Airxcel Aqua-Hot 100 Series Service Manual
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Airxcel Aqua-Hot 100 Series Service Manual

Airxcel Aqua-Hot 100 Series Service Manual

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Service Manual
100
Series
AHE-125-DN1

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Summary of Contents for Airxcel Aqua-Hot 100 Series

  • Page 1 Service Manual Series AHE-125-DN1...

  • Page 2: Table Of Contents

    Introduction Introduction Contents Caution Notes System Overview The Aqua-Hot 125DN Series is a Hydronic Heating System located in the Aqua-Hot. The water is heated by transfer from Caution Notes ................2 As you read this information, take particular note of the NOTICE, that can provide heat and hot water on demand using a built-in the heated antifreeze and distilled water solution.

  • Page 3: Introduction

    Introduction Introduction Introduction to this Document Heat Priority Option: Important Notes: • A qualified installer or service technician must perform The Aqua-Hot comes equipped with the three-way valve Welcome to the Aqua-Hot 125DN Service Manual. This equipment installation or service. Contact Aqua-Hot for (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 accomplished by visually checking the coolant level in the Aqua- Hot’s expansion bottle;...

  • Page 5: Component Cut-Aways

    Component Cut-Aways Basic Components Component Cut-Aways Basic Components Aqua-Hot 125DN Aqua-Hot Diesel Burner 1. Fluid Circulation Pump 1. Combustion Air Fan 2. Tempering Valve 2. Fluid Outlet 3. Aqua-Hot Controller 3. Fluid Inlet 4. Antifreeze and Water Heating Solution Tank 4.

  • Page 6: Operational Flowchart

    Operational Flowchart Operating the LCD Operational Flow Chart Operating the LCD Section A: A heat source is selected from This section shows current zone Interior Control Panel temperature (shown as 71°F in the example Introduction: to the bottom left) as well as a button to turn the zone on or off This document will outline the basic operating instructions If the zone temperature is set, but this item...
  • Page 7 Operating the LCD Controller The Aqua-Hot Controller Electrical Element Activation(3): System Voltage: System voltage faults indicate that there is Similar to the external diesel burner, tapping this button Introduction: a problem with the coach-side power supply will signal to the controller to activate the AC electric relay, which powers the Aqua-Hot.

  • Page 8: Aqua-Hot Controller

    Controller Controller Diagnostic Screens (DIAG) Electric: Burner Status: The Electric section indicates the controller’s The Burner Status element on this page The diagnostic screens will show the current operational status current handling status of the AC electric relay. indicates the status of the diesel burner. of different elements within the Aqua-Hot.

  • Page 9: Controller Replacement Procedure

    Controller Controller Testing Functionality: 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 One of the new features of this control system is the ability to corner of the LCD screen.
  • Page 10 Controller Controller Lean the top of the mounting bracket out from the unit 13. Using the previously removed hex nut, fasten the Instructions for Controller Setup after Installation: wall, and then slide the controller and mounting plate mounting plate to the wall of the Aqua-Hot. After replacement and installation of the Controller, the system will need to be updated via the LCD Screen or RV Control panel.

  • Page 11: Fluid Level Sensor

    Fluid Level Sensor Fluid Level Sensor Fluid Level Sensor Troubleshooting Procedure: Locate the fluid level Introduction: sensor (Figure 35) The fluid level sensor monitors the current fluid level within the Aqua-Hot. This device is intended as a fail-safe measure Expansion Bottle can either Before continuing to the replacement procedure, Using a multi-meter, test be found mounted to the...

  • Page 12: High-Limit Thermostats

    High-Limit Thermostats High-Limit Thermostats High-Limit Thermostats Troubleshooting Procedure: Replacement Procedure: NOTE: The AC access cover will need to be removed if the AC high-limit thermostat is the issue or needs to be tested. See If it has been determined that one, or multiple high-limit Locate the high-limit the image below.

  • Page 13: Low-Temperature Cutoff Thermostat

    Low-Temp Cutoff Thermostat Three-Way Valve Low-Temperature Cutoff Thermostat Three-Way Valve Locate the Aqua-Hot Continue trouble- Continue trouble- LCD screen. Navigate to shooting here shooting here INPUTS FROM AQUA-HOT. Introduction: Introduction: Locate the LTCO at the The Low-Temperature Cutoff Thermostat (LTCO) is installed unit, and using a multi- The three-way valve (aka the summer/winter valve) is Grab the hoses...

  • Page 14: Three-Way Valve

    Three-Way Valve Tempering Valve • There may be residual fluid that exits the fittings - Tempering Valve Testing Procedure: use towels or other clean up items as necessary. Follow the testing procedure to the right in order to diagnose Introduction: the tempering valve.

  • Page 15: Fluid Circulation Pump

    Tempering Valve Fluid Circulation Pump Power cycle the Aqua-Hot Fluid Circulation Pump Replacement Procedure: any other components in the Aqua-Hot. to clear any current faults. 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.

  • Page 16: Ac Electric System

    Fluid Circulation Pump Fluid Circulation Pump AC Electric System AC Electric System Replacement Procedure: Locate the Aqua-Hot LCD Introduction: screen. Navigate to the 1. Drain coolant from system. Pour into a bucket to be reused The AC Electric system of the Aqua-Hot 125DN unit functions to TESTING page (Figure 61) later.

  • Page 17: Ac Relay

    Fluid Circulation Pump AC Electric System Fluid Circulation Pump AC Relay AC Relay Replacement Procedure: Replacement Procedure: 1. Ensure that the Aqua-Hot has been completely shut down 1. Ensure that the Aqua-Hot has been completely shut down and all power sources have been disconnected. Be sure the and all power sources have been disconnected.

  • Page 18: Ets Module

    ETS Module ETS Module ETS Module Replacement Procedure: Using the 14mm wrench, tighten the module until it is snug Using a meat thermometer, in place. measure the temperature If the ETS Module has been diagnosed and a replacement of the tank face. Record 8.

  • Page 19: High Altitude Replacement

    High Altitude Replacement ETS Module High Altitude Replacement ETS Module 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 Figure 73 1.

  • Page 20: Fuel Purge Procedure

    High Altitude Replacement ETS Module Fuel Purge Procedure ETS Module Fuel Purge Procedure: • Ground goes to Pin #1 Burner Bottom View The fuel lines should be automatically primed with the first • Power goes to Pin #2 operation of the burner. It may need to be power cycled a few •...

  • Page 21: General Troubleshooting

    Burner First Operation ETS Module General Troubleshooting Lack of Interior Heat or Hot Water The first operation of the burner with the Aqua-Hot after service Fill Cap 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- Upper Fitting Introduction:...

  • Page 22: Burner Troubleshooting

    Winterizing the Aqua-Hot General Troubleshooting General Troubleshooting Burner Troubleshooting External Diesel Burner Troubleshooting Winterizing the Aqua-Hot 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 The Aqua-Hot’s domestic water heating system must be completely drained of domestic water at any time the heater is determining the failure.

  • Page 23: Appendix A: System Schematics

    General Troubleshooting Burner Troubleshooting System Schematics PIN OUT INFORMATION 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 No combustion after start or automatic Switch off burner and switch back on.
  • Page 24 System Schematics System Schematics p. 46 ©Aqua-Hot® 125-DN1 Service Manual REV 220421 ©Aqua-Hot® 125-DN1 Service Manual REV 220421 p. 47...
  • Page 25 System Schematics System Schematics p. 48 ©Aqua-Hot® 125-DN1 Service Manual REV 220421 ©Aqua-Hot® 125-DN1 Service Manual REV 220421 p. 49...
  • Page 26 System Schematics System Schematics Parts NOTE: Service parts and accessories are available through Aqua-Hot Factory Authorized Service Centers or www.aquahot.com. Click on the part number to route you to the Aqua-Hot web store for purchase. ELE-014-711 ELX-THM-309 Thermistor, Tank Temperature Sensor Thermistor, 10K, NTC, Room Temperature Sensor ELE-102-211 ELE-102-201...
  • Page 27 System Schematics Parts System Schematics Parts ELE-HLT-426 ELE-LTC-200 PLE-063-200 PLX-100-900 VAC High Limit Thermostat 215°F w/ Leads Low-Temperature Cutoff Thermostat w/ Spade Terminals 3 Qt. Expansion Tank w/Internal Fluid Level Sensor, 5/8” Barb Fluid Circulation Pump ELE-100-010 ELX-2E7-102 PLX-111-125 PLX-125-3WV Controller, 12VDC, 100/200 Series, Kit 125DN Element, 1”...
  • Page 28 System Schematics Parts Appendix Measuring Antifreeze Using a Refractometer Calibration Screw Prism Assembly Daylight Plate Assembly ELX-232-948 SME-102-080 AC Relay Cover, AC Element Cover for 125DN & 100DE 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 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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