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Table of Contents
Troubleshooting
Related Manuals for Airxcel Aqua-Hot 125 Series
Summary of Contents for Airxcel Aqua-Hot 125 Series
- Page 1 Service Manual Series AHE-125-DN2...
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Page 2: Table Of Contents
Caution Notes System Overview located in the Aqua-Hot. The water is heated by transfer from The Aqua-Hot 125 Series is a Hydronic Heating System that Caution Notes ................2 As you read this information, take particular note of the NOTICE, the heated antifreeze and distilled water solution. The heated can provide heat and hot water on demand using a built-in CAUTION, WARNING, and DANGER symbols when they appear. -
Page 3: Introduction
Introduction Introduction Introduction to this Document Heat Priority Option: External Diesel Burner: The diesel 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 125-DN2 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 diesel 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 125-DN2 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, 8. -
Page 6: Operational Flowchart
Component Cut-Aways Basic Components Operational Flowchart Operational Flow Chart Belief Diesel 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 Diesel 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 diesel burner, tapping the electric If the zone temperature is set, but this item 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 Overheat, and Burner Failed to Ignite. These will be explained below. Aqua-Hot related issues. For more complex issues, it may be burner.
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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 diesel independently activate specific elements within the Aqua-Hot burner. -
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: Troubleshooting Procedure
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 Before continuing to the replacement procedure, The Aqua-Hot is equipped with three resettable High-Limit Expansion Bottle can either ensure that the unit has cooled to ambient temperature, 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. Introduction: Follow the testing procedure to the right in order to diagnose 1. -
Page 16: Fluid Circulation Pump
Fluid Circulation Pump Fluid Circulation Pump Power cycle the Aqua-Hot Fluid Circulation Pump Replacement Procedure: to clear any current faults. 1. Drain coolant from system. Pour into a bucket to be reused later. Introduction: Locate the Aqua-Hot LCD 2. Remove the top and side panels from the Aqua-Hot. Save 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 AC Electric System Replacement Procedure: Locate the Aqua-Hot LCD Introduction: 1. Ensure that the Aqua-Hot has been completely shut down screen. Navigate to the and all power sources have been disconnected. Be sure the The AC Electric system of the Aqua-Hot 125-DN2 unit functions TESTING page (Figure 60) to provide heat to the Aqua-Hot boiler tank. -
Page 18: Ac Relay
Fluid Circulation Pump AC Relay ETS Module AC Relay ETS Module Replacement Procedure: Using a meat thermometer, measure the temperature 1. Ensure that the Aqua-Hot has been completely shut down of the tank face. Record and all power sources have been disconnected. Be sure the Introduction: Introduction: this temperature on a... -
Page 19: Fuel System Replacement
ETS Module Fuel System Replacement ETS Module FUEL FILTER CLAMPS? 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 Fuel Purge Procedure • Ground goes to Pin #1 CORRECT CORRECT WRONG • 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 Diesel Burner Troubleshooting External Diesel Burner Faults & Remedies The troubleshooting procedures listed below are arranged in order of repair complexity. Do not replace parts without Fault Fault correctly determining the failure. Follow the directions below in order to troubleshoot the diesel burner. Do not skip through the Fault Cause Remedy Fault Cause... - Page 22 Burner Troubleshooting ETS Module Burner Operation ETS Module General Failure Symptoms of the Burner The first 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 first start-up after service, This section will cover the typical failures of the diesel burner.
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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 System Schematics PIN OUT INFORMATION NOTE: All connectors are shown from Pin insertion side. p. 46 ©Aqua-Hot® 125-DN2 Service Manual REV 220427 ©Aqua-Hot® 125-DN2 Service Manual REV 220427 p. 47... - Page 25 System Schematics System Schematics p. 48 ©Aqua-Hot® 125-DN2 Service Manual REV 220427 ©Aqua-Hot® 125-DN2 Service Manual REV 220427 p. 49...
- Page 26 System Schematics Parts System Schematics Parts 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 ELE-LCD-050 ELE-125-200 1500W, 120 VAC Electric Element, 1” NPSM Aqua-Hot LCD Screen, RVC 3.5in RV-Side Wire Harness (optional) Controller, 12VDC, 100-200 Series, Kit...
- Page 27 System Schematics Parts System Schematics Parts PLE-063-200 PLX-100-900 ELX-232-948 SME-102-080 3 Qt. Expansion Tank w/Internal Fluid Level Sensor, 5/8” Barb Fluid Circulation Pump AC Relay, 30A 277VAC Cover, AC Element Cover for 125 Series PLX-111-125 ELE-400-900 PLX-000-200 GBX-125-117 Pressure Relief Valve, 125 PSI Harness, Buehler C20 Pump Hose, ⅝”...
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Page 28: Measuring Antifreeze Using A Refractometer
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) Eye Piece (Couplers & check valve included) 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-DN2 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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