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Vehicle Systems Aqua-Hot AHE-100-02S Shop Manual

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Shop Manual
Model Numbers
AHE-100-02S - 12 VDC
AHE-200-02S - 24 VDC
Aqua-Hot™ Hydronic Heating System Shop Manual
REV-A 03/02

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Summary of Contents for Vehicle Systems Aqua-Hot AHE-100-02S

  • Page 1 Shop Manual Model Numbers AHE-100-02S - 12 VDC AHE-200-02S - 24 VDC Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02...
  • Page 2 T T T T T ABLE OF C ABLE OF C ABLE OF CONTENT ABLE OF C ONTENT ONTENT ONTENTS S S S S ABLE OF C ONTENT Sections Aqua-Hot Information Aqua-Hot Component Overview Aqua-Hot Identification Plate Aqua-Hot Wiring Information Wiring Diagram Control / High-Limit Thermostat Wiring Diesel-Burner Information...
  • Page 3 Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Aqua-Hot Component Overview Overview Expansion Tank Zone # A Supply Zone # A Fill / Radiator Return Zone # B Return Zone # B Thermostat...
  • Page 4 Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Section 1: Aqua-Hot Information Aqua-Hot Identification Plate Aqua-Hot I.D. Plate The I.D. Plate is located on the right sidewall of heating unit, directly below the VAC Access Panel, see Figure 1.
  • Page 5 S S S S S ection 2: A ection 2: A ection 2: A ection 2: Aqua-H qua-H qua-H qua-Hot ot ot ot ot W W W W W iring I iring I iring I iring Infor nfor nformation nfor mation mation mation...
  • Page 6 S S S S S ection 2: A ection 2: A ection 2: A ection 2: Aqua-H ection 2: A qua-H qua-H qua-H qua-Hot ot ot ot ot W W W W W iring I iring I iring I iring I iring Infor nfor nfor...
  • Page 7 Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Overview Diesel-Burner Component Overview 1. Control Unit Combustion Chamber 2. Motor Heat Exchanger 3. Ignition Coil Exhaust Port 4. Clutch Flame Detection Photocell 5.

  • Page 8: Diesel-Burner Operational Flow-Chart

    Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Diesel- Operational Flow-Chart Burner ~ Reference Figure 5 for all numbers indicated inside parenthesis. (i.e #8). Operational Flow-Chart Operation sequence once the Simultaneously the The "MOTOR"...
  • Page 9 Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Section 3: Diesel-Burner Information Diesel Diesel-Burner Identification Plate Burner I.D. Plate Fabrikschild-Duplikat gultig nur zusammen mit Original Thermosysteme GmbH MADE IN GERMANY Model Type DBW 2010.75 HEIZGERAT Typ Spannung / El.
  • Page 10 S S S S S ection 4: D ection 4: D ection 4: D ection 4: Diesel-B iesel-B iesel-B iesel-Bur ur ur ur urner ner W W W W W iring I iring I iring Infor iring I nfor nfor nformation mation mation...
  • Page 11 Section 5: Diesel-Burner Service, Maintenance, and Repair Information Section 5: Diesel-Burner Service, Maintenance, and Repair Information Section 5: Diesel-Burner Service, Maintenance, and Repair Information Section 5: Diesel-Burner Service, Maintenance, and Repair Information Section 5: Diesel-Burner Service, Maintenance, and Repair Information Upkeep General Maintenance Monthly...
  • Page 12 S S S S S ection 5: D ection 5: D ection 5: Diesel-B ection 5: D iesel-B iesel-Bur ur ur ur urner S iesel-B ner S ner S ner Ser er er er ervice, M vice, M vice, M vice, Maintenance, and R aintenance, and R aintenance, and R...

  • Page 13: Ignition Electrodes

    S S S S S ection 5: D ection 5: D ection 5: D iesel-B iesel-B iesel-Bur ur ur ur urner S ner S ner Ser er er er ervice, M ner S vice, M vice, M aintenance, and R aintenance, and R epair I epair I...
  • Page 14 S S S S S ection 5: D ection 5: D ection 5: D ection 5: D ection 5: Diesel-B iesel-B iesel-B iesel-Bur ur ur ur urner S iesel-B ner S ner S ner Ser er er er ervice, M ner S vice, M vice, M...
  • Page 15 S S S S S ection 5: D ection 5: D ection 5: Diesel-B ection 5: D iesel-B iesel-B iesel-Bur ur ur ur urner S ner S ner S ner Ser er er er ervice, M vice, M vice, M vice, Maintenance, and R aintenance, and R aintenance, and R...

  • Page 16: Troubleshooting Flowchart

    S S S S S ection 6: ection 6: ection 6: ection 6: T T T T T r r r r r oubleshooting ection 6: oubleshooting oubleshooting oubleshooting oubleshooting Troubleshooting Flow-Chart 1. Check indicator light bulb. Troubleshooting Flow-Chart Replace if necessary. 2.
  • Page 17 S S S S S ection 6: ection 6: ection 6: ection 6: T T T T T r r r r r oubleshooting oubleshooting oubleshooting oubleshooting ection 6: oubleshooting 1. Check for fuel leaks in the Diesel-Burner's 1. Turn the Control Switch OFF. "DIESEL FUEL SUPPLY"...
  • Page 18 S S S S S ection 6: ection 6: ection 6: ection 6: T T T T T r r r r r oubleshooting oubleshooting oubleshooting ection 6: oubleshooting oubleshooting Within 15 seconds, after turning ON Does a spark the Control Switch, disconnect one appear across the of the two wires from the "FLAME Ignition...
  • Page 19 S S S S S ection 6: ection 6: ection 6: ection 6: ection 6: T T T T T r r r r r oubleshooting oubleshooting oubleshooting oubleshooting oubleshooting 1. Turn the Control Switch OFF. 2. Reconnect "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire. 3.
  • Page 20 S S S S S ection 6: ection 6: ection 6: ection 6: ection 6: T T T T T r r r r r oubleshooting oubleshooting oubleshooting oubleshooting oubleshooting 1. Turn the Control Switch OFF. 1. Check "FUEL SOLENOID VALVE" (#6) (see Figure 13) wires for 2.

  • Page 21: Warranty Policy

    WARRANTY POLICY - FOR AQUA-HOT MODELS - Vehicle Systems Inc. warrants the AQUA-HOT Heater, to the original owner, to be free from defects in material and workmanship under design usage and service conditions for a period of two (2) years on parts and labor beginning on the date of purchase of the vehicle. Replacement parts are covered for the remainder of the heating system's warranty or for six months (180 days) whichever is greater.
  • Page 22 S S S S S ection 8: P ection 8: P ection 8: P ection 8: Par ar ar ar arts List ts List ts List ection 8: P ts List ts List Control Unit 1 2 3 WPX-287-962 Control Unit, 12 VDC, DBW 2010-300, AH/HH/WH WPX-306-07B Control Unit, 24 VDC, DBW 2010-300, AH/HH/WH WPX-101-838...
  • Page 23 S S S S S ection 9: S ection 9: S ection 9: Special ection 9: S pecial pecial pecial T T T T T ools ools ools ools ection 9: S pecial ools WPX-310-646 Gauge, Adjustment, Electrode, DBW 2010-300, AH/HH/WH WPX-440-280 Control Box, Tester, DBW 2010-300, AH/HH/WH WPE-600-190...
  • Page 24 15549 East Highway 52 • • • • • Fort Lupton, Colorado 80621 • • • • • 1-800-685-4298 • • • • • Fax: 303-857-9000      Copyright 2002 Vehicle Systems, Inc. All rights reserved www.aqua-hot.com...

This manual is also suitable for:

Aqua-hot ahe-200-02s