Aqua-Hot AHE-450-DE2 Service Manual
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Aqua-Hot AHE-450-DE2 Service Manual

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AHE-450-DE2
SERVICE MANUAL
© 2009 Aqua-Hot Heating Systems Inc.

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Summary of Contents for Aqua-Hot AHE-450-DE2

  • Page 1 AHE-450-DE2 SERVICE MANUAL © 2009 Aqua-Hot Heating Systems Inc.
  • Page 2 — Page 2 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 3: Table Of Contents

    Table of Contents Section 1: Introduction to the Aqua-Hot 450-DE Introduction ....................... ..Page 6-7 Danger, Warning, Caution, and Note Box Definitions ............Page 6 Section 2: Aqua-Hot Hydronic Heating System Overview Technical Information ......................Page 8 I.D. Label Sample ......................Page 9 Component Overview ....................Page 9-11...
  • Page 4 Fuel Nozzle ......................Page 62-63 Fuel Solenoid ....................... Page 64 Fuel Pump ......................Page 65-67 Bearings ......................... Page 68-70 Ignition Coil ......................Page 71-72 Controller ........................ Page 73-74 — Page 4 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 5 If the Aqua-Hot is Black Smoking ................. Page 75 If the Aqua-Hot is Blue/White Smoking ................ Page 76 If one of the Aqua-Hot’s Heating Zones will not get hot ..........Page 77 If there is a lack of domestic continuous hot water ............Page 78 If there is antifreeze leaking ...................

  • Page 6: Section 1: Introduction To The Aqua-Hot 450-De Introduction

    In order for the diesel-burner to ing, independent interior zone heating, and engine preheat- be considered as a heating source by the Aqua-Hot, it must ing. Be sure to reference Figures 3 through 5 for a com- have an adequate fuel supply, receive power from the elec- plete component overview.
  • Page 7 Until the thermo- stat signals that heat is no longer required, the Aqua-Hot will continue to send the heated antifreeze and water solution through the loop, which returns the cooled solution to the —...

  • Page 8: Section 2: Aqua-Hot Hydronic Heating System Overview Technical Information

    450-DE O ECTION VERVIEW Figure 1 Aqua-Hot 450-DE Technical Specifications Diesel-Burner, Heat Input (Firing Rate) ..............................56,000 BTU/hr Diesel-Burner, Fuel Consumption (Continuous Operation) ........................0.40 gal/hr Heater, Voltage/Maximum Power Consumption ........................12 Volt-DC/60 watts Electric Heating Element specifications ..........................120 Volt-AC/1650 watts Zone Heat Circulation Pump specifications ........................

  • Page 9: Label Sample

    2: A 450-DE O ECTION VERVIEW Figure 2 Figure 3 — Page 9 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 10 2: A 450-DE O ECTION VERVIEW Figure 4 — Page 10 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 11 2: A 450-DE O ECTION VERVIEW Figure 5 — Page 11 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 12: Aqua-Hot Operational Flow-Chart

    2: A 450-DE O ECTION VERVIEW — Page 12 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 13: Antifreeze & Water Heating Solution

    Aqua-Hot Heating of chemical inhibitors. Due to their potentially hazardous Systems Inc. recommends CAMCO’s Boiler Antifreeze properties, they should never be used in the Aqua-Hot’s -100°. Hydronic Heating System. Antifreeze Types:...
  • Page 14 Boiling Point: The Aqua-Hot utilizes the antifreeze and water heating solu- tion as a transportation means for the heat produced from the internal processes. The antifreeze absorbs the heat created until its boiling point is reached;...

  • Page 15: Diesel-Burner Switch

    The interior switch panel is used to control the two potential Electric Element Switch: heating sources for the Aqua-Hot’s boiler tank, as well as to control the engine preheat feature. When a switch is activat- When the motor home is plugged into an AC power source ed, the indicator light on the switch will illuminate.

  • Page 16: Pin Label

    3: I ECTION NTERIOR WITCH ANEL Figure 7 Back of the Interior Switch Panel with the Switches Installed — Page 16 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 17: Section 4: Exhaust System Requirements Exhaust System Requirements

    4: E ECTION XHAUST YSTEM EQUIREMENTS Because the Aqua-Hot’s exhaust is hot and must be kept The exhaust must be able to freely exit away from the  away from any heat-sensitive material, the exhaust system vehicle without any obstructions.

  • Page 18: Interlock Switch

    Remove the defective interlock switch from the Aqua- Hot. The interlock switch is a safety device designed to ensure that the Aqua-Hot’s access cover is securely installed before Install the replacement interlock switch onto the Aqua- allowing the diesel-burner to operate.

  • Page 19: Fluid Level Sensor

    COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Troubleshooting: Ensure that the Aqua-Hot has been completely shut Verify that the Aqua-Hot’s boiler tank is full of the anti- down and that all power sources have been disconnect- freeze and water heating solution.

  • Page 20: Control Thermostat

    B. Disconnect the control thermostat’s wires from their perature and when it requires heat. The Aqua-Hot is consid- connections, and, using an ohmmeter, check for ered to be at operating temperature between 158°F and 190°...
  • Page 21 Screw the replacement control thermostat into the port AILURE TO DISCONNECT ALL POWER SUPLIES AND OR TO on the Aqua-Hot’s boiler tank and tighten securely with ALLOW THE HEATER TO COOL BEFORE SERVICING COULD a 7/8 socket. CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Connect the replacement control thermostat’s wires in...

  • Page 22: High Limit Thermostat

    215°F. Should this temperature be reached, the Ensure that the Aqua-Hot has been completely shut high-limit thermostat blocks the current to the element, down and that all power supplies have been disconnect- which prevents it from continuing to provide heat to the boil- er tank.

  • Page 23: High Limit Thermostats

    Ensure that the Aqua-Hot has been completely shut NOTE: Bypassing the high-limit thermostats is for testing down and that all power sources have been disconnect- only and must not be used for the Aqua-Hot’s nor- mal functioning. Remove the two wires from the defective high-limit Disconnect the DC high-limit thermostats’...

  • Page 24: Low-Temperature Cutoff Thermostat

    Troubleshooting: B. Inspect the wiring to ensure that the Aqua-Hot is wired properly and that the low-temperature cutoff Determine if the conditions are right for the ―L o w thermostat has not been bypassed via jumper wires.

  • Page 25: Check Valves

    5: A ECTION OMPONENTS Figure 14 Ensure that the Aqua-Hot has been completely shut down and that all power sources have been disconnect- Locate the low-temperature cutoff thermostat on the Low Temperature cold domestic water inlet pipe at the back of the Aqua- Cut-Off Thermostat Hot.
  • Page 26 Remove the hose from the defective check valve. 10. Slide the hose back onto the replacement pump and set the constant tension clamp back into place. 11. Refill the Aqua-Hot’s boiler tank with the antifreeze and water heating solution. Figure 15 Zone Check Valve —...

  • Page 27: Tempering Valve

    Remove the pressure relief valve assembly from the tempering valve assembly as the tempering valve cannot The tempering valve for the Aqua-Hot mixes the heated do- be removed from the Aqua-Hot with the pressure relief mestic water from the boiler tank with cold domestic water at valve still attached.

  • Page 28: Circulation Pumps 1

    The circulation pumps first draw the heated antifreeze and the electronic controller for illumination. water heating solution from the Aqua-Hot’s boiler tank, then propel it through the Hydronic heating system’s interior heat If the ― Heating Zone Status‖ indicator light does not plumbing.
  • Page 29 Replacement Procedure: wire harness on the heater by uniting the red quick- disconnect terminals. 12. Refill the Aqua-Hot’s boiler tank with the antifreeze and AILURE TO DISCONNECT ALL POWER SUPPLIES AND water heating solution. TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 13.
  • Page 30 The stir pump circulates the antifreeze and water heating the proper jumper pin formation. solution within the Aqua-Hot’s boiler tank in order to ensure even-heating of the solution. To accomplish this, the stir pump draws the solution from the bottom of the tank and Verify that the ―...
  • Page 31 If the indicator light is illuminated green, complete the COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY following: Ensure that the Aqua-Hot has been completely shut A. Using a voltmeter, check for 12 Volts of DC power down and that all power sources have been disconnect- on the JP3 plug between pins 1 and 2 (―...

  • Page 32: Stir Pump

    Reconnect the wires on the replacement pump to the wires connected to the heater by uniting the red quick- disconnect terminals. 10. Refill the Aqua-Hot’s boiler tank with the antifreeze and water heating solution. Stir Pump Figure 18 —...

  • Page 33: Electric Heating Element

    If the boiler tank is above 158°F, the Aqua-Hot is at operating temperature and requires no heat. Troubleshooting: 3. Verify the Electronic Controller is sending 12 Volt DC to NOTE: For continuous domestic hot water to be present, the the A.C.
  • Page 34 Reinstall the AC access cover. A. Disconnect all power supplies. Refill the Aqua-Hot’s boiler tank with the antifreeze and B. Remove the AC access cover. water heating solution. C. Remove all wires from the electric heating element.

  • Page 35: Relay

    COULD CAUSE SERIUOS DAMAGE OR PERSONAL INJURY Disconnect the AC power source to the motorhome Ensure that the Aqua-Hot has been completely shut (unplugging from shore power or shutting off the gener- down and that all power sources have been disconnect- ator).

  • Page 36: Section 6: Electronic Controller General Facts

    Electronic Controller Overview The electronic controller is an electronic circuit board that Aqua-Hot unit. Indicator lights on the front panel will illu- controls the electrical functions of the Aqua-Hot heating minate red if there is a short circuit, overload, or fault condi- system.

  • Page 37: Secondary 12 Volt Dc Battery Connection

    Secondary 12 Volt-DC Battery Connection: The electronic controller is equipped with two 12 Volt-DC ensure that the Aqua-Hot will be protected in the event that power source connections, which allow for a secondary 12 the primary power is interrupted while the diesel-burner is Volt-DC battery connection.

  • Page 38: Low Voltage Reset Feature

    Low-Voltage Reset Feature: button on the electronic controller (use a thin, straight, non- Whenever the Aqua-Hot’s DC power is interrupted, for long- metallic object to access the button through the faceplate) or er than 5 minutes, the ― low battery voltage fault‖ red indica- by turning off the diesel-burner switch on the interior switch tor light on the electronic controller will illuminate.

  • Page 39: Replacement Procedure

    TO ALLOW THE HEATER TO COOL BEFORE SERVICING Ensure that the pin jumpers are properly configured for COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY an Aqua-Hot 450-DE; reference information in this sec- tion for proper pin-jumper configuration. Ensure that the Aqua-Hot has been completely shut...

  • Page 40: Section 7: Electronic Controller Indicator Lights Electric Heating Element Status Indicator Light

    AC illuminated because an adequate level of antifreeze and water relay. heating solution within the Aqua-Hot’s boiler tank exists. Heating Zone Status (1-5) When illuminated (red only), three possible issues exist - the...

  • Page 41: [Circulation] Pump #1 Indicator Light

    Pump #3 - Stir Pump This light illuminates red when the Aqua-Hot is shut down due to excessive DC voltage (over 14.8 Volts) and/or the This indicator light shows the status of the stir pump by illu- electronic controller has overheated.

  • Page 42: Section 8: Diesel-Burner Overview

    IESEL URNER Diesel-Burner Overview The Aqua-Hot’s diesel-burner is a device that ignites a mix- from the flame is transferred to the antifreeze and water heat- ture of diesel fuel and air within a controlled setting to serve ing solution where it can be used for each system of the Aq- as a heat source.

  • Page 43: Diesel-Burner Overview

    8: D ECTION IESEL URNER Figure 28 — Page 43 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 44: Diesel-Burner Operational Flow Chart

    The Motor (#2), which turns the unassisted. Combustion Air Blower (#5) NOTE: and drives the Fuel Pump (#14), When the Aqua-Hot’s Diesel Burn- will begin to operate. er is switched OFF by the VDC/ The combustion process will con- NOTE:...

  • Page 45: Diesel-Burner Operational Overview

    Use the tions are experienced, use this sequence of operating events “KEY” provided to understand each symbol shown. Figure 29 — Page 45 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 46 8: D ECTION IESEL URNER Figure 30 — Page 46 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 47 8: D ECTION IESEL URNER Figure 31 — Page 47 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 48: Detaching The Diesel-Burner

    Diesel-Burner and disconnect power could result in serious bodily injury. CAUTION! Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua-Hot prior to beginning this replacement procedure. Step 1: Turn Off the Diesel Switch Figure 32 1.
  • Page 49 Step 3: Disconnect the Diesel Burner’s Controller Figure 34 1. Locate the Diesel-Burner’s Controller and disconnect both plugs. Step 4: Remove the fuel lines from the Aqua-Hot Figure 35b Figure 35a 1. Locate where the fuel lines on the diesel burner 2.
  • Page 50 Step 5: Remove the Diesel Burner from the Aqua-Hot Figure 36a Figure 36b 1. The Diesel-Burner is secured to the Aqua-Hot with two nuts that can be loosened, and swung out of the way by using a 10mm socket wrench with a 10 inch long exten- sion.

  • Page 51: Reattaching The Diese-Burner

    Step 1: Reattaching the Diesel Burner to the Aqua-Hot Figure 37a 1. The Diesel-Burner is secured to the Aqua-Hot with two eye-bolt nuts that can be swung into place, after the diesel burner has been properly aligned and set in place.
  • Page 52 CAUTION! Be sure to remove the clamps, off of the Fuel Supply and Return lines at the ports on top of the Aqua-Hot prior to start- ing the diesel burner, or serious damage will occur to the diesel-burner’s fuel pump.
  • Page 53 Step 4: Reinstall the Access Cover NOTE: The access cover must be installed prior to operation as a safety switch exists, which will prevent the Aqua-Hot from operating whenever the access cover is not properly installed. Figure 40b Figure 40a 1.

  • Page 54: Section 10: Diesel-Burner Components And Repair Information Diesel-Burner Component Overview

    10: D ECTION IESEL URNER OMPONENTS Figure 41 — Page 54 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 55: Motor

    A. Using a volt meter, check for 12 Volt-DC on the NOTE: The Aqua-hot 600 Series is equipped with a 20A JP4 plug, on the B4 + pin (red wire #3). If no Fast Blow Fuse, located on the red #20 wire, between the power is present verify the electronic controller is electronic controller and the diesel burner controller’s B-...
  • Page 56 Disconnect the motor’s black (+) and brown (-) wires from the C-plug harnesses black (+) and brown (-) wires. Figure 43 — Page 56 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 57 Reinstall a clutch half on both the new motor’s shaft nect the Diesel-Burner’s power supply before de- and the combustion air blower shaft. Attach the taching the Diesel-Burner from the Aqua-Hot. Fail- motor and flange assembly, with the recessed edge ure to turn off the Diesel-Burner and disconnect of the motor flange in-line with the wiring access power could result in serious bodily injury.
  • Page 58 10: D ECTION IESEL URNER OMPONENTS Motor Replacement Procedure: (continued) — Page 58 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 59: Flame Sensor

    C-plug harness wires. Figure 45 Flame Sensor Green Wire Blue Wire — Page 59 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 60 Follow the directions for reattaching the diesel blue wires from the C-plug harness’ green and vio- burner, in section 9 of this manual. let wires, and remove flame sensor. Figure 46 — Page 60 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 61: Ignition Electrodes

    If it is missing, replace the electrode boot. Figure 47 — Page 61 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 62: Fuel Nozzle

    Fuel Nozzle Component Test: Figure 48 1. Follow the directions for detaching the diesel burner, in section 9, of this manual. — Page 62 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 63 A partially plugged orifice will restrict fuel flow, which will affect the combustion process of the diesel-burner. Figure 49 — Page 63 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 64: Fuel Solenoid

    Using an 8mm wrench, remove the lock nut and flat washer from the end of the fuel solenoid shaft and then pull the fuel solenoid away from the nozzle — Page 64 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 65: Fuel Pump

    145 PSI, A. Check the motor home fuel tank for fuel. If the which is required for proper fuel atomization. Ref- fuel level is below 1/4 the Aqua-Hot diesel erence the illustration below for a basic overview burner will not operate.
  • Page 66 9 of this manual. NOTE: Do not adjust the fuel pressure regulator of the new fuel pump, as it has been factory preset. — Page 66 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 67 10: D ECTION IESEL URNER OMPONENTS Fuel Pump: (continued) Figure 52 — Page 67 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 68: Bearings

    C-plug harness wires, prior to removing. Remove the protection cap from the diesel-burner so that the motor and clutch halves are exposed. Figure 53 — Page 68 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 69 Discard the retaining nut, steel drive gear, snap rings, bear- ings, spacer tube, and washers, as replacements are provided in the new bearing kit. — Page 69 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 70 Figure 55 — Page 70 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 71: Ignition Coil

    4. Ensure the electrode boots are not broken inside the igni- (-) wires from the C-plug harness’ yellow (+) and tion coil wires. brown (-) wires. Figure 56 — Page 71 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 72 Follow the instructions for reattaching the diesel Lift the ignition coil and disconnect its wires from burner and test for proper operation. the C-plug harness wires, prior to removing. Figure 57 — Page 72 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 73: Controller

    2-way male plug to the 6-way female plug. circuit test. The diesel-burner will not ignite during normal operation if the VDC high-limit thermostat is left VDC/VAC Control Thermostat Circuit Test: disconnected. — Page 73 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 74 Failure to do so, will result in moisture collecting in the ports and potential damage to the diesel-burner controller’s internal circuitry. Figure 58a Figure 58b — Page 74 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 75: If The Aqua-Hot Is Black Smoking

    Impeller Fan Not Gapped Properly The impeller needs to be gapped at 3-5 thousands or tighten fan down until it rubs, back it off ¼ turn. — Page 75 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 76: If The Aqua-Hot Is Blue/White Smoking

    Fuel Pump Intermittent Ignition Coil - If the coil doesn’t turn on, the fuel sprays for 20 seconds, before the photo eye shuts the fuel off. — Page 76 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 77: If One Of The Aqua-Hot's Heating Zones Will Not Get Hot

    (i.e.) the fans for the bedroom come on but the pump for the living room comes on. 2. If Fans and Pumps are Running A. Stuck Check Valve B. Kinked Line C. No Antifreeze in system — Page 77 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 78: If There Is A Lack Of Domestic Continuous Hot Water

    3. The diesel burner must be on for continuous hot water, the electric element is for lim- ited use only. 2: Things to test for a lack of hot water problem. 1. Aqua-Hot Heater Bypassed 2. Outside Water Faucet is left on. 3. Washing Machine Valve has gone bad 4.

  • Page 79: If There Is Antifreeze Leaking

    NOTE: To find an antifreeze leak, the system must be Hot (up to operating temperature) Or pressurized to 15PSI. Inspect the following components on the Aqua-Hot Heating System for Leaks: 1. On the Front-Side of Aqua-Hot - 1. Fluid Level Sensor a.
  • Page 80 Note: If no leaks are found on the Aqua-Hot, it is possible that there is a leak within the motor home. Check all Heat exchangers, connections, and tubing for leaks.

  • Page 81: Appendix A: Wiring Diagram

    A: W PPENDIX IRING IAGRAM — Page 81 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 82 NFORMATION Because all Aqua-Hot heating systems are designed to operate only when there is an adequate supply of DC (Direct Current) voltage, it is imperative that the proper wire gauge be determined and used for the DC power supply and ground wires. This bulletin address- es how to determine the DC amperage draw of the heating system, including heat exchangers, then, how to determine the proper wire gauge based upon those findings for a specific application.

  • Page 83: Appendix B: Wire Gauge Chart

    PPENDIX AUGE NFORMATION For example, an Aqua-Hot 600-D with six Aqua-Hot Cozy heat exchangers has a total amperage draw of 23.38 amps. Determining the Proper Wire Gauge: 1. Measure the total length of the wire required for the distance between the vehicle’s battery and the elec- tronic controller for Aqua-Hot models 450-DE, 450-DM, 525-D, 600-D, and 675-D and the heater itself for the Aqua-Hot 375-D model.
  • Page 84 Step 2: Install fuel line bypass fittings onto the diesel burner. Figure C2 1/4‖ Fuel Tube unions 1. Locate the 1/4 ― fuel tube unions on the bottom side of diesel burner. — Page 84 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...

  • Page 85: Appendix C: Fuel Pressure Check And Adjustment

    2. Using a 13mm and a 9/16‖ wrench remove Steel Fuel lines from the diesel Burner Figure C4 3. Using a 13mm and a 9/16‖ wrench install the fuel bypass fittings onto the diesel Burner — Page 85 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 86 1. Using a 5/8‖ and a 3/4‖ wrench remove the fuel nozzle. Figure C6 2. Using a 5/8‖ and a 3/4‖ wrench install the fuel pressure gauge. — Page 86 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 87 2. Turn the diesel burner switch to the on position. A pressure will register on the fuel pressure gauge once the fuel solenoid opens (after approx. 10-20 seconds. — Page 87 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 88 2. Turn the diesel burner switch to the on position. A pressure will register on the fuel pressure gauge once the fuel solenoid opens (after approx. 10-20 seconds. — Page 88 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 89 NOTE: If the fuel pressure cannot be adjusted refer to the fuel pump section in section ? Of this manu- al for troubleshooting tips. — Page 89 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 90 B. Is the Diesel Fuel liquid or Jelled? C. Are the electrodes properly adjusted? NOTE: The Aqua-Hot can continue to be used for interior zone heating once the domestic water heating system D. When was the last time an Annual Service has been drained and winterized.

  • Page 91: Appendix D: Extreme Cold Weather Operation

    If there is a lack of interior Heat: Note: The 120 Volt-AC Electric Heating Element is the Aqua-Hot’s secondary heat source for heating both the interior and/or the domestic hot water during low heat- ing demand situations (such as when moderate ambient temperatures exist and/or when there is a low demand for domestic hot water).

  • Page 92: Appendix E: Aqua-Hot Annual Maintenance

    TO ALLOW THE HEATER TO COOL BEFORE SERVICING water heating solution within the expansion tank should only COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY be checked when the Aqua-Hot is at maximum operating temperature. To keep the Aqua-Hot running smoothly, it is recommended to have the diesel-burner tuned up annually.
  • Page 93 E: A PPENDIX AINTENANCE Aqua-Hot Maintenance Procedure: 3. Replace fuel filter, with proper replacement Note: canister. Before performing an annual maintenance, it is recommended to test run NOTE: It is recommended that the replacement fuel filter the Diesel-Burner. While testing inspect be filled with clean diesel fuel, prior to installation exhaust for smoke.
  • Page 94 AINTENANCE Aqua-Hot Maintenance Procedure: Step 4: Remove The Diesel Burner CAUTION! Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua-Hot prior to beginning this replacement procedure. Figure E4a Figure E4b 1.
  • Page 95 Diesel Burner’s white Thermostat Plug 4. Carefully pull the Diesel-Burner away from the Aqua-Hot 4 to 5 inches before rotating the burner, and then remove. NOTE: To remove the diesel burner, it may be necessary to disconnect the control and hi limit thermo- stats from the diesel-burner’s white thermostat plug.
  • Page 96 16 inches. fer tabs, to loosen soot deposits. Failure to do so will reduce the Aqua-Hot’s heat transfer capabilities. NOTE: If the heat transfer tabs are excessively sooty, it may be necessary to vacuum the soot out of the heat transfer tabs.
  • Page 97 A. Inspect the outer ring that the photo disc seats against for signs of warping. B. Inspect the back side of the Air Swirler for signs of warping between screws. — Page 97 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 98 Seam on stainless steel tube 1. Reinstall the combustion chamber into the Aqua-Hot. Please note: the seam on the stainless steel tube must be in the ― up‖ position. Failure to do so could result in premature failure of the combustion chamber.
  • Page 99 Broken or cracked ― Ears‖ Harness & Ignition Coil Wires - due to over tightening of eyebolts. - crack or bare wires - Hard or brittle wires — Page 99 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 100 A. For light dirt, dust, and/or carbon deposits, simply wipe off the flame sensor with a soft cloth. B. Should heavy carbon deposits be present, completely remove the flame sensor from the photo disc and clean with brake cleaner. — Page 100 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 101 Be sure to reattach the diesel-burner head prior to switching the heater ON. Failure to do so may result in ignition of the diesel-burner and serious bodily injury. — Page 101 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 102 Lay the clamp’s beveled side down on a solid flat surface and align the thick end of the punch at dead center. Tap the punch lightly until the retaining clamp returns to proper form. 4. Remove the electrode adjustment gauge. — Page 102 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 103 NOTE: When reinstalling the diesel burner be careful not to damage the photo disc or bend the electrodes. Also, be careful to not pinch any wires between the burner and the Aqua-Hot Tank. 1. Align the Diesel-Burner with the Aqua-Hot, using the alignment tabs welded on the Aqua-Hot.
  • Page 104 CAUTION! Be sure to remove the clamps, off of the Fuel Supply and Return lines at the ports on top of the Aqua-Hot prior to start- ing the diesel burner, or serious damage will occur to the diesel-burner’s fuel pump.
  • Page 105 Step 15: Re-Install the Aqua-Hot Access Cover NOTE: The access cover must be installed prior to operation as a safety switch exists, which will prevent the Aqua-Hot from operating whenever the access cover is not properly installed. Figure E15a Figure E15b 1.

  • Page 106: Appendix F: Winterization Process

    Not winterizing the Aqua-Hot when freezing temperatures this procedure for both the hot and cold faucets. are present will result in serious damage to the Aqua-Hot’s Domestic Water Heating System. Also, be sure to use an Turn off Demand Water pump and remove the hose and re- FDA approved, “GRAS”...

  • Page 107: Appendix G: Filling/Draining The Aqua-Hot

    Department at 1-800-685-4298. FDA shall be used in the Aqua-Hot’s hydronic heating NOTE: To Fill the Aqua-Hot it is recommended to use a system. Failure to use the above specified antifreeze type fluid transfer pump, and pump the antifreeze into the Boiler could result in serious injury or death.
  • Page 108 (negative) wire and clip the opposite end of the cable to a ground source. 9. Check the Aqua-Hot’s expansion tank and top it off to the cold level mark with the 50/50 antifreeze and water mixture, if necessary.
  • Page 109 G: F PPENDIX ILLING RAINING THE OT WITH HEATING SOLUTION Figure G3 Zone 1 Zone 2 Circulation Pump Circulation Pump — Page 109 — — Page 109 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 110 Open the Aqua-Hot’s drain valve located at the front of bay floor prior to beginning this antifreeze and water heating the heater. Reference Figure G4.
  • Page 111 — Page 111 — ® © 2009 Aqua-Hot 450-D Hydronic Heating System Service Manual—Rev. A...
  • Page 112 SERVICE MANUAL 15549 East Highway 52 | Fort Lupton, CO 80621 Toll free: 800.685.4298 | phone: 303.659.8221 | fax:303.857.7881 www.aquahot.com...
  • Page 113 This manual has been provided courtesy of My RV Works, Inc. www.myrvworks.com You can find more RV service manuals here: www.myrvworks.com/manuals Over the years of running a mobile RV repair service, having a dedicated place to access service manuals for all the different appliances and components found on RVs was something that I always had a desire to create.

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