tank surface considered to be at operating temperature between 155°F and with the thermometer set to “High Emissivity”...
Page 18 9. Reﬁ ll the Aqua-Hot using an external ﬁ ll pump, ﬁ lling 2. Clamp the hoses indicated below with pinch off pliers to through the zone ﬁ ll port.
Page 19: Ac High-Limit Thermostat
2. Ensure that the unit has been shut down and completely Introduction: cooled before continuing. 3. Shut off the coach-side power breaker to the Aqua-Hot. The AC high-limit thermostat serves as a safety measure in the event that the electric heating element continues 4.
Page 20 12. Reposition the tempering valve assembly onto its mounting 1. Shut off gas, electric, and water supply to the Aqua-Hot. stud on the left cabinet wall. 2. Disconnect the domestic water inlet and outlet line ﬁ ttings 13.
Page 21: Burner High-Limit Thermostats
• The ﬂ uid expansion bottle is ﬁ lled to at least the “COLD” mark. 1. Ensure that the Aqua-Hot has been completely shut down, • Verify that all in-line fuses are functional. all power sources disconnected, and the unit is allowed to cool completely before continuing.
Page 22: Low-Temperature Cutoff Thermostat
Cutoff Thermostat. Lack of Hot Water 1. If the LTCO indicator light does not illuminate when domestic water is being used or when the Aqua-Hot falls below operating temperature, complete the following: • Using a temperature sensor, verify that the LTCO thermostat is below 90°F.
Page 23 Low-Temp Cutoff Thermostat Replacing the Low-Temperature Cutoff Thermostat: 1. Ensure that the Aqua-Hot has been completely shut down and that all the power sources have been disconnected. 2. Locate the Low-Temperature Cutoff Thermostat on the Failure to disconnect all power supplies and/or allow Aqua-Hot.
Page 24: Three-Way Valve
Three-Way Valve Three-Way Valve Introduction: The Aqua-Hot has a three-way directional valve to control coolant priority within the unit. This ensures that there will be a supply when heated water is being called for, but can provide interior heating when the need arises.
Page 25 Connect to wire #22 “Faston” connector. Slide the hoses onto the valve and set the constant tension 9. Reﬁ ll the Aqua-Hot’s boiler tank, purging the heating loop clamps back into place. if necessary. Clamp...
Page 26: Tempering Valve
6. Using a back-up wrench, unscrew the tempering valve 1. Inspect the tempering valve to ensure that it is not from the Aqua-Hot. Failure to use a back-up wrench could leaking. result in damage to the cold water inlet pipe.
Page 27: Fluid Circulation And Stir Pump
The propane burner is hidden in the view above to better show the location of the zone/stir pump. • If the pump does not operate with 12V DC directly applied to it, the pump will need to be replaced. ©Aqua-Hot® 250 Series Propane Service Manual p. 27...
Page 28 Fluid Circulation Pump Replacement Procedure: 1. Ensure that the Aqua-Hot has been completely shut down, all power sources have been disconnected, and that the unit has been allowed to cool completely. Failure to disconnect all power supplies and/or allow 2. Clamp the zone outlet, and the zone return with hose pinch- the unit to cool before servicing could cause serious pliers as shown below.
Page 29: Ac Electric System
2. Allow the unit to cool completely. functions to provide supplementary heat to the Aqua-Hot boiler 3. Verify that the Aqua-Hot is connected to an AC power source tank. This is done with an electric element, an electric relay, such as shore power or an AC generator.
Page 30 Aqua-Hot Molex terminal. 9. Reﬁ ll the Aqua-Hot boiler tank with the previously drained • Resistance should be between approximately 11-13 ﬂ uid, add more 50/50 mix of propylene glycol and distilled ohms.
Page 31: Propane Burner
Propane Burner Propane Burner Overview The propane burner operates on standard, readily available The Aqua-Hot’s propane burner is the heart of the Aqua-Hot unit. propane found at a local propane store. The propane burner is the device which ignites and sustains the combustion of a propane-air mixture.
Page 32: Propane Burner Flow Chart
NOTE: If the Aqua-Hot’s coolant • Checking for a ﬂ ame temperature approximately • Checking the Control Thermostat The Control Thermostat 190°F or higher, the Motor will not...
Page 33: Propane Switch Panel
DO NOT INSTALL JUMPER WIRES ACROSS THE SWITCHES IN THE SWITCH PANEL. JUMPER WIRES ARE ONLY TO BE INSTALLED BETWEEN PIN 4 AND PIN 10 ON EACH SWITCH. FAILURE TO ADHERE TO THIS GUIDELINE MAY RESULT IN DAMAGE TO YOUR AQUA-HOT AND/OR COACH. Switch Panel Wiring AC Electric Switch...
Page 34: Fenwal Control Card
4. Move the burner switch on the interior switch panel to the The purpose of the Fenwal card is to control the propane ON position. burner. Please note that the Aqua-Hot 250P units do not have a • Verify that 12V DC power is present at Pin 10 of the uniﬁ...
Page 36: Detaching The Propane Burner
1. Disconnect the Aqua-Hot from all electrical sources. Backing Wrench 2. Close the propane ball valve on top of the Aqua-Hot cabinet. 3. Shut off the coach propane bottle at the source. 4. Using a ⅜” socket or nut driver, remove the two nuts from the ground studs located on top of the propane burner Loosen this ﬁ...
Page 37 Aqua-Hot cabinet. Figure 50 19. Continue to carefully remove the burner from the Aqua-Hot cabinet. Please note that wires may have become entangled in your unit complicating removal. Take care to not damage any wires or other hardware within the Aqua-Hot.
Page 38: Reinstalling The Propane Burner
15. Retrieve the Fenwal control card and reconnect wire #17 to 11. Using a ½” socket and extension, re-secure the propane the pin labeled “PWR”. burner to the mounting studs on the Aqua-Hot tan face as 16. Reconnect wire #48 to pin labeled “BLO”. p. 38 ©Aqua-Hot®...
Page 39 24. Reconnect the Aqua-Hot to a propane source to check for leaks in the propane ﬁ ttings. 25. Open the propane ball valve on the Aqua-Hot and open any propane shutoff valves present within the coach. 26. Check for propane leaks around the recently reconnected propane ﬁ...
Page 40: Mounting Gasket
The mounting gaskets create a tight seal between the boiler tank and the combustion chamber, and the combustion Aqua-Hot operates on both AC and DC power. Be sure chamber and the burner mounting plate. to disconnect the 120V AC power supply from the Aqua- Hot prior to servicing.
Page 41: Hot Surface Igniter
The hot surface igniter ignites the propane gas and air mixture inside of the combustion chamber. It will activate Aqua-Hot operates on both AC and DC power. Be sure approximately 10 seconds after the initial start-up sequence to disconnect the 120V AC power supply from the Aqua- begins, and approximately ﬁ...
Page 42 Aqua-Hot. 2. Turn off the propane at the ball valve on top of the Aqua- Hot. 3. Remove the access cover of the Aqua-Hot to gain access to internal components. 4. Disconnect the hot surface igniter from the buck boost module.
Page 43: Refractory Insulation
The refractory acts as an insulator to protect the hot surface igniter from being overheated by the ﬂ ame. Troubleshoot the Aqua-Hot operates on both AC and DC power. Be sure refractory if the propane burner “pops” on ignition, or if the to disconnect the 120V AC power supply from the Aqua- propane burner fails to ignite.
Page 44: Dual-Stage Propane Gas Valve
Before troubleshooting the dual-stage propane gas valve, ensure that the coach has an adequate supply of propane gas, and that all valves and shutoffs are open, allowing propane ﬂ ow to the Aqua-Hot. Replacement Procedure: 1. Shut off the propane gas supply by turning the propane Troubleshooting: inlet port ball valve to the OFF position.
Page 45 Tighten this ﬁ tting Figure 66 Figure 64 12. Tighten the bulkhead ﬁ tting to the Aqua-Hot cabinet. Remove the ﬁ ttings present at the top and bottom of the dual stage propane gas valve shown below. Backing Wrench here Tighten this ﬁ...
Page 46: Propane Combustion Blower Fan
9. Using a ⅜” socket, secure the now repaired assembly to the top of the propane burner. 10. Reconnect the wires of the blower fan to the buck boost module. p. 46 ©Aqua-Hot® 250 Series Propane Service Manual...
Page 47: Adjustment Of The Propane Air Shutter
This will set the gap at approximately 0.275”. 3. While holding the bit in place, tighten the set screw. 4. Remove the drill bit and ensure that the air shutter is secure. Set Screw 0.275” Figure 70 ©Aqua-Hot® 250 Series Propane Service Manual p. 47...
Page 48: Exhaust "High Back" Pressure Switch
“back-ﬂ ows” into the 3. Remove the defective switch. cabinet of the Aqua-Hot, or if there is an obstruction or damage to the exhaust system. 4. Secure the replacement switch to the side of the propane burner.
Page 49: Fan Validation Switch
” Allen wrench, remove the nuts securing the 3 / 16 Replace the fan validation switch if the switch fails to operate fan validation switch to the cabinet wall of the Aqua-Hot. or if its physically damaged. 5. Remove the defective switch.
Page 50: Buck Boost Converter - Combustion Blower Fan
11V DC and 15V DC. • If the buck boost converter does not output approximately 12.5V DC and the supply voltage is between 11V DC and 15V DC, the buck boost will need to be replaced. p. 50 ©Aqua-Hot® 250 Series Propane Service Manual...
Page 51: Buck Boost Converter - Hot Surface Igniter
If the buck boost converter does not output Figure 78 approximately 12.5V DC and the supply voltage is between 11V DC and 15V DC, the buck boost will need to be replaced. ©Aqua-Hot® 250 Series Propane Service Manual p. 51...
Page 52 1. Move the propane burner switch on the interior switch panel to the OFF position. If necessary, allow the propane burner to completely shut down. 2. Disconnect the Aqua-Hot from any power source. 3. Locate the buck boost module to be replaced. Reference Figure 80.
Page 53: Propane Flame Sensor
The ﬂ ame sensor produces a small current, measured in micro-amperes (µA). This current is too small to be detected by most retail multimeter. This functionality is necessary to troubleshoot properly. Please contact Aqua-Hot Heating Systems at 574-AIR-XCEL (574-247-9235) to assist in diagnosing the ﬂ ame sensor.
Page 54 ﬂ ame sensor once it has been deemed to be non-functional. Replacement Procedure: 1. Disconnect the Aqua-Hot from any and all power sources. 2. Ensure that the Aqua-Hot has cooled down completely. 3. Disconnect #35 from the ﬂ ame sensor.
Page 55: Fill And Purge Procedure
Fluid Expansion Bottle Procedure: • Control Thermostat 1. Attach an external ﬁ ll pump and hose to the Aqua-Hot • Electric Element at the ball valve located just above the three-way valve. If the interior heating loop is not purged, it may contain...
Page 56: Winterization
The warranty does not cover freeze damage. De-Winterization: NOTE: The Aqua-Hot can continue to be used for interior heat once the domestic hot water system has been winterized. 1. To de-winterize the unit, connect a freshwater source to the coach.
Page 57: General Troubleshooting
• Ensure that all coach-side hot water faucets are closed. • Tempering Valve • Locate the relay control board within the Aqua-Hot unit. See ○ Reference Page 26 to troubleshoot the tempering valve. Page 10 to identify this component. Once these components have been diagnosed, restart the •...
Page 58 A seized circulation pump contact Technical Support at 574-AIR-XCEL (574-247-9235), • Air trapped in the coach heating loop or take the coach to an Aqua-Hot Factory Authorized Service Center. One can be found at www.aquahot.com. • A malfunctioning low-temperature cutoff thermostat Stage 1: •...
Page 59: Burner Troubleshooting
This section will cover troubleshooting the propane burner if 14. Follow the instructions on Page 36 to remove the propane it becomes inoperative. burner from the Aqua-Hot. This will grant access to components for troubleshooting. If additional assistance if needed, please contact the technical support department at 574-AIR-XCEL (574-247-9235).
Page 60: Antifreeze Information
“boiler” type antifreeze in the concentrated propylene glycol antifreeze with water; suppliers Aqua-Hot. Propylene glycol is a safer alternative to the more of premixed antifreeze are responsible for the use of high- toxic ethylene glycol antifreeze; however, as mandated by...
Page 61 Generally Recognized As Safe (“GRAS”) by the FDA could Therefore, as water is an excellent heat conductor, it is result in serious bodily harm to damage to the Aqua-Hot added to the mixture. Propylene glycol antifreeze solution, system.
Page 62: Appendix: Measuring Antifreeze
Refractometer Sight Glass Application of Propylene Glycol Upper Blue Field Poor Poor Good Boundary Line Adjust to 32°F Lower White Field p. 62 ©Aqua-Hot® 250 Series Propane Service Manual...
Page 63 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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