Aqua-Hot 200 Series Service Manual

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200

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AHE-250-D01

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Page 1 Service Manual Series AHE-250-D01...
Page 2: Table Of Contents
Component Cut-Aways ..............7 Aqua-Hot system. Operational Flowchart..............8 NOTICE signals a situation where potential damage to the Relay Control Board ..............9 Aqua-Hot could occur. Interior Switch Panel ..............11 Exhaust System Requirements ..........12 Interlock Switch ................. 13 Fluid Level Sensor ..............14 Control Thermostat ..............16...
Page 3: Introduction
Welcome to the Aqua-Hot 250D 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 The Aqua-Hot’s exhaust is HOT and must be kept away from heat sensitive material. • DO NOT connect the 12-volt DC power to the Aqua-Hot if the NOTE: Should any additional assistance be needed, please vehicle requires welding. contact the Technical Support Department at 574-AIR-XCEL (574-247-9235).
Page 5: Maintenance Schedule
223°F (106°C). Refer to the table below to determine the best protection mixture ratio. Reference page 64 To maintain the Aqua-Hot at its full potential, it is highly for measuring the antifreeze mixture with a refractometer. recommended to have the diesel burner tuned up annually. This involves the fuel ﬁ...
Page 6: 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 7: Component Cut-Aways
13. Heating Zone Outlet Port NOT remove these panels. Doing so risks irreparable damage 14. Heating Zone Return Port to the Aqua-Hot. Only remove the service panel for service. 15. 120V AC Connection 16. Boiler Tank 17. Domestic Hot-Water Coil 18.
Page 8: 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 p. 8 ©Aqua-Hot® 250 Series Diesel Service Manual...
Page 9: 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 Diesel board and may need to be replaced if they cease to function. Series is designed to function in conjunction with the Diesel The cradles for these fuses are labeled FH1, FH2, and FH3 and Burner Controller to allow the heater to operate.
Page 10 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. p. 10 ©Aqua-Hot®...
Page 11: Interior Switch Panel
The interior switch panel is used to control the two potential the boiler tank if the need arises. A cold boiler tank can expect heating 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 12: Exhaust System Requirements
The exhaust must be able to freely exit away from the Introduction: vehicle without any obstructions. The Aqua-Hot’s exhaust is hot and must be kept away from any • Use standard two-inch automotive-type exhaust piping heat-sensitive material. Therefore, the exhaust system should and avoid bends if possible.
Page 13: Interlock Switch
574-AIR-XCEL (574-247-9235) quick connectors from the switch spade terminals. 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 interlock switch.
Page 14: 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 15 9. Crimp the new faston connectors to the new ﬂ uid level sensor. Lower Fitting to Fluid Return Hose 10. Connect these wires to their receptacles on the Aqua-Hot harness. Figure 14 11. Reconnect the overﬂ ow hose to the upper ﬁ tting.
Page 16: 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 17 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.
Page 18: 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 19 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 20: 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, all power sources disconnected, and the unit is allowed to • Verify that all in-line fuses are functional.
Page 21: 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 22 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 23: 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 24 Connect to wire #22 “Faston” connector. 5. Remove the hose from the defective valve as shown in 9. Reﬁ ll the Aqua-Hot’s boiler tank, purging the heating loop Figure 30. if necessary. 6. Remove the two remaining hoses from the defective three- way valve.
Page 25: 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 26: Fluid Circulation And Stir Pump
If the pump operates with 12V DC applied, begin diagnosing the relay control board. • If the pump does not operate with 12V DC directly applied to it, the pump will need to be replaced. p. 26 ©Aqua-Hot® 250 Series Diesel Service Manual...
Page 27 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 28: 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 29 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 30: Diesel Burner
The diesel burner serves as the primary heating source for the serial numbers. Aqua-Hot 250D. The diesel burner is responsible for mixing and 1. Igniter 6. Fuel Pump igniting diesel fuel within the combustion chamber. Heat energy 2.
Page 31: Diesel Burner Flow Chart
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 Diesel Service Manual p. 31...
Page 32: Diesel Switch Panel
Pin 2 Pin 10 PIN 10 ON EACH SWITCH. FAILURE TO ADHERE TO THIS GUIDELINE MAY Pin 9 Chassis Ground RESULT IN DAMAGE TO YOUR AQUA-HOT AND/OR COACH. Burner Switch 8-Pin Harness Plug Pin 4 Pin 4 NOTE: The AC control circuit connections have been integrated into the 12-Pin Mate-N-Lock receptacle.
Page 34: Diesel Burner Controller
Battery Negative (Black) Control Light/Operation Indicator (Green) Replacement Procedure: Battery Positive (Red) 1. Disconnect the Aqua-Hot from any and all power sources. Thermostat Input (White) 2. Using a ⅜” socket, remove the two bolts on the left side of Thermostat Output (Orange)
Page 35 There is a problem with Is the voltage between 10V DC the power supply to the and 16V DC? Aqua-Hot. The burner is faulting. Troubleshoot the burner by following the directions on Page 61. Check for 12V DC power...
Page 36 Is voltage present at Pin C2 as described above? to replaced. Begin troubleshooting the Can you hear the fuel solenoid opening? solenoid on Page 44. Contact Aqua-Hot Heating Systems Technical Support Department at 574-AIR-XCEL (574-247-9235). p. 36 ©Aqua-Hot® 250 Series Diesel Service Manual...
Page 37: Disassembly Of The Burner Heat Sub-Assembly
ﬂ ange. Do NOT pull on the air shutter or the blower fan. 1. Disconnect the Aqua-Hot from any and all electrical sources. 2. Remove the access cover from the front of the Aqua-Hot. 3. Locate the diesel burner controller on the left side of the burner.
Page 38: Reassembly Of The Burner Head Sub-Assembly
Take care to ensure that wires are correctly reconnected to the Aqua-Hot harness. Failure to correctly reconnect these wires may result in damage to the Aqua-Hot and/or the enclosed components. 6. Reconnect the plugs of the diesel burner controller to the wiring harness present within the Aqua-Hot.
Page 39: Detaching The Diesel Burner
7 / 16 This section details how to safely remove and reinstall the diesel burner found on the Aqua-Hot 250D. It may be necessary to perform this procedure for repair and maintenance. Be sure to move the burner switch on the interior...
Page 40 DC electrical system. Remove the wires afﬁ xed to the left ground stud. See below. Figure 103 12. Disconnect wires #2 and #8 from the high-limit thermostats. 13. Carefully remove the diesel burner assembly from the Aqua-Hot cabinet. p. 40 ©Aqua-Hot® 250 Series Diesel Service Manual...
Page 41: Reattaching The Diesel Burner
Figure 107 9. Reinstall the heater cover and test for normal operation. Figure 105 4. Reconnect wires #6 and #8 to the left and right high-limit thermostats. ©Aqua-Hot® 250 Series Diesel Service Manual p. 41...
Page 42: Diesel Igniter Module
Figure 108 Replacement Procedure: 1. Follow the directions on Page 39 to remove the diesel burner head from the Aqua-Hot. 1.34” 2. Using a ⅛” Hex or Allen wrench, remove the bolt securing the igniter assembly to the top of the fuel tower as shown below.
Page 43: Ignition Coil
OFF position. 5. Discard the defunct igniter coil. 2. Remove the access cover of the Aqua-Hot. 6. Position the new igniter coil on the ﬂ ange, aligning the 3. Follow the directions on Page 39 to remove the diesel four holes on either side of the igniter coil with their burner head.
Page 44: Diesel Fuel Delivery System
The motor fails to operate at all • The motor operates with excessive noise and/or heat • The in-line fuse of the Aqua-Hot continually burns out Figure 114 The fuel pump must be replaced if it meets any of the following conditions: 3.
Page 45 1. Move the diesel burner switch on the interior panel to the OFF position. Shut off or disconnect any fuel and electric sources connected to the Aqua-Hot. 2. Remove the access cover of the Aqua-Hot. 3. Follow the directions on Page 39 to remove the diesel burner head.
Page 46 1. Move the diesel burner switch on the interior panel to the bolts OFF position. Shut off or disconnect any fuel and electric sources connected to the Aqua-Hot. 2. Remove the access cover of the Aqua-Hot. 3. Follow the directions on Page 39 to remove the diesel burner head. Figure 123 4.
Page 47: Diesel Combustion Blower Fan
• If voltage is not present during this time, it may point location. This arrow to a bad burner controller. Please contact the Aqua-Hot will be black on your Technical Support Department to verify this diagnosis. blower fan.
Page 48: Diesel Air Shutter Adjustment
ﬁ rst startup after maintenance. Follow the steps below in order to correctly set the diesel air shutter. 1. Remove the access cover from the Aqua-Hot to gain access to the air shutter. 2. Using a Phillips screwdriver, loosen, but do not remove the adjustment screw located at the top of the air shutter.
Page 49: Buck Boost Converter - Combustion Blower Fan
If the buck boost converter does not output approximately 13.5V DC when the supply voltage is between 11V DC and 15V DC, the buck boost will need to be replaced. Figure 131 ©Aqua-Hot® 250 Series Diesel Service Manual p. 49...
Page 50 Procedure: 1. Before removing the defunct buck boost module from the Aqua-Hot, the replacement buck boost must be ﬁ rst set to the correct output voltage. 2. Locate the new buck boost and a multimeter. Set the meter to measure for voltage.
Page 51: Photo-Eye
NOTE: The Photo-disc has been removed in the view above eye assembly as shown below. to aid in the location of the photo-eye. The 200 Series heaters use a Troubleshooting Procedure: 3-Way directional valve to control the coolant priority. Therefore, the In order to determine that the photo-eye is functioning correctly system must be ﬁ...
Page 52 13. Using a ¼” wrench or socket, re-secure the blower fan and the air shutter in place. 14. Follow the instructions on Page 38 to reinstall the diesel burner head into the Aqua-Hot. 15. Test the unit for normal operation. p. 52 ©Aqua-Hot®...
Page 53: Performing The Diesel Annual Service
Purpose: fuel nozzle without ﬁ rst removing Every Aqua-Hot 250D is equipped with a diesel burner that the igniter. This may services as the primary heat source. This burner will need to cause damage to the be serviced annually in order to ensure optimal performance.
Page 54 Reference Figure 143 to properly position the igniter in place. ⅛ ” 3. Follow the directions on Page 41 to reinstall the diesel burner head. Figure 142 4. Test the unit for normal operation. Figure 143 p. 54 ©Aqua-Hot® 250 Series Diesel Service Manual...
Page 55: Fill And Purge Procedure
• Fluid Expansion Bottle • 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. Ensure that the hose is of adequate length to allow the If the interior heating loop is not purged, it may contain easy movement of the external ﬁ...
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
Instructions for the annual service are on Page 80 the three-way valve, the low-temperature cutoff thermostat, or or may be performed by an Aqua-Hot Factory Certiﬁ ed Service the tempering valve. Center. They can be found on the website at www.aquahot.com.
Page 58: Lack Of Heat
The Aqua-Hot has an adequate supply of fuel contact Technical Support at 574-AIR-XCEL (574-247-9235), • All coach-side fuses are functional and able to supply or take the coach to an Aqua-Hot Factory Authorized Service power Center. One can be found at www.aquahot.com. •...
Page 59: Blue/White Smoke
Purpose: Smoke During the Burn Cycle: It is possible that the Aqua-Hot 250D may smoke upon ﬁ rst start-up. There are many possible causes for smoke as listed 1. It is possible that the electrodes of the igniter module below.
Page 60: Black Smoke
General Troubleshooting Black Smoke: 1. Ensure that the Aqua-Hot is receiving 12V DC power from the coach. 2. Inspect the exhaust system for any damage or restrictions. Remedy these issues. 3. Remove the access cover of the unit. 4. Ensure that the air shutter is completely open.
Page 61: Burner Troubleshooting
Diesel Burner Troubleshooting 8. Locate the left and right high-limit thermostats and press the red center button on both thermostats to reset. This section will assist in troubleshooting the Aqua-Hot • Test for continuity on both thermostats. Both should diesel burner.
Page 62: 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 63 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 64: 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. 64 ©Aqua-Hot® 250 Series Diesel Service Manual...
Page 65: Warranty
Thus, problems due to improper speciﬁ cations, improper installations, improper use, the use of accessory parts or parts not authorized by Aqua-Hot Heating Systems Inc., repair by unauthorized persons, and damage or abuse of the heater are specially excluded from warranty coverage.
Page 66 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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