Airxcel AQUA-HOT 100 Series Manual
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Airxcel AQUA-HOT 100 Series Manual

Airxcel AQUA-HOT 100 Series Manual

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Service Manual
100
Series
AHE-125-GN1

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Summary of Contents for Airxcel AQUA-HOT 100 Series

  • Page 1 Service Manual Series AHE-125-GN1...

  • Page 2: Table Of Contents

    Introduction Introduction Contents Caution Notes System Overview located in the Aqua-Hot. The water is heated by transfer from The Aqua-Hot 125GN Series is a Hydronic Heating System Caution Notes ................2 As you read this information, take particular note of the NOTICE, the heated antifreeze and distilled water solution.

  • Page 3: Introduction

    Introduction Introduction Introduction to this Document 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 Welcome to the Aqua-Hot 125GN Service Manual. This heat source, and provides all of the heating and hot water (sometimes known as the summer/winter valve).

  • Page 4: Maintenance Schedule

    Maintenance Schedule Introduction System Features 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 DO NOT operate the gas burner and/or electric heating accomplished by visually checking the coolant level in the Aqua- element without antifreeze and distilled water heating Hot’s expansion bottle;...

  • Page 5: System Features

    System Features 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 NOTE: This product label is attached to the top of the Plate-to-plate Heat Exchanger burner and provides a ready reference to specifications, test standards, and important safety notices.

  • Page 6: Operational Flowchart

    Component Cut-Aways Basic Components Operational Flowchart Operational Flow Chart Belief Gas Burner A heat source is selected from Interior Control Panel 1. Combustion Air Fan 12. Fuel Pipe 2. Burner Outer Casing 13. Coolant Pump 3. Burner Inner Casing 14. Fuse External Gas Burner Electric Element 4.

  • Page 7: Operating The Aqua-Hot & Lcd

    Operating the LCD Operating the LCD Operating the Aqua-Hot & LCD only be done if thermistors are installed. Electrical Element Activation (3): Thermostats would only show ON/OFF.) Similar to the external gas burner, tapping the electric item If the zone temperature is set, but this item will signal to the controller to activate the AC electric relay, Introduction: is not set to ON, the zone heat exchanger will...
  • Page 8 Controller Controller The Aqua-Hot Controller The fault codes shown above will cover the most common FAULT indicates that there is an issue with the be utilized; System Voltage, Low-Level Cutoff, Over-Current, Overheat, and Burner Failed to Ignite. These will be explained Aqua-Hot related issues.

  • Page 9: Aqua-Hot Controller

    Controller Controller Burner Status: Testing Functionality: The Burner Status element on this page One of the new features of this control system is the ability to indicates the status of the external gas burner. independently activate specific elements within the Aqua-Hot for testing purposes.

  • Page 10: Controller Replacement Procedure

    Controller Controller Controller Replacement Procedure: 4. Using a ⅜” (10mm) socket, remove the hex nut from the Lean the top of the mounting bracket out from the unit 13. Using the previously removed hex nut, fasten the top of the mounting plate (SAVE THE NUT TO USE AGAIN) wall, and then slide the controller and mounting plate mounting plate to the wall of the Aqua-Hot.

  • Page 11: Fluid Level Sensor

    Controller Fluid Level Sensor Fluid Level Sensor Instructions for Controller Setup after Installation: Troubleshooting Procedure: Locate the fluid level After replacement and installation of the controller, the system will need to be updated via the LCD Screen or RV Control panel. Introduction: sensor (Figure 35) Please follow the following steps to set up the heating system.

  • Page 12: High-Limit Thermostats

    Fluid Level Sensor 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 Expansion Bottle can either Before continuing to the replacement procedure, be found mounted to the Thermostats.

  • Page 13: Low-Temperature Cutoff Thermostat

    High-Limit Thermostats Low-Temp Cutoff Thermostat Low-Temperature Cutoff Thermostat Replacement Procedure: AC Cover Removal Locate the Aqua-Hot LCD screen. Navigate to If it has been determined that one, or multiple high-limit INPUTS FROM AQUA-HOT. thermostats need to be replaced, they can be easily replaced Introduction: by following the directions below.

  • Page 14: Three-Way Valve

    Three-Way Valve Three-Way Valve Three-Way Valve • There may be residual fluid that exits the fittings - Continue trouble- Continue trouble- use towels or other clean up items as necessary. shooting here shooting here 9. Carefully remove the Three-Way Valve from the last ¾” Introduction: heater hose on the right of the valve.

  • Page 15: Tempering Valve

    Tempering Valve Tempering Valve Tempering Valve Testing Procedure: Replacement Procedure: Remove the P-clamp from the stud on the wall of the Aqua- Hot. Save the P-clamp for reuse later. Follow the testing procedure to the right in order to diagnose 1.

  • Page 16: Fluid Circulation Pump

    Fluid Circulation Pump Fluid Circulation Pump Fluid Circulation Pump Replacement Procedure: Power cycle the Aqua-Hot to clear any current faults. 1. Drain coolant from system. Pour into a bucket to be reused later. Introduction: 2. Remove the top and side panels from the Aqua-Hot. Save Locate the Aqua-Hot LCD The fluid circulation pump operates to provide fluid circulation the screws and washers to be reused later.

  • Page 17: Ac Electric System

    Fluid Circulation Pump AC Electric System Fluid Circulation Pump AC Electric System Replacement Procedure: AC Electric System Locate the Aqua-Hot LCD 1. Ensure that the Aqua-Hot has been completely shut down screen. Navigate to the Introduction: and all power sources have been disconnected. Be sure the TESTING page (Figure 60) boiler tank is completely cooled.

  • Page 18: Ac Relay

    Fluid Circulation Pump AC Relay ETS Module AC Relay ETS Module Using a meat thermometer, measure the temperature of the tank face. Record Replacement Procedure: Introduction: Introduction: this temperature on a piece of paper. The AC Relay is an electrical device where the DC circuit from 1.

  • Page 19: Fuel System Replacement

    ETS Module Fuel System Replacement ETS Module Replacement Procedure: 6. Place the replacement ETS module in its position on the tank face, and finger 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 20: Fuel System Purge Procedure

    Fuel System Replacement ETS Module Fuel System Purge ETS Module CORRECT CORRECT WRONG Fuel Purge Procedure • Ground goes to Pin #1 • Power goes to Pin #2 The fuel lines should be automatically primed with the first • If you would rather use a plug instead of the wire operation of the burner.

  • Page 21: Burner Troubleshooting

    Burner Troubleshooting ETS Module Burner Troubleshooting ETS Module External Gas Burner Troubleshooting External Gas Burner Faults & Remedies The troubleshooting procedures listed below are arranged in order of repair complexity. Do not replace parts without correctly Fault Fault determining the failure. Follow the directions below in order to troubleshoot the gas burner. Do not skip through the troubleshooting Fault Cause Remedy Fault Cause...

  • Page 22: Burner Operation After Service

    Burner Troubleshooting ETS Module Burner Operation ETS Module General Failure Symptoms of the Burner Burner Operation after Service This section will cover the typical failures of the gas burner. Refer to the table more fails and their remedies. The first operation of the burner (after service or maintenance) with the Aqua-Hot may not light up perfectly.

  • Page 23: General Troubleshooting

    General Troubleshooting Winterizing the Aqua-Hot General Troubleshooting Lack of Interior Heat or Hot Water Winterizing the Aqua-Hot Fill Cap The Aqua-Hot’s domestic water heating system must be Introduction: completely drained of domestic water at any time the heater is Upper Fitting stored where freezing temperatures may be experienced.
  • Page 24 System Schematics System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. p. 46 ©Aqua-Hot® 125-GN1 Service Manual REV 220427 ©Aqua-Hot® 125-GN1 Service Manual REV 220427 p. 47...
  • Page 25 System Schematics System Schematics p. 48 ©Aqua-Hot® 125-GN1 Service Manual REV 220427 ©Aqua-Hot® 125-GN1 Service Manual REV 220427 p. 49...

  • Page 26: Appendix B: Parts

    System Schematics 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 ELE-HLT-426 ELE-LTC-200 Thermistor, Tank Temperature Sensor Thermistor, 10K NTC, Room Temperature Sensor VAC High Limit Thermostat 215°F w/ Leads Low-Temperature Cutoff Thermostat w/ Spade Terminals ELE-100-010 ELX-2E7-102...
  • Page 27 System Schematics Parts System Schematics Parts PLE-063-200 PLX-100-900 ELX-232-948 SME-102-080 Fluid Circulation Pump AC Relay, 30A 277VAC Cover, AC Element Cover for 125 Series 3 Qt. Expansion Tank w/Internal Fluid Level Sensor, ⅝” Barb PLX-111-125 ELE-400-900 PLX-000-200 GBX-125-117 Pressure Relief Valve, 125 PSI Harness, Buehler C20 Pump Hose, ⅝”...
  • Page 28 System Schematics Parts Appendix Measuring Antifreeze Using a Refractometer Calibration Screw Prism Assembly Daylight Plate Assembly GBX-125-121 GBX-125-122 Fuel Hose to Burner Fuel Hose to Fuel Tank (blue) (clear) (Couplers & check valve included) 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.
  • Page 29 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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