Aqua-Hot AHE-200-02S-24 VDC User manual

Aqua-Hot AHE-200-02S-24 VDC User manual

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

T

ABLE OF C ONTENT S

Sections

4

5

1

2

3

6

7

8

9

Aqua-Hot Information

1.1

Aqua-Hot Component Overview

1.2

Aqua-Hot Identification Plate

Aqua-Hot Wiring Information

2.1

Wiring Diagram

2.2

Control / High-Limit Thermostat Wiring

Diesel-Burner Information

3.1

3.2

Diesel-Burner Component Overview

Operational Flow-Chart

5.1

5.2

5.3

5.4

3.3

Diesel-Burner Identification Plate

Diesel-Burner Wiring Information

4.1

Control Unit Wiring

Diesel-Burner Service, Maintenance, and Repair

Information

General Maintenance

Detaching the Diesel-Burner Head

Flame Detection Photocell

Ignition Electrodes

5.5

5.6

Fuel Nozzle

Fuel Solenoid Valve

5.7

Fuel Pump

Troubleshooting

6.1

Troubleshooting Flow-Chart

Aqua-Hot Warranty Information

Parts List

Special Tools

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Overview

1.1

Aqua-Hot Component Overview

Hot

Zone # A

Supply

Expansion

Tank

Zone # A

Return

Zone # B

Return

Zone # B

Supply

Zone # C

Return

Zone # C

Supply

Cold

Fill / Radiator

Cap

Thermostat

Access Panel

VAC Service

Input

Zone

Circulation

Pump

VAC Access

Panel

Fuse Block

Engine Preheat

Circulation

Pump

I.D Plates

Zone Relay #A

Diesel-Burner

Head

Zone Relay #B

Engine Coolant

Supply

Diesel Fuel

Supply

Diesel Fuel

Return

Pressure-Relief

Valve

Hot Water

Outlet

(Domestic Water)

Engine

Coolant

Return

Cold Water

Inlet

(Domestic Water)

Zone Relay #C

Electric Heating

Element Access

Panel

Diesel-Burner

Control

Unit

Mixer

Valve

Figure 1

Page 1

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Aqua-Hot

I.D. Plate

1.2

Aqua-Hot Identification Plate

Figure 2

MODEL No.

AHE-100-02S

SERIAL No.

02-637

Install in strict compliance with local codes, NFPA

501c and manufacturer's instructions. For installation only in compartment completely closed off from living quarters and accessible only from the outdoors.

Exhaust pipe must not terminate beneath the vehicle.

Caution! Do not adjust the Heater's

Tempering Valve. Tampering with the

Tempering Valve can increase the risk of scald injury.

Use copper electrical conductors only. Approved for use in recreational vehicles and in marine applications.

Complies with the requirements of

UL 307A and (USCG) CFR33.

12 VDC/110 VAC 1650 W

Fuel: Diesel 1 or 2

Firing rate: 50,000 btu/hr patent No. 5,025,985 and 5,067,652

PO BOX 7025 SALT LAKE CITY, UTAH 84157

Listing No.

15717

The I.D. Plate is located on the right sidewall of heating unit, directly below the VAC Access

Panel, see Figure 1.

Serial Number

Box

Model Number

Box

The lower portion of the

I.D. Plate is located inside the heating unit to the right of the Electric

Heating Element Access

Panel, see Figure 1.

MODEL No.

SERIAL No.

AHE-100-02S

02-637

Serial Number

Box

Model Number

Box

Page 2

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 2: A qua-H ot W iring I nfor mation

Wiring

Diagram

2.1

Wiring Diagram

(C)

Zones

(B) (A)

T-

STAT

T-

STAT

T-

STAT

Key

( )

Indicates Field

Wiring

Chassis Ground

Brown

Living Room

Pump

Green

A-Zone

Red

Bathroom

Pump

Fresh Water

Tank / Bay

Pump

B-Zone

Blue

Bedroom

Pump

Brown

Power Post

(+) Battery Connection

Blue

Red

Green

Green

Blue

White

A B

C D

E

F

C-Zone

Ground Post

(-) Battery

Connection

Engine

Pump

Figure 3

( - )

(+)

Living Room

(A-Zone ) Cozy

Heat Exchanger

( - ) (+)

Bathroom

(B-Zone ) Cozy

Heat Exchanger

( - )

(+)

Bedroom

(C-Zone ) Cozy

Heat Exchanger

Yellow

( - )

(+)

Fresh Water Tank

/ Bay Whisper

Heat Exchanger

Blue

T-

STAT

Orange

Black

Fresh Water Tank

/ Bay Thermostat

(B-Zone )

C-2

6

4

+

6

4

+

6

4

+

+

+

+

+

+

+

+

+

+

+

+

Pumps

Fans

B-1 B-4

Black

Red

White

Black

Red

+ +

A-Zone

Relay

+

+ +

+

+

B-Zone

Relay

+

+

+

+ +

C-Zone

Relay

+ +

+ +

Brown

Diesel-Burner

C-Plug (8 Pin)

B-2

For Technical Support call 1-800-685-4298

Diesel-Burner

B-Plug (6 Pin)

Page 3

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 2: A qua-H ot W iring I nfor mation

Control /

High-Limit

Thermostat

Wiring

Orange Wire

2.2

Control / High-Limit Thermostat Wiring

Blue Wire

VAC High-Limit

Thermostat,

230˚ F White Dot

12-2 ROMEX

Cable w/ground

VAC Service

Input /

ROMEX Clamp

"COMMON"

White Wire to

White ROMEX Wire

Green Wire

(Ground)

Black Wire

VDC Control

Thermostat,

190˚F, Blue Dot

Thermostat Thermostat

Thermostat

Thermostat Thermostat

Thermostat

Ground

Post

Thermostat Thermostat

Thermostat

RED

110

Thermostat Thermostat

Thermostat

Element

Aqua-Hot

Junction Box

Black Wire

VAC Control

Thermostat,

198˚F, Red Dot

"GROUND"

Green Wire to

ROMEX Copper Wire

VDC High-Limit

Thermostat,

230˚F, Black

Black Wire

White Wire

Purple Wire

"120 VAC POWER SUPPLY"

Black ROMEX Wire to

"LOAD" Black Wire

White Wire

Figure 4

120 VAC / 1650 Watt

Electric Heating Element

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Page 4

Overview

3.1

Diesel-Burner Component Overview

1.

Control Unit

2.

Motor

3.

Ignition Coil

4.

Clutch

5.

Combustion Air Fan

6.

Fuel Solenoid Valve

7.

Electrode Holder

8.

Ignition Electrodes

9.

Fuel Nozzle

10.

Combustion Chamber

11.

Heat Exchanger

12.

Exhaust Port

13.

Flame Detection Photocell

14.

Fuel Pump

15.

Fuel Ports (Supply / Return)

16.

Combustion Air Port (Intake) with Adjustable Shutter

Figure 5

Page 5

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Diesel-

Burner

Operational

Flow-Chart

Operation sequence once the

Aqua-Hot's Diesel-Burner

Control Switch is turned ON.

3.2

Operational Flow-Chart

~ Reference Figure 5 for all numbers indicated inside parenthesis. (i.e #8).

The Control Switch's indicator light will illuminate.

The "MOTOR" (#2) (which turns the "COMBUSTION AIR

FAN" (#5) and drives the

"FUEL PUMP" (#14)) will begin to run.

NOTE:

If the Aqua-Hot's Coolant reservoir temperature is approximately 175 degrees

Fahrenheit, or higher, the

"MOTOR" (#2) will not operate.

Only when the temperature has dropped below 175 degrees

Fahrenheit will the "VDC

CONTROL THERMOSTAT"

(see Figure 4) allow the

"MOTOR" (#2) to operate.

After approximately 10 - 25 seconds the "FUEL

SOLENOID VALVE" (#6) opens and fuel is sprayed into the "COMBUSTION

CHAMBER" (#10) through the "FUEL NOZZLE" (#9).

Simultaneously the

"IGNITION COIL" (#3) produces a High Voltage

Spark across the "IGNITION

ELECTRODES" (#8) which ignites the incoming Air / Fuel

Once the ignited Air / Fuel mixture (FLAME) is observed by the "FLAME DETECTION

PHOTOCELL" (#13), the

"IGNITION COIL" (#3) will automatically switch OFF. The combustion process now continues to operate unassisted.

The "MOTOR" (#2) will continue to run for approximately three (3) additional minutes. This is called the "Purge-Cycle", which cools down the Heater's internal components and purges the "COMBUSTION

CHAMBER" (#10) of any residual exhaust gases.

NOTE:

When the Aqua-Hot Diesel-

Burner is switched OFF by the

"VDC CONTROL

THERMOSTAT" (see Figure 4):

A.) The "MOTOR" (#2) will shut-off once the three (3) minute "Purge-Cycle" has expired.

B.) The Aqua-Hot's Diesel-

Burner will automatically turn back ON once the coolant temp. reaches the preset temperature of approximately

175 degrees Fahrenheit.

The combustion process will continue to operate in this manner until:

A.) The "VDC CONTROL

THERMOSTAT", (see Figure 4)

(which senses Coolant Temp.), reaches the preset temperature of approximately 190 degrees

Fahrenheit.

B.) The Aqua-Hot's Diesel-

Burner Control Switch is turned

OFF.

Once the Heater switches

OFF, thermostatically or manually, the "FUEL

SOLENOID VALVE" (#6) closes, which interrupts the supply of diesel fuel to the

"FUEL NOZZLE" (#9).

SUMMARY:

The Aqua-Hot's Diesel-Burner is operational anytime the operator activates the Diesel-Burner

Control Switch to the ON position. The Diesel-Burner will then automatically maintain the temperature of the coolant without any additional involvement from the operator.

Page 6

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Diesel

Burner

I.D. Plate

3.3

Diesel-Burner Identification Plate

Fabrikschild-Duplikat gultig nur zusammen mit Original

Thermosysteme GmbH

MADE IN GERMANY

HEIZGERAT Typ

Spannung / El. Leistung

Warmestrom

Brennstoff zul. Betriebsuberdruck

Prufzeichen

Fabriknummer

Inbetriebnahmejahr

DBW 2010.75

12 V / 60W

13,2 kW

Diesel

2 bar

1B230410

2001 2002 2003

Model Type

Voltage / Wattage

Fuel Type

Serial Number (230410)

Diesel-Burner I.D. Plate is located on the left side of the Diesel-Burner Head

Diesel-Burner

Head

Figure 6

Page 7

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 4: D iesel-B ur ner W iring I nfor mation

Control

Unit Wiring

4.1

Control Unit Wiring

( + ) VDC Control Thermostat (Orange)

( + ) Blower Motor (Black)

( - ) To Overheat Circuit

And Solenoid Valve (Blue)

( + ) Indicator Light (Blue)

( - ) Battery (Brown)

( + ) On / Off Switch With

Low Voltage Protection

(White)

B-Plug

1 2

3

4

5 6

( + ) Battery (Red)

( - ) Indicator Light (Green)

1 2

4

5 6 7

8

C-Plug

( + ) To Ignition Coil (Yellow)

( + ) From Normally Closed

VDC Control Thermostat (White)

( + ) Flame Detector (Green)

( - ) For All Heater Components (Brown)

Figure 7

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Page 8

Upkeep

5.1

General Maintenance

Monthly

Check the Aqua-Hot's solution of water and antifreeze to ensure that it is at the proper level. Do this by visually checking the coolant level in the Aqua-Hot's Expansion Tank, see Figure 1. This should be checked only when the Aqua-Hot is at full operating temperature, “HOT.”

Annually

CAUTION: Before cleaning or servicing, disconnect all power supplies.

It is ideal to have your Aqua-Hot tuned-up yearly. A tune-up should consist of a Fuel Nozzle and Fuel Filter replacement and a thorough cleaning of the Combustion Chamber, if necessary, see Figure 8. This simple tune-up will keep your Aqua-Hot running smoothly throughout the year. This annual tune-up will also allow service personnel to inspect for wear and tear of other components.

CAUTION: Operating the Aqua-Hot’s Diesel-Burner or the 120 VAC

Electric Heating Element without the water and antifreeze solution will cause serious damage to the Heater.

Fuel

Nozzle

Fuel Filter

Combustion

Chamber

Page 9

Figure 8

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 5: D iesel-B ur ner S er vice, M aintenance, and R epair I nfor mation

Detaching

Diesel-Burner

Head

5.2

Detaching the Diesel-Burner Head

Grommets

Eye-Bolts and Nuts

Blower

Casing

Diesel

Fuel Supply

Diesel

Fuel Return

Figure 9

Instructions For Detaching the Diesel-Burner Head from the Aqua-Hot

CAUTION: Before detaching the Diesel-Burner Head, disconnect all power supplies.

1.

Loosen the two Eye-Bolt Nuts and swing the Eye-Bolts out of the way.

2.

With both hands, carefully pull the Diesel-Burner away from the Aqua-

Hot, approximately 4-5 inches. Please note that you may have to lift the head slightly while pulling it away from the Aqua-Hot.

3.

Rotate the head approximately 90 angular degrees to the right or until all the internal components are visible.

NOTE: It may be necessary to disconnect the two RED wires, which are connected to pin #6 of the B-Zone relay, when rotating the head beyond 90 degrees, see Figure 3.

CAUTION: When reattaching the Diesel-Burner Head to the Aqua-Hot, be sure to properly align the head and DO NOT over tighten the Eye-Bolt

Nuts. An improper alignment and or an over tightening of the Eye-Bolt

Nuts can cause damage to the Diesel-Burner Head's aluminum-cast housing (Blower Casing), see Figure 9.

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Page 10

SS ection 5: D iesel-B ur ner S er vice, M aintenance, and R epair I nfor mation

Flame

Detection

Photocell

5.3

Flame Detection Photocell

Flame Detection

Photocell

Ignition

Electrodes

Green Wire

Figure 10

5.4

Blue Wire

Photo Disc

Flame Detection Photocell

Cleaning Notes

For light dirt, dust and carbon deposits simply wipe off the Flame Detection

Photocell with a soft cloth. Should heavy carbon deposits be present, completely remove the Flame Detection Photocell from the Photo Disc and clean with carburetor cleaner.

Ignition Electrodes

Note: Electrode Adjustment

Gauge is located on the outside surface of the Diesel-

Burner on the lefthand side.

Electrode Adjustment Gauge

Note: Once adjustment is complete, remove Electrode

Adjustment Gauge and reattach to Diesel-Burner.

Ignition Electrodes

Page 11

Figure 11

Adjustment gauge properly positioned

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 5: D iesel-B ur ner S er vice, M aintenance, and R epair I nfor mation

Fuel

Nozzle

5.5

Fuel Nozzle

Solenoid

Valve

Figure 12

Fuel Nozzle

Fuel Nozzle

Stand

Note: When replacing the Fuel

Nozzle, be sure to tighten the Nozzle, then loosen 1/4 turn and firmly retighten. This will establish a seated fit and avoid any leaks.

5.6

Fuel Solenoid Valve

Electrical Terminals

(+) (-)

Fuel Solenoid Valve

Fuel Solenoid

Kit

Figure 13

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Page 12

SS ection 5: D iesel-B ur ner S er vice, M aintenance, and R epair I nfor mation

Fuel

Pump

5.7

Fuel Pump

Fuel Pump

Pressure

Regulation

(Adjustment)

Note: Adjust fuel pressure to

145 PSI.

(+) Clockwise rotation increases fuel pressure.

(-) Counter Clockwise rotation decreases fuel pressure.

Fuel Pressure Gauge

Note: Fuel Pressure gauge replaces the Fuel Nozzle when adjusting fuel pressure.

Page 13

Figure 14

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 6: T

Troubleshooting

Flow-Chart

6.1

Troubleshooting Flow-Chart

Turn the Control

Switch ON.

Is the indicator light illuminated?

Yes

1. Remove the Aqua-

COVER.

2. Check Aqua-Hot

fuse (F) for continuity, see

Figure 3. Replace if

necessary.

NOTE: The indicator light will illuminate for only 30 seconds if fuse

(F) is blown (open circuit).

3. Attempt heater

restart.

No

Is the Diesel-

Burner's

"MOTOR" (#2) operating?

Check the Diesel-

Burner's

"VDC CONTROL

THERMOSTAT" (blue dot) for continuity, see

Figure 4.

1. Replace

Thermostat.

NOTE: Aqua-Hot operating temperature must be below 170 degrees Fahrenheit when checking the

"VDC CONTROL

THERMOSTAT"

for continuity, see

Figure 4.

2. Attempt heater

restart

No

Is there continuity across the

Thermostat?

Yes

No

Yes

1. Check indicator light bulb.

Replace if necessary.

2. Remove the Aqua-Hot's

ACCESS COVER.

3. Check Aqua-Hot fuses

(E & F) for continuity, see

Figure 3. Replace if necessary.

4. Check DC power supply at the

"POWER POST" and

"GROUND POST", see Figure

3.

5. Attempt heater restart.

1. Remove the Aqua-Hot's

ACCESS COVER.

2. Remove the "THERMOSTAT

ACCESS PANEL", see Figure

1.

3. Check the Diesel-Burner's

"VDC HIGH-LIMIT

THERMOSTAT" for continuity,

NOTE: This Thermostat protects against overheating temperatures.

Yes

Is there continuity across the

Thermostat?

No

1. Replace the Thermostat.

2. Attempt heater restart.

Page 14

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 6: T

1. Turn the Control Switch OFF.

2. Remove the fuel-line from the

Aqua-Hot's

RETURN" (see Figure 1) and place a short piece of fuel line in its

place.

3. Put the opposite end of the fuel line in a container.

4. Place the probes of a DC- multi meter into plug locations,

B-1 (+) and B-2 (-), of the Diesel- see Figures 1 and 7. Also, measure the voltage across B-2 (-) and B-4 (+).

5. Turn the Control Switch ON.

6. Observe the fuel flow. Flow should be consistent without air bubbles.

1. Check the voltage level of the DC-multi meter.

NOTE: Voltage level should be within 0.5 volts of the system's

DC battery voltage.

1. Inspect the "FLAME

(#13) (see Figure 10) for dust and or sooty carbon deposits. Clean if necessary.

2. Completely cover the

"FLAME DETECTION

PHOTOCELL" (#13) (see

Figure 10) with a shop rag.

3. Turn the Control Switch ON.

After approx. 20 seconds of operation a bright blue arc (spark) should appear

ELECTRODES" (#8), see

Is the fuel flow consistent without air bubbles?

No

1. Check for fuel leaks in

"DIESEL FUEL

SUPPLY" line, see

Figure 9. Repair if

necessary.

2. Check the Aqua-Hot's

"FUEL FILTER" (see

Figure 8) for clogging.

Replace if necessary.

3. Reattach "DIESEL

FUEL RETURN" line, see Figure 1.

4. Attempt heater restart.

Yes

Does the DCmulti meter indicate acceptable system voltage?

No

1. Check the Control

Switch's:

3.

2. Check DC power supply wires and connections, see Figure 3.

3. Reattach "DIESEL

FUEL RETURN" line, see Figure 1.

4. Attempt heater restart.

Yes

1. Turn the Control Switch OFF.

2. Reattach "DIESEL FUEL RETURN" line, see Figure 1.

3. Detach the "DIESEL-BURNER HEAD" from the Aqua-Hot, see Figures 1 and 9.

4. Disconnect one of the wires from the "FUEL SOLENOID

VALVE" (#6), see Figure 13.

NOTE: Do not remove or cut any of the external wires attached to the "DIESEL-BURNER HEAD".

!

WARNINGS:

1. DO NOT attempt to restart the Aqua-Hot when the "DIESEL-

BURNER HEAD" is detached. An open flame can result and cause serious personal injury.

2. To prevent a fire hazard, be sure to disconnect one of the

"FUEL SOLENOID VALVE" (#6) (see Figure 13) wires.

Page 15

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 6: T

Does a spark appear across the

Ignition

Electrodes?

No

Within 15 seconds, after turning ON the Control Switch, disconnect one of the two wires from the "FLAME

DETECTION PHOTOCELL" (#13)

(blue or green), see Figure 10. A spark should now appear across the "IGNITION ELECTRODES"

(#8), see Figure 11.

Does a spark appear across the

Ignition

Electrodes?

Yes

Yes

Remove shop rag from the "FLAME

DETECTION PHOTOCELL" (#13)

(see Figure 10), exposing it to a light source. The spark should disappear.

Does a spark disappear after the

Photocell is exposed to light?

No

1. Turn the control switch OFF.

2. Check "FLAME DETECTION

PHOTOCELL" (#13) (See Figure 10) for proper operation by: Removing both wires from the Photocell and covering with a shop rag. When dark,

Photocell wire leads should read

300,000 ohms, or greater, of electrical resistance. Remove shop rag and expose to light; electrical resistance should be 300 ohms or less.

1. Turn the Control Switch

OFF.

2. Check "IGNITION COIL"

(#3) for proper operation by: Removing C-plug from

"CONTROL UNIT" (#1), see Figure 7. Apply DC power (+) to C-8 plug

(yellow wire) and ground

(-) to C-5 plug (brown wire). A spark should now appear across the

"IGNITION ELECTRODES"

(#8), see Figure 11.

No

Yes

1. Replace "FLAME DETECTION

No

Does the Photocell operate properly?

2. Reconnect "FUEL SOLENOID

VALVE" (#6) (see Figure 13)

wire.

3. Reattach "DIESEL-BURNER

HEAD" (see Figure 9) and attempt heater restart.

Yes

1. Replace "CONTROL UNIT" (#1), see

Cover "FLAME DETECTION

PHOTOCELL" (#13) (see

Figure 10) again with a shop rag. The spark should reappear and continue for approx. 15 seconds and then switch off.

2. Reconnect "FLAME DETECTION

PHOTOCELL" (#13) (see Figure 10)

(#6) (see Figure 13) wire.

3. Reattach "DIESEL-BURNER HEAD"

(see Figure 9) and attempt heater

restart.

1. Replace "CONTROL UNIT" (#1), see

2. Reconnect "FLAME DETECTION

PHOTOCELL" (#13) (see Figure 10)

(#6) (see Figure 13) wire and C-plug.

3. Reattach "DIESEL-BURNER HEAD"

(see Figure 9) and attempt heater

restart.

Yes

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Does the Ignition

Coil operate properly?

No

1. Replace "IGNITION COIL"

(#3).

2. Reconnect "FLAME

DETECTION PHOTOCELL"

(#13) (see Figure 10) wire,

"FUEL SOLENOID VALVE"

(#6) (see Figure 13) wire and

C-plug.

3. Reattach "DIESEL-BURNER

HEAD" (see Figure 9) and attempt heater restart.

Page 16

SS ection 6: T

1. Turn the Control Switch OFF.

2. Reconnect "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire.

Does the spark reappear?

Yes

3. Remove both ignition wires from the "IGNITION ELECTRODES" (#8)

see Figure 11) or connect a jumper wire across the Electrodes.

!

CAUTION: To prevent a HIGH VOLTAGE shock and or a fire hazard, be sure to remove both "IGNITION ELECTRODES" (#8)

(see Figure 11) (tape the ends and separate the wires) or connect a jumper wire across the Electrodes.

No

1. Turn the Control Switch OFF.

2. Replace "CONTROL UNIT" (#1),

see Figure 7.

4. Turn the Control Switch ON. After approx. 20 seconds the "FUEL

"CONTROL UNIT" (#1), see Figure 7. A fine mist of fuel should appear

3. Reconnect "FUEL SOLENOID

VALVE" (#6) (see Figure 13) wire.

4. Reattach "DIESEL-BURNER

HEAD" (see Figure 9) and attempt

Is a mist of fuel

(cone-shaped) present?

1. Replace "FUEL SOLENOID VALVE" (#6),

see Figure 13.

2. Retest fuel flow (without Fuel Nozzle).

Yes

No

3. Install "FUEL NOZZLE" (#9), see Figure 12.

4. Retest Fuel Nozzle spray pattern (fine mist of

1. Turn the Control Switch OFF.

1. Turn the Control Switch

OFF.

5. Reconnect ignition wires to "IGNITION

ELECTRODES" (#8) (see Figure 11) or

remove jumper wire.

2. Reconnect ignition wires to

"IGNITION ELECTRODES"

(#8) (see Figure 11) or

2. Remove "FUEL NOZZLE"

(#9), see Figure 12.

6. Reattach "DIESEL-BURNER HEAD" (see

Figure 9) and attempt heater restart.

No

3. Reattach "DIESEL-BURNER

HEAD" (see Figure 9) and

attempt heater restart.

3. Turn the Control Switch ON.

After approx. 20 seconds

fuel should flow freely from

the fuel nozzle port.

No

1. Turn the Control Switch OFF.

Does the

Solenoid Valve operate properly

(click)?

2. Check "FUEL SOLENOID VALVE"

(#6) (see Figure 13) for proper

operation by: Removing both wires

from the Solenoid Valve and

applying VDC power (+) and

ground(-) to the Solenoid Valve

No

Does fuel flow freely from the port?

Yes

Figure 13) should click when VDC

power is applied.

Yes

Page 17

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 6: T

1. Check "FUEL SOLENOID VALVE"

(#6) (see Figure 13) wires for

continuity. Replace wires if

necessary.

2. Replace "CONTROL UNIT" (#1)

(see Figure 7) if wires indicate

continuity.

3. Retest fuel flow (without Fuel

Nozzle).

4. Install "FUEL NOZZLE" (#9),

see Figure 12.

5. Retest Fuel Nozzle spray pattern

(fine mist of fuel present?).

7. Reattach "DIESEL-BURNER

HEAD" (see Figure 9) and attempt

1. Turn the Control Switch OFF.

2. Replace "FUEL NOZZLE" (#9),

see Figure 12.

3. Retest Fuel Nozzle spray pattern

(fine mist of fuel present?).

4. Reconnect ignition wires to

"IGNITION ELECTRODES" (#8)

(see Figure 11) or remove jumper

wire.

5. Reattach "DIESEL-BURNER

HEAD" (see Figure 9) and attempt

NOTE: If an improper fuel spray is still observed (a normal spray pattern should be observed as a coned-shaped mist) the Diesel-

Burner's "FUEL PUMP" (#14) (see Figure 14) should be calibrated for the proper fuel pressure setting.

End of Troubleshooting Flow-

Chart.

For additional troubleshooting information please contact:

Vehicle System's Service Dept.

at 303-857-2901

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Page 18

SS ection 7: A qua-H ot W arranty I nfor mation

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.

This warranty does not apply to damage or failure of the AQUA-HOT Heater or the vehicle into which it was installed due to improper installation, assembly, maintenance, abuse, neglect, accident, or the use of parts not supplied by Vehicle Systems Inc. Vehicle Systems is not responsible for incidental or consequential damages.

The intent of this warranty is to protect the end user of the heating system from such defects which would occur in the manufacture of the product. The warranty is not intended to protect the end user from problems which are outside the ability of Vehicle Systems’ control.

To obtain warranty repair authorization or for additional information, please contact our Technical

Support Department at 1-800-685-4298 (8 AM to 5 PM) Mountain Standard Time.

Page 19

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 8: P ar ts List

90

91

Control Unit

1

2

1 2 3

4 5 6

1

5

2 4

6 7 8

A B C

97

126

125

61

59

72

62

56

5

2

27

98

51

99

100

50

2

2*

WPX-287-962

WPX-306-07B

5

5*

WPX-101-838

WPX-101-846

27 WPX-425-060

27* WPX-425-079

56

59

61

62

72

50 WPX-322-083

50* WPX-322-091

51 WPX-386-650

WPX-274-313

WPX-638-78A

WPX-887-71A

WPX-886-41A

WPX-502-05A

90

91

WPX-265-53A

WPE-905-83A

91* WPE-905-84A

97 ELE-L08-190

98

99

100

125

126

ELE-L08-230

ELE-254-010

ELE-010-198

FLX-120-VS1

FLX-R12-TRA

Control Unit, 12 VDC, DBW 2010-300, AH/HH/WH

Control Unit, 24 VDC, DBW 2010-300, AH/HH/WH

Coil, Ignition, 12 VDC, DBW 2010-300, AH/HH/WH

Coil, Ignition, 24 VDC, DBW 2010-300, AH/HH/WH

Motor, Combustion Air/Fuel Pump, 12 VDC, DBW-2010, AH/HH/WH

Motor, Combustion Air/Fuel Pump, 24 VDC, DBW-2010, AH/HH/WH

Valve, Fuel Solenoid, 12 VDC, DBW 2010-300, AH/HH/WH

Valve, Fuel Solenoid, 24 VDC, DBW 2010-300, AH/HH/WH

Valve, Kit, Fuel Solenoid, DBW 2010-300, AH/HH/WH

Electrode, Ignition, DBW-2010, AH/HH/WH

Sensor, Flame, DBW 2010-300, AH/HH/WH

Photo Disc, DBW-2010, AH/HH/WH

Nozzle, Fuel, .35 GPH, DBW-2010, AH/HH/WH

Pump, Fuel, 10 Bar, DBW 2010-300, AH/HH/WH

Combustion Chamber, DBW-2010, AH/HH/WH

Burnerhead, Modified, VSI DBW-2010, 12 VDC, AH

Burnerhead, Modified, VSI DBW-2010, 24 VDC, AH

Thermostat, VDC Control, 190

°

F, Blue Dot, AH

Thermostat, VDC High-Limit, 230

°

F, Black, AH

Thermostat, VAC High-Limit, 230

°

F, White Dot, AH

Thermostat, VAC Control, 198

°

F, Red Dot, AH

Filter, Fuel, System, 10 Micron, AH/HH

Filter, Fuel, Spin-On Element, 10 Micron, AH/HH

* Asterick denotes 24 volt model

Page 20

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

SS ection 9: S pecial T ools

139

102

138

102 WPX-310-646

138 WPX-440-280

139 WPE-600-190

140 ****************

Gauge, Adjustment, Electrode, DBW 2010-300, AH/HH/WH

Control Box, Tester, DBW 2010-300, AH/HH/WH

Gauge Kit, Fuel Pressure, DBW 2010-300, AH/HH/WH

Tester, CO-2, DBW 2010-300, AH/HH/WH

Order item #140 from a Grainger Industrial Supply Store near you or visit the Grainger website at www.grainger.com.

(Grainger Part# 6

T

153)

140

Page 21

Aqua-Hot™ Hydronic Heating System Shop Manual REV-A 03/02

Motor Coach Heating Specialists

·····

Manufacturers and Distributors

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

LTE-LMA-004

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