Airxcel Aqua-Hot 100 Series Service Manual

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100

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AHE-125-GN1

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Page 1 Service Manual Series AHE-125-GN1...
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 located in the Aqua-Hot. The water is heated by transfer from The Aqua-Hot 125GN Series is a Hydronic Heating System the heated antifreeze and distilled water solution. The heated that can provide heat and hot water on demand using a built-in domestic water then ﬂ...
Page 4 Introduction Heat Priority Option: External Gas Burner: The gas burner is the Aqua-Hot’s primary and most powerful The Aqua-Hot comes equipped with the three-way valve heat source, and provides all of the heating and hot water (sometimes known as the summer/winter valve). This controls needs when cold temperatures exist, and/or when there is a the ﬂ...
Page 5 Introduction Introduction to this Document Welcome to the Aqua-Hot 125GN 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 87 on page 44. DO NOT operate the gas burner and/or electric heating element without antifreeze and distilled water heating Please note that the coolant level should be checked ONLY...
Page 7: System Features
System Features Figure 6 System Speciﬁ cations Electric Element Power Consumption ........1500 W (maximum) Voltage ................110V AC DC Power Consumption ............. 57 W (maximum) Zone Heat Circulation Pumps ...................1 Power Consumption (max) ..........20W/1.7A Voltage ................12V DC Interior Heating Maximum Heating Zones .............3 Cozy............6W/0.5A - 8,000 BTU/hr Whisper..........4.5W/0.37A - 4,000 BTU/hr H.E.
Page 8 System Features NOTE: This product label (shown above) is attached to the top of the burner and provides a ready reference to speciﬁ cations, test standards, and important safety notices. Figure 7 System Speciﬁ cations TECHNICAL SPECIFICATIONS Heating Medium Ethylene Glycol/Distilled Water Gasoline Burner High Power Operation: 5000W Heat Flow..........5,188 to 17,060 BTU/hr...
Page 9: Component Cut-Aways
Component Cut-Aways Basic Components Aqua-Hot 125GN 1. Fluid Circulation Pump 2. Tempering Valve 3. Aqua-Hot Controller 4. Antifreeze and Water Heating Solution Tank Figure 9 5. AC Electric Element 6. AC Activation Relay Plate-to-plate Heat Exchanger 8. Three-Way Valve 9. Zone Air-Bleed Valve 10.
Page 10 Component Cut-Aways Basic Components Belief Gas Burner 1. Combustion Air Fan 11. Mufﬂ er 12. Fuel Pipe 2. Burner Outer Casing 13. Coolant Pump 3. Burner Inner Casing 14. Fuse 4. Combustion Chamber 15. Main Wire Harness 5. Glow Plug Connector 6.
Page 11: Operational Flowchart
Operational Flowchart Operational Flow Chart A heat source is selected from Interior Control Panel External Gas Burner Electric Element Electric Heating Element The gas burner will begin will activate, providing 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 12: Operating The Aqua-Hot & Lcd
Operating the LCD Operating the Aqua-Hot & LCD only be done thermistors are installed. Thermostats would only show ON/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 13 Operating the LCD Electrical Element Activation (3): Similar to the external gas burner, tapping the electric item will signal to the controller to activate the AC electric relay, energizing the 1500W electric element within the Aqua-Hot. The electric element also has two modes: ON and OFF. While set to ON, the electric element will work to maintain a tank temperature of 180°...
Page 14: Aqua-Hot Controller
Controller The Aqua-Hot Controller Overheat, and Burner Failed to Ignite. These will be explained below. System Voltage: Introduction: System voltage faults indicate that there is a The Aqua-Hot 125GN operates on a controller platform problem with the RV-side power supply which which has been modernized and updated from the previously powers the Aqua-Hot.
Page 15 Controller The fault codes shown above will cover the most common FAULT indicates that there is an issue with the Aqua-Hot related issues. For more complex issues, it may be burner. necessary to utilize the DIAG screens, which will be explained Electric: next.
Page 16 Controller Burner Status: The Burner Status element on this page indicates the status of the external gas burner. 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.
Page 17 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 Electric (C): Activating the Electric heating sub-system will energize the relay which controls the AC electric element. Figure 21 After tapping this button on the screen, there should be an audible click from within the Aqua-Hot cabinet.
Page 18: Controller Replacement Procedure
Controller Controller Replacement Procedure: 4. Using a ⅜” (10mm) socket, remove the hex nut from the top of the mounting plate (SAVE THE NUT TO USE AGAIN) 1. If possible, tap the three lines icon at the bottom right corner of the LCD screen. •...
Page 19 Controller Lean the top of the mounting bracket out from the unit 13. Using the previously removed hex nut, fasten the wall, and then slide the controller and mounting plate mounting plate to the wall of the Aqua-Hot. upwards and out of the unit. 14.
Page 20 Controller Instructions for Controller Setup after Installation: After replacement and installation of the controller, the system will need to be updated via the LCD Screen or RV Control panel. Please follow the following steps to set up the heating system. 1.
Page 21: Fluid Level Sensor
Fluid Level Sensor Fluid Level Sensor Troubleshooting Procedure: Locate the ﬂ uid level Introduction: sensor (Figure 35) 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 22 Fluid Level Sensor Expansion Bottle can either Before continuing to the replacement procedure, be found mounted to the ensure that the unit has cooled to ambient temperature, side of the Aqua-Hot unit or all power sources have been disconnected, and the within the RV.
Page 23: 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 24 High-Limit Thermostats Replacement Procedure: AC Cover Removal 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 41).
Page 25: 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 26: 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 27 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 28: 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 29 Tempering Valve Replacement Procedure: Remove the P-clamp from the stud on the wall of the Aqua- Hot. Save the P-clamp for reuse later. 1. Shut off the external domestic water connection, and open 8. Slide the tempering valve assembly gently backwards a hot water faucet valve within the RV to relieve the water towards the coolant tank until the PEX tubes of the pressure.
Page 30: Fluid Circulation Pump
Fluid Circulation Pump Fluid Circulation Pump Power cycle the Aqua-Hot 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 57a).
Page 31 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 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 32: 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 125GN unit functions to TESTING page (Figure 60) provide heat to the Aqua-Hot boiler tank. This is done with an electric element and an electric relay.
Page 33 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 34: 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 35: 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 36 ETS Module Replacement Procedure: 6. Place the replacement ETS module in its position on the tank face, and ﬁ nger tighten it into place. If the ETS Module has been diagnosed and a replacement Using the 14mm wrench, tighten the module until it is snug must be made, follow the instructions below.
Page 37: Fuel System Replacement
ETS Module Fuel System Replacement Figure 75 NOTE: The diagram above is not drawn to scale. It is simply a reference for proper installation of the fuel system for the Belief Gas Burner. Fuel Lines Requirements Fuel Pump • The fuel pump is a combined pumping, metering, and shut- •...
Page 38 ETS Module Fuel System Replacement CORRECT CORRECT WRONG Bubble WRONG Bubble NOTE: The fuel lines must be secured and supported properly to avoid air Fuel Line to Coupler Hose traps or bubbles. Avoid unnecessary dips or bends, the line should not run A Clamp B Coupler C Fuel Hose...
Page 39: Fuel System Purge Procedure
Fuel System Purge ETS Module Fuel Purge Procedure • Ground goes to Pin #1 • Power goes to Pin #2 The fuel lines should be automatically primed with the ﬁ rst • If you would rather use a plug instead of the wire operation of the burner.
Page 40: Burner Troubleshooting
Burner Troubleshooting ETS Module External Gas Burner Troubleshooting The troubleshooting procedures listed below are arranged in order of repair complexity. Do not replace parts without correctly determining the failure. Follow the directions below in order to troubleshoot the gas burner. Do not skip through the troubleshooting steps, as this may needlessly complicate unit diagnosis and repair.
Page 41 Burner Troubleshooting ETS Module External Gas Burner Faults & Remedies Fault Fault Fault Cause Remedy Fault Cause Remedy Code Code • Check power supply Burner: Voltage too high • Wait for ﬂ ame sensor (exceeds 16V) Burner: Failed to Ignite cooling Combustion chamber •...
Page 42 Burner Troubleshooting ETS Module General Failure Symptoms of the Burner This section will cover the typical failures of the gas burner. Refer to the table more fails and their remedies. Failure Symptom Possible Cause Remedy No combustion after start or automatic Switch off burner and switch back on.
Page 43: Burner Operation After Service
Burner Operation ETS Module Burner Operation after Service The ﬁ rst operation of the burner (after service or maintenance) with the Aqua-Hot may not light up perfectly. It may take 5-6 starts for the burner to ignite for the ﬁ rst start-up after service, Failure to follow instructions on the fuel delivery system can because the fuel pump needs to ﬁ...
Page 44: General Troubleshooting
General Troubleshooting Lack of Interior Heat or Hot Water Fill Cap Upper Fitting Introduction: Hot Fluid Line A lack of interior heat or hot water when provided with adequate heat from either the electric element and/or the gas burner can be attributed to an overheat thermostat, the Aqua- Hot controller, the three-way valve, or the ﬂ...
Page 45: 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 46: Appendix A: System Schematics
System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. p. 46 ©Aqua-Hot® 125-GN1 Service Manual...
Page 50: Appendix B: Parts
System Schematics Parts NOTE: For more parts & information, please reference the 125- GN1 Parts manual found online at aquahot.com/library.aspx. ELE-014-711 ELX-THM-309 (white) Thermistor, Tank Temperature Sensor Thermistor ELE-LCD-050 ELE-125-200 Aqua-Hot LCD Screen, RVC 3.5in RV-Side Wire Harness (optional) ELE-RVC-100 ELE-125-100 RVC Display Cable Aqua-Hot Series 125 Mainframe Harness...
Page 51 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-100-010 ELX-2E7-102 Controller, 12VDC, 100-200 Series, Kit 125GN Element, 1” NPSM, 120 VAC, 1500W, Heating ELE-HLT-425 EXE-103-0EX VAC High Limit 215°F Thermostat w/ Spade Connectors Heat Exchanger, Cozy III ©Aqua-Hot®...
Page 52 System Schematics Parts PLE-063-200 PLX-100-900 Fluid Circulation Pump 3 Qt. Expansion Tank w/Internal Fluid Level Sensor, ⅝” Barb PLX-111-125 ELE-400-900 Pressure Relief Valve, 125 PSI Harness, Buehler C20 Pump PLX-362-100 PLX-125-3WV Tempering Valve Kit, Three-Way Motorized Valve, ½” NPT p. 52 ©Aqua-Hot®...
Page 53 System Schematics Parts ELX-232-948 SME-102-080 AC Relay Cover, AC Element Cover for 125DN & 125GN PLX-000-200 GBX-125-117 Assembled Fuel Pump Hose, ⅝” Safety Stripe, Rubber MSX-907-162 GBX-125-103 Refractometer Belief 5kW Gas Burner Circulation Pump ©Aqua-Hot® 125-GN1 Service Manual p. 53...
Page 54 System Schematics Parts GBX-125-121 GBX-125-122 Fuel Hose to Burner Fuel Hose to Fuel Tank (blue) (clear) (Couplers & check valve included) HDX-102-111 HDX-102-113 Clamp, (10.5mm), Soft Hose and Tube Clamp, ⅜ to (11.3mm), Soft Hose and Tube GBX-125-102 GBX-125-112 Burner K_Line Converter Burner Wiring Harness p.
Page 55: 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 56 Service Manual SERIES AHE-125-GN1 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). ©2022 Aqua-Hot Heating Systems, LLC. Printed in the USA...

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Airxcel Aqua-Hot 100 Series Service Manual

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