Aqua-Hot Shop Manual 08-24

Aqua-Hot Shop Manual 08-24
Shop Manual
Model Numbers
AHE-100-04S - 12 VDC
AHE-120-04X - 12 VDC
AHE-130-04X - 12 VDC
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
TABLE OF CONTENTS
Section 1
General Heater Information
1.1
1.2
Section 2
Electronic Controller
Electric Heating Element Status Indicator Light
Heating Zones Status Indicator Lights
Low Voltage Reset
Low Tank-Level Cutoff Indicator Light
Heating Status Indicator Light
Engine Preheat Pump Indicator Light
Pump #1 Indicator Light
Pump #2 Indicator Light
Pump #3 Indicator Light
Low Battery Voltage Fault Indicator Light
Low Temp Cutoff Status Indicator Light
Diesel-Burner Status Indicator Light
Overload Fault Indicator Light
6
6
6
7
7
7
7
7
7
8
8
8
8
8
Component Overview
Operational Flow-Chart
Operational Sequence
Identification Plate
9
10
11
14
Diesel-Burner Controller
15
Troubleshooting
7.1
Section 8
4
4
4
5
Diesel-Burner Wiring
6.1
Section 7
Interior Switch Panel
Diesel Switch
Electric Switch
Engine Preheat Switch
Diesel-Burner
5.1
5.2
5.3
5.4
Section 6
3
Electronic Controller
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Section 5
Aqua-Hot Model Differentiation
Switch Panel
3.1
3.2
3.3
3.4
Section 4
1
2
Model Differentiation
2.1
Section 3
Component Overview
Marking Plate
Page
Troubleshooting
16
Diesel-Burner Service, Maintenance, and Repair Information
8.1
8.2
8.3
8.4
8.5
8.6
General Recommended Maintenance
Detaching and Reattaching the Diesel-Burner Head
Motor
Flame Sensor
Ignition Electrodes
Fuel Nozzle
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
42
43
44
48
49
51
TABLE OF CONTENTS
Section 8
Diesel-Burner Service, Maintenance, and Repair Information
8.7
8.8
8.9
8.10
8.11
Section 9
Fuel Solenoid Valve
Fuel Pump
Bearings
Ignition Coil
Diesel-Burner Controller
Page
53
55
61
65
66
Warranty Information
9.1
Warranty Information
71
Section 10 Spare Parts List
72
Section 11
73
Special Tools
Referenced Illustrations
Figure 1:
Figure 2:
Figure 4:
Figure 5:
Figure 6:
Figure 7:
Figure 8:
Figure 9:
Figure 10:
Figure 11:
Figure 12:
Figure 13:
Figure 14:
Figure 15:
Figure 16:
Figure 17:
Figure 18:
Figure 19:
Figure 20:
Figure 21:
Figure 22:
Figure 23:
Figure 24:
Figure 25:
Figure 26:
Figure 27:
Appendix A
Aqua-Hot Hydronic Heating System and Inclusive Components
Aqua-Hot Marking Plate
Aqua-Hot Interior Switch Panels
Electronic Controller
Diesel-Burner Component Overview
Diesel-Burner Marking Plate
Controller Wiring
Diesel-Burner Components Requiring Annual Maintenance
Detaching and Reattaching the Diesel-Burner Head
Diesel-Burner Motor Component Test
Diesel-Burner Motor RPM Test
Diesel-Burner Motor Replacement
Diesel-Burner Motor Replacement (continued)
Diesel-Burner Flame Sensor Components
Diesel-Burner Ignition Electrodes
Diesel-Burner Fuel Nozzle
Diesel-Burner Fuel Solenoid Valve
Diesel-Burner Fuel Pump
Diesel-Burner Fuel Pressure Gauge
Diesel-Burner Pressure Regulator Adjustment Screw
Diesel-Burner Fuel Pump Replacement
Diesel-Burner Bearings
Diesel-Burner Ignition Coil
Diesel-Burner Controller
Diesel-Burner Controller Voltage Check
Diesel-Burner Controller Replacement
Wiring Diagrams
Wiring Information (AHE-100-04S)
Wiring Information (AHE-120-04X)
Wiring Information (AHE-130-04X)
Appendix B
1
2
4
5
8
13
14
42
43
44
45
47
47
49
50
52
54
56
58
58
60
64
65
66
67
70
A1
A2
A3
Illustrations
Resetting the High-Limit Thermostat
Hydronic Heating System Overview
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
B1
B2
SECTION 1: GENERAL HEATER INFORMATION
Component
Overview
1.1
Component Overview
ELECTRONIC CONTROLLER
������ ���
R
Motor Coach Heating Specialists
Switch Panel
Low Tank-Level
Cutoff
Electric Heating
Element Status
Low Voltage
Heating Status
Reset
������������������
Engine Preheat
Pump
#5
#4
Pump #1
Heating Zones
Status
Diesel
Electric
Engine
Preheat
#3
Pump #2
#2
#1
Pump #3
Low Battery
Voltage Fault
Diesel-Burner
Status
Low Temp
Cutoff Status
Ho
Overload Fault
Electronic
Controller
Expansion
Tank
t
Co
ld
Heating Zones
Supply and Return
Ports
Fill / Radiator
Cap
Circulation
Pump #1
VAC Service
Input
Circulation
Pump #2
VAC Access
Cover
Circulation
Pump #3
Hour Meter
Engine Preheat
Circulation
Pump
Thermostat
Access Cover
Marking
Plates
Diesel-Burner
Head
Electric Heating
Element Access
Cover
Engine Coolant
Supply
Boiler Tank
Drain Valve
Diesel Fuel
Supply
Diesel-Burner
Controller
Diesel Fuel
Return
Hot Water
Outlet
(Domestic Water)
Mixer
Valve
Cold Water
Inlet
(Domestic Water)
Engine
Coolant
Return
Pressure-Relief
Valve
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Figure 1
Page 1
SECTION 1: GENERAL HEATER INFORMATION
Marking
Plate
1.2
Marking Plate
By Vehicle Systems, Inc. Ft. Lupton, CO 80621
Model Number
Box
AHE-100
04S
Model Number
Serial Number
Box
Diesel-Burner / DC Power
04-637
120 VAC, 60 Hz / 1.65 kW
Serial Number
Manufactured
Date Box
Electric Heating
Element / AC Power
06-04
DIESEL / 50,000 BTU
Fuel Type / Firing Rate
Manufactured Date
Testing
Engineers
International
R
Listing No. 02L01
12 VDC / 184 Watts
Complies with the requirements
of UL 307A
Made in U.S.A.
For Installation Only in Compartment Completely Closed Off from Living Quarters and Accessible
Only from the Outdoors.
Exhaust system MUST NOT terminate beneath the vehicle or under an openable window or vent.
Combustion Air MUST BE supplied from outside the vehicle.
�
CAUTION: This appliance operates on both AC and DC Electrical Power.
The AC Powered Electrical Heating Element can be wired using flexible nonmetallic cable (ROMEX).
USE COPPER CONDUCTORS ONLY
Use 25 Amp fuse for over current protection for DC Power Supply.
Use 20 Amp Circuit Breaker for over current protection for AC Power Supply.
Mount Heater near a Bay / Storage Door so Access Cover can be easily removed.
Minimum Heater clearances
Front (Decal Sides) - Open Access
Back - 0 inches
Top - 6 inches
Install in strict compliance with local codes, NFPA
501c and manufacturer’s instructions.
For additional product installation information visit www.aqua-hot.com or call 1-800-685-4298
Figure 2
Reference Figure 1
for Marking Plate
locations.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 2
SECTION 2: MODEL DIFFERENTIATION
Aqua-Hot
Models
2.1
Aqua-Hot Model Differentiation
Vehicle Systems, Inc. manufactures three individual models of the Aqua-Hot Hydronic
Heating System. The varying factor between these three models is the number of
Electric Heating Elements featured, as well as the voltage employed by each Electric
Heating Element. In order to determine which of the following Aqua-Hot models has
been employed, locate the Marking Plate on the Heating System (reference Figures 1
and 2 for Marking Plate information) and view the Model number.
AHE-100-04S:
This model features a single 120 VAC/1650 Watt Electric Heating Element.
NOTE: Reference “Appendix A” for Wiring Diagram.
AHE-120-04X:
This model features one 120 VAC/1650 Watt Electric Heating Element and one 240
VAC/4500 Watt Electric Heating Element.
NOTE: Reference “Appendix A” for Wiring Diagram.
AHE-130-04X:
This model features two 120 VAC/2000 Watt Electric Heating Elements.
NOTE: Reference “Appendix A” for Wiring Diagram.
������������������
Indicator
Light
Diesel
Electric
Engine
Preheat
Figure 4
AHE-100-04S Model
XE
EXTRA
ELEMENT
������������������
High
Indicator
Light
Diesel
Engine
Preheat
Electric
Low
AHE-120-04X and AHE-130-04X Models
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 3
SECTION 3: SWITCH PANEL
Switch Panel
3.1
Interior Switch Panel
The Interior Switch Panel serves as an interior means of controlling the separate heating
sources of the Aqua-Hot, as well as activating the “Engine Preheat” system, when
necessary. The AHE-120-04X and AHE-130-04X dual element Heating Systems feature
a “High/Low” switch, in addition to the “Diesel,” “Electric,” and “Engine Preheat” switches,
as utilized by all three Aqua-Hot models; reference Figure 4. Please reference sections
3.2, 3.3, and 3.4 for information regarding the functions of the Interior Switch Panel.
3.2
Diesel Switch
Function: The “Diesel” switch activates the Diesel-Burner, thereby illuminating the
indicator light on the switch; reference Figure 4. This procedure allows the DieselBurner to operate, which supplies heat to the Aqua-Hot’s Boiler Tank. The DieselBurner will heat the Aqua-Hot System to the maximum operating temperature (190°F
(+/- 5 degrees)) in approximately 10-20 minutes. Please note that the Diesel-Burner is
the Aqua-Hot’s primary heat source for heating both the interior and/or the domestic
hot water (such as when cool ambient temperatures exist and/or when there is a high
demand for domestic hot water). It should also be noted that the “Diesel” switch indicator light will turn off anytime the Diesel-Burner malfunctions.
Additionally, the “Diesel” switch serves as a method of resetting the “Low Battery
Voltage Fault.” This reset can be accomplished by turning OFF the “Diesel” switch for
approximately 30 seconds, then turning the switch back ON; reference Section 4.4 and
4.11.
3.3
Electric Switch
NOTE: The Electric Heating Element(s) is the Aqua-Hot’s secondary heat source for
heating both the interior and/or the domestic hot water during low heating
demand situations (such as when moderate ambient temperatures exist and/or
when there is a low demand for domestic hot water). This feature is only
operational whenever the Motorhome is connected to VAC power or when the
generator is operating.
AHE-100-04S Model
Function: The “Electric” switch activates the Aqua-Hot’s Electric Heating Element,
thereby illuminating the indicator light on the switch; reference Figure 4. This procedure
allows the 120 VAC Electric Heating Element to supply heat to the Aqua-Hot’s Boiler
Tank. The 120 VAC Electric Heating Element will heat the Aqua-Hot System to the
maximum operating temperature (190°F (+/- 5 degrees)) in approximately 1-2 hours.
AHE-120-04X Model
Function: The “Electric” switch, in conjunction with the “High/Low” switch, activates the
Aqua-Hot’s Electric Heating Element(s), thereby illuminating the indicator light on the
switch; reference Figure 4.
Low:
The process of moving the “High/Low” switch to the “Low” position, in conjunction with
the activation of the “Electric” switch, allows the 120 VAC/1650 Watt Electric Heating
Element to supply heat to the Aqua-Hot’s Boiler Tank. The 120 VAC/1650 Watt Electric
Heating Element will heat the Aqua-Hot System to the maximum operating temperature
(190°F (+/- degrees)) in approximately 1-2 hours.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 4
SECTION 3: SWITCH PANEL
Switch Panel,
continued
High:
The process of moving the “High/Low” switch to the “High” position, in conjunction with
the activation of the “Electric” switch, allows both the 120 VAC/1650 Watt and the 240
VAC/4500 Watt Electric Heating Elements to supply heat to the Aqua-Hot’s Boiler Tank.
The 120 VAC/1650 Watt and 240 VAC/4500 Watt Electric Heating Elements will heat the
Aqua-Hot System to the maximum operating temperature (190°F (+/- 5 degrees)) in
approximately 0.5-1 hour.
AHE-130-04X Model
Function: The “Electric” switch, in conjunction with the “High/Low” switch, activates the
Aqua-Hot’s Electric Heating Element(s), thereby illuminating the indicator light on the
switch; reference Figure 4.
Low:
The process of moving the “High/Low” switch to the “Low” position, in conjunction with
the activation of the “Electric” switch, allows one 120 VAC/2000 Watt Electric Heating
Element to supply heat to the Aqua-Hot’s Boiler Tank. The 120 VAC/2000 Watt Electric
Heating Element will heat the Aqua-Hot System to the maximum operating temperature
(190°F (+/- 5 degrees)) in approximately 1-2 hours.
High:
The process of moving the “High/Low” switch to the “High” position, in conjunction with
the activation of the “Electric” switch, allows both 120 VAC/2000 Watt Electric Heating
Elements to supply heat to the Aqua-Hot’s Boiler Tank. These 120 VAC/2000 Watt
Electric Heating Elements will heat the Aqua-Hot System to the maximum operating
temperature (190°F (+/- 5 degrees)) in approximately 0.5-1 hour.
3.4
Engine Preheat Switch
Function: The “Engine Preheat” switch activates the Aqua-Hot’s Engine Preheat
Circulation Pump, thereby illuminating the indicator light on the switch; reference Figure
4. This procedure allows the Engine Preheat Circulation Pump to circulate the engine’s
coolant through a separate double-wall copper coil in the Aqua-Hot’s Boiler Tank, resulting in a warm engine for easy start-ups in cool temperatures. Please note that this
feature will be effective only if the “Engine Preheat” switch is ON in conjunction with
either the “Diesel” and/or the “Electric” switch.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 5
SECTION 4: ELECTRONIC CONTROLLER
Electronic
Controller
4.1
Electronic Controller
ELECTRONIC CONTROLLER
Low Tank-Level
Cutoff
Electric Heating
Element Status
Low Voltage
Heating Status
Reset
Engine Preheat
Pump
#5
#4
Pump #1
Heating Zones
Status
#3
Pump #2
#2
#1
Pump #3
Low Battery
Voltage Fault
Diesel-Burner
Status
Low Temp
Cutoff Status
Overload Fault
Figure 5
4.2
Electric Heating Element Status Indicator Light
This indicator light will illuminate GREEN whenever the Aqua-Hot’s 120 VAC Electric
Heating Element is operating and providing the heat to the Aqua-Hot’s Boiler Tank;
reference Figure 5. Please note that this light will only be active if the “Electric” switch is
in the ON position; reference Figure 4. If this indicator light illuminates RED, it indicates
an electrical or overload condition (i.e., a short) has occurred in the Electric Heating
Element’s VDC powered circuitry.
4.3
Heating Zone Status Indicator Lights
These five indicator lights (separately) will illuminate GREEN whenever a Zone Thermostat for a particular zone is calling for heat; reference Figure 5. The GREEN indicator
lights also indicate that VDC power is being supplied to the particular interior heating
zone’s Heat Exchangers (i.e., fan motors). If any of the five indicator lights illuminate
RED, it indicates that an electrical overload condition (i.e., a short) has occurred in a
particular heating zone’s circuitry.
NOTE: A short, in either a heating zone’s Thermostat or a heating zone’s Heat
Exchanger circuit, will cause the indicator light to illuminate RED.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 6
SECTION 4: ELECTRONIC CONTROLLER
Electronic
Controller,
continued
4.4
Low Voltage Reset
The Aqua-Hot’s Electronic Controller must be manually reset whenever the Low Battery
Voltage fault indicator light has been activated; reference Figure 5. The Electronic
Controller can be manually reset either by depressing the “Low Voltage Reset” button
located on the Electronic Controller (use a thin, straight object to access the reset button
through the small hole in the faceplate) or by turning OFF the “Diesel” switch on the
Heater’s Interior Switch Panel for approximately 30 seconds, then turning the switch back
ON.
4.5
Low Tank-Level Cutoff Indicator Light
This indicator light will illuminate RED when either the 120 VAC Electric Heating Element
and/or the Diesel-Burner have automatically shut down due to a low water and antifreeze
solution level inside the Aqua-Hot’s Boiler Tank; reference Figure 5. This fault will
automatically reset when the low-level condition is corrected.
4.6
Heating Status Indicator Light
This indicator light will illuminate GREEN whenever the Aqua-Hot’s VDC/VAC Control
Thermostat is calling for heat, allowing the water and antifreeze solution in the
Aqua-Hot’s Boiler Tank to be heated by either the Diesel-Burner and/or the 120 VAC
Electric Heating Element; reference Figure 5. When this indicator light is off, no heat is
being supplied to the Aqua-Hot’s Boiler Tank. Please note that this light will only be
active if either the “Diesel” and/or the “Electric” switch are turned ON; reference Figure 4.
NOTE: The Aqua-Hot’s VDC/VAC Control Thermostat will automatically activate the
Diesel-Burner and/or the 120 VAC Electric Heating Element only if the “Diesel” and/or
the “Electric” switch is in the ON position. In order to heat the motorhome/domestic hot
water, simply choose the desired heat source(s) and leave the switch(s) (i.e., “Diesel”
and/or “Electric”) ON.
4.7
Engine Preheat Pump Indicator Light
This indicator light will illuminate GREEN whenever the Engine Preheat Pump is operating; reference Figures 1 and 5. Please note that this light will only be active if the
“Engine Preheat” switch is ON in conjunction with either the “Diesel” and/or the “Electric”
switch; reference Figure 4. If this indicator light illuminates RED, it indicates an electrical
overload condition (i.e., a short) has occurred in this particular component’s circuitry.
4.8
Pump #1 Indicator Light
This indicator light will illuminate GREEN whenever Circulation Pump #1 is operating;
reference Figures 1 and 5. Please note that this light will only be active if the Aqua-Hot is
at normal operating temperature (i.e., between 160°F and 190°F) and Heating Zone #5 is
calling for heat; reference Appendix A. If this light illuminates RED, it indicates an
electrical overload condition (i.e., a short) has occurred in this particular component’s
circuitry.
4.9
Pump #2 Indicator Light
This indicator light will illuminate GREEN whenever Circulation Pump #2 is operating;
reference Figures 1 and 5. Please note that this light will only be active if the Aqua-Hot is
at normal operating temperature (i.e., between 160°F and 190°F) and if either Heating
Zones #2, #3, or #4 are calling for heat; reference Appendix A. If this light illuminates
RED, it indicates an electrical overload condition (i.e., a short) has occurred in this
particular component’s circuitry.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 7
SECTION 4: ELECTRONIC CONTROLLER
Electronic
Controller,
continued
4.10
Pump #3 Indicator Light
This indicator light will illuminate GREEN whenever Circulation Pump #3 is operating;
reference Figures 1 and 5. Please note that this light will only be active if the Aqua-Hot is
at normal operating temperature (i.e., between 160°F and 190°F) and Heating Zone #1 is
calling for heat; reference Appendix A. If this light illuminates RED, it indicates an
electrical overload condition (i.e., a short) has occurred in this particular component's
circuitry.
4.11
Low Battery Voltage Fault Indicator Light
This indicator light will illuminate RED whenever the VDC voltage level is too low for the
Aqua-Hot to operate properly; reference Figure 5. This fault must be manually reset after
the voltage level has been restored to the VDC battery system; reference Section 4.4 for
reset instructions.
4.12
Low Temp Cutoff Status Indicator Light
NOTE: This indicator light circuitry is not utilized on these Aqua-Hot models.
4.13
Diesel-Burner Status Indicator Light
This indicator light will illuminate GREEN whenever the Aqua-Hot’s Diesel-Burner is
operating and supplying heat to the Aqua-Hot’s Boiler Tank; reference Figures 1 and 5.
Please note that this light will only be active if the “Diesel” switch is turned ON; reference
Figure 4.
4.14
Overload Fault Indicator Light
This indicator light will illuminate RED (reference Figure 5) whenever one of the following
conditions have occurred:
1. The Aqua-Hot is off due to an electrical overload (i.e., a short) in the main
VDC power supply circuitry.
2. The Aqua-Hot is off due to a combination of high electrical VDC power loads
and a high surface temperature of the Electronic Controller.
The Electronic Controller will automatically reset once the electrical overload (i.e., a
short) and/or the high heat condition is corrected.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 8
SECTION 5: DIESEL-BURNER
Component
Overview
1.
2.
3.
4.
5.
6.
7.
8.
9.
5.1
Component Overview
Diesel-Burner Controller
Motor
Ignition Coil
Clutch
Combustion Air Blower
Fuel Solenoid Valve
Electrode Boots
Ignition Electrodes
Fuel Nozzle
10.
11.
12.
13.
14.
15.
16.
Heat Exchanger
Combustion Chamber
Exhaust Port
Flame Sensor
Fuel Pump
Fuel Tubes (Supply / Return)
Combustion Air Intake Port,
with Adjustable Shutter
Figure 6
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 9
SECTION 5: DIESEL-BURNER
Operational
Flow-Chart
5.2
Operational Flow-Chart
Operation sequence once the
Aqua-Hot’s Diesel switch is
turned ON.
NOTE:
The Diesel switch’s Indicator
Light will illuminate (reference
Figure 4), while the Aqua-Hot
Heating Status and DieselBurner Status lights illuminate
on the Electronic Controller;
reference Figure 5.
The Motor (#2), which turns
the Combustion Air Blower
(#5) and drives the Fuel Pump
(#14), will begin to operate.
NOTE:
If the Aqua-Hot’s coolant
temperature is approximately
190 (+/- 5) degrees Fahrenheit
or higher, the Motor (#2) will not
operate. Only when the
coolant temperature has
dropped below 160 (+/- 5)
degrees Fahrenheit, and the
VDC / VAC Control Thermostat
(reference Figure 3) is calling
for heat, will the Motor (#2)
begin to operate.
Simultaneously, the Ignition
Coil (#3) produces a high
voltage spark across the
Ignition Electrodes (#8),
which ignites the incoming
air-fuel mixture.
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).
Once the ignited air-fuel
mixture (FLAME) is observed
by the Flame Sensor (#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
process is refered to as the
purge-cycle, which cools
the heater’s internal
components and purges the
Combustion Chamber (#11)
of any residual exhaust
gases.
The combustion process will
continue to operate in this
manner until one of the following
occurs:
When the Aqua-Hot’s DieselBurner is switched OFF by the
VDC / VAC Control Thermostat
(see Figure 3), the following
process will take place:
A.) The VDC / VAC Control
Thermostat (reference
Figure 3), which senses
coolant temperature,
reaches the preset
temperature of
approximately 190 (+/- 5)
degrees Fahrenheit.
NOTE:
If process "A" occurs, the Low
Temp Cutoff Status, Aqua-Hot
Heating Status, and DieselBurner Status lights on the
Electronic Controller will go
OFF; reference Figure 5.
B.) The Aqua-Hot’s Diesel
switch is turned OFF.
NOTE:
After approximately 10 - 25
seconds, the Fuel Solenoid
Valve (#6) opens and fuel is
sprayed into the Combustion
Chamber (#11) through the
Fuel Nozzle (#9).
If process "B" occurs, the Diesel
switch’s Indicator Light, on the
Switch Panel (reference Figure
4), will go OFF along with the
Heating Status and DieselBurner Status lights on the
Electronic Controller; reference
Figure 5.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
NOTE:
1.) The Motor (#2) will shut off
once the three (3) minute purgecycle has expired.
-THEN2.) The Aqua-Hot’s DieselBurner will automatically turn
back ON once the coolant
reaches the preset
temperature of approximately
160 (+/- 5) degrees
Fahrenheit.
SUMMARY:
The Aqua-Hot’s Diesel-Burner
is operational anytime the
operator moves the Diesel
switch (reference Figure 4) to
the ON position. The DieselBurner will then automatically
maintain the coolant
temperature in the Aqua-Hot’s
Boiler Tank without additional
involvement from the operator.
Page 10
SECTION 5: DIESEL-BURNER
Operational
Sequence
5.3
Operational Sequence
The following sequence illustrates how the Aqua-Hot’s Diesel-Burner operates once it is
activated. Also, if Diesel-Burner malfunctions are experienced, use the following
sequence of operating events as a diagnostic tool to determine the point in the
Diesel-Burner’s operation that the malfunction occurs. Use the “KEY” provided to
understand each symbol shown.
KEY
Diesel Fuel Spray
Exhaust Gases
Combustion Air
The particular component begins to operate.
The component is currently operating.
Diesel-Burner Operation
1
When the Diesel switch is turned ON, the Motor
and Combustion Air Blower begin to operate. This
process is referred to as the prime-cycle.
Motor
NOTE: The Motor and Combustion
Air Blower will begin to operate
only if the VDC / VAC Control
Thermostat is closed and calling
for heat; reference Figure 3.
2
Combustion
Air Blower
Combustion
Air
The Fuel Pump builds up pressure
against the Fuel Solenoid Valve. After
approximately 10-25 seconds, the Fuel
Solenoid Valve opens, and fuel is released into the
Fuel Nozzle, then sprayed into the Combustion Chamber.
Fuel Solenoid Valve
Fuel Nozzle
Combustion
Chamber
Fuel Pump
Diesel Fuel
(Supply and Return)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 11
SECTION 5: DIESEL-BURNER
Operational
Sequence,
continued
5.3
Operational Sequence
KEY
Diesel Fuel Spray
Combustion Air
Exhaust Gases
The particular component begins to operate.
The component is currently operating.
Diesel-Burner Operation, continued
3
The Ignition Coil produces a high voltage spark, which is transferred
across the Ignition Electrodes. The incoming air-fuel mixture is then
ignited, creating combustion.
Ignition Coil
Ignition
Electrodes
Combustion
4
The combustion’s flame is detected by the
Flame Sensor and the Ignition Coil is then
automatically switched off (no more spark
across the Ignition Electrodes).
Hot Exhaust
Gases
Flame
Sensor
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 12
SECTION 5: DIESEL-BURNER
Operational
Sequence,
continued
5.3
Operational Sequence
KEY
Diesel Fuel Spray
Combustion Air
The particular component begins to operate.
The component is currently operating.
Diesel-Burner Operation, continued
5
6
The Diesel-Burner will continue to produce heat in this manner until
it is switched off either manually or by the VDC / VAC Control
Thermostat, which occurs when the coolant temperature in the AquaHot’s Boiler Tank reaches 190 (+/- 5) degrees Fahrenheit.
Once the Diesel-Burner has switched
OFF, the Motor and Combustion Air
Blower will continue to operate for approximately
2-3 minutes. This process is referred to
as the purge-cycle.
Cool Exhaust
Gases
NOTE: Whenever the Diesel-Burner is switched off by the VDC/VAC
Control Thermostat, it will automatically be reactivated once the
Aqua-Hot Boiler Tank’s coolant reaches the preset temperature of
approximately 160 (+/-) 5 degrees Fahrenheit.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 13
SECTION 5: DIESEL-BURNER
I.D. Plate
5.4
Identification Plate
Fabrikschild-Duplikat
gultig nur zusammen mit Original
Thermosysteme GmbH
To be shipped with
Original Heater
MADE IN GERMANY
DBW 2010.75
HEIZGERAT Typ
Spannung / El. Leistung
12 V / 60W
13,2 kW
Warmestrom
Brennstoff
Diesel
zul. Betriebsuberdruck
2 bar
Prufzeichen
Fabriknummer
1B230410
Inbetriebnahmejahr
2001 2002 2003
Model Type
Voltage / Wattage
Fuel Type
Serial Number (1B230410)
Year Manufactured
Diesel-Burner
I.D. Plate
Diesel-Burner
Head
Figure 7
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 14
SECTION 6: DIESEL-BURNER WIRING
Controller
Wiring
6.1
Diesel-Burner Controller
NOTE: Reference Figure 3 for all "JP" Plug
and Pin locations on the Electronic Controller
C-1 ( + ) VDC / VAC Control Thermostat
Circuit (Orange Wire) to JP-4 (Pin 5).
C-2 ( + ) Motor Circuit (Black Wire)
to Diesel-Burner.
B-3 (+) Indicator Light Circuit (Blue
Wire) to JP-4, (Pin 2).
C-4 ( - ) VDC High-Limit Thermostat
Circuit (Blue Wire) to Hydro-Hot’s
Boiler Tank.
B-2 ( - ) Battery Circuit (Brown Wire)
to JP-4 (Pin 4)
B-1 ( + ) On / Off Switch
Circuit, with Low Voltage
Protection (Yellow Wire) to
JP-4 (Pin 7).
B-1 B-2 B-3
B-6
B-4
B-Plug
B-4 ( + ) Battery Circuit (Red Wire)
to JP-4 (Pin 3)
B-6 ( - ) Indicator Light Circuit
(Green Wire) to JP-4 (Pin 1).
C-4
C-1 C-2
C-5 C-6 C-7 C-8
C-Plug
C-8 ( + ) Ignition Coil Circuit (Yellow Wire)
to Diesel-Burner.
C-7 ( + ) VDC / VAC Control Thermostat Circuit
(White Wire) to JP-4 (Pin 6).
C-6 ( + ) Flame Sensor Circuit (Green Wire)
to Diesel-Burner.
C-5 ( - ) Ground Circuit (Brown Wire), for
Diesel-Burner components, to Diesel-Burner.
Figure 8
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 15
SECTION 7: TROUBLESHOOTING
Troubleshooting
This Troubleshooting Section has been separated into various Aqua-Hot Troubleshooting Scenarios,
which may be experienced by the heater. Each section listed below begins with the most probable cause
and remedy and proceeds to the least probable cause and remedy. This concept has been put in place to
expedite the troubleshooting process and pinpoint the problem quicker. However, if additional assistance
is needed, please feel free to contact Vehicle Systems’ Technical Support Department at 1-800-685-4298
or E-mail the issue to Vehicle Systems’ Technical Support Department by going to www.vehiclesys.com
and clicking on “Technical Support.” Also, please review the following “KEY” prior to troubleshooting, as it
may be helpful in understanding the abbreviations used.
KEY:
TS#: (i.e., TS1, TS2, ....) = Troubleshooting Scenario 1, Troubleshooting Scenario 2, ....
Q#: (i.e., Q1, Q2,....) = Question 1, Question 2, ....
A: = Answer
After turning the “Diesel” switch ON:
Section
TS1 - The Aqua-Hot’s Diesel-Burner fails to operate
7.1
TS2 - The Aqua-Hot’s Diesel-Burner operates (3-minute prime cycle only),
but does not ignite
7.2
TS3 - The Aqua-Hot’s Diesel-Burner ignites after several starting attempts
7.3
TS4 - The Aqua-Hot’s Exhaust System sputters
7.4
TS5 - The Aqua-Hot’s Exhaust System produces white smoke after ignition
7.5
TS6 - The Aqua-Hot’s Exhaust System produces black smoke after ignition
7.6
Other troubleshooting issues:
TS7 - The Aqua-Hot is at operating temperature, but an Interior and/or Fresh
Water Tank Heating Zone is not producing heat
7.7
TS8 - The Aqua-Hot is at operating temperature, however the fans of an Interior
and/or Fresh Water Heat Exchanger fans are not operating
7.8
TS9 - The Aqua-Hot is at operating temperature, but the Domestic Hot Water
System is not producing hot water
7.9
After turning the Electric switch ON:
TS10 - The Aqua-Hot’s 120 VAC Electric Heating Element does not operate
(i.e., lack of hot water and/or interior heat)
7.10
After turning the Engine Preheat switch ON:
TS11 - The Aqua-Hot’s Engine Preheat System does not preheat the engine
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
7.11
Page 16
SECTION 7: TROUBLESHOOTING
Section 7.1
After turning the “Diesel” switch ON:
Section 7.1,
continued
Illustration 7.1-1
TS1 : The Aqua-Hot’s Diesel-Burner fails to
operate.
NOTE (7.1-A): In order to perform the following
checks, it is necessary to locate the Aqua-Hot’s
Electronic Controller and Switch Panel; reference
“Illustration 7.1-1.”
Q1 : Is the Electronic Controller’s Low TankLevel Cutoff light illuminated?
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A: If YES:
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procedures, as necessary, until
the problem is resolved.
If NO:
Proceed to Q2.
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heater is at maximum operating
temperature; reference Figure 1.
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serious personal injury may result.
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VEHICLE
SYSTEMS
INC.
HYDRO-HOT
CONTROLLER
ELE-PC4-008
I.
Check the coolant level in the Aqua-Hot’s
Expansion Tank and the Boiler Tank, if
necessary.
Electronic Controller
Faceplate
A: If coolant level is satisfactory:
Continue troubleshooting.
If coolant level is low:
Add coolant and attempt heater
restart.
II.
Check for continuity at the Float Switch;
reference Figure 1 and Appendix A.
A: If continuity exists:
Continue troubleshooting.
If continuity does not exist:
The Float Switch must be
replaced. Please contact the
Technical Support Department
at 1-800-685-4298 for assistance.
III.
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Aqua-Hot
Diesel
Electric
������������������
Engine
Preheat
Switch Panel
Remove the Electronic Controller’s
Faceplate and use a jumper wire to make a
connection from Pin 15 to Pin 16 on the
JP-3 Plug; reference Appendix A.
Does the Emergency Cutoff light go off?
(continued on next page)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 17
SECTION 7: TROUBLESHOOTING
Section 7.1,
continued
Section 7.1,
continued
A: If YES:
Check the JP-3 Plug for loose
wire connections and/or harness
damage
If NO:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
Q2 : Is the Electronic Controller’s Low Battery
Voltage Fault light illuminated?
A: If YES:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
If NO:
Proceed to Q3.
I.
Remove the Electronic Controller’s Face plate. Check the DC battery voltage at the
supply batteries and at the Electronic
Controller’s Battery Connections; reference
Appendix A. Both voltage readings should
be between 11.5 and 14.0 volts.
inspect battery wiring for damage
and/or loose connections, and
ensure that all of the Aqua-Hot’s
electrical motors are operating
normally when under load.
NOTE (7.1-B): If, after testing and correcting the
battery system, the Low Battery Voltage Fault
indicator light continues to illuminate, and/or the Low
Voltage Reset (button) will not reset, the Electronic
Controller must be replaced. Please contact the
Technical Support Department at 1-800-685-4298 for
assistance.
Q3 : Is the Electronic Controller’s Diesel-Burner
Status light illuminated?
A: If NO:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
If YES:
Proceed to Q5.
I.
A: If the voltage level is within specs:
Continue Troubleshooting.
If the voltage level is out of specs:
Recharge and/or replace
batteries.
II.
Reset the Low Voltage Reset (button) on the
Electronic Controller (this can be accomplished either by using a thin, straight object
to access the reset button through the small
hole in the Faceplate or by turning OFF the
“Diesel” switch on the Heater’s Interior
Switch Panel for approximately 30 seconds,
then turning the switch back ON). Continue
to read the voltage level at the Electronic
Controller’s Battery Connections, then, turn
the “Diesel” switch ON.
Under load, is the voltage level within 0.5
volts of the supply battery’s voltage?
A: If YES:
Reference “NOTE (7.1-B).”
If NO:
Load-test the supply batteries,
(continued in the next column)
Remove the Electronic Controller’s Face plate. Use a jumper wire to make a
connection from the Diesel (O) to the Diesel
(I) on the JP-2 Plug; reference Appendix A.
Does the Diesel-Burner Status light
illuminate?
A: If YES:
The “Diesel” switch must be
replaced. Please contact the
Technical Support Department
at 1-800-685-4298 for assistance.
Attempt heater restart.
If NO:
Continue Troubleshooting.
II.
Turn the “Diesel” switch OFF (also, make
sure the “Electric” switch is OFF). Use a
jumper wire to make a connection from Pin
13 to Pin 14 on the JP-3 Plug; reference
Appendix A. With the jumper wire in place,
turn the “Diesel” switch ON.
Does the Diesel-Burner ignite and the
Diesel-Burner Status light illuminate?
A: If YES:
The VDC/VAC Control Thermostat
(continued on next page)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 18
SECTION 7: TROUBLESHOOTING
Section 7.1,
continued
Section 7.1,
continued
must be replaced; reference
Appendix A. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
If NO:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
NOTE (7.1-C): If no problems were discovered up to
this point, the problem most likely lies within the
Diesel-Burner Head. However, prior to troubleshooting the Diesel-Burner Head, please review the
“Operational Flow-Chart” in Section 5.2, the
“Operational Sequence” in Section 5.3, and the
“Function” section for each of the Diesel-Burner
Components; reference Sections 8.3 through 8.11.
This information may help determine at what point
the Diesel-Burner fails to operate.
Q4 : Is the Diesel-Burner’s Motor operating?
Quick Check: Listen at the heater for the
Diesel-Burner’s Motor to operate or check
for output air at the heater’s exhaust pipe.
A: If the Motor does not seem to be
operating:
Reference Section 8.3 and
perform the Motor’s “Component
Test.”
If the Motor is operating:
Continue troubleshooting.
Ignition
Electrodes
Flame Sensor
Fuel Pump
Q5 : Is the Diesel-Burner Controller functioning
properly?
I.
In order to determine if the Diesel-Burner
Controller is functioning properly, reference
Section 8.11 and perform the Controller’s
“Component Test.”
A: If the Diesel-Burner Controller is not
functioning properly:
The Controller must be replaced;
reference Section 8.11 for
replacement instructions.
If the Controller is functioning properly:
Reference “NOTE (7.1-D).”
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Photo Disc
Fuel Solenoid
SECTION 7: TROUBLESHOOTING
Section 7.1,
continued
Section 7.2,
continued
NOTE (7.1-D): If the Aqua-Hot still does not
operate after performing all of the listed checks,
contact the Technical Support Department at
1-800-685-4298 for additional assistance.
II.
Section 7.2
A: If there is no continuity at the VDC
High-Limit Thermostat, but there is
continuity at the VAC/VDC Control
Thermostat:
The VAC/VDC Control Thermostat
must be replaced. Please contact
the Technical Support Department
at 1-800-685-4298 for assistance.
If there is continuity at the VDC HighLimit Thermostat, but none at the
VAC/VDC Control Thermostat:
The overheat condition may have
been caused by another faulty
component, and no further
troubleshooting is necessary;
reference “NOTE (7.2-C)” and
please contact the Technical
Support Department at
1-800-685-4298 for additional
assistance.
After turning the “Diesel” switch ON:
TS2: The Aqua-Hot’s Diesel-Burner operates
(3-minute prime cycle only) but does not
ignite.
NOTES (7.2-A):
A.
It is ideal to have the Aqua-Hot’s Fuel Filter
replaced yearly; reference Section 8.1. A
plugged Fuel Filter will not allow the DieselBurner to operate properly. Also, before
proceeding to the following procedures, be
sure to check that the vehicle’s fuel tank
has a sufficient level of fuel.
B.
In order to perform some of the following
procedures, it may be necessary to detach
the Diesel-Burner Head from the Aqua-Hot.
Therefore, be sure to reference Section 8.2
for detaching and reattaching instructions.
Q1 : Has the Aqua-Hot’s VDC High-Limit
Thermostat tripped?
I.
Locate the VDC High-Limit Thermostat and
check for continuity; reference Figure 1 and
Appendix B.
Is continuity present?
A: If YES:
Proceed to Q2.
If NO:
Press the red reset button located
on the VDC High-Limit Thermostat and attempt heater restart.
NOTE (7.2-B): Although the Diesel-Burner is now
functioning, be sure to perform the following steps
until the cause for overheating has been discovered
and corrected. Failure to do so could result in
additional overheating incidents.
Turn the “Diesel” switch ON and allow the
Aqua-Hot to reach operating temperature
(i.e., until the Diesel-Burner cycles OFF).
Locate both the VDC High-Limit Thermostat
and the VAC/VDC Control Thermostat and
check them for continuity; reference Figure
1 and Appendix B.
NOTE (7.2-C): If the VDC High-Limit Thermostat
continues to trip, and no overheating problems were
discovered (i.e., faulty VAC/VDC Control Thermostat
or Diesel-Burner Controller), it may be that the VDC
High-Limit Thermostat is not operating properly and
may need to be replaced.
Q2 : Is the Diesel-Burner’s Fuel Nozzle
functioning properly?
I.
In order to determine if the Fuel Nozzle is
functioning properly, reference Section 8.6
and perform the Fuel Nozzle’s “Component
Test.”
A: If the Fuel Nozzle is not functioning
properly:
The Fuel Nozzle must be
replaced; reference Section 8.6
for replacement instructions.
If the Fuel Nozzle is functioning properly:
Continue troubleshooting.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 20
SECTION 7: TROUBLESHOOTING
Section 7.2,
continued
Section 7.2,
continued
Illustration 7.2-1
Q3 : Is the Diesel-Burner’s Fuel Solenoid Valve
functioning properly?
I.
In order to determine if the Fuel Solenoid
Valve is functioning properly, reference
Section 8.7 and perform the Fuel Solenoid
Valve’s “Component Test.”
A: If the Fuel Solenoid Valve is not functioning properly:
The Fuel Solenoid Valve must be
replaced; reference Section 8.7
for replacement instructions.
If the Fuel Solenoid Valve is functioning
properly:
Continue troubleshooting.
Q4 : Is the Diesel-Burner Controller functioning properly?
I.
In order to determine if the Controller is
functioning properly, reference Section 8.11
and perform the Controller’s “Component
Test.”
A: If the Controller is not functioning
properly:
The Controller must be
replaced; reference Section 8.11
for replacement instructions.
If the Controller is functioning properly:
Continue troubleshooting.
Q5 : Is the Diesel-Burner’s Ignition Coil
functioning properly?
I.
Diesel-Burner
Controller
Diesel-Burner
Head
Ignition Coil
Ignition
Electrodes
Flame Sensor
Photo Disc
Fuel Solenoid
Fuel Pump
In order to determine if the Ignition Coil is
functioning properly, reference Section 8.10
and perform the Ignition Coil’s “Component
Test.”
A: If the Ignition Coil is not functioning
properly:
The Ignition Coil must be
replaced; reference Section 8.10
for replacement instructions.
If the Ignition Coil is functioning properly:
Continue troubleshooting.
Diesel-Burner
Controller
Fuel
Nozzle
Q6 : Are the Diesel-Burner’s Ignition Electrodes
in good condition and properly adjusted?
(continued on next page)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 21
SECTION 7: TROUBLESHOOTING
Section 7.2,
continued
I.
Section 7.2,
continued
In order to determine if the Ignition Electrodes are in good condition and properly
adjusted, reference Section 8.5.
A: If the Ignition Electrodes are in poor
condition:
The Ignition Electrodes must be
replaced; reference Section 8.5
for replacement instructions.
If the Ignition Electrodes are not properly
adjusted:
Adjust the Ignition Electrodes;
reference Section 8.5 for adjustment instructions.
If the Ignition Electrodes are both in good
condition and properly adjusted:
Continue troubleshooting.
Q7 : Is the Diesel-Burner’s Flame Sensor
functioning properly?
I.
Section 7.3
After turning the “Diesel” switch ON:
TS3: The Aqua-Hot’s Diesel-Burner ignites after
several starting attempts.
NOTES (7.3-A):
A.
It is ideal to have the Aqua-Hot’s Fuel Filter
replaced yearly; reference Section 8.1. A
plugged Fuel Filter will not allow the DieselBurner to operate properly. Also, before
proceeding to the following procedures, be
sure to check that the vehicle’ fuel tank has
a sufficient level of fuel
B.
In order to perform the following procedures,
it is necessary to detach the Diesel-Burner
Head from the Aqua-Hot. Be sure to reference Section 8.2 for detaching and reattaching instructions.
In order to determine if the Flame Sensor is
functioning properly, reference Section 8.4
and perform the Flame Sensor’s
“Component Test.”
A: If the Flame Sensor is not functioning
properly:
The Flame Sensor must be
replaced; reference Section 8.4
for replacement instructions.
If the Flame Sensor is functioning
properly:
Continue troubleshooting.
Q8 : Is the Diesel-Burner’s Fuel Pump
functioning properly?
I.
NOTE (7.2-D): If the Aqua-Hot still does not ignite
after performing all of the listed checks, contact
the Technical Support Department at 1-800-6854298 for additional assistance.
In order to determine if the Fuel Pump is
functioning properly, reference Section 8.8
and perform the Fuel Pump’s “Component
Test.”
A: If the Fuel Pump is not functioning
properly:
The Fuel Pump must be replaced;
reference Section 8.8 for replacement instructions.
If the Fuel Pump is functioning properly:
Reference “NOTE (7.2-D).”
Q1 : Is the Diesel-Burner’s Fuel Nozzle functioning properly?
I.
In order to determine if the Fuel Nozzle is
functioning properly, reference Section 8.6
and perform the Fuel Nozzle’s “Component
Test.”
A: If the Fuel Nozzle is not functioning
properly:
The Fuel Nozzle must be
replaced; reference Section 8.6
for replacement instructions.
If the Fuel Nozzle is functioning properly:
Continue troubleshooting.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 22
SECTION 7: TROUBLESHOOTING
Section 7.3,
continued
Section 7.3,
continued
Illustration 7.3-1
Q2 : Is the Diesel-Burner’s Flame Sensor
functioning properly?
I.
In order to determine if the Flame Sensor is
functioning properly, reference Section 8.4
and perform the Flame Sensor’s “Component Test.”
A: If the Flame Sensor is not functioning
properly:
The Flame Sensor must be
replaced; reference Section 8.4
for replacement instructions.
If the Flame Sensor is functioning
properly:
Continue troubleshooting.
Q3 : Are the Diesel-Burner’s Ignition Electrodes
in good condition and properly adjusted?
I.
In order to determine if the Ignition Electrodes are in good condition and properly
adjusted, reference Section 8.5.
A: If the Ignition Electrodes are in poor
condition:
The Ignition Electrodes must be
replaced; reference Section 8.5
for replacement instructions.
If the Ignition Electrodes are not properly
adjusted:
Adjust the Ignition Electrodes;
reference Section 8.5 for adjustment instructions.
If the Ignition Electrodes are both in good
condition and properly adjusted:
Continue troubleshooting.
Q4 : Is the Diesel-Burner’s Fuel Pump
functioning properly?
I.
Diesel-Burner
Head
Diesel-Burner
Controller
Ignition Coil
Ignition
Electrodes
Flame Sensor
Photo Disc
Fuel Solenoid
Fuel Pump
Diesel-Burner
Controller
Fuel
Nozzle
In order to determine if the Fuel Pump is
functioning properly, reference Section 8.8
and perform the Fuel Pump’s “Component
Test.”
A: If the Fuel Pump is not functioning
properly:
The Fuel Pump must be replaced;
reference Section 8.8 for replacement instructions.
If the Fuel Pump is functioning properly:
Continue troubleshooting.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 23
SECTION 7: TROUBLESHOOTING
Section 7.3,
continued
Section 7.3,
continued
Illustration 7.3-2
Q5 : Is the Diesel-Burner’s Fuel Supply System
functioning properly?
Fuel Filter
Quick Check: With the Diesel-Burner
ignited, listen for constant sputtering from
the Aqua-Hot’s exhaust system.
A: If constant sputtering exists:
Continue troubleshooting.
If constant sputtering does not exist:
Proceed to Q6.
NOTE (7.3-B): Inspect the clear bowl of the Fuel
Filter for water. If water exists, be sure to purge the
Aqua-Hot’s entire fuel system prior to replacing the
Fuel Filter. Attempt heater restart; reference
“Illustration 7.3-2.”
Clear Bowl
I.
TOP VIEW:
of Fuel Filter Head
Plug
input
from Fuel Tank /
fuel pick-up
2
4
1
3
output to
Aqua-Hot’s Fuel
"Supply" Port
Plug
Clamp off and remove the Aqua-Hot’s Fuel
Return Line; reference Figure 1. Now attach
a short piece of fuel line to the Aqua-Hot’s
Fuel Return Port and place the other end in
a container of diesel fuel. Remove the
clamp and ensure that the fuel line is completely submersed in the fuel, then, turn the
“Diesel” switch ON.
Are air bubbles visible in the container of
fuel when the Diesel-Burner is operating?
SUPPLY PORT:
to Aqua-Hot’s
Fuel Filter
RETURN PORT:
from Aqua-Hot’s
"Return" Port
dedicated
fuel pick-up
Fuel Pick-up Pipe Illustration
A: If air bubbles are not visible:
Proceed to Q6.
If air bubbles are visible:
You will need to inspect the fuel
system (supply side) for air leaks.
Therefore, be sure to perform the
inspections listed below until the
air leak has been detected:
1. Inspect the fuel system (supply
side) from the vehicle’s fuel
tank to the Diesel-Burner.
Inspect the fuel system for
loose fuel connections at the
Aqua-Hot and Diesel-Burner,
as well as the vehicle’s fuel
tank. Tighten, if necessary.
Also, check that all Fuel Filter
Head fittings are securely
tightened; reference “NOTE
(7.3-C).”
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 24
SECTION 7: TROUBLESHOOTING
Section 7.3,
continued
Section 7.3,
continued
NOTE (7.3-C): Be sure to check that each fitting at
the Fuel Filter Head contains thread sealant. A
fitting without thread sealant could result in an air
leak. Be sure to clamp off both fuel lines at the filter
head prior to any fitting removal. If fittings are
removed and reinstalled, be sure to remove the fuel
line clamps prior to attempting a heater restart.
Failure to do so could result in serious damage to
the Diesel-Burner’s Fuel Pump.
2. Once the potential air leak has
been discovered and
corrected, reattach the
Aqua-Hot’s Fuel Return Line
and attempt heater restart.
Does the Aqua-Hot’s exhaust
system still sputter?
If the exhaust system is still sputtering:
Continue performing air leak
inspections until all air leaks have
discovered and corrected.
Q6 : Is the Diesel-Burner’s Controller functioning properly?
I.
Illustration 7.3-3
If the Ignition Coil is functioning properly:
Reference “NOTE (7.3-D).”
NOTE (7.3-D): If the Aqua-Hot still does not ignite
after several starting attempts and all of the listed
checks were performed, contact the Technical
Support Department at 1-800-685-4298 for additional assistance.
Ignition Coil
Ignition
Electrodes
Flame Sensor
Photo Disc
Fuel Solenoid
Fuel Pump
In order to determine if the Controller is
functioning properly, reference Section 8.11
and perform the Controller’s “Component
Test.”
A: If the Controller is not functioning
properly:
The Controller must be replaced;
reference Section 8.11 for replacement instructions.
If the Controller is functioning properly:
Continue troubleshooting.
Diesel-Burner
Controller
Fuel
Nozzle
Q7 : Is the Diesel-Burner’s Ignition Coil
functioning properly?
I.
In order to determine if the Ignition Coil is
functioning properly, reference Section 8.10
and perform the Ignition Coil’s “Component
Test.”
A: If the Ignition Coil is not functioning
properly:
The Ignition Coil must be
replaced; reference Section 8.10
for replacement instructions.
(continued in the next column)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 25
SECTION 7: TROUBLESHOOTING
Section 7.4
Section 7.4,
continued
Illustration 7.4-1
After turning the “Diesel” switch ON:
TS4: The Aqua-Hot’s exhaust system sputters.
Fuel Filter
NOTE (7.4-A): Before advancing to the following
procedures, be sure to check that the vehicle’s fuel
tank has a sufficient level of fuel.
Q1 : Is the Diesel-Burner’s Fuel Nozzle
functioning properly?
I.
In order to determine if the Fuel Nozzle is
functioning properly, reference Section 8.6
and perform the Fuel Nozzle’s “Component
Test.”
A: If the Fuel Nozzle is not functioning
properly:
The Fuel Nozzle must be
replaced; reference Section 8.6
for replacement instructions.
If the Fuel Nozzle is functioning
properly:
Continue troubleshooting.
Q2 : Is the Diesel-Burner’s Fuel Supply System
functioning properly?
Clear Bowl
TOP VIEW:
of Fuel Filter Head
Plug
input
from Fuel Tank /
fuel pick-up
2
4
1
3
output to
Aqua-Hot’s Fuel
"Supply" Port
Plug
Quick Check: With the Diesel-Burner
ignited, listen for constant sputtering from
the Aqua-Hot’s exhaust system.
A: If constant sputtering exists:
Continue troubleshooting.
NOTE (7.4-B): Inspect the clear bowl of the Fuel
Filter for water. If water exists, be sure to purge
the Aqua-Hot’s entire fuel system prior to replacing
the Fuel Filter. Attempt heater restart; reference
“Illustration 7.4-1.”
I.
Clamp off and remove the Aqua-Hot’s Fuel
Return Line; reference Figure 1. Now attach
a short piece of fuel line to the Aqua-Hot’s
Fuel Return Port and place the other end in
a container of diesel fuel. Remove the
clamp and ensure that the fuel line is completely submersed in the fuel, then, turn the
“Diesel” switch ON.
SUPPLY PORT:
to Aqua-Hot’s
Fuel Filter
RETURN PORT:
from Aqua-Hot’
"Return" Port
dedicated
fuel pick-up
Fuel Pick-up Pipe Illustration
Are air bubbles visible in the container of
fuel when the Diesel-Burner is operating?
(continued on next page)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 26
SECTION 7: TROUBLESHOOTING
Section 7.4,
continued
Section 7.4,
continued
A: If air bubbles are not visible:
Reference “NOTE (7.4-D).”
If air bubbles are visible:
You will need to inspect the fuel
system (supply side) for air leaks.
Therefore, be sure to perform the
inspections listed below until the
air leak has been detected:
1. Inspect the fuel system (supply
side) from the vehicle’s fuel
tank to the Diesel-Burner.
Inspect the fuel system for
loose fuel connections at the
Aqua-Hot and Diesel-Burner,
as well as the vehicle’s fuel
tank. Tighten, if necessary.
Also, check that all Fuel Filter
Head fittings are securely
tightened; reference “NOTE
(7.4-C).”
NOTE (7.4-C): Be sure to check that each fitting at
the Fuel Filter Head contains thread sealant. A
fitting without thread sealant could result in an air
leak. Be sure to clamp off both fuel lines at the filter
head prior to any fitting removal. If fittings are
removed and reinstalled, be sure to remove both
clamps prior to attempting a heater restart. Failure
to do so could result in serious damage to the
Diesel-Burner’s Fuel Pump.
2. Once the potential air leak has
been discovered and
corrected, reattach the
Aqua-Hot’s Fuel Return Line
and attempt heater restart.
Does the Aqua-Hot’s exhaust
system still sputter?
If the exhaust system is still sputtering:
Continue performing air leak
inspections until all air leaks have
been discovered and corrected.
NOTE (7.4-D): If the Aqua-Hot’s exhaust system
still sputters after performing all of the listed checks,
contact the Technical Support Department at 1-800685-4298 for additional assistance.
Illustration 7.4-2
Fuel Filter
Clear Bowl
TOP VIEW:
of Fuel Filter Head
Plug
input
from Fuel Tank /
fuel pick-up
2
4
1
3
SUPPLY PORT:
to Aqua-Hot’s
Fuel Filter
output to
Aqua-Hot’s Fuel
"Supply" Port
Plug
RETURN PORT:
from Aqua-Hot’s
"Return" Port
dedicated
fuel pick-up
Fuel Pick-up Pipe Illustration
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 27
SECTION 7: TROUBLESHOOTING
Section 7.5
After turning the “Diesel” switch ON:
Section 7.5,
continued
Illustration 7.5-1
TS5: The Aqua-Hot’s exhaust system produces
white smoke after ignition.
Q1 : Is the Diesel-Burner’s Fuel Nozzle functioning properly?
I.
In order to determine if the Fuel Nozzle is
functioning properly, reference Section 8.6
and perform the Fuel Nozzle’s “Component
Test.”
A: If the Fuel Nozzle is not functioning
properly:
The Fuel Nozzle must be
replaced; reference Section 8.6
for replacement instructions.
If the Fuel Nozzle is functioning properly:
Continue troubleshooting.
Diesel-Burner
Controller
Diesel-Burner
Head
Q2 : Is the Diesel-Burner’s Fuel Pump producing
the proper pressure?
I.
In order to determine if the Fuel Pump is
producing the proper pressure, reference
Section 8.8 and perform the Fuel Pump’s
“Fuel Pressure Adjustment Check.”
A: If the Fuel Pump is not producing the
correct pressure:
Adjust the fuel pressure to 145
psi.
If the Fuel Pump is producing the correct
pressure:
Continue troubleshooting.
NOTE (7.5-A): Be sure to check that the Ignition
Electrode’s Retaining Clamp Bolt has not been
overtightened; reference Figure 16. Overtightening
can result in a bound-up (i.e., rigid) Photo Disc.
Not allowing the Photo Disc to float freely (i.e., a
loose fit) will cause poor combustion and result in
smoky exhaust. If a tight Photo Disc exists, reference Section 8.5 and perform the “Ignition
Electrode Adjustment Procedure.”
Ignition Coil
Ignition
Electrodes
Flame Sensor
Photo Disc
Fuel Solenoid
Fuel Pump
Diesel-Burner
Controller
Fuel
Nozzle
Q3 : Is the Diesel-Burner’s Fuel Supply System
functioning properly?
Quick Check: With the Diesel-Burner
ignited, look for constant white smoke from
the Aqua-Hot’s exhaust system.
(continued on next page)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 28
SECTION 7: TROUBLESHOOTING
Section 7.5,
continued
Section 7.5,
continued
Illustration 7.5-2
A: If constant white smoke exists:
Continue troubleshooting.
Fuel Filter
NOTE (7.5-B): Inspect the clear bowl of the Fuel
Filter for water. If water exists, be sure to purge
the Aqua-Hot’s entire fuel system prior to replacing
the Fuel Filter. Attempt heater restart; reference
“Illustration 7.5-2.”
I.
Clamp off and remove the Aqua-Hot’s Fuel
Return Line; reference Figure 1. Now attach
a short piece of fuel line to the Aqua-Hot’s
Fuel Return Port and place the other end in
a container of diesel fuel. Remove the
clamp and ensure that the fuel line is completely submersed in the fuel, then, turn the
“Diesel” switch ON.
Are air bubbles visible in the container of
fuel when the Diesel-Burner is operating?
A: If air bubbles are not visible:
Proceed to Q6.
If air bubbles are visible:
You will need to inspect the fuel
system (supply side) for air leaks.
Therefore, be sure to perform the
inspections listed below until the
air leak has been detected:
1. Inspect the fuel system (supply
side) from the vehicle’s fuel
tank to the Diesel-Burner.
Inspect the fuel system for
loose fuel connections at the
Aqua-Hot and Diesel-Burner,
as well as the vehicle’s fuel
tank. Tighten, if necessary.
Also, check that all Fuel Filter
Head fittings are securely
tightened; reference “NOTE
(7.5-C).”
NOTE (7.5-C): Be sure to check that each fitting at
the Fuel Filter Head contains thread sealant. A
fitting without thread sealant could result in an air
leak. Be sure to clamp off both fuel lines at the filter
head prior to any fitting removal. If fittings are
removed and reinstalled, be sure to remove both
clamps prior to attempting a heater restart. Failure
to do so could result in serious damage to the
Diesel-Burner's Fuel Pump.
Clear Bowl
TOP VIEW:
of Fuel Filter Head
Plug
input
from Fuel Tank /
fuel pick-up
2
4
1
3
SUPPLY PORT:
to Aqua-Hot’s
Fuel Filter
output to
Aqua-Hot’s Fuel
"Supply" Port
Plug
RETURN PORT:
from Aqua-Hot’s
"Return" Port
dedicated
fuel pick-up
Fuel Pick-up Pipe Illustration
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 29
SECTION 7: TROUBLESHOOTING
Section 7.5,
continued
Section 7.6,
continued
2. Once the potential air leak has
been discovered and
corrected, reattach the
Aqua-Hot’s Fuel Return Line
and attempt heater restart.
Does the Aqua-Hot’s exhaust
system still sputter?
If the exhaust system is still sputtering:
Continue performing the air leak
inspection until all air leaks have
been discovered and corrected.
Illustration 7.6-1
ELECTRONIC CONTROLLER
Hydro-Hot
Aqua-Hot
TM
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NOTE (7.5-D): If the Aqua-Hot’s exhaust system
still produces white smoke after performing all of the
listed checks, contact the Technical Support Department at 1-800-685-4298 for additional assistance.
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Section 7.6
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After turning the “Diesel” switch ON:
TS6: The Aqua-Hot’s exhaust system produces
black smoke after ignition.
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VEHICLE
SYSTEMS
INC.
HYDRO-HOT
CONTROLLER
ELE-PC4-008
Electronic Controller
Faceplate
NOTE (7.6-A): In order to perform the following
checks, it is necessary to locate the Aqua-Hot’s
Electronic Controller and Switch Panel; reference
“Illustration 7.6-1.”
Q1 : Is the Electronic Controller’s Low Battery
Voltage Fault light illuminated?
A: If YES:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
If NO:
Proceed to Q2.
I.
Diesel-Burner’s
Indicator
Light
Remove the Electronic Controller’s Face plate. Check the DC battery voltage level at
the supply batteries and at the Electronic
Controller’s Battery Connections; reference
Appendix A. Both voltage readings should
be between 11.5 and 14.0 volts.
Aqua-Hot
Diesel
Electric
������������������
Engine
Preheat
A: If the voltage level is within specs:
Continue troubleshooting.
If the voltage level is out of specs:
Recharge and/or replace batteries, if necessary.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 30
SECTION 7: TROUBLESHOOTING
Section 7.6,
continued
II.
Section 7.6,
continued
Illustration 7.6-1
Reset the Low Voltage Reset (button) on the
Electronic Controller (this can be accomplished either by using a thin, straight object
to access the reset button through the small
hole in the Faceplate or by turning OFF the
“Diesel” switch on the Heater’s Interior
Switch Panel for approximately 30 seconds,
then turning the switch back ON). Continue
to read the voltage level at the Electronic
Controller’s Battery Connections and then
turn the “Diesel” switch ON.
Under load, is the voltage level within 0.5
volts of the supply batteries’ voltage.
A: If YES:
Reference “NOTE (7.6-A).”
If NO:
Load-test the supply batteries,
inspect battery wiring for damage
and/or loose connections, and
ensure that all of the Aqua-Hot's
electrical motors are operating
normally when under load.
NOTE (7.6-B): If, after testing and correcting the
battery system, the Low Battery Voltage Fault
indicator light continues to illuminate, and/or if the
Low Voltage Reset (button) will not reset, the Electronic Controller must be replaced. Please contact
the Technical Support Department at 1-800-6854298 for assistance.
Diesel-Burner
Head
Diesel-Burner
Controller
Ignition Coil
Ignition
Electrodes
Flame Sensor
Photo Disc
Fuel Solenoid
Fuel Pump
NOTE (7.6-C): In order to perform some of the
following procedures, it may be necessary to detach
the Diesel-Burner Head from the Aqua-Hot. Therefore, be sure to reference Section 8.2 for detaching
and reattaching instructions.
Q2 : Is the Diesel-Burner’s Fuel Nozzle functioning properly?
I.
Diesel-Burner
Controller
Fuel
Nozzle
In order to determine if the Fuel Nozzle is
functioning properly, reference Section 8.6
and perform the Fuel Nozzle’s “Component
Test.”
A: If the Fuel Nozzle is not functioning
properly:
The Fuel Nozzle must be
replaced; reference Section 8.6
for replacement instructions.
(continued on next page)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 31
SECTION 7: TROUBLESHOOTING
Section 7.6,
continued
Section 7.6,
continued
Illustration 7.6-3
If the Fuel Nozzle is functioning properly:
Continue troubleshooting.
Q3 : Is the Diesel-Burner’s Motor operating at
the proper RPM speed?
I.
In order to determine if the Motor is operating properly, reference Section 8.3 and
perform the Motor’s “RPM Test.”
#3 - Plunger
#4 - Rubber Ball
CO2 Gas
Analyzer
A: If the Motor is not operating at the proper
RPM:
The Motor must be replaced;
reference Section 8.3 for replacement instructions.
If the Motor is operating at the proper
RPM:
Continue troubleshooting.
Q4 : Is the Diesel-Burner’s Combustion Air
Intake adjusted properly?
A: See the “NOTE” below.
NOTE (7.6-D): In order to determine if the
Diesel-Burner’s Combustion Air Intake is adjusted
properly, a CO2 Gas-Analyzer will be required;
reference “Illustration 7.6-3.” Also, reference
Section 11 for the Bacharach Fyrite CO2 Analyzer’s
part number information, if necessary.
I.
When using the Bacharach Fyrite CO2
Analyzer, turn the “Diesel” switch ON and
allow the Diesel-Burner to ignite and operate
for approximately 2 minutes. Then
perform the following procedures:
1. Place the small end of the CO 2
Analyzer’s suction hose into
the Aqua-Hot’s Exhaust Pipe.
2. Place the round plunger
connection of the suction hose
on the CO 2 Analyzer’s
“Plunger.” Press down on the
suction hose with the palm of
your hand until the CO 2
Analyzer’s “Plunger” is fully
compressed. This will allow a
sample of the Aqua-Hot’s
exhaust to enter the CO 2
Analyzer; reference
“Illustration 7.6-3.”
CO2 -
+ CO2
Combustion Air Intake
Adjustment
Vol %
13
12
11
CO2
Percentage
10
9
8
7
20
10
24 26 28
12
14
DC Voltage Level
22
V-
CO2 - Value Chart
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 32
SECTION 7: TROUBLESHOOTING
Section 7.6,
continued
Section 7.6,
continued
3. Pump the rubber ball 18 times.
4. Release the suction hose from
the CO2 Analyzer’s plunger.
5. Turn the CO2 Analyzer
upside down to allow the fluid
to advance to the top, then,
turn the Analyzer right side up
again. Perform this procedure
twice.
6. Place the CO 2 Analyzer on a
flat surface and read the CO 2
level.
7. The CO 2 level should be
between 10.5 and 11.5 percent
(at a nominal 12 volts-DC). If
the CO 2 level is not within the
specs, an adjustment of the
Diesel-Burner’s Combustion
Air Intake will be necessary;
reference “Illustration 7.6-3.”
Once the proper CO 2
adjustment has been made, be
sure to tighten the adjustment
screw.
NOTE (7.6-E): In temporary high altitude situations
(less available oxygen) the CO 2 will rise by 0.3%
CO 2 per 1,000 feet of elevation (e.g., a DieselBurner adjusted at sea level should register
approximately a 1.5% higher CO 2 reading when in
Denver, Colorado (5,000 above sea level)). If
permanently residing in a high altitude area, be
sure to properly adjust the Diesel-Burner so that it
operates within the 10.5% - 11.5% CO 2 range.
NOTES (7.6-F): If the proper CO 2 value cannot be
obtained, perform each of the following inspections,
as necessary, until the cause has been detected:
A. Check the rubber Grommets on the top
and bottom of the Diesel-Burner Head’s
cast-aluminum Blower Casing to ensure
they are securely in place.
B. Check the Diesel-Burner Head for proper
alignment (torque specification =
approximately 20-40 in.lbs.); reference
Section 8.2.
C. Check to ensure that the Diesel-Burner’s
Fuel Pump is producing the proper
pressure. In order to determine if the
Fuel Pump is producing the proper
pressure, reference Section 8.8 and
perform the Fuel Pump’s “Fuel Pressure
Adjustment Check.”
D. Check and reset the Combustion Air
Blower gap, if applicable. In order to
determine if the Combustion Air Blower’s
gap is set properly, reference Section 8.9
and perform Steps 1-6 and 11-17 of the
Bearings “Replacement Procedure.”
E. Reference “NOTE (7.6-F).”
NOTE (7.6-G): If the Aqua-Hot’s exhaust system
still produces black smoke after performing all of
the listed checks, contact the Technical Support
Department at 1-800-685-4298 for additional
assistance.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 33
SECTION 7: TROUBLESHOOTING
Section 7.7
Section 7.7,
continued
After turning the “Diesel” switch ON:
TS7: The Aqua-Hot is at operating temperature,
but an Interior and/or Fresh Water Tank Heating
Zone is not producing heat.
Q1 : Is the particular Heating Loop’s Circulation
Pump operating?
Quick Check - Remove the Aqua-Hot’s
Access Cover and determine if the problem
Heat Exchanger(s) is plumbed with Circulation Pump #1, Circulation Pump #2, or
Circulation Pump #3; reference Figure 1 and
“Appendix B.” Once the particular
Circulation Pump has been isolated, locate
and activate the Room Thermostat for that
particular heating zone. View the Circulation
Pump’s Motor through the clear, plastic
cover to check for operation.
Observe the DC voltage on the
voltmeter.
Does a nominal 12 Volt-DC
voltage reading register on the
voltmeter?
A: If YES:
The Circulation Pump must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
If NO:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
Is the Circulation Pump
operating/rotating?
A: If YES:
Check the particular Heating
Loop’s plumbing system for kinks
and/or any other types of flow
restrictions.
If NO:
Perform each of the following
procedures, as necessary, until
the problem is resolved:
1. Locate the Electronic Controller and remove the Faceplate.
2. Locate the Electronic
Controller’s JP-3 Plug and
insert the probes of a DC
voltmeter into the particular
Circulation Pump’s Pin locations; reference Appendix A:
Circulation Pump #1
Pins 6(-) and 5(+)
Circulation Pump #2
Pins 4(-) and 3(+)
Circulation Pump #3
Pins 2(-) and 1(+)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 34
SECTION 7: TROUBLESHOOTING
Section 7.8
Section 7.8,
continued
Illustration 7.8-1
After turning the “Diesel” switch ON:
TS8: The Aqua-Hot is at operating temperature;
however, the Interior and/or Fresh Water
Tank Heat Exchanger fans are not
operating.
ELECTRONIC CONTROLLER
���������
R
Low Tank-Level
Cutoff
Electric Heating
Element Status
Remove the Faceplate from the Electronic
Controller, allowing the Electronic
Controller’s Printed Circuit Board to be
exposed. Locate the “TANK SEN” Pins
located on the bottom right-side of the
Electronic Controller’s Printed Circuit Board;
reference “Illustration 7.8-1.”
Is the Pin Jumper properly installed with
the Pin Jumper covering both pins in
order to provide continuity?
Heating Status
Reset
Engine Preheat
Pump
#5
Q1 : Is the Tank Sensor Pin Jumper on the
Electronic Controller properly installed?
I.
Low Voltage
#4
Pump #1
#3
Heating Zones
Status
Pump #2
#2
#1
Pump #3
Low Battery
Voltage Fault
Diesel-Burner
Status
Low Temp
Cutoff Status
Overload Fault
Electronic Controller
Faceplate
A: If YES:
Continue troubleshooting.
If NO:
Reseat the Pin Jumper on both
pins.
Electronic Controller
Printed Circuit Board
NOTE: If reseating the Pin Jumper does
not correct the non-functioning
Heat Exchanger Fan failure, the
Electronic Controller may need to
be replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
“TANK SEN”
Pin Jumper
Properly
Installed
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
AH
J4
TANK SEN
“TANK SEN”
Pin Jumper
Location
Page 35
SECTION 7: TROUBLESHOOTING
Section 7.9
Section 7.9,
continued
After turning the “Diesel” switch ON:
TS9: The Aqua-Hot is at operating temperature,
but the domestic hot water system is not
producing hot water.
Q1 : Is the Aqua-Hot’s Tempering Valve properly
set?
Quick Check: The Tempering Valve should
be preset on the valve’s number “3” setting;
reference “Illustration 7.9-1.”
A: If YES:
Continue troubleshooting.
If NO:
Adjust the Tempering Valve to the
number “3” setting and retest the
domestic hot water system.
NOTE (7.9-B): Domestic hot water flow rates
exceeding 1.5 Gallons per Minute (GPM) can
contribute to poor domestic hot water performance.
However, this is directly dependent upon the
temperature of the incoming domestic cold water to
the Aqua-Hot’s domestic hot water system. Therefore, please be sure to reference the informational
graph, contained within Section 7.9, regarding the
theoretical performance of the Aqua-Hot’s domestic
hot water system.
Quick Check: Utilizing a one-gallon Graduated
Cylinder (or an equivalent one-gallon container),
measure the time it takes the shower to produce one
gallon of hot water, then utilize the chart below to
determine the shower’s GPM flow rate:
15 seconds = 4.0 GPM
20 seconds = 3.0 GPM
25 seconds = 2.4 GPM
30 seconds = 2.0 GPM
35 seconds = 1.7 GPM
40 seconds = 1.5 GPM
45 seconds = 1.3 GPM
50 seconds = 1.2 GPM
55 seconds = 1.1 GPM
60 seconds = 1.0 GPM
Q2 : Is the Aqua-Hot’s heating solution utilizing
the proper mixture of antifreeze and water?
Quick Check: Utilizing an antifreeze
refractometer (reference Section 11 for
special tools information), test the
concentration of the antifreeze and water
heating solution. An antifreeze concentration higher than 50% will cause poor
domestic hot water performance.
A: If YES:
Continue troubleshooting.
If NO:
Adjust the antifreeze and water
heating solution accordingly until
the proper concentration is
obtained.
Q3 : Is the shower’s flow rate (i.e., Gallons per
Minute), of domestic hot water, too high?
Reference “NOTE (7.9-B).”
A: If YES:
Please contact the Technical
Support Department at
1-800-685-4298 for additional
assistance.
If NO:
If the shower’s flow rate is less
than 1.5 GPM and the Aqua-Hot
still fails to produce hot water,
please contact the Technical
Support Department at
1-800-685-4298 for additional
assistance.
Illustration 7.9-1
3
NOTE (7.9-A): This Aqua-Hot product utilizes an
FDA approved GRAS Propylene Glycol (P.G.)
antifreeze and water heating solution. This P.G.
based heating solution utilizes a Boiler type
antifreeze, which is Generally Recognized as Safe
(”GRAS”) by the FDA. A 50/50 heating solution of
P.G. antifreeze and water is recommended to
provide the best overall domestic hot water and
interior heating performance (50% P.G. antifreeze
and 50% water).
C
H
H
Tempering Valve
correctly set to
“3.”
1/2
MIX
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 36
SECTION 7: TROUBLESHOOTING
Section 7.9,
continued
The chart below is a graphical representation of how the Aqua-Hot’s Domestic Hot Water System
theoretically performs under varying incoming domestic cold water temperatures. Because each AquaHot has a performance tolerance, this graphic should be used as a general guideline and not as actual
domestic hot water performance data.
F
hot
wa
ter
c
urv
e
70
dom
est
ic
60
50
115
F
Input (i.e., incoming) Temperature of Domestic
Cold Water to the Aqua-Hot.
80
40
0.5
1.0
1.5
2.0
2.5
3.0
GPM
(GPM - Gallons per Minute)
The estimated domestic cold water flow rate required to maintain an
approximate 115 °F domestic hot water output temperature.
Notes of Interest
When water is heated to...
156 degrees - Hot water causes a third-degree burn in one second
149 degrees - Hot water causes a third-degree burn in two seconds
133 degrees - Hot water causes a third-degree burn quickly
115-120 degrees - General purpose temperatures
107 - 109 degrees - Average “Hot-Tub” temperatures
105 degrees - Average “Shower” temperature
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 37
SECTION 7: TROUBLESHOOTING
Section 7.10
Section 7.10,
continued
After turning the “Electric” switch ON:
A: If YES:
Check for loose wire connections
at the “Electric” switch and at the
JP-2 Plug’s Electric (O) and
Electric (I) pins. If connections
are in good condition, replace the
“Electric” switch.
If NO:
Locate the Electronic Controller’s
JP-2 Plug and check for DC
voltage at the Electric (O) and
Electric (I) pins; reference
Appendix A and “NOTE (7.10-B).”
TS10: The Aqua-Hot’s 120 VAC Electric Heating
Element does not operate (i.e., lack of hot
water and/or interior heat).
Q1 : Is the Electronic Controller’s Electric
Heating Element Status light illuminated?
(Reference Figure 5.)
NOTE (7.10-A): The temperature of the Aqua-Hot’s
Boiler Tank must be below 160°F prior to performing
this test.
A: If YES:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
1. Locate the Electronic
Controller and remove the
Faceplate.
2. With the “Electric” switch ON,
locate the Electronic
Controller’s JP-3 Plug and
check for DC voltage at Pin 11
(+) and Pin 12 (-); reference
Appendix A.
If voltage is present:
Check for loose wire connections
at Pin 11 (+) and Pin 12 (-) of the
JP-3 Plug. If the wire connections
are in good condition, proceed to
Q2.
If no voltage is present:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
If NO:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
1. Locate the Electronic Controller and remove the Faceplate.
2. Locate the Electronic
Controller’s JP-2 Plug. Use a
jumper wire to make a connection from the Electric (O) pin to
the Electric (I) pin; reference
Appendix A.
Does the Electronic Controller’s
Electric Heating Element Status
light illuminate?
(continued in next column)
NOTE (7.10-B): Both “Electric” pins (i.e., (O) and (I))
should indicate a positive (+) DC voltage. Therefore,
be sure to utilize the “JP7 GND” stud as a ground (-)
source when performing this DC voltage check.
If no voltage is present:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
Q2 : Has the Aqua-Hot’s VAC High-Limit
Thermostat tripped?
!
I.
WARNING: Turn the VAC breaker
OFF prior to performing the following
checks. Failure to do so may result
in serious bodily injury
(i.e., electrical shock).
Remove the Aqua-Hot’s Thermostat Access
Cover and locate the VAC High-Limit
Thermostat; reference Figure 1. Check for
continuity at the VAC High-Limit Thermostat.
Is continuity present?
A: If YES:
Proceed to Q3.
If NO:
Press the red reset button located
on the VAC High-Limit Thermostat and retest for continuity.
NOTE (7.10-C): Although the 120 VAC Electric
Heating Element should now function properly, be
sure to perform the following steps until the cause for
overheating has been discovered and corrected.
Failure to do so could result in additional overheating
incidents.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 38
SECTION 7: TROUBLESHOOTING
Section 7.10,
continued
I.
Section 7.10,
continued
Turn the “Diesel” switch ON and allow the
Aqua-Hot to reach maximum operating
temperature (i.e., until the Diesel-Burner
cycles OFF). Locate both the VAC HighLimit Thermostat and the VAC/VDC Control
Thermostat and check for continuity;
reference Figure 1.
A: If there is no continuity at the VAC
High-Limit Thermostat, but there is
continuity at the VAC/VDC Control
Thermostat:
The VAC/VDC Control Thermostat
must be replaced. Please contact
the Technical Support Department
at 1-800-685-4298 for assistance.
If there is continuity at the VAC HighLimit Thermostat, but none at the
VAC/VDC Control Thermostat:
The overheat condition may have
been caused by another faulty
component, and no further
troubleshooting is necessary;
reference “NOTE (7.10-D).”
Please contact the Technical
Support Department at 1-800685-4298 for additional
assistance.
NOTE (7.10-D): If the VAC High-Limit Thermostat
continues to trip, and no overheating problems were
discovered (i.e., faulty VAC/VDC Control Thermostat), it may be that the VAC High-Limit Thermostat
is not operating properly and may need to be
replaced.
Q3 : Is VAC power being supplied to the VAC
Relay?
!
WARNING: The following checks
need to be performed with the
motorhome connected to VAC
power. Therefore, be sure to use
extreme caution when performing
each check, as 120 VAC power will
be present at each of the electrical
components. Failure to do so may
result in serious bodily injury (i.e.,
an electrical shock).
NOTE (7.10-E): The Temperature of the Aqua-Hot’s
Boiler Tank must be below 160°F prior to performing
this test.
I.
Turn the “Electric” switch ON and uncover
the VAC Relay located on the reverse side
of the Thermostat Access Cover; reference
Figure 1. Check for AC voltage at both
Black (+) wires (“120 VAC Power Supply”)
connections on the VAC Relay; reference
Appendix A. Be sure to utilize the “JP7
GND” stud as a ground source when
performing this AC voltage check.
Is voltage present?
A: If YES:
Proceed to Q4.
If NO:
1. Check for loose wire connections at the Motorhome’s VAC
junction box.
2. If the VAC wire connections
are in good condition, please
proceed to step 3.
3. Check the VAC Relay to ensure
that it is functioning properly.
NOTE (7.10-F): Inspect the VAC Relay for damage.
If visual signs of damage exist, the relay must be
replaced.
I.
Disconnect both Black VAC wires from the
VAC Relay terminals. Activate the “Electric”
switch ON and OFF, then check for continuity across the two open terminals. Please
note, with the “Electric” switch ON, continuity
should be present at the relay’s terminals.
With the “Electric” switch OFF, no continuity
should be present.
Is continuity present across the two
terminals of the VAC Relay?
A: If YES:
Proceed to Q4.
If NO:
The VAC Relay must be replaced.
Please contact the Technical
Support Department at 1-800685-4298 for assistance.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 39
SECTION 7: TROUBLESHOOTING
Section 7.10,
continued
Section 7.11
Q4 : Is the 120 VAC Electric Heating Element
functioning properly?
!
I.
WARNING: The following checks
need to be performed with the
Motorhome connected to VAC
power. Therefore, be sure to use
extreme caution when performing
each check, as 120 VAC power will
be present at each of the electrical
components. Also, be sure to
disconnect VAC power prior to
replacing any electrical
components. Failure to do so may
result in serious bodily injury (i.e.,
an electrical shock).
Disconnect the Motorhome from VAC shore
power and switch-off the Motorhome’s
Generator. Uncover the 120 VAC Electric
Heating Element located behind the Electric
Heating Element Access Cover; reference
Figure 1. Remove both the Black and White
wires from the 120 VAC Electric Heating
Element terminals. Check for continuity
across the two open terminals.
Is continuity present?
A: If YES:
Reference “NOTE (7.10-F).”
If NO:
The 120 VAC Electric Heating
Element must be replaced.
Please contact the Technical
Support Department at 1-800685-4298 for assistance.
NOTE (7.10-F): If the 120 VAC Electric Heating
Element still does not seem to operate after
performing all of the listed checks, contact the
Technical Support Department at 1-800-685-4298
for additional assistance.
After turning the “Engine Preheat” switch ON:
TS11: The Aqua-Hot’s Engine Preheat System
does not preheat the engine.
NOTE (7.11-A): The “Diesel” or “Electric” switch
must be activated, along with the “Engine Preheat”
switch, prior to performing the following checks.
Q1 : Is the Electronic Controller’s Engine
Preheat Pump light illuminated?
(Reference Figure 5.)
A: If YES:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
1. Locate the Electronic Controller and remove the Faceplate.
2. Locate the Electronic
Controller’s JP-3 Plug and
check for DC voltage at Pin 7
(+) and Pin 8 (-); reference
Appendix A.
If voltage is present:
Check for loose wire connections
at Pin 7 (+) and Pin 8 (-) of the
JP-3 Plug. Also, check the wire
connections at the Engine
Preheat Pump. If all connections
are in good condition, observe
the Engine Preheat Pump to
ensure that it is
operating/rotating; reference
Figure 1. If the Engine Preheat
Pump is not operating/rotating, it
must be replaced. Please contact
the Technical Support Department
at 1-800-685-4298 for assistance.
If no voltage is present:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
If NO:
Perform each of the following
procedures, as necessary, until
the problem is resolved.
1. Locate the Electronic Controller and remove the Faceplate.
2. Locate the Electronic
Controller’s JP-2 Plug. Use a
jumper wire to make a connection from the Preheat (O) pin to
the Preheat (I) pin; reference
Appendix A.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 40
SECTION 7: TROUBLESHOOTING
Section 7.11,
continued
Does the Electronic Controller’s Engine
Preheat Pump light now illuminate?
A: If YES:
Check for loose wire connections
at the “Engine Preheat” switch
and at the JP-2 Plug’s Preheat (O)
and Preheat (I) pins; reference
Appendix A. If connections are
in good condition, the “Engine
Preheat” switch must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
If NO:
Locate the Electronic Controller’s
JP-2 Plug and check for DC
voltage at the Preheat (O) pin;
reference Appendix A.
NOTE (7.11-B): Be sure to utilize the “JP7 GND”
stud as a ground (-) source when performing this
DC voltage check.
If no voltage is present:
The Electronic Controller must be
replaced. Please contact the
Technical Support Department at
1-800-685-4298 for assistance.
If voltage is present:
Reference “NOTE (7.11-C).”
NOTE (7.11-C): If the Engine Preheat Pump still
does not appear to operate after performing all of
the listed checks, contact the Technical Support
Department at 1-800-685-4298 for additional
assistance.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 41
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
General
Recommended
Maintenance
8.1
General Recommended Maintenance
Monthly
Check the Aqua-Hot’s water and antifreeze solution to ensure that it is at the proper level.
Do this by visually checking the coolant level in the Aqua-Hot’s Expansion Tank; reference Figure 1. This should be checked only when the Aqua-Hot is at maximum operating temperature (i.e., when the Diesel-Burner cycles OFF), “HOT.”
!
WARNING: When the Aqua-Hot is at maximum operating temperature (HOT),
DO NOT loosen the Radiator Cap. If removed, scalding by hot
vapor or coolant could result.
If the coolant needs replenishing, fill the Aqua-Hot’s Expansion Tank to the FULL HOT
level mark. Be sure to reference the Aqua-Hot “Owner’s Manual” for the proper
antifreeze type and mixture. If coolant frequently needs replenishing, please contact the
Technical Support Department at 1-800-685-4298 for assistance.
Annually
!
WARNING: Before cleaning or servicing, disconnect all power supplies.
To keep the Aqua-Hot running smoothly, it is ideal to have the Diesel-Burner tuned-up
annually. A tune-up should consist of a new Fuel Nozzle and Fuel Filter, along with a
thorough cleaning of the Combustion Chamber, if necessary (reference Figure 9). To
ensure maximum Diesel-Burner performance, always use the recommended Fuel Nozzle
and Fuel Filter (i.e., 10 Micron) when replacing these parts. Reference Section 10 for
spare parts information.
NOTE: Be sure to use care when handling the Fuel Nozzle. Oils and/or small
dust or dirt particles from your hands may plug the nozzle’s small orifice.
A partially plugged orifice will restrict fuel flow, which will affect the
combustion process of the Diesel-Burner (i.e., excessive smoking).
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.
Combustion
Chamber
Fuel Nozzle
(0.35 GPH)
Fuel Filter
(10 Micron)
small orifice
Figure 9
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 42
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Detaching and
Reattaching the
Diesel-Burner
Head
8.2
Detaching and Reattaching the Diesel-Burner Head
Grommets
Eye-Bolts
and Nuts
Diesel-Burner
Head
Blower
Casting
Figure 10
!
Diesel
Fuel Supply
Diesel
Fuel Return
WARNING: Be sure to turn the “Diesel” switch OFF and disconnect the B-Plug
Harness from the Diesel-Burner’s Controller prior to detaching
the Diesel-Burner Head; reference Figures 8 and 26. Failure to do
so may result in the ignition of the Diesel-Burner and serious bodily
injury.
1.
Loosen the two Eye-Bolt Nuts and swing the Eye-Bolts out of the way; reference
Figure 10.
2.
With both hands, carefully pull the Diesel-Burner Head away from the Aqua-Hot
(approximately 4-5 inches). Please note that you may have to lift the DieselBurner Head slightly while pulling it away from the Aqua-Hot.
3.
Rotate the Diesel-Burner Head upward until all internal components are visible.
CAUTION: When reattaching the Diesel-Burner Head, be sure to properly align
the Diesel-Burner Head before tightening the Eye-Bolt Nuts. Also,
visually inspect all of the rubber Grommets on the top and bottom of
the Diesel-Burner Head’s cast-aluminum Blower Casting to ensure
they are in place. DO NOT overtighten the Eye-Bolt Nuts (torque
specification = approximately 20-40 in. lbs.). An improper alignment
and/or an overtightening of the Eye-Bolt Nuts can cause damage to
the Diesel-Burner Head’s cast-aluminum Blower Casting; reference
Figure 10.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 43
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Motor
8.3
Motor
Function: The Motor drives the Combustion Air Blower and the Fuel Pump.
NOTE: In order to perform the following procedures, it may be necessary to
detach and reattach the Diesel-Burner Head. Therefore, be sure to
reference Section 8.2 for detaching and reattaching instructions.
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed in the “Component Test,” or the components can be tested by using a “Controller Tester.” Reference Section
11 for Special Tools information.
Component Test: Locate the Diesel-Burner Controller’s C-Plug and insert the probes of
a DC voltmeter into the C-2 (+) and C-5 (-) locations; reference Figure 11. Turn the
“Diesel” switch ON and observe the voltage level. If a nominal voltage registers on the
voltmeter and the Motor is not operating, inspect the C-Plug Harness for loose or damaged wire connections. If the C-Plug Harness and connections are in good condition, the
Motor must be replaced; reference the Motor’s “Replacement Procedure” in this section.
Cleaning Tips/Maintenance: N/A
Figure 11
C-2 ( + ) Motor Circuit (Black Wire)
to Diesel-Burner.
12.5 V
COM (-)
(+)
C-4
C-1 C-2
C-5 C-6 C-7 C-8
C-Plug
C-5 ( - ) Ground Circuit (Brown Wire), for
Diesel-Burner components, to Diesel-Burner.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 44
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Motor,
continued
Adjustment Procedure: N/A
RPM Test: Disconnect the Ignition Cables from the Ignition Electrodes; reference Figure
16. Remove the four Ignition Coil Screws, which secure the Ignition Coil to the Protection
Housing; reference Figure 13. Lift the Ignition Coil and disconnect its wires from the
C-Plug Harness wires prior to removing. Remove the Protection Housing from the
Diesel-Burner, allowing the Motor and Clutch Halves to be exposed; reference Figures 12
and 13. Place a few wraps of black electrical tape around the Clutch Halves, then, place
a small piece of reflective tape over the black tape as illustrated in Figure 12. Disconnect
the Motor’s Black (+) and Brown (-) wires from the C-Plug Harnesses’ Black (+) and
Brown (-) wires; reference Figures 12 and 13. Connect the Motor’s wires directly to a 12
Volt-DC power supply; reference Figure 12. Turn the power supply ON and use a
photo-tachometer to test for a proper RPM reading; reference Figure 12. At approximately 12.5 Volts-DC, the RPM reading should be 4500 RPMs (+/- 300 RPMs). If the
Motor’s RPM reading is not within the above specs, the Motor must be replaced; reference the Motor’s Replacement Procedure” in this section. Reference Section 10 for
spare part number information.
NOTE: Prior to reattaching the Diesel-Burner Head or replacing the Motor (if
applicable), be sure to test the Diesel-Burner’s Bearings. Worn Bearings can cause lower than normal RPM readings and premature Motor
wear. To properly test for worn Bearings, reference Section 8.9 for the
Bearings “Function Test.”
Figure 12
Photo
Tachometer
M
0 RP
450
Reflective
Tape
Motor
Black
Wire (+)
Brown
Wire (-)
Black Electrical
Tape on Clutch Halves
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 45
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Motor,
continued
Replacement Procedure:
1.
Remove the four Ignition Coil Mounting Screws, which secure the Ignition Coil to
the Protection Housing; reference Figure 13. Lift the Ignition Coil to disconnect
its wires from the C-Plug Harness wires prior to removing. Remove the
Protection Housing from the Diesel-Burner to expose the Motor and Clutch
Halves; reference Figures 13 and 14.
2.
Remove the three Hex Head Screws, which secure the Motor and flange assembly to the Blower Housing; reference Figure 13. Remove the Motor and flange
assembly along with the Clutch Halves; reference Figures 13 and 14. Disconnect the Motor’s Black (+) and Brown (-) wires from the C-Plug Harness’ wires;
reference Figure 13.
NOTE: Inspect the Clutch Halves for cracks and ensure that the flat portion in
each shaft hole is free of wear and tear. Too much play on the shaft
produces a loud clacking noise. If any cracks or wear are detected, the
Clutch Half must be replaced. Reference the Aqua-Hot’s “Parts Manual”
for spare parts information.
3.
Detach the Motor from the Motor Flange by removing the two Phillips Head
Screws, which fasten the two parts together; reference Figure 13.
NOTES:
4.
A:
Be sure to test the Diesel-Burner’s Bearings prior to reinstalling the
Motor. Worn Bearings can cause lower than normal RPM readings and
premature Motor wear. To properly test for worn Bearings, reference
Section 8.9 for the Bearings “Function Test.”
B:
The Motor must be mounted to the flange with the wires and drain hole
pointing downward and the recessed edge of the Motor Flange pointing
upward; reference Figure 14. This will ensure a proper Protection
Housing fit.
Reinstall a Clutch Half on both the new Motor’s shaft and the Combustion Air
Blower’s shaft. Attach the Motor and the flange assembly, with the recessed
edge of the Motor Flange in-line with the Wiring Access Slot of the Blower Casting, to the Blower Housing with the three Hex Head Screws; reference Figure 14.
NOTE: Inspect the Blower Casing’s O-Ring for damage or wear prior to reinstalling the Diesel-Burner Head’s Protection Housing; reference Figure 14.
If damage or wear exists, replace the O-Ring. Reference the Aqua-Hot’s
“Parts Manual” for spare parts information.
5.
Connect the Black (+) and Brown (-) wires of the new Motor to the C-Plug
Harness’ Black (+) and Brown (-) wires; reference Figure 13. Feed the C-Plug
Harness’ Yellow and Brown wires back through the Wiring Access Hole in the
Protection Housing; reference Figure 13.
6.
Reinstall the Protection Housing. Reconnect the Black (+) and Brown (-) wires
of the Ignition Coil to the C-Plug Harness’ Yellow (+) and Brown (-) wires; reference Figure 24. Reinstall the Ignition Coil and secure to the Protection Housing
with the four Ignition Coil Mounting Screws; reference Figure 13.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 46
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Motor,
continued
Ignition Coil
Mounting
Screws
Housing
Casting
Figure 13
Casting
Motor
Figure 14
Clutch
Halves
Black Wire
(to Diesel-Burner)
Brown Wire
(to Diesel-Burner)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 47
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Flame
Sensor
8.4
Flame Sensor
Function: The Flame Sensor is a photoresistive device, which supplies the
Diesel-Burner’s Controller with a DC voltage signal when it detects a flame (i.e., a light
source).
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information
NOTES:
A:
In order to perform the following procedures, it is necessary to detach
and reattach the Diesel-Burner Head. Therefore, be sure to review
Section 8.2 for detaching and reattaching instructions.
B:
Be sure to calibrate your ohmmeter prior to checking the Flame Sensor
for proper resistance values.
Component Test: Locate and detach the Flame Sensor’s Green and Blue wires from
the C-Plug Harness wires; reference Figure 15. Connect the Flame Sensor's Green and
Blue wires to an ohmmeter; reference Figure 15. Check resistance by placing a shop rag
over the Flame Sensor's glass surface to simulate a no-flame condition, then, remove the
rag (and expose to a light source) to simulate a flame condition. If the Flame Sensor is
operating properly, the ohmmeter should register high resistance (i.e., 100K Ω +) when
the glass surface is covered and less than 300 Ω when exposed to a light source. If
these resistance numbers cannot be obtained, the Flame Sensor must be replaced;
reference the Flame Sensor's “Replacement Procedure” in this section. Reference
Section 10 for spare parts information.
Cleaning Tips/Maintenance: For light dirt, dust, and/or carbon deposits, simply wipe off
the Flame Sensor with a soft cloth. Should heavy carbon deposits exist, completely
remove the Flame Sensor form the Photo Disc and clean with brake cleaner; reference
Figure 15.
Adjustment Procedure: N/A
Replacement Procedure:
1.
Remove the Screw, which fastens the Flame Sensor to the Photo Disc
and detach the sensor’s Green and Blue wires from the C-Plug Harness’
Green and Violet wires; reference Figure 15.
2.
Slide the tab of the new Flame Sensor into the provided slot in the Photo
Disc and secure in place with the screw; reference Figure 15. Connect
the Flame Sensor’s Green wire to the Green C-Plug Harness wire and
the Blue wire to the C-Plug Harness’ Violet wire; reference Figure 15.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 48
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Flame
Sensor,
continued
Figure 15
Flame
Sensor
Green
Wire
Photo
Disc
Green Wire
(to Diesel-Burner)
Blue
Wire
NOTE: This screw is used to
fasten the Flame Sensor to
the Photo Disc. Remove
when replacing the Flame
Sensor.
Violet Wire
(to Diesel-Burner)
Ignition
Electrodes
8.5
Ignition Electrodes
Function: The Diesel-Burner’s Ignition Coil (reference Figure 24) produces a high
voltage ignition spark across the Ignition Electrodes, which ignites the incoming air/fuel
mixture.
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information.
NOTE: In order to perform the following procedures, it is necessary to detach
and reattach the Diesel-Burner Head. Therefore, be sure to review
Section 8.2 for detaching and reattaching instructions.
Component Test: N/A
Cleaning Tips/Maintenance: Polish away any carbon deposits, which may have baked
onto the metal tips of the Ignition Electrodes with a Scotch Brite® pad (or similar);
reference Figure 16. If the Ignition Electrode’s electrical insulator (reference Figure 16) is
cracked and/or damaged, the Ignition Electrode must be replaced; reference the Ignition
Electrode “Replacement Procedure” in this section. Reference Section 10 for spare parts
information.
NOTE: The Electrode Adjustment Gauge is used to set the gap between the
Ignition Electrodes. The Electrode Adjustment Gauge is located on the
outside surface of the Diesel-Burner Head on the left side.
Adjustment Procedure: An adjustment of the Ignition Electrodes can be accomplished
by performing the following procedure:
1.
Slightly loosen the Retaining Clamp Bolt; reference Figure 16.
2.
Place the Electrode Adjustment Gauge on the Fuel Nozzle Manifold Hex
(reference Figure 17) and insert the metal tips of the Ignition Electrodes
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 49
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Ignition
Electrodes,
continued
into the appropriate notches of the Electrode Adjustment Gauge as
illustrated in Figure 16.
3.
Tighten the Retaining Clamp Bolt.
NOTE: Be sure not to overtighten the Retaining Clamp Bolt when readjusting
the Ignition Electrodes. Overtightening the Retaining Clamp Bolt will
bend the Retaining Clamp and prevent the Photo Disc from floating
freely (i.e., loose fit). Not allowing the Photo Disc to float freely will
cause poor combustion and result in a smoky exhaust. A bent Retaining
Clamp can be restraightened with a punch and hammer. 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 (i.e., flat).
4.
Remove the Electrode Adjustment Gauge and reattach to the DieselBurner Head.
Replacement Procedure:
1.
Disconnect the Ignition Cables from the Ignition Electrodes and slightly
loosen the Retaining Clamp Bolt just enough to allow the Ignition Electrodes to be removed; reference Figure 16.
2.
Slide the new Ignition Electrodes up through the Retaining Clamp and
Photo Disc. Do not tighten the Retaining Clamp Bolt at this time.
3.
Perform Steps 2 through 4 of this section’s “Adjustment Procedure” to
complete the Ignition Electrode installation. Once Steps 2 through 4
have been performed, reconnect the Ignition Cables to the Ignition Electrodes; reference Figure 16.
Electrode Adjustment
Gauge
Igniton
Electrodes
(metal tips)
Electrode
Boots
Ignition
Electrodes
Photo Disc
Ignition
Cables
Figure 16
Retaining
Clamp Bolt
Retaining
Clamp
Electrode
Adjustment Gauge
(Properly Positioned)
Electrical Insulators
Fuel Nozzle
Manifold
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Fuel
Nozzle
Page 50
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel
Nozzle
8.6
Fuel Nozzle
Function: The Fuel Nozzle is simply a fuel atomizer. It reduces the diesel fuel into a
fine spray, which is mixed with incoming combustion air and ignited within the Combustion Chamber.
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information.
NOTE: In order to perform the following procedures, it is necessary to detach
and reattach the Diesel-Burner Head. Therefore, be sure to review
Section 8.2 for detaching and reattaching instructions.
Component Test: Remove both Ignition Cables from the Ignition Electrodes; reference
Figure 16.
!
WARNING: Failure to remove the Ignition Cables/Electrode Boots from the
Ignition Electrodes (reference Figure 16), will result in a HIGH
VOLTAGE shock and/or a fire. Also, be sure to place a piece of
electrical tape on the end of each Electrode Boot.
Remove the B-Plug from the Diesel-Burner’s Controller; reference Figure 8. Turn the
“Diesel” switch ON (reference Figure 4), then, plug the B-Plug back into the Controller to
activate the Diesel-Burner. After approximately 20 seconds, the Fuel Solenoid will “click”
and a fine mist of fuel should appear from the Fuel Nozzle in a cone-shaped spray
pattern. Remove the B-Plug from the Controller. If the cone-shaped spray pattern did
not appear, the Fuel Nozzle must be replaced; reference the Fuel Nozzle’s “Replacement
Procedure” in this section. Reference Section 10 for spare parts information.
Cleaning Tips/Maintenance: The Fuel Nozzle is a precision calibrated part and cannot
be cleaned or serviced. A replacement of the Fuel Nozzle is recommended annually.
Reference Section 8.1 for maintenance information.
Adjustment Procedure: N/A
Replacement Procedure:
1.
Use a 3/4 in. wrench to hold the Fuel Nozzle Manifold Hex while
loosening the Fuel Nozzle with a 5/8 in. wrench; reference Figure 17.
NOTE: Be sure to use care when handling the new Fuel Nozzle. Oils and/or
small dust or dirt particles from your hands may plug the nozzle’s small
orifice. A partially plugged orifice will restrict fuel flow, which will affect
the combustion process of the Diesel-Burner (i.e., excessive smoking).
2.
When replacing the Fuel Nozzle, be sure to tighten the nozzle, loosen it
a 1/4 turn, then, firmly retighten. This will establish a seated fit and avoid
any leaks.
NOTE: An adjustment of the Ignition Electrodes may be necessary after
replacing the Fuel Nozzle. Reference Section 8.5 for the Ignition
Electrode “Adjustment Procedure.”
3.
After replacing the Fuel Nozzle, reattach the Diesel-Burner Head.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 51
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel
Nozzle,
continued
!
WARNING: Be sure to reattach the Diesel-Burner Head prior to switching the
heater ON. Failure to do so may result in ignition of the DieselBurner and serious bodily injury.
4.
Turn ON the “Diesel” switch (reference Figure 4) for 5 seconds, then turn
it OFF. This will activate the Diesel-Burner’s prime-cycle (will operate
the Diesel-Burner’s “Motor” for 2-3 minutes) and flush the fuel system of
any potential contaminants. Perform this procedure twice.
Ignition Electrodes
Fuel Nozzle
Fuel Nozzle
Diesel-Burner
Head
Fuel Nozzle
Manifold Hex
Figure 17
5/8 in.
Wrench
3/4 in.
Wrench
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 52
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel
Solenoid
Valve
8.7
Fuel Solenoid Valve
Function: The Fuel Solenoid Valve allows the flow of diesel fuel to the Diesel-Burner’s
Fuel Nozzle.
NOTE: In order to perform the following procedures, it is necessary to detach
and reattach the Diesel-Burner Head. Therefore, be sure to review
Section 8.2 for detaching and reattaching instructions.
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information.
Component Test: Locate and detach the C-Plug Harness’ Violet (+) and Brown (-) wires
from the Fuel Solenoid Valve. Connect the (-) lead of a 12 Volt-DC power supply to the
Fuel Solenoid’s (-) Electrical Terminal; reference Figure 18. Now, intermittently apply the
(+) lead of the power supply to the Fuel Solenoid’s (+) Electrical Terminal and listen for
the Fuel Solenoid to click (i.e., open and close). If the Fuel Solenoid does not click, it
must be replaced; reference the Fuel Solenoid Valve‘s “Replacement Procedure” below.
Reference Section 10 for spare parts information.
Cleaning Tips/Maintenance: N/A
Adjustment Procedure: N/A
Replacement Procedure:
1.
Disconnect the Ignition Cables from the Ignition Electrodes and loosen
the Retaining Clamp Bolt; reference Figure 16.
2.
Remove the Retaining Clip, which secures the Photo Disc in place.
Gently lift the Photo Disc (with Flame Sensor attached) so that it
releases from the Fuel Nozzle Manifold and the Ignition Electrodes;
reference Figures 16 and 19.
3.
Disconnect the C-Plug Harness’ Violet (+) and Brown (-) wires from the
Fuel Solenoid Valve; reference Figure 18.
4.
Remove the four Fuel Nozzle Manifold Plate Screws, which secure the
Fuel Nozzle Manifold Plate in place; reference Figure 19. Remove the
Fuel Nozzle Manifold Plate by pulling on the Fuel Nozzle Manifold until
the plate releases from the cast-aluminum Blower Casting; reference
Figures 13 and 19.
5.
Remove the Lock Nut and Flat Washer from the end of the Fuel Solenoid
Shaft, then, remove the Fuel Solenoid Valve Coil. With a 5/8 wrench,
now remove the Fuel Solenoid Shaft from the Fuel Nozzle Manifold.
Discard the shaft and valve kit, as replacements are provided with the
new Fuel Solenoid Assembly; reference Figure 18.
6.
Insert the contents of the new Fuel Solenoid Valve Kit into the new Fuel
Solenoid Shaft as illustrated in Figure 18. Thread the new Fuel Solenoid
Shaft to the Fuel Nozzle Manifold and tighten. Slide the new Fuel
Solenoid Valve Coil onto the Fuel Solenoid Shaft and secure in place
with the new Flat Washer and Lock Nut.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 53
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Solenoid
Valve,
continued
7.
Fit the Fuel Nozzle Manifold Plate inside the cast-aluminum Blower Casting and
secure in place with the four Fuel Nozzle Manifold Plate Screws.
8.
Reinstall the Photo Disc and secure in place with the Retaining Clip. Connect
the C-Plug Harness’ Violet (+) and Brown (-) wires to the Fuel Solenoid Valve‘s
(+) and (-) Electrical Terminals; reference Figure 18.
9.
Perform the Ignition Electrodes’ “Adjustment Procedure” in Section 8.5 to
complete the Fuel Solenoid Valve installation.
Retaining Clamp
Ignition Cable
Violet wire
Brown wire
Photo Disc
Retaining Clip
Fuel Solenoid
Valve Coil
Lock Nut
Electrical Terminals
Fuel
Solenoid Shaft
(+)
(-)
Fuel Solenoid
Valve Kit
Fuel
Solenoid
Valve
Coil
Fuel Solenoid
Valve Assembly
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Figure 18
Page 54
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Pump
8.8
Fuel Pump
Function: The Fuel Pump draws diesel fuel from the vehicle’s fuel tank and creates a
preset pressure of 145 psi (required for proper fuel atomization). Reference the illustration below for a basic overview and understanding of how the Fuel Pump operates.
1
FUEL PUMP
OVERVIEW
6
4
3
5
1.
2.
3.
4.
5.
6.
Fuel Nozzle
Air Relief Bore
Fuel Supply Line
Fuel Return Line
Fuel Pressure Regulator
Fuel Solenoid
2
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information.
NOTE: In order to perform some of the following procedures, it may be necessary to detach and reattach the Diesel-Burner Head. Therefore, be
sure to reference Section 8.2 for detaching and reattaching instructions.
Component Test:
Clamp off and remove the Aqua-Hot’s Fuel Return and Fuel Supply Lines; reference
Figure 1. Attach a short piece of fuel line to both the Aqua-Hot’s Fuel Return and Fuel
Supply ports; reference Figure 1. Submerse the opposite end of the temporary fuel
supply line in a container of diesel fuel. Place the opposite end of the temporary fuel
return line in an empty container. Turn the “Diesel” switch ON to activate the DieselBurner; reference Figure 4. If fuel does not flow out of the return line into the empty
container, the Fuel Pump must be replaced; reference the Fuel Pump’s “Replacement
Procedure” in this section. Reference Section 10 for spare parts information.
Cleaning Tips/Maintenance:
1.
Check all Fuel Connections for tightness (i.e., Banjo Bolts, High Pressure Fuel Pipe Connections); reference Figure 19.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 55
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Pump,
continued
Ignition Cable (1)
Fuel Nozzle Manifold
Plate Screw (1)
Retaining
Clamp
Retaining Clip
Ignition
Electrodes
Photo Disc
Flame Sensor
Supply
Banjo Bolt
Fuel Pump
Fuel Tube
Return
Fuel Tube
Supply
Fuel Nozzle Manifold
Plate Screw (4)
Fuel Supply
Line
Fuel Nozzle Manifold
Plate Screw (2)
Ignition Cable (2)
Top Cover
Plate Screws
High Pressure
Fuel Tube Connections
Pump Mounting
Screw
Fuel Nozzle Manifold
Plate
Fuel Pressure
Regulator
Fuel Nozzle Manifold
Plate Screw (3)
Fuel Return
Line
Return
Banjo Bolt
Figure 19
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 56
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Pump,
continued
Fuel Pressure Function Test:
NOTES:
A: A Fuel Pressure Gauge (reference Section 11 for special tools
information) is used to properly check the Fuel Pump’s pressure
setting; reference Figure 21. The Fuel Pump is preset to 145 psi
(the pressure required for proper fuel atomization at the Fuel
Nozzle). Perform the following procedures to check for a proper
fuel pressure setting.
B: Be sure to use care when handling the Fuel Nozzle. Oils and/or
small dust or dirt particles from your hands may plug the nozzle’s
small orifice; reference Figure 9. A partially plugged orifice will
restrict fuel flow, which will affect the combustion process of the
Diesel-Burner (i.e., excessive smoking from the exhaust pipe).
1.
!
Remove the Fuel Nozzle (reference Figure 17) and replace it with the
Fuel Pressure Gauge; reference Figure 21.
WARNING: A spark will appear across the Ignition Electrodes (reference Figure
16) for a brief moment after the Diesel-Burner has been activated.
DO NOT attempt to make any fuel pressure adjustments until the
spark has disappeared. Failure to do so may result in serious
bodily injury (i.e., an electrical shock).
2.
Turn the “Diesel” switch ON; reference Figure 4. A pressure will register
on the Fuel Pressure Gauge once the Fuel Solenoid opens (after
approximately 10-25 seconds).
3.
If the Fuel Pressure Gauge registers a 145 psi pressure reading, no
pressure adjustment is necessary. Turn the “Diesel” switch OFF and
wait until the motor stops running. Remove the Fuel Pressure Gauge
and reinstall the Fuel Nozzle (reference Section 8.6 for the Fuel
Nozzle’s “Replacement Procedure”). Reattach the Diesel-Burner
Head.
NOTE: If the Fuel Pressure Gauge registers below or above 145 psi, perform
the adjustment procedures listed below.
Fuel Pressure Adjustment Procedure:
1.
Turn the “Diesel” switch ON and wait until a pressure reading registers
on the Fuel Pressure Gauge (after approximately 10-25 seconds).
Then, adjust the fuel pressure by simply turning the Pressure Regulator
Adjustment Screw clockwise to increase fuel pressure or counterclockwise to decrease fuel pressure; reference Figure 21.
NOTE: If the fuel pressure will not maintain a 145 psi setting, the Fuel Pump
must be replaced; reference the Fuel Pump’s “Replacement Procedure”
in this section. Also, reference Section 10 for spare parts information.
2.
Once the pressure adjustment has been made, turn the “Diesel” switch
OFF and wait until the motor stops running. Remove the Fuel Pressure
Gauge and reinstall the Fuel Nozzle (reference Section 8.6 for the Fuel
Nozzle’s “Replacement Procedure”). Reattach the Diesel-Burner Head.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 57
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Pump,
continued
60
80 100 120
140
40
160
20
psi
0
180
200
Fuel Pressure
Gauge
ASHCROFT
MADE IN U.S.A
Figure 20
Fuel Pump
increase
Pressure Regulator decrease
Screw (Adjustment)
Figure 21
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 58
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Pump,
continued
Replacement Procedure:
1.
Locate and disconnect the C-Plug Harness wires, which connect to the
Flame Sensor and the Fuel Solenoid Valve; reference Figures 3, 15, and
18. Also, disconnect the Ignition Cables from the Ignition Electrodes;
reference Figures 16 and 19.
2.
Remove the Retaining Clip, which secures the Photo Disc in place;
reference Figure 19. Gently lift the Photo Disc (with Flame Sensor
attached) so that it releases from the Fuel Nozzle Manifold and the
Ignition Electrodes; reference Figures 16 and 19.
3.
Clamp off both the Fuel Supply Line and Return Line from the DieselBurner Head; reference Figures 19 and 22. Loosen the Supply and
Return Banjo Bolts to remove both Fuel Tubes (with the fuel lines
attached) from the Fuel Pump; reference Figures 19 and 22. Also,
disconnect the High Pressure Fuel Tube from both the Fuel Pump and
the Fuel Nozzle Manifold; reference Figures 19 and 22. Discard the
High Pressure Fuel Tube, Gasket Rings, Banjo Bolts, and Grommets, as
these replacements are provided in the new Fuel Pump Kit. Reference
Section 10 for spare parts information.
4.
Remove the four Fuel Nozzle Manifold Plate Screws, which secure the
Fuel Nozzle Manifold Plate in place; reference Figure 19. Remove the
Fuel Nozzle Manifold Plate by pulling on the Fuel Nozzle Manifold until
the plate releases from the cast-aluminum Blower Casting; reference
Figures 13 and 19.
5.
Remove the two Fuel Mounting Screws, which secure the Fuel Pump in
place; reference item 70 of Figure 22. Turn the Fuel Nozzle Manifold
Plate over and remove the Snap Ring from the Fuel Pump shaft using
Snap Ring pliers; reference item 77 of Figure 22. Remove the nylon
Fuel Pump Gear, then the Fuel Pump; reference items 88 and 72 of
Figure 22.
6.
Attach the new Fuel Pump to the Fuel Nozzle Manifold Plate with the
two Fuel Pump Mounting Screws. Turn the Fuel Nozzle Manifold Plate
over to install the nylon Fuel Pump Gear on the Fuel Pump’s shaft and
secure in place with the Snap Ring. Dab the teeth of the nylon Fuel
Pump Gear with white lithium grease (Isoflex LDS-18 is recommended).
NOTES:
A: All new Fuel Pumps are factory preset to 145 PSI; therefore, no fuel
pressure adjustment is necessary.
B: Inspect the nylon Fuel Pump Gear’s cavity inside the cast aluminum
Blower Casting for fuel stains. If fuel stains are present, a replacement of the Bearings and/or the entire Blower Casting may be
necessary (leaking fuel could cause Bearing seizure, resulting in
potential damage to the internal bore/bearing cavity of the Blower
Casting). Reference Section 8.9 for the Bearing “Replacement
Procedure” and contact the Technical Support Department at
1-800-685-4298 for additional assistance.
7.
Fit the Fuel Nozzle Manifold Plate inside the cast-aluminum Blower Casting
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 59
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Fuel Pump,
continued
and secure in place with the four Fuel Nozzle Manifold Plate Screws.
Install the new Grommets on both Fuel Tubes (Supply and Return) and
secure the tubes to the Fuel Pump with the new Banjo Bolts and Gasket
Rings; reference Figures 19 and 22.
NOTE: Reference Figure 22 for the correct order placement of the (4) Gasket
Rings. Failure to use the new Gasket Rings, and/or the correct order
placement, will result in a leaky Fuel Pump.
8.
Reconnect the C-Plug Harness’ Violet (+) and Brown (-) wires to the Fuel
Solenoid’s (+) and (-) Electrical Terminals; reference Figure 18. Insert
both Ignition Cables into the new rubber Grommet and slide into the
appropriate notch on the Blower Casting; reference Figure 19. Reconnect the Ignition Cables to the Ignition Electrodes, then remove the fuel
line clamps from both the Fuel Return Line and the Fuel Supply Line;
reference Figure 19.
9.
Reinstall the Photo Disc and secure it in place with the Retaining Clip;
reference Figure 19. Reconnect the Flame Sensor’s Green wire to the
Green C-Plug Harness wire and the Blue wire to the C-Plug Harness’
Violet wire; reference Figure 15.
NOTE: Check the Ignition Electrodes for proper adjustment; reference Steps 2
through 4 of the “Adjustment Procedure” in Section 8.5 to ensure proper
Ignition Electrode adjustment.
59
74
72
61
60
74
74
66
74
77
76
67
68
75
46
45
73
65
62
71
70
71
70
69
67
66
Figure 22
45
46
59
60
61
62
65
66
67
68
Grommet, Blower Casting, Left
Grommet, Blower Casting, Right
Sensor, Flame
Clip, Retaining, Photo Disc
Disc, Photo
Pump, Fuel
Tube, Fuel, High Pressure
Bolt, Banjo
Gasket, Ring, Copper
Tube, Fuel, Banjo, Supply
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
69
70
71
72
73
74
75
76
77
Tube, Fuel, Banjo, Return
Screw, Mounting, Fuel Pump
Washer, Lock, Fuel Pump
Nozzle, Fuel, 0.35 GPH
Manifold, Fuel Nozzle, Brass
Screw, Manifold Plate
Plate, Manifold
Gear, Fuel Pump, Nylon
Ring, Snap
Page 60
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Bearings
8.9
Bearings
Function: The Bearings support the Combustion Air Blower’s shaft and allows the
blower to turn smoothly.
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information.
NOTE: In order to perform some of the following procedures, it is necessary to
detach and reattach the Diesel-Burner Head. Therefore, be sure to
review Section 8.2 for detaching and reattaching instructions.
Function Test: Remove the Motor (reference Section 8.3 for the Motor’s “Replacement
Procedure”) and spin the Combustion Air Blower by hand (place one of the Clutch Halves
to the end of the shaft to assist with this spinning exercise). If the Combustion Air Blower
rotates smoothly without any friction or noise, the Bearings are in proper working condition. However, if the Combustion Air Blower does not rotate smoothly and/or produces
noise, the Bearings are worn and must be replaced; reference the Bearings “Replacement Procedure” in this section.
Component Test: N/A
Cleaning Tips/Maintenance: N/A
Adjustment Procedure: N/A
Replacement Procedure:
1.
Clamp off and remove the Fuel Supply Line and Fuel Return Line from
the Diesel-Burner Head; reference Figures 19 and 22.
2.
Locate and disconnect the C-Plug Harness wires, which connect to the
Flame Sensor and Fuel Solenoid; reference Figures 3, 15, and 18.
Also, disconnect the Ignition Cables from the Ignition Electrodes; reference Figures 16 and 19.
3.
Remove the four Fuel Nozzle Manifold Plate Screws, which secure the
Fuel Nozzle Manifold Plate in place; reference Figure 19. Remove the
Fuel Nozzle Manifold Plate by pulling on the Fuel Nozzle Manifold until
the plate releases from the cast-aluminum Blower Casting; reference
Figures 13, 16, and 19.
4.
Remove the four Ignition Coil Mounting Screws, which secure the
Ignition Coil to the Protection Housing; reference Figure 13. Lift the
Ignition Coil and disconnect its Black (+) and Brown (-) wires from the
C-Plug Harness wires, prior to removing; reference Figures 3 and 24.
Remove the Protection Housing from the Diesel-Burner to expose the
Motor and Clutch Halves; reference Figures 12, 13 and 14.
5.
Remove the three Hex Head Screws, which secure the Motor and Motor
Flange to the Blower Housing; reference Figure 13. Remove the Motor
and flange assembly along with the Clutch Halves; reference Figures 13
and 14. Disconnect the Motor’s Black (+) and Brown (-) wires from the
C-Plug Harness’ wires; reference Figure 13.
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Page 61
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Bearings,
continued
NOTE: Inspect the Clutch Halves for cracks and ensure that the flat portion
in each shaft hole is free of wear and tear. Too much play on the shaft
produces a loud clacking noise. If any cracks or wear are detected, the
Clutch Half must be replaced. Reference the Aqua-Hot’s “Parts Manual”
for spare parts information.
6.
Remove the four Blower Housing Screws, which secure the Blower
Housing to the Blower Casting; reference Figure 23. Remove the Blower
Housing to expose the Combustion Air Blower; reference Figure 23.
NOTE: Be sure to observe the placement of the three Washers of the Bearing
Kit illustrated in Figure 23. To ensure proper tension, the same order
and direction of the dished surfaces of the Washers must be followed
when reassembling.
7.
Hold Side-B of the Blower Casting and loosen the Retaining Nut located
in Side-A of the Blower Casting. Remove the Retaining Nut, steel Drive
Gear, and thick Flat Washer from the Combustion Air Blower’s shaft.
Lightly tap the threaded end of the shaft so the Combustion Air Blower
can be easily removed from the Blower Casting.
8.
With a pair of Snap-Ring pliers, remove the Snap Rings from both Side-A
and Side-B of the Blower Casting; reference Figure 23. Push all the
contents of the Bearing Kit out of the Blower Casting's bore/bearing
cavity. Discard the Retaining Nut, steel Drive Gear, Snap Rings, Bearings, Spacer Tube, and Washers, as replacements are provided in the
new Bearing Kit.
NOTE: Be sure to inspect the Blower Casting’s bore/bearing cavity for signs of
damage due to potentially seized Bearings. If damage is present, the
Blower Casting must be replaced. Reference the Aqua-Hot’s “Parts
Manual” for spare parts information.
9.
Install a new Snap Ring into Side-A of the Blower Casting; reference
Figure 23. Once the Snap Ring is in place, insert the remaining
contents of the new Bearing Kit into Side-B of the Blower Casting
starting with the Wave Washer, as illustrated in Figure 23. Secure the
Bearing Kit assembly in place with the remaining Snap Ring (Side-B).
NOTES:
A: Prior to installation, reference Figure 23 for the exact placement of
the three Washers, which slide over the threaded end of the Combustion Air Blower’s shaft. Failure to follow the correct order and
direction of the dished surfaces on the Washers will result in a
restricted rotation of the Combustion Air Blower.
B: Inspect the Combustion Air Blower for warpage and/or damage. If
warpage or damage is visible, the Combustion Air Blower must be
replaced. Reference the Aqua-Hot’s “Parts Manual” for spare parts
information.
10.
Slide the Combustion Air Blower’s shaft (with the three washers) up
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 62
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Bearings,
continued
through the Bearing Kit assembly until the threaded portion appears on
Side-A of the Blower Casting; reference Figure 23. Place the new thick
flat Washer and steel Drive Gear on the threaded end of the Combustion
Air Blower’s shaft. Thread the new Retaining Nut on the Combustion Air
Blower’s shaft until it is finger tight (DO NOT TIGHTEN).
11.
Place a feeler gauge between the Combustion Air Blower and the flat
surface of the Blower Casting. Slowly tighten (or loosen) the Retaining
Nut, holding the Combustion Air Blower, until a .003 - .005 gap is
achieved.
12.
Spin the Combustion Air Blower to ensure a friction-free rotation.
NOTE: If the Combustion Air Blower is rubbing, loosen the Retaining Nut slightly
and lightly tap on the Combustion Air Blower’s shaft (opposite side (i.e.,
Side-B)), then readjust the gap (repeat Steps 11 and 12).
13.
Reattach the Blower Housing to the Blower Casting using the four
Blower Housing Screws. Reinstall a Clutch Half on both the Motor’s
shaft and on the Combustion Air Blower’s shaft. Attach the Motor and
flange assembly, with the recessed edge of the Motor Flange in-line with
the Wiring Access Slot of the Blower Casting, to the Blower Housing with
the three Hex Head Screws; reference Figures 13 and 14. Reconnect
the Black (+) and Brown (-) wires of the Motor to the C-Plug Harness’
Black (+) and Brown (-) wires; reference Figures 13 and 14. Feed the
C-Plug Harness’ Yellow and Brown wires back through the Wiring
Access Hole in the Protection Housing; reference Figure 13.
14.
Reinstall the Protection Housing. Reconnect the Black (+) and Brown (-)
wires of the Ignition Coil to the C-Plug Harness’ Yellow (+) and Brown (-)
wires; reference Figure 24. Reinstall the Ignition Coil, securing it to the
Protection Housing utilizing the four Ignition Coil Mounting Screws;
reference Figure 13.
15.
Fit the Fuel Nozzle Manifold Plate inside the cast-aluminum Blower
Casting and secure in place with the four Fuel Nozzle Manifold Plate
Screws. Reattach the Fuel Supply Line and Fuel Return Line to the
Diesel-Burner Head.
16.
Reconnect the Violet (+) and Brown (-) wires to the Fuel Solenoid’s (+)
and (-) Electrical Terminals; reference Figure 18. Also, reconnect the
Flame Sensor’s Green wire to the Green C-Plug Harness wire and the
Blue wire to the C-Plug Harness’ Violet wire; reference Figure 15.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 63
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Bearings,
continued
Side-B
Blower Casting
Blower Housing
Rubber
Grommets
Blower Casing
O-Ring
Combustion Air
Blower w/shaft
Blower Housing
Screws
Side-A
Dished
Surface
Washer
Dished
Surface
Washer
Flat
Washer
Snap
Ring
Spacer
Tube
Wave
Washer
Bearing
Snap
Ring
Flat
Washer
(Thick)
Drive
Gear
(Steel)
Retaining
Nut
Bearing
Bearing Kit
Figure 23
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 64
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Ignition Coil
8.10
Ignition Coil
Function: The Ignition Coil produces a high voltage ignition spark (approximately 8000
volts), which is released across the metal tips of the Ignition Electrodes during the initial
Diesel-Burner start-up.
!
WARNING: Use extreme care when testing the Ignition Coil, as a High Voltage
Shock may result.
NOTE: The functionality of each component can be determined by completing
the manual checks, as listed under the “Component Test” area for each
individual component, or the components can be tested by using a
“Controller Tester.” Reference Section 11 for Special Tools information.
NOTE: In order to perform some of the following procedures, it is necessary to
detach and reattach the Diesel-Burner Head. Therefore, be sure to
review Section 8.2 for detaching and reattaching instructions.
Component Test: Remove the four Ignition Coil Mounting Screws, which secure the
Ignition Coil in place; reference Figure 13. Disconnect the Ignition Coil’s Black (+) and
Brown (-) wires from the C-Plug Harness’ Yellow (+) and Brown (-) wires. Connect the
Ignition Coil wires directly to a 12 Volt-DC power supply (i.e., Black (+) wire to (+) lead
and Brown (-) wire to (-) lead). Turn the power supply ON and watch for a spark to
appear across the metal tips of the Ignition Electrodes; reference Figure 16. If a spark
does not appear, the Ignition Coil must be replaced; reference the Ignition Coil’s
“Replacement Procedure” below. Reference Section 10 for spare parts information.
Cleaning Tips/Maintenance: N/A
Adjustment Procedure: N/A
Replacement Procedure:
1.
Disconnect the Ignition Cables from the Ignition Electrodes; reference
Figures 16 and 19. Remove the four Ignition Coil Mounting Screws,
which secure the Ignition Coil to the Protection Housing; reference
Figure 13. Lift the Ignition Coil and disconnect its wires from the C-Plug
Harness wires, prior to removing; reference Figures 3 and 24.
2.
Connect the new Ignition Coil’s Black (+) and Brown (-) wires to the
C-Plug Harness’ Yellow (+) and Brown (-) wires; reference Figure 24.
Attach the Ignition Coil to the Protection Housing with the four Ignition
Coil Mounting Screws; then, reconnect the Ignition Cables to the Ignition
Electrodes.
Ignition
Coil
Ignition
Cable
Figure 24
Brown
Wire (-)
Brown Wire (-)
(to Diesel-Burner)
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Black
Wire (+)
Yellow Wire (+)
(to Diesel-Burner)
Page 65
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Diesel-Burner
Controller
8.11
Diesel-Burner Controller
Function: The Controller operates all the components of the Diesel-Burner Head and
safely shuts the heater OFF in the event of an overheat, flameout, or low voltage condition. It also receives Diesel-Burner operation status signals from the Flame Sensor, VDC
Control Thermostat, and VDC High-Limit Thermostat.
NOTE: The functionality of each component can be determined by completing the
manual checks, as listed under the “Component Test” area for each individual
component, or the components can be tested by using a “Controller Tester.”
Reference Section 11 for Special Tools information.
Component Test: The following conditions must exist prior to performing the Controller
circuit tests in this section. If one of the conditions below does not exist, please contact
the Technical Support Department at 1-800-685-4298 for additional assistance.
Condition #1
A battery voltage level of between 11.5 and 14.0 Volts-DC must be present at the
Diesel-Burner’s Controller during all testing; reference Figure 25. It may be
necessary to perform a voltage check to ensure that this condition exists. To
perform the voltage check, locate the Controller’s B-Plug, and insert the probes
of a DC voltmeter into the B-4 (+) and B-2 (-) locations; reference Figure 26.
Condition #2
A voltage level of between 11.5 and 14.0 volts must be present at the DieselBurner Controller’s ON/OFF switch circuit during all testing. It may be necessary
to perform a voltage check to ensure that this condition exists. To perform the
voltage check, locate the Controller’s B-Plug, and insert the probes of a DC
voltmeter into the B-1 (+) and B-2 (-) locations; reference Figures 8 and 26.
Turn the “Diesel” switch ON and observe the voltage level; reference Figure 4.
Figure 25
Diesel-Burner
Controller
Diesel-Burner
Head
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 66
SECTION 8: DIESEL-BURNER, MAINTENANCE, AND REPAIR INFORMATION
Diesel-Burner
Controller,
continued
B-2 ( - ) Battery Circuit (Brown Wire)
to JP-4 (Pin 4)
12.5 V
COM (-)
(+)
B-Plug
B-1 B-2 B-3
B-6
B-4
B-4 ( + ) Battery Circuit (Red Wire)
to JP-4 (Pin 3)
Figure 26
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 67
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Diesel-Burner
Controller,
continued
NOTE: If, after performing the following circuit tests, the Controller is determined to be defective and must be replaced, reference the Controller’s
“Replacement Procedure” in this section. Reference Section 10
for spare parts information.
Ground Circuit Test
Locate the Controller’s B-Plug and C-Plug; reference Figure 8. Insert the probes of a DC
voltmeter into the B-4 (+) and C-5 (-) locations and turn the “Diesel” switch ON; reference
Figures 4 and 8. If a voltage reading does not register on the voltmeter, the Controller
must be replaced. If voltage is present, proceed to the next circuit test.
NOTE: The temperature of the Aqua-Hot’s Boiler Tank must be below 160°F
prior to performing the following tests.
VAC/VDC Control Thermostat Circuit Test
Locate the Controller’s B-Plug and C-Plug; reference Figure 8. Insert the probes of a DC
voltmeter into the C-1 (+) and B-2 (-) locations and turn the “Diesel” switch ON; reference
Figures 4 and 8. If a voltage reading does not register on the voltmeter, the Controller
must be replaced. If voltage is present, proceed to the next circuit test.
VDC High-Limit Thermostat Circuit Test
Locate the Controller’s B-Plug and C-Plug; reference Figure 8. Insert the probes of a DC
voltmeter into the C-4 (+) and B-2 (-) locations and turn the “Diesel” switch ON; reference
Figures 4 and 8. If a voltage reading does not register on the voltmeter, the Controller
must be replaced. If voltage is present, proceed to the next circuit test.
Motor Circuit Test
Locate the Controller’s C-Plug; reference Figure 8. Insert the probes of a DC voltmeter
into the C-2 (+) and C-5 (-) locations and turn the “Diesel” switch ON; reference Figures 4
and 8. If no voltage reading registers on the voltmeter, the Controller must be replaced.
If voltage is present, proceed to the next circuit test.
Ignition Coil Circuit Test
Locate the Controller’s C-Plug; reference Figure 8. Insert the probes of a DC voltmeter
into the C-8 (+) and C-5 (-) locations and turn the “Diesel” switch ON; reference Figures 4
and 8. If no voltage reading registers on the voltmeter 18-25 seconds after the
Diesel-Burner’s initial start-up, the Controller must be replaced. If voltage is present,
proceed to the next circuit test.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 68
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Diesel-Burner
Controller,
continued
Cleaning Tips/Maintenance: N/A
Adjustment Procedure: N/A
Replacement Procedure:
1.
Remove both the B-Plug and C-Plug from the Controller; reference
Figure 8. Gently pry away each side of the Controller Mounting Bracket
from the Controller’s locking posts with a flat-head screwdriver. Once
the locking posts have been released, pull on the Controller to remove it
from the Diesel-Burner Head.
2.
Slide the new Controller into the Controller Mounting Bracket; reference
Figure 27. Push down on the Controller until the locking posts snap
into the bracket slots. Reinstall both the B-Plug and C-Plug.
NOTE: Be sure to install the Controller with its C-Plug and B-Plug ports facing
downward. Failure to do so will result in moisture collecting in the ports
and potential damage to the Controller’s internal circuitry; reference
Figure 27.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 69
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Diesel-Burner
Controller,
continued
7.11
Diesel-Burner Controller
Bracket Slot
Locking Post
Diesel-Burner
Controller
Controller
Mounting
Bracket
Figure 27
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 70
SECTION 9: WARRANTY INFORMATION
WARRANTY INFORMATION
- FOR ALL AQUA-HOT MODELS Vehicle Systems, Inc. warrants the AQUA-HOT Heater to be free from defects in material and
workmanship under normal use and service for a period of two (2) years on both parts and labor
commencing upon the original date of registration of the vehicle. The warranty period may not,
however, exceed 36 months from the original “Manufactured Date” by Vehicle Systems, Inc. Replacement parts are warranted for the remainder of the Heater’s standard warranty period or for six
months (180 days), whichever is greater.
This warranty is conditional upon proper use of the Heater by the end-user. 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 no 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 enduser from problems, which are outside the ability of Vehicle Systems’ control.
To obtain warranty repair authorization or for additional product information, please contact the
Technical Support Department at 1-800-685-4298 (8 AM to 5 PM Mountain Standard Time).
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 71
SECTION 10: SPARE PARTS LIST
Control Unit
162
1
2
164
A
1 2 3
4 5 6
B
1 2
4
5 6 7 8
2455RM8589-6 L220
62
189
190
C
99
96
GEMS
2
59
97
2455RM8589-6 L220
72
98
61
50
5
56
2
5
27
50
51
56
59
61
62
72
96
97
98
99
162
164
189
190
WPX-287-962
WPX-101-838
WPX-425-060
WPX-322-083
WPX-386-650
WPX-274-313
WPX-638-78A
WPX-887-71A
WPX-886-41A
WPX-502-05A
ELX-01G-ML7
ELE-C14-001
ELE-HLT-222
ELE-ASY-001
WPE-905-834
WPX-265-53A
FLX-120-VS1
FLX-R12-TRA
27
51
Controller, Diesel-Burner, 12 VDC
Coil, Ignition, 12 VDC
Motor, Combustion Air/Fuel Pump, 12 VDC
Valve, Fuel Solenoid, 12 VDC
Valve, Fuel Solenoid, Kit
Electrode, Ignition
Sensor, Flame
Disc, Photo
Pump, Fuel, Kit
Nozzle, Fuel, 0.35 GPH
Switch, Float
Thermostat, Control
Thermostat, High-Limit, 12 VDC
Thermostat, High-Limit, 120 VAC
Burner, Diesel, 12 VDC
Chamber, Combustion
Filter, Fuel, Kit
Filter, Fuel
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 72
SECTION 11: SPECIAL TOOLS
60
80 100 120
140
40
160
20
psi
0
180
200
ASHCROFT
MADE IN U.S.A
141
102
138
139
140
WPX-310-646
WPX-440-280
WPE-600-190
****************
141
****************
Gauge, Adjustment, Electrode
Tester, Controller
Gauge, Fuel Pressure
Gas Analyzer, CO �
Order Grainger Part # 6T153 from a
Grainger Industrial Supply Store near
you or visit the Grainger website at
www.grainger.com.
Refractometer, Battery/Coolant
Order Grainger Part # 3MY57 from a
Grainger Industrial Supply Store near
you or visit the Grainger website at
www.grainger.com.
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Page 73
Appendix A
Wiring Diagrams
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
+
1
TO 12VDC
POWER SUPPLY
(I.E., BATTERY
CONNECTIONS)
���
4
2
-
+
+
ENGINE
PREHEAT
BEDROOM
HEATING ZONE
-
����������
4
6
+
-
1
2
-
+
4
6
1
2
DIESEL
(OPTIONAL)
ELECTRIC
SWITCH PANEL
����������
+
TO COZY
12VDC
HEAT EXCHANGERS
24 WATTS MAX.
BATHROOM
HEATING ZONE
WHT
GRN
VIO
BLU
YEL
BLU
RED
BLK
VIO
VIO
RED
BLK
BLU
BLU
RED
BLK
WHT
WHT
RED
BLK
ORG
ORG
BRN
ORG
IND-LT (+)
B3
IND-LT (-)
B6
������
������
WIRING DIAGRAM
�����������������
����������������
BLU
BLK
C2
YEL
GRN
BRN
C6
C8
����
�������������
������
������������
FUEL
SOLENOID
12 VDC
��������������
C5
C4
12VDC
MOTOR
�
CIRCULATION PUMP 3
12VDC
�
- +
�
CIRCULATION PUMP 1
12VDC
RED
�
12VDC
CIRCULATION PUMP 2
BLK
12VDC PUMP
���
ENGINE PREHEAT
�
���������
GRN
BLK
3-WHT
BLK
�����
JP7
GND
7 YEL
6 WHT
5 ORG
4 BRN
3 RED
2 BLUE
1 GRN
11 ORG
12 BLU
BLK
JUNCTION BOX
����
JP8
JP5
B4 IN +12V
1
1
8 BRN
7 RED
6 WHT
5 VIO
4 GRN
3 BRN
2 BLK
1 RED
���������������
���������������
��������������
����
G
L1
N
�������������������������
�������������
PREHEAT-I
B6 -
B3 +
B4 +
B2 -
C1-O
C7-I
B1 +
PUMP3 +
PUMP3 -
PUMP2 +
PUMP2 -
PUMP1 +
PUMP1 -
EPPUMP+
EPPUMP-
LTCO-O
LTCO-I
AC REL +
AC REL -
1-BLK
PREHEAT-O
ELECTRIC-I
ELECTRIC-O
DIESEL-I
DIESEL-O
#1 THERM-I
#1 THERM-O
#1 FAN -
#1 FAN +
#2 THERM-I
#2 THERM-O
#2 FAN -
#2 FAN +
#3 THERM-I
#3 THERM-O
#3 FAN -
#3 FAN +
#4 THERM-I
#4 THERM-0
#4 FAN -
#4 FAN +
#5 THERM-I
#5 THERM-O
#5 FAN -
#5 FAN +
TSTAT-O
TSTAT-I
LLCO-O
LLCO-I
16 RED
15 RED
14 BLK
13 BLK
12 BLU
11 ORG
������
������
3-WHT
������
6
����������
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
����������
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
FRESH WATER
TANK
HEATING ZONE
OPTIONAL
HEATING
ZONE
LIVING ROOM/
KITCHEN
HEATING ZONE
JP 1
JP 2
Circ. Pump 1
Circ. Pump 2
Circ. Pump 3
JP 3
JP 4
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
APPENDIX A
WIRING INFORMATION (AHE-100-04S)
A1
TO 120 VAC
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
���
�
�
�
�
����������
�
�
�
�
�
�
�
�
�
�
�
�
ENGINE
PREHEAT
ELECTRIC
SWITCH PANEL
BEDROOM
HEATING ZONE
�
����������
�
�
�
�
DIESEL
+
TO COZY
12VDC
HEAT EXCHANGERS
24 WATTS MAX.
BATHROOM
HEATING ZONE
�
�
GRN
WHT
GRN
YEL
+
IND-LT (+)
B3
IND-LT (-)
B6
JP7
GND
������
������
RED
BLK
WIRING DIAGRAM
��������������
������������
�������������
BLU
BLK
GRN
BRN
- +
YEL
�
C8
C2
ENGINE PREHEAT
����
C6
����
�
�
�
12VDC
CIRCULATION PUMP 3
12 VDC
�������������
�������������
������������
FUEL SOLENOID
G
GRN
12VDC
CIRCULATION PUMP 2
��������������
C5
C4
�
L1
N
L2
12VDC
CIRCULATION PUMP 1
5 RED
3 WHT
2 BLK
6-BLK
������������������������
��������������
������������������������
�������������
JUNCTION BOX
1 BLK
4 RED
3-WHT
1-BLK
�����
�����
��������������
��������������
����
5 RED
����
��������������
2 BLK
12VDC PUMP
���������
�����
JP5
+12V
7 YEL
6 WHT
5 ORG
4 BRN
3 RED
2 BLUE
1 GRN
+
���������
����
JP8
B4 IN
1
1
8 BRN
7 RED
6 WHT
5 VIO
4 GRN
3 BRN
2 BLK
1 RED
12 BLU
11 ORG
���������������
���������������
-
+
-
PREHEAT-I
B6 -
B3 +
B4 +
B2 -
C1-O
C7-I
B1 +
PUMP3 +
PUMP3 -
PUMP2 +
PUMP2 -
PUMP1 +
PUMP1 -
EPPUMP+
EPPUMP-
LTCO-O
LTCO-I
AC REL +
AC REL -
TSTAT-O
JP 3
PREHEAT-O
ELECTRIC-I
ELECTRIC-O
DIESEL-I
DIESEL-O
TO 12VDC
POWER SUPPLY + (OPTIONAL)
(I.E., BATTERY
CONNECTIONS) -
ORG
VIO
BRN
BLU
YEL
BLU
#1 THERM-I
#1 THERM-O
#1 FAN -
#1 FAN +
#2 THERM-I
#2 THERM-O
#2 FAN -
#2 FAN +
#3 THERM-I
#3 THERM-O
#3 FAN -
#3 FAN +
#4 THERM-I
#4 THERM-0
#4 FAN -
#4 FAN +
#5 THERM-I
#5 THERM-O
#5 FAN -
#5 FAN +
TSTAT-I
16 RED
15 RED
14 BLK
13 BLK
12 BLU
11 ORG
7 BLK
�
+
RED
BLK
VIO
VIO
RED
BLK
BLU
BLU
RED
BLK
WHT
WHT
RED
BLK
ORG
ORG
LLCO-I
LLCO-O
������
������
������
ELECTRIC
HI / LOW
����������
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
����������
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
FRESH WATER
TANK
HEATING ZONE
OPTIONAL
HEATING
ZONE
LIVING ROOM/
KITCHEN
HEATING ZONE
JP 1
JP 2
Circ. Pump 1
Circ. Pump 2
Circ. Pump 3
������
JP 4
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
APPENDIX A
WIRING INFORMATION (AHE-120-04X)
A2
���
TO 120 VAC
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
���
�
�
�
�
�
����������
�
�
�
�
�
�
�
�
�
�
�
�
ENGINE
PREHEAT
ELECTRIC
SWITCH PANEL
BEDROOM
HEATING ZONE
�
�
�
�
DIESEL
�
�
GRN
WHT
GRN
YEL
-
+
+
IND-LT (+)
B3
IND-LT (-)
B6
PREHEAT-I
PREHEAT-O
ELECTRIC-I
ELECTRIC-O
DIESEL-I
DIESEL-O
TO 12VDC
POWER SUPPLY
(I.E., BATTERY
CONNECTIONS)
ORG
VIO
BRN
BLU
YEL
BLU
#1 THERM-I
#1 THERM-O
#1 FAN -
#1 FAN +
#2 THERM-I
#2 THERM-O
#2 FAN -
#2 FAN +
#3 THERM-I
#3 THERM-O
#3 FAN -
#3 FAN +
#4 THERM-I
#4 THERM-0
#4 FAN -
#4 FAN +
#5 THERM-I
#5 THERM-O
#5 FAN -
#5 FAN +
(OPTIONAL)
JP8
JP5
B4 IN +12V
JP7
GND
1
1
JP 3
7 YEL
6 WHT
5 ORG
4 BRN
3 RED
2 BLUE
1 GRN
8 BRN
7 RED
6 WHT
5 VIO
4 GRN
3 BRN
2 BLK
1 RED
�������������
������������
�������������
������
������
12 BLU
11 ORG
���������������
����������
WIRING DIAGRAM
B6 -
B3 +
B4 +
B2 -
C1-O
C7-I
B1 +
PUMP3 +
PUMP3 -
PUMP2 +
PUMP2 -
PUMP1 +
PUMP1 -
EPPUMP+
EPPUMP-
LTCO-O
LTCO-I
AC REL +
AC REL -
TSTAT-O
16 RED
15 RED
14 BLK
13 BLK
12 BLU
11 ORG
BLK
BLU
BLK
RED
7 BLK
�
����������
+
TO COZY
12VDC
HEAT EXCHANGERS
24 WATTS MAX.
BATHROOM
HEATING ZONE
RED
BLK
VIO
VIO
RED
BLK
BLU
BLU
RED
BLK
WHT
WHT
RED
BLK
ORG
ORG
TSTAT-I
LLCO-O
LLCO-I
������
������
+
-
+
-
YEL
GRN
BRN
- +
�����
C8
C2
����
C6
�
����
12VDC
MOTOR
�
12VDC
CIRCULATION PUMP 3
12 VDC
�������������
������������
�
12VDC
CIRCULATION PUMP 2
FUEL SOLENOID VALVE
������������
C5
�
GRN
L2
N
G
12VDC
CIRCULATION PUMP 1
5 RED
3 WHT
2 BLK
L1
N
������������������������
�������������
������������������������
�������������
JUNCTION BOX
3-WHT
4 RED
3-WHT
1-BLK
��������������
C4
��������������
12VDC PUMP
�
5 RED
����
��������������
2 BLK
ENGINE PREHEAT
���������
���������
����
������
ELECTRIC
HI / LOW
����������
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
����������
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
FRESH WATER
TANK
HEATING ZONE
OPTIONAL
HEATING
ZONE
LIVING ROOM/
KITCHEN
HEATING ZONE
JP 1
JP 2
Circ. Pump 1
Circ. Pump 2
Circ. Pump 3
������
JP 4
+
TO COZY
HEAT EXCHANGERS 12VDC
24 WATTS MAX.
-
APPENDIX A
WIRING INFORMATION (AHE-130-04X)
A3
���
TO 120 VAC
Appendix B
Illustrations
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
APPENDIX B: RESETTING THE HIGH-LIMIT THERMOSTAT
To RESET:
Simply press the
Red button on the
Thermostat.
h-
C
VD
g
Hi
it
m
Li
at
t
os
rm
e
Th
To RESET:
Simply press the
Red button on the
Thermostat.
h-
C
VA
g
Hi
it
m
Li
rm
e
Th
at
t
os
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
B1
APPENDIX B: HYDRONIC HEATING SYSTEM OVERVIEW
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Circulation
Pump #1
Circulation
Pump #2
Circulation
Pump #3
Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
B2
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Fort Lupton, Colorado 80621
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Aqua-Hot ® Hydronic Heating System Shop Manual 09/04
Fax: 303-857-9000
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