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SERVICE MANUAL - Aqua-Hot Heating Systems, Inc.

1. Page 49 50 Overload Fault Indicator Light sasa eiie rh er rh ar hn er an pnr hn enr heo nre hne Page 50 Section 8 Diesel Burner OVOIVIBW c oi axe 51 NOM MTM RETI DNE Page 51 Di amp sel B urrier Overview tror xe pa rs besoin asa ed Yanan pda oes pK es fa uar Page 52 Diesel Burner Operational Flow Chart Page 53 Diesel Burner Operational Overview Page 54 56 Section 9 Detaching and Reattaching the Diesel Burner Detaching the Diesel Burner 1 1 1 2 1211 1 57 59 Reattaching the 2 2 2 2 2 1 01 2 2 crece eese 60 62 Section 10 Diesel Burner Components and Repair Information Diesel Burner Component Overview Page 63 MOLOT sani MI T Page 64 67 Flame Sensor ak aka aa aka aa Emm Page 68 69 70 71 FuelNezzlez E EE Page 71 72 Jt ees sem Page 73 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Section 10 Diesel Burner Components and Repair Information continued uM e M
2. Page 45 Terminal Strips with Screw Type Page 45 Low Voltage ceti Page 46 Replacement OCS CN u 47 Proper Jumper Pin Formation RM MERO Page 47 Electric Heating Element Status Indicator Light Page 48 Heating Zones Status Indicator Lights 1 5 1111 Page 48 Low Battery Voltage Fault Indicator Light Page 48 Low Temp Cutoff Status Indicator Light Page 48 Low Tank Level Cutoff Indicator Light Page 48 Heating Status Indicator uc uote pat qp aote qp axo Page 48 Engine Preheat Pump Indicator Light Page 49 Circulation Pump 1 Indicator Light ea iiie et Page 49 Circulation Pump 2 Indicator Light itte Page 49 Circulation Pump 3 Indicator Page 49 Diesel Burner Status Indicator Light
3. TANK SEN Page 47 SECTION 7 ELECTRONIC CONTROLLER INDICATOR LiGHTS Electric Heating Element Status NOTE The Electric Heating Element Status indicator light does not indicate AC Voltage at the Electric element It only indicates the status of the Side of the Electric element i e interior switch electronic control board relay This indicator light shows the status of the electric heating element by illuminating green for on red for fault or by turning off when the electric element switch is turned off If the light is off and the electric element switch on the interi or switch panel is off then the system is functioning correct ly If the indicator light is green and the electric element switch on the interior switch panel is on the system 18 also functioning correctly If the light is red and the electric element switch on the inte rior switch panel is on then there 1s a short in the electric element circuit This could be due to a bad connection a bad switch on the interior switch panel or an issue with the AC relay Heating Zone Status 1 5 NOTE The Low Temp Cut Off light must be illuminated for the Heating Zones to be activated These lights indicate the status of each of the motor home s room thermostat and the respective heat exchanger fan s The indicator light will illuminate green when the system is on and functioning properly red when on and not function
4. MEI ee wee ee eee M Page 74 76 allg qi P Pe 77 79 80 81 NA D MR d D Mid AA a AEA RS 82 83 Section 11 Troubleshooting If the Aqua Hot is Black Smoking Page 84 If the Aqua Hot is Blue White Smoking eese Page 85 If one of the Aqua Hot s Heating Zones will not get Page 86 If there is a lack of domestic continuous hot Page 86 87 If there is antifreeze leaking Po rb Page 87 Appendix A Wiring Diagram 12 1 1 1 1 1 nana na nana nana na annu Page 88 91 Appendix B Wire Gauge 1 111111111111 111 92 93 Appendix C Fuel Pressure check and 1 1 Page 94 99 Appendix D Extreme Cold Weather Operation sees Page 100 101 Appendix E Aqua Hot Annual Maintenancoe J J Page 102 115 Appendix F Winterization e res cepe Sp Su ENERO EE FERES anna Page 116 Page 5 2010 Aqua Hot
5. Switch Button Locking Tab Connect Wire 24 L Connect Wire 25 COM Page 21 Fluid Level Sensor The Fluid Level Sensor monitors the level of antifreeze and water heating solution within the Aqua Hot s boiler tank to ensure that an adequate volume exists Troubleshoot the Fluid Level Sensor if one of the following conditions has occurred e diesel burner and or electric heating element fails to operate e Aqua Hot fails to operate and the Low Tank Level Cutoff indicator light on the electronic controller 18 illuminated Troubleshooting 1 Verify that the Aqua Hot s boiler tank is full of the anti freeze and water heating solution 2 Verify that the wire connector 1s securely plugged into the fluid level sensor and secured with the attached clip 3 Verify that the fluid level sensor s wires are securely installed in the terminal strip on the wire harness as well as tightly fastened to the electronic controller The fluid level sensor requires power to operate and possesses a third wire for power 17 which advances from the sensor to join the red 1 wire on the PUMP 3 terminal on the electronic controller s plug NOTE If pump number 3 shorts out i e indicator light is red it will cause the Low Tank Level Cutoff light to illumi nate red as well 4 Verify the functionality ofthe fluid level sensor by completing the following
6. Combustion Air Sleeve Tray Mounting Tray gt Flange 1 Reinstall the Aqua Hot s access cover 2 Securely tighten the bolts and screws securing the access cover in place Page 62 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i IND Bre G Diesel Burner Controller Motor Ignition Coil Clutch Combustion Air Blower Fuel Solenoid Valve Electrode Boots Ignition Electrodes Fuel Nozzle SECTION 10 DiESEL BURNER COMPONENTS 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 T 16 15 14 13 12 11 10 Page 63 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 10 DiESEL BURNER COMPONENTS Diesel Burner Motor If there is no 12 Volts D C present on the C 2 pin con tinue The motor drives the combustion air blower and the fuel pump In order to perform the following proce 2 Inspect the Fast Blow fuse on the 20 wire dures it may be necessary to detach the diesel between the electronic controller and the burner head Webasto burner controller NOTE The Aqua hot 600 Series is equipped with a 20A 3 Verify the Electronic Controller is sending power Fast Blow Fuse located on the red 20 wire between the to the diesel burner motor electronic controll
7. a te SNILV3H TWNOUdO SANZ 002 2vAOZI Nawan 3NOZ ONILV3H WOO3 ONIAN IWISOW23Hi MOOZ 2vAOEL INCITS oe i U cA ACER AZOO OL WIRING DIAGRAM FOR AHE 675 D03 MANUFACTURED BEFORE JANUARY 2011 AHE 675 D03 APPENDIX A AlddNS H3MOd B GAZ OL ZL 5 0069 OVA OvZ 0002 OVA 021 ree 200 519 1oH enby sempe ud vn WAYSIDE wa I 3oH enbv es I I asny mojg 1503 YOZ I i1v3H3Hd 1N3W313 13530 3NISN3 215193713 19373 i HOLIMS 1 amp J d 1viSOVvem3HI 3NOZ ONILV3H woods XVW SLYM vC S83ONVHOX3 1V3H OL E HM 1VISOWB3HI 3NOZ ONILV3H MEET paq WOO8 HIV8 NYO OL N3901 E af xoomnaiNIT SLYM F S 3ONVHOX3 1V3H 581 A202 Ol H nec 1 NSB H lo v i Mna c 3NOZ ONILV3H H iHM 9 NNV1 H HS334 N388 SLYM y I S83ONVHOXG 1V3H I A202 OL JNO Y Ka pen i es ANS 3NOZ ONIV3H 1 LVISOWSSHL N3H IN i 8 WOO3 ONIAN 1 n H z i O nU SLYM F IL Je o4uo JAPS o S33ONVHOX
8. Page 18 SECTION 3 INTERIOR SwiTCH PANEL Fi cure 8 For Heaters Manufactured Before January 2011 Back of Switch Panel O Electric High Low Electric Element Engine Preheat Diesel Burner Switch Switch Switch sene Electronic Fine 1 re rames vete wire rse pe po Poza re wocreres pers remoxrose Diesel Switch to Electronic Controller connections Electric High Low Switch to Electronic Controller connections seen comroner_ Powe re Gres Electric Switch to Electronic Controller connections swash Ecos conroner eee Engine Preheat Switch to Electronic Controller connections Back of Switch Panel Electric High Low Electric Element Engine Preheat Diesel Burner Switch Switch Switch Switch Jumper Wire Jumper Wire Jumper Wire sens Conner Swick Convair To Hames vete es moss pee emoon Diesel Switch to Electronic Controller connections Electric High Low Switch to Electronic Controller connections Swa Escroncconroter Powe To crasse oues Electric Switch to Electronic Controller connections seien meer Engine Preheat Switch to Electronic Controller connections Page 19 2
9. Oldar lt Ca iar 3NOZ ONILW3H wooadag XVW SLYM PZ OGAZL SH3JONVHOX3 LV3H OL gt ir 3NOLONUVIM B Sz TBA 2 FZ g m 9 3 9 sf YOOTAIINIT SUY Fe p o I adr a 8 sama Fi L 4Wn4 s p 1VISOWa3ML 3NOZ ONILWIH ANVL HS334 I XVW SLIVM vC SYIONVHOXG 1V3H OL 3NOZ 1VISOWB3HL wouna UM nq 1 1 rmt eine ONS 3NOZ ONU V3H 1VISOW3HL N3HO 1I3 WOO3 A XVW SLYM vZ 2 o SH3ONVH2X3 1V3H A205 OL Page 88 2010 Aqua Hot 600 003 Hydronic Heating System Service Manual Rev WIRING DIAGRAM FOR AHE 600 DO3 MANUFACTURED AFTER JANUARY 2011 APPENDIX A 2 38 r zoi 3a1 AlddNS 43MOd 1 M 91 OGAZL 0 009 1503 VOZ 1V3H 3Hd MO 1H 135310 9419313 Jyo en NV IM 5 HOLIMS 1 e 3NOZ woosadas SLLVM 2 SH3ONVHOX3 LVSH 2 AZOO OL p ge LWISOWS3HL 3NOZ ONILWSH 6 WOO 06 6 7 XVI SLLYM tZ d g OGO CL SH3ONVHOX3 1V3H S 19 20201 lt 8 gt 1 150 4 3NOZ ONILV3H JNYL 5383 XVN S LLVM rZ SH39NVHOX3 1V3H 3NOZ
10. RISK OF SHOCK ATTENTION Page 11 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 2 AQUA HoT 600 SERIES OVERVIEW E ion Tank Inlet Ports wav 0102 91004 2 1 131110 way LOH Zone 1 2 and 3 Outlet Ports Product ID Label Engine Preheat Inlet Outlet Ports Domestic Water Inlet Outlet Ports ENI MNE PREHEAT POR S WARNING RISK OF SHOCK Tan Comperen Se AVERTISSEMENT ATTENTION RISQUE DE CHOC ELECTRIQUE Diesel Fuel Inlet Outlet Ports FUEL PORTS DIILSEL FUEL ONLY Page 12 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 2 AQUA HoT 600 SERIES OVERVIEW Thermostat Access Panel D C High Limit 2 Thermostats 2 A C High Limit Thermostat Page 13 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 2 AaqUA Hor 600 SERIES OVERVIEW Heat Source is selected from the Chart 1 Interior Switch Panel Diesel Burner Electric Element Switch Turned On Switch Turned On Diesel Burner heat Electric Heating Element source selected by heat source selected by Diesel Burner Switch Electric Element Switch Diesel Burner fires Electric Heating Element into the Combustion activates which heats the Chamber which heats antifreeze and water heat the antifreeze and wa ing solution in the Boi
11. A Remove the faceplate from the electronic controller B Install a jumper wire on the JP3 plug between pins 15 and 16 between LWCO T and LWCO O on the electronic controller in order to bypass the fluid level sensor If the Low Tank Level Cutoff indicator light on the electronic controller extinguishes when the 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS jumper wire is installed inspect the wire harness for damaged or severed wires If no wires are found to be damaged or severed follow the instructions in this section to replace the fluid level sensor If however the Low Tank Level Cutoff indicator light continues to illuminate once the jumper wire is installed follow the instructions in this manual to replace the electronic controller Replacement Procedure DANGER FAILURE DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be sure the heater has adequately cooled 2 Drain the antifreeze and water heating solution from the Aqua Hot s boiler tank using the drain valve 3 Remove the Thermostat Access Panel 4 Disconnect th
12. DBW201075 Voltage Power 12V 60W Output 13 2kW 45000Btu h Fue Type Diesel No 1 No 2 and Artic ratin Pressure 2 bar 29PS TR TR T III Heater No 90915E Vers 75 Serial No Year of ier 08 09 10 11 12 Figure 28 Fuel Nozzle Fuel Banjo Electrode Adjustment Gauge Air Intake Page 51 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev pg NOE pre p o 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 SECTION 8 DIESEL BURNER Heat Exchanger Combustion Chamber Exhaust Port Flame Sensor Fuel Pump Fuel Tubes Supply Return Combustion Air Intake Port with Adjustable Shutter 8 9 16 15 14 13 12 11 10 Page 52 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Operation sequence once the Aq ua Hot s Diesel switch is turned ON NOTE The Diesel switch s indicator light will illuminate anytime the Diesel Burner switch is in the ON position The Motor 2 which turns the Combustion Air Blower 5 and drives the Fuel Pump 714 will begin to operate NOTE If the Aqua Hot s coolant temper ature is approximately 190 F 5 F or higher the Motor 2 will not operate Only when the coolant temperature has dropped below 160 5 F and the VDC V
13. Flame Sensor 1 Electrodes cracked damaged overheated purple color improperly adjusted melted wires dirty 2 Fuel Pump leaks Rubber Grommets hard brittle 3 Photo disc rubber has been cut out warped right left bent Broken or cracked Ears 4 Harness amp Ignition Coil Wires due to over tightening of eyebolts crack or bare wires Hard or brittle wires Page 109 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev S te APPENDIX E AQUA HoT MAINTENANCE 7 Clean Ienition Electrodes and Flame Sensor 1 Ignition electrodes A Polish away any carbon deposits that may have baked onto the metal tips of the ignition electrodes with a course sponge 2 Flame Sensor A For light dirt dust and or carbon deposits simply wipe off the flame sensor with a soft cloth B Should heavy carbon deposits be present completely remove the flame sensor from the photo disc and clean with brake cleaner Page 110 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HoT MAINTENANCE Step 8 Replace The Fuel Nozzle Ignition Electrodes Fuel Nozzle Diesel Burner Head Fuel Nozzle Fuel Nozzle Manifold Hex 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 and remove NOTE Be sure to use care when handling the
14. Page 96 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 3 Running the burner off of an external fuel source Figure C7 Using an external fuel source and rubber fuel line hook the Webasto burner supply and return fuel lines up to run off of the external fuel source WARNING A spark will appear across the ignition electrodes 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 In some installations it may be necessary to shine a light on the flame sensor to simulate a flame condition to shot of the ignition coil Figure C7 HYDRONIC HEATING SYSTEM Diesel Engine Electric Burner Preheat Element 2 Turn the diesel burner switch to the on position pressure will register on the fuel pressure gauge once the fuel solenoid opens after approx 10 20 seconds Page 97 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 1 Follow the directions for Checking the Fuel Pressure in this section Figure C8 Using an external fuel source and rubber fuel line hook the Webasto burner supply and return fuel line
15. volve the potential for hot coolant be sure the heater 18 8 Install the replacement pump onto the mounting bracket adequately cooled Drain the antifreeze and water heating solution from the by aligning the Nylatch plungers to their respective holes and pushing the plungers in to secure the pump to the bracket Aqua Hot s boiler tank using the drain valve 9 Reconnect the wires on the replacement pump to the 3 Disconnect the defective circulation pump s wires by wire harness on the heater by uniting the red quick separating the quick disconnect terminals disconnect terminals 4 Using constant tension pliers loosen and slide back the 10 Refill the Aqua Hot s boiler tank with the antifreeze and constant tension clamps securing the hoses to the circu water heating solution lation pump 11 Test the Aqua Hot for normal operation WARNING RISK OF SHOCK ATTENTION RISQUE DL CHOC ELECTRIQUE Zone 1 Circulation Pump Zone 3 Circulation Pump Zone 2 Circulation Pump Nylatch Plunger Page 33 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 5 AQUA HOT COMPONENTS Pumps A Verify that the low temperature cutoff light and the Engine Preheat Pump diesel burner electric heating element status lights are illuminated on the electronic controller The Engine Preheat circulation pump draws the cold anti freeze and water heating solution from the motor
16. 2 Is the Exhaust Pipe Damaged or Restricted A Inspect the exhaust pipe for damage or excessive bends NOTE The Access cover will need to be removed to check the following SECTION 11 TROUBLE SHOOTING Is the Combustion Chamber warped or melted A Remove the Combustion Chamber and inspect for signs of damage Inspect the aluminum for signs of warping or melted aluminum Is the Nozzle bad Is the Fuel Pressure set at 145 PSI A Check the fuel pressure with the fuel pressure gauge NOTE The Diesel Burner will need to be tore down to check 3 Is the Air Intake closed off The Air Intake is located on the bottom of the diesel burner should be adjusted to the halfway point B There is a rubber air intake sleeve on the air intake and If it is collapsed it will need to be replaced 4 15 the Protection Cap damaged or cracked A Inspect the protection cap for cracks or holes 5 Are the Right and Left Grommets Worn out A Are they hard and brittle 13 B Has the rubber been cut out around the wires C Are they positioned correctly 6 Isthe burner properly positioned and secured properly Inspect the burner to ensure it is aligned properly B Tighten the Eye Bolts securing the burner in place Caution Do not over tighten the eye bolts or damage to the diesel burner may result Tighten the Eye Bolts to 20 40 inch pounds NOTE The Diesel Burner must be removed to check the fol
17. 7 Connect the wires removed from the defective high limit thermostat to the replacement high limit thermostat 8 Secure the Thermostat Access Panel cover back into place 9 Test for proper operation Page 25 AC High Limit Thermostat Left Electric Element The AC high limit thermostat serves as a safety measure in the event that the electric heating element continues to oper ate after the maximum operating temperature is reached The high limit thermostat allows the current for the heating element to pass through it until the boiler tank reaches a tem perature of 215 F Should this temperature be reached the high limit thermostat blocks the current to the element which prevents it from continuing to provide heat to the boil er tank Troubleshoot the AC high limit thermostat for the Left Elec tric element if the following condition has occurred e The Left Electric Heating Element fails to operate Troubleshooting 1 Disconnect all power supplies 2 Remove Thermostat Access Panel 3 Verify that the boiler tank s temperature is below 215 F 4 Locate the AC high limit thermostat for the left electric element and remove its wires 5 Using an ohmmeter check the thermostat for continuity If there is no continuity press the white reset button on the thermostat and re check for continuity If continuity 1s still not present after the reset button has been pressed follow the instructions in thi
18. Black brown wires Feed the C plug harness yellow and brown wires back through wiring access hole in the protection cap 8 Reinstall the protection cap Reconnect the ignition coil wires black to yellow and brown to brown wires 9 Reinstall the ignition coil and secure to the protection cap with the four ignition coil screws 10 Follow the directions for reattaching the diesel burner in section 9 11 Test for proper operation Page 66 SECTION 10 DiESEL BURNER COMPONENTS Motor Replacement Procedure continued Casting Motor Flange 2 62 p Page 67 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev i SECTION 10 DiESEL BURNER COMPONENTS Flame Sensor The flame sensor is a photo resistive device which supplies the diesel burner s controller with a DC voltage signal when it detects a flame When the flame sensor senses the light of the flame it will shut the ignition coil off and send a signal to the diesel burner controller indicating that everything 1s working properly If the flame sensor does not sense the flame it will shut the diesel burner down in a default after 20 seconds In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching instructions Connect the flame sensor s green and blue wires
19. Over tightening the retaining clamp bolt will bend the retaining clamp and prevent the photo disc from floating freely Not allowing the photo disc to float freely will cause poor combustion and result in a smoky exhaust A bent retaining clamp can be re straightened 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 4 Remove the electrode adjustment gauge Page 112 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX E AQUA HOT MAINTENANCE Step 10 Inspect Photo Disc Photo Disc 1 Ifthe photo disc is not free floating the electrode clamp bolt has been over tightened and has bent the electrode clamp Using a 10mm socket remove the electrode clamp and re straighten 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 Step 11 Re Install Diesel Burner Figure E14a I NOTE When reinstalling the diesel burner be careful not to damage the photo disc or bend the electrodes Also be careful to not pinch any wires between the burner and the Aqua Hot Tank Align the Diesel Burner with the Aqua Hot using the alignment tabs welded on the Aqua Hot Swing the Eye Bolts around the E
20. Remove the electronic controller from the mounting bracket by unsnapping each corner Proper Pin Jumper Configuration 1 Verify that the pin jumpers are configured as in the illus tration in this section If the pin jumpers do not match the illustration the Aqua Hot 600 will not function properly 2 If the jumpers pins need to be reconfigured simply tug gently on the black cap covering the pins to pull the black cap off 3 Reseat the cap on the pins appropriately as per the illus tration 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Snap the replacement electronic controller into the mounting bracket Ensure that the pin jumpers are properly configured for an Aqua Hot 600 reference information in this section for proper pin jumper configuration Reference Figure 26 Install each terminal strip plug back onto the electronic controller and tighten the screws on the terminal strips plugs to secure them to the controller 10 Connect the ground wire followed by the main 12 Volt DC power wire then the secondary power wire 1f appli cable to the appropriate screw terminals on the replace ment electronic controller board Reference Appendix A for additional wiring information Reinstall the faceplate onto the electronic controller and secure with the four screws previously removed 0 COM COM AHSTIR M
21. ing and the light will be off when the system is off If a fault condition occurs this could be due to a wiring is sue a faulty thermostat or issues with the heat exchanger fans Low Battery Voltage Fault This indicator light illuminates red when the DC voltage is below 10 5 Volts for Longer than 5 minutes and it will be off when the system has adequate voltage 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A If the light becomes red the switch may be reset after re storing voltage by pressing the Low Voltage Reset Button on the electronic controller with a long thin nonmetallic object or by turning the diesel burner switch on the interior switch panel off for 30 seconds then turning it back on Low Temp Cutoff Status The Low Temp Cutoff thermostat does not function on the Aqua Hot 600 series Therefore the Low Temp Cutoff ther mostat has been bypassed with the bottom jumper pin on the Electronic Controller and therefore the Low Temp Cutoff Status light will always be illuminated Low Tank Level Cutoff The Low Tank Level Cutoff is controlled by the fluid level sensor that senses the level of antifreeze in the Boiler Tank and will shut the Diesel Burner and the Electric Heating ele ment OFF when the light illuminates red Under normal operating conditions this light will not be illuminated because an adequate level of antifreeze and water heating solution within the Aqua Hot s Boile
22. motor s RPM reading is not within the above specs the motor must be replaced NOTE Test the diesel burner s bearings prior to reattach ing the diesel burner head or replacing the motor Worn bearings can cause lower than normal RPM readings and premature motor wear To properly test for worn bearings reference the bearings function test section Photo Tachometer Reflective Black Electrical Tape on Clutch Halves Page 65 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 10 DiESEL BURNER COMPONENTS Motor Replacement Procedure Be sure to move the Diesel Burner switch on the In terior Switch Panel to the OFF position and discon nect the Diesel Burner s power supply before de taching the Diesel Burner from the Aqua Hot Fail ure to turn off the Diesel Burner and disconnect power could result in serious bodily injury 1 Follow the directions for detaching the diesel burner in section 9 2 Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil to disconnect its wires from the C plug harness wires prior to removing Remove the protection cap from the diesel burner so that the motor clutch halves are exposed 3 Remove the three hex head screws that secure the motor and flange assembly to the blower housing Remove the motor and flange assembly along with the clutch halves Disconnec
23. the diesel burner switch can be used to reset a low voltage condition This is accomplished by turning off the diesel burner switch for 30 seconds then turning it back on SECTION 3 INTERIOR SWITCH PANEL Engine Preheat Switch The engine preheat switch activates the engine preheat pump which draws the motor home s engine coolant through the boiler tank to heat it before returning it to the engine block to transfer the heat there Either the diesel burner switch or the electric element switch must also be activated in order for the engine preheat feature to function The engine preheat switch does not need to be activated for the motor aide feature to work and should be shut off when traveling Electric Element 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 situa tions 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 Motor Home is connected to VAC power or when the generator is operat ing When the motor home is plugged into an AC power source e g shore power generator etc and the electric element switch is on the electric heating element will be used to pro vide heat to the boiler tank if the need arises A cold boiler tank can expect to be brought to operating temperature by the ele
24. 5 Add the total heat exchanger amperage draw to the amperage of the installed Aqua Hot Page 92 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX B WIRE GAUGE INFORMATION For example an Aqua Hot 600 D with six Aqua Hot Cozy heat exchangers has a total amperage draw of 23 38 amps Determining the Proper Wire Gauge 1 Measure the total length of the wire required for the distance between the vehicle s battery and the elec tronic controller for Aqua Hot models 450 DE 450 DM 525 D 600 D and 675 D and the heater itself for the Aqua Hot 375 D model 2 Using the determined length and total amperage draw consult the wire gauge chart included in this bulle tin Round up to the closest amp draw listed on the left then round up to the closest length at the top of the chart For example an Aqua Hot 600 D heater with six Aqua Hot Cozy heat exchangers with the electronic con troller placed 15 feet from the vehicle s battery would require an 8 gauge wire Wire Gauge Chart Figure B2 AMERICAN BOAT AND YACHT COUNCIL RECOMMENDATIONS TOTAL CONDUCTORS SIZES FOR 3 DROP IN VOLTAGE CURRENT Length of Conductor from Source of Current to Device and back to Source Feet INAMPS 10 15 20 25 30 40 50 80 79 80 390 100 110 120 130 140 150 160 170 Page 93 2010 Aqua Hot 600 003 Hydronic Heating System Service Manual Rev i APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT
25. Blower w shaft Blower Housing Screws Dished Surface Washer Dished Snap Ring Bearing Bearing Kit 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Surface Snap Retaining Washer Beari Ring Flat Drive Nut Flat Spacer Washer Gear Washer Tube Thick Steel NOTE Inspect the clutch halves for cracks and also en sure that the flat portion in each shaft hole is free of wear and tear Too much play on the shaft produces a loud clack ing noise If any cracks or wear are detected the clutch half must be replaced 15 Reinstall the protection cap Reconnect the black and brown wires of the ignition coil to the C plug harness yellow and brown wires Rein stall the ignition coil and secure to the protection cap with the four ignition coil screws Reconnect the ignition cables to the ignition electrodes 16 Fit the nozzle stand plate inside the cast aluminum blower casing and secure in place with the four noz zle stand plate screws Reattach the fuel supply and return lines to the diesel burner head 17 Reconnect the blue and brown wires to the fuel solenoid s and electrical terminals Al so 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 18 Follow the instructions for reattaching the diesel burner in the detaching reattaching sectio
26. If the ignition electrode s electrical insulator is cracked or damaged the ignition electrode must be replaced NOTE The electrode adjustment gauge is used to set the gap between the ignition electrodes The electrode adjust ment gauge is located on the outside surface of the diesel burner head on the left hand side Ignition Electrode Adjustment Procedure 1 Follow the directions for detaching reattaching the diesel burner in section 9 of this manual 2 Using a 10mm socket slightly loosen the retaining clamp bolt 3 Place the electrode adjustment gauge on the nozzle manifold hex and insert the metal tips of the ignition electrodes into the appropriate notches of the elec trode adjustment gauge Igniton _ mu 23 metal tips Retaining Clamp Bolt Retaining Clamp Ignition Cables Electrical Insulators NOTE Be sure not to over tighten the retaining clamp bolt when readjusting the ignition electrodes Over tightening the retaining clamp bolt will bend the retaining clamp and prevent the photo disc from floating freely Not allowing the photo disc to float freely will cause poor com A bent retaining bustion and result in a smoky exhaust clamp can be re straightened 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 4 Using
27. Relief Bore Fuel Supply Line Fuel Return Line Fuel Pressure Regulator Fuel Solenoid Page 74 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 10 DiESEL BURNER COMPONENTS CAUTION Inspect the nylon drive gear s cavity inside the cast alumi num blower casting for fuel stains If fuel stains are present a replacement of the bearings and or the entire blower cas Fuel Pump Replacement Procedure NOTE To perform the following procedure it will be nec essary to remove the diesel burner Follow the section on detaching and reattaching the diesel burner section 9 of this manual 1 Locate and disconnect the C Plug harness wires that connect to the flame sensor and the fuel solenoid Also disconnect the ignition cables from the igni tion electrodes 2 Remove the retaining clip that secures the photo disc in place Gently lift the photo disc so that it releases from the nozzle stand and the ignition elec trodes 3 Loosen the supply and return banjo bolts to remove the fuel supply and return pipes from the fuel pump Also disconnect the high pressure fuel pipe from both the fuel pump and the nozzle stand Discard the high pressure fuel pipe gasket rings and banjo bolts as replacements are provided in the new fuel pump kit 4 Remove the four nozzle stand plate screws that se cure the nozzle stand plate in place Remove the nozzle stand plate by pulling on the no
28. Watt Electric Heating Elements NOTE Reference Appendix A for Wiring Diagram AHE 675 D03 This model features a single 120 Volt A C 2000 Watt Electric Heating Element and one 240 Volt A C 4500 Watt Electric Heating Element NOTE Reference Appendix A for Wiring Diagram Page 8 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 2 AQUA HoT 600 SERIES OVERVIEW 600 D ut ys 7 Diesel Burnet Heat Input Firing Rate riisi EISSA SISESE 56 000 BTU hr Diesel Burner Fuel Consumption Continuous Operation 0000seseseeen eea anane aana menan 0 40 gal hr Heater Voltage Maximum Power Consumption tentent tenente aga na naa 12 Volt DC 60 watts Electric Heating Element specifications 60D ure tette ttn nates ena TAN ag na testate enki a do 2 120 Volt AC 2000 watts Electric Heating Element specifications 675 sse 1 120 Volt AC 2000 watts amp 1 240 Volt AC 4500 watts Zone Heat Circulation Pump specifications sessssseeeeeeeneeneenete tenete 3 12 Volt DC 21 watts each Number of Heating Zon s Maximum of 5 plus Engine Preheat Domestic Water Heating Capacity ette tu tetti reins ga apan tnt e apte re Ee tegit Continuous On Demand IDHE
29. back on and check for leaks and the presence of hot domestic water Verify that the replacement tempering valve has been set to the proper setting by taking a digital thermometer to a hot water faucet and set the water temperature between 115 F 123 F Secure both the Domestic Water Access Panel and the Thermostat Access Panel in place Page 30 SECTION 5 AQUA HOT COMPONENTS 7 DOMESTIC WH WATER PORTS COLO WATER HOT WATER OUTLET Mixer Valve Assembly Hot Water Outlet Port Cold Water inlet Port Page 31 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Pumps Circulation Pumps 1 72 and 23 The circulation pumps first draw the heated antifreeze and water heating solution from the Aqua Hot s boiler tank then propel it through the Hydronic heating system s interior heat plumbing Troubleshoot the circulation pumps 1f the following condi tion has occurred e The circulation pump is not operating and the Low Temp Cutoff Status indicator light is illuminated on the electronic controller e The Zone Pump indicator light illuminates red on the electronic controller Troubleshooting 1 Verify that the Low Temp Cutoff Status indicator light on the electronic controller is illuminated as it will be continuously with the 600 Series Aqua Hot SECTION 5 AQUA HOT COMPONENTS B With the jumper wire installed check the indicator light corresp
30. electric heating ele ment to be considered as a heating source by the Aqua Hot it must receive power from either a generator or from shore power and be selected as a heating source from the interior switch panel Once the antifreeze and water heating solution achieves operating temperature as determined by the Aqua Hot s control thermostat the domestic water system the engine preheat system and the interior heating system are permitted to operate as needed Domestic Hot Water System When hot water is requested domestic water from the motor home s fresh water tank 1s transported through a copper coil in the Aqua Hot s boiler tank where heat 15 transferred from the heated antifreeze and water heating solution to the do mestic water flowing through the copper coil The heated domestic water then flows through the tempering valve to be mixed with cool water from the fresh water tank to achieve an appropriate temperature before it flows to the faucet re questing hot water Engine Preheat System The engine preheat system is responsible for heating the mo tor home s engine block in order to make it easier to start up when cool weather conditions exist When the engine preheat system 15 activated via the interior switch panel the motor home s engine coolant is circulated through a dedicated copper coil in the Aqua Hot s boiler Page 6 SECTION 1 INTRODUCTION TO THE AQuUA HoT 600 SERIES tank where heat from the anti
31. emeret Approx 15mA Low voltage cutoff threshold 10 0V Under voltage lockout delay Approx 5 minutes Input Load Currents Zone thermostats Approx 4mA Diesel Burner switch Approx 12mA Electric Element switch Approx 4mA Engine Preheat switch Approx 4mA Low level cutoff switch Approx 10 Control 2 Approx 8mA Low temperature cutoff switch Approx 5mA 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Output Current Capacity Zone fans each sse 2 0A max Circulation pumps each 2 0A max Engine 2 2 0A max relay 500mA max B4 burner Webasto power 6 0A max B1 burner master control 2 0A max C1 C7 burner thermostat control 1 0A max Page 44 Electronic Controller Features Secondary 12 Volt DC Battery Connection The electronic controller is equipped with two 12 Volt DC power source connections which allow for a secondary 12 Volt DC battery connection This 12 Volt DC battery con
32. er casing If the burner is assembled improperly the protec tion cap will not go on 4 Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the 1gnition coil and disconnect its black and brown wires from the C plug harness wires prior to removing Remove the protection cap from the diesel burner so that the motor and clutch halves are exposed 5 Remove the three hex head screws that secure the motor and motor flange to the blower housing Re move the motor and flange assembly along with the clutch halves Disconnect the motor s black and brown wires from the C plug harness wires 6 Remove the four blower housing screws that secure the blower housing to the blower casing Remove the blower housing so that the combustion air blow er is exposed 7 Hold side B of the blower casing and loosen the retaining nut located in side A of the blower casing 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 that the combustion air blower can be easily removed from the blower casing NOTE Be sure to observe the placement of the three washers of the bearing kit To ensure proper tension the same order and direction of the dished surfaces of the wash ers must be followed when reassembling 8 With a pair of snap ring pliers remove the snap rings from both side A and side B
33. home s B Using a jumper wire bypass the engine preheat switch on the JP3 plug by connecting pins Preheat O and Preheat I together engine and then propels it through the Engine Preheat Heat exchanger located inside the boiler tank Troubleshoot the Engine Preheat Pump if the following con If the engine preheat pump indicator light illuminates dition has occurred with the jumper installed inspect for loose wires If no loose wires are found replace the engine preheat switch The Engine Preheat Pump is not operating and the on the interior switch panel inside the motor home Engine Preheat Switch on the Switch Panel inside the motor Home is in the ON position and the Low Temp If the engine preheat pump indicator light does not illuminate and the Low Temperature Cut Off Light is illuminated along with either the diesel or the electric Cutoff Status indicator light is illuminated on the electronic controller element status indicator light follow the instructions in e Engine Preheat Pump indicator light illuminates red this manual to replace the electronic controller on the electronic controller The Engine Preheat Pump indicator light illuminates Troubleshooting green on the electronic controller but the pump is not troubleshooting running NOTE Either the diesel burner switch or the electric ele ment switch must also be activated in order for the engine preheat feature to function A Us
34. nection is a product safety feature that should be utilized whenever the Aqua Hot s main 12 Volt DC power supply is connected to a battery disconnect switch This feature will Optional connection to the Negative Ground house battery disconnect Terminal Strips with Screw Type Fasteners The electronic controller uses terminal strips plugs that are equipped with screw type fasteners which are molded di rectly into the terminal strip plug itself This will ensure a positive mechanical connection between the electronic con troller and all wire harnesses attached to it 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev SECTION 6 ELECTRONIC CONTROLLER ensure that the Aqua Hot will be protected in the event that the primary power is interrupted while the diesel burner is operating e g during a burn cycle This secondary 12 Volt DC battery connection will ensure completion of the re quired 3 minute purge cycle of the Aqua Hot s diesel burner Screws 2 per Plug MAD P PR ba be ba ba ba bas Ad LARAHAN Page 45 SECTION 6 ELECTRONIC CONTROLLER Low Voltage Reset Feature button on the electronic controller use a thin straight non Whenever the Aqua Hot s DC power is interrupted for long metallic object to access the button through the faceplate or er than 5 minutes the low battery voltage fault red indica by turning off the diesel burner switch on
35. numerously CAUTION Before replacing the ignition coil Verify the ignition electrodes are not cracked or broken Verify that the ignition electrodes are adjusted properly Ensure the electrode boots are securely holding the electrodes in place Ensure the electrode boots are not broken inside the igni tion coil wires Ignition Cable Yellow Wire to Diesel Burner Page 80 SECTION 10 DiESEL BURNER COMPONENTS Ignition Coil 3 Connect the new ignition coil cables to the ignition electrodes NOTE In order to perform the following procedures it is 4 C h black and b necessary to detach and reattach the diesel burner head Be 5 ji C Jand brown sure to review the section for detaching and reattaching the wires hamess yen diesel bunar brown wires Attach the ignition coil to the protection cap with the four ignition coil screws then reconnect the ignition cables to the ignition Replacement Procedure electrodes 1 Disconnect the ignition cables from the ignition NOTE Ifthe new ignition coil does not function check electrodes Remove the four ignition coil screws wire connections and ensure they are properly connected that secure the ignition coil to the protection cap Lift the ignition coil and disconnect its wires from the C plug harness wires prior to removing 5 Follow the instructions for reattaching the diesel 2 D
36. remove NOTE To remove the diesel burner it may be necessary to disconnect the control and hi limit thermo stats from the diesel burner s white thermostat plug Page 105 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 5 Clean and Inspect the Combustion Chamber and Heat Transfer Tabs A DANGER A Use caution when handling the combustion chamber it may be extremely hot and serious burns could result from touching a hot combustion chamber iii Pi Combustion Chamber Assembly iu f Combustion Chamber Gasket ahi Air Swirler Nut Securing the Combustion Chamber 2 Remove the combustion chamber by loosening and 2 Once the combustion chamber has been removed the 4 nuts securing the combustion chamber Use a long handled wire brush and brush the heat trans n tank and pulling it straight out approxi fer tabs to loosen soot deposits Failure to do so will malah JG nah n reduce the Aqua Hot s heat transfer capabilities NOTE If the heat transfer tabs are excessively sooty it may be necessary to vacuum the soot out of the heat transfer tabs If there is a minimal amount of soot it may be left in the heat transfer tabs and will be evacuated out the exhaust pipe upon start up of diesel burner Page 106 2010 Aqua Hot 600 003 Hydronic Heating System Service
37. shown KEY Diesel Fuel Spray Combustion Air gt Exhaust Gases The particular component begins to operate E The component is currently operating When the Diese switch is turned ON the Motor and Combustion Air Blower begin to operate This process is referred to as the prime cycle Combustion Air Blower NOTE The Motor and Combustion Air Blower will begin to operate only if the VDC VAC Control Thermostat is closed and calling for heat Combustion Air The Fuel Pump builds up pressure against the 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 Diesel Fuel Chamber Fuel Pump Supply and Return Page 54 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 8 DiESEL BURNER Diesel Fuel Spray Combustion Air gt Exhaust Gases The particular component begins to operate The component is currently operating Diesel Burner Operation continued The gnition Coil produces a high voltage spark which is transferred across the gnition Electrodes The incoming air fuel mixture is then ignited creating combustion Ignition Coil Ignition Electrodes Combustion The c
38. terminals 9 Insert both the ignition cables into the rubber grom met and slide into the appropriate notch on the blower casing 10 Reconnect the ignition cables to the ignition elec trodes 11 Reinstall the photo disc and secure it in place with the retaining clip 12 Reconnect the flame sensor s green wire to the green C plug harness and the blue wire to the C plug harness violet wire Install rubber grommet around the harness wires and set into place NOTE Check the ignition electrodes for proper adjustment prior to reattaching the diesel burner 13 Follow the directions for reattaching the diesel burner in section 9 of this manual Page 75 SECTION 10 DiESEL BURNER COMPONENTS Fuel Pump continued Return Grommet Blower Casting Left Tube Fuel Banjo Return Grommet Blower Casting Right Screw Mounting Fuel Pump Sensor Flame Washer Lock Fuel Pump Clip Retaining Photo Disc Nozzle Fuel 0 35 GPH Disc Photo Manifold Fuel Nozzle Brass Pump Fuel Screw Manifold Plate Tube Fuel High Pressure Plate Manifold Bolt Banjo Gear Fuel Pump Nylon Gasket Ring Copper Ring Snap Tube Fuel Banjo Supply Page 76 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 10 DiESEL BURNER COMPONENTS Bearings 5 Remove the three hex head screws that secure the motor and motor flange to the blower housing Re The bearings support the combustio
39. the constant tension clamp back into place 11 Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution 4 Remove the hose from the defective check valve 5 Unscrew the defective check valve from the Aqua Hot s boiler tank Check Valve Page 29 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev 8 Tempering Valve The tempering valve for the Aqua Hot mixes the heated do mestic water from the boiler tank with cold domestic water at a preset ratio to reduce the risk of scalding Troubleshoot the tempering valve if the following condition has occurred There is a lack of hot domestic water Troubleshooting NOTE Prior to trouble shooting the tempering valve it is recommended to review the Lack of Hot Water Trouble Shooting guide in section 11 1 Inspect the tempering valve to ensure that it is not leaking 2 Test the temperature of the hot water using a digital thermometer at one of the hot water faucets Water Temperature should range between 115 F 123 F If the proper range cannot be set follow the instructions in this section to replace the tempering valve 3 Test the tempering valve s functionality by turning the knob If the tempering valve s knob does not turn freely fol low the instructions in this section to replace the temper ing valve Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND
40. their connections and using an ohmmeter check for continuity If there is no continuity follow the instructions in Troubleshoot the control thermostat if one of the following this section for replacing the control thermostat conditions has occurred If continuity exists complete the following e There is a lack of hot domestic water and interior heat e The heating Status light does not illuminate on the elec a Inspect the control thermostat s wiring and tronic controller when the Aqua Hot is below 158 F connections e Excessive Blue or white smoke is expelled from the ex haust b Install a jumper wire on the JP3 plug between pins 13 and 14 and TSTAT O Troubleshooting on the electronic controller in order to bypass the control thermostat 1 Turn the diesel burner and electric element switches on the interior switch panel on and check the electronic NOTE The diesel burner and or electric element switch controller to ensure that the Electric Heating Element must be in the on position for the Heating Status indicator Status and Diesel Burner Status indicator lights are light on the electronic controller to illuminate illuminated If the Heating Status indicator light on the electronic 2 Verify that the Heating Status indicator light on the controller does not illuminate with the jumper wire in electronic controller is illuminated as it should be when s
41. volts must be present at the diesel ON OFF switch circuit of the diesel burner controller 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 diesel burner controller s B plug and insert the probes of a DC voltmeter into the B 1 and B 2 locations Turn the diesel switch ON and observe the voltage level Ground Circuit Test Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the B 4 and C 5 locations and turn the diesel switch ON If a voltage reading does not register on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A VDC VAC Control Thermostat Circuit Test Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the C 1 and 2 locations and turn the diesel switch ON Ifa voltage reading does not register on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test VDC High Limit Thermostat Circuit Test Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the C 4 and B 2 locations and turn the diesel switch ON Ifa voltage reading does not register on the voltmete
42. within the combustion chamber NOTE In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review section 9 for detaching and reattaching in structions Fuel Nozzle Component Test 1 Follow the directions for detaching the diesel burner in section 9 of this manual 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A 2 Hook the diesel burner up to an alternate fuel source A Disconnect the steel fuel lines from the diesel burner B Install a fuel line bypass adapter fitting onto the diesel burners fuel line C Install rubber fuel lines on both the supply and return fuel pipes and install the other end of the rubber fuel lines into an adequate supply of diesel fuel Reference figure 49 3 Remove both the ignition cables from the ignition electrodes or connect a jumper wire with alligator clips across the metal tips of the electrodes A DANGER A Failure to connect a jumper wire across the ignition elec trodes or to remove the ignition cables from the ignition electrodes will result in a HIGH VOLTAGE shock and or a fire If the ignition cables are removed be sure to place a piece of electrical tape on the end of each cable 4 Remove the B plug from the diesel burner head s controller 5 Turn the diesel switch ON and then plug the B plug back into the diesel burner controller to activate the diesel bur
43. 0 DiESEL BURNER COMPONENTS Flame Sensor Replacement Procedure l Figure 47 In order to perform the following procedures it is necessary to detach diesel burner head Be sure to review the detaching attaching instructions in sec tion 9 Remove the screw that fastens the flame sensor to the photo disc and detach the sensor s green and blue wires from the C plug harness green and vio let wires and remove flame sensor Flame Sensor Green Wire Green Wire to Diesel Burner Blue Wire Violet Wire to Diesel Burner 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A 4 Slide the tab of the new flame sensor into the pro vided slot in the photo disc and secure in place with the screw 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 Follow the directions for reattaching the diesel burner in section 9 of this manual NOTE This screw is used to fasten the F ame Sensor to the Photo Disc Remove when replacing the Flame Sensor Page 69 SECTION 10 DiESEL BURNER COMPONENTS Ignition Electrodes The diesel burner s ignition coil produces a high voltage ignition spark across the ignition electrodes which ignites the incoming air fuel mixture Cleaning and Maintenance 1 Polish away any carbon deposits that may have baked onto the metal tips of the ignition electrodes with a course sponge 2
44. 010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 4 Because the Aqua Hot s exhaust 15 hot and must be kept away from any heat sensitive material the exhaust system should be checked to ensure that it continues to meet the following requirements e The exhaust must not be directed downward as a fire could result when parked in dry grassy areas e The exhaust must not terminate underneath the vehicle underneath an openable window or vent in the awning area of the motor home if applicable or near slide out areas CAUTION EXHAUST 5 REQUIREMENTS The exhaust must be able to freely exit away from the vehicle without any obstructions Two inch standard automotive type exhaust piping should be used with a maximum of two 90 degree pipe bends and should not exceed 20 feet The 3 inch and 4 inch black pipe nipples and the ex haust elbow originally supplied with the Aqua Hot must be present The two black pipe exhaust fittings MUST be utilized with all installations Failure to conform could create a hazardous situation and will void the Aqua Hot s ETL product listing NOTE A maximum of two 90 bends are exhaust pipe Also the exhaust pipe cannot be longer than 20 feet 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A allowed in the Page 20 This section details various components of the Aqua Hot that may require troubl
45. 03 620 6003 visiting them online at www rvia com or writing to them at the following address Recreation Vehicle Industry Association 1896 Preston White Drive P O Box 2999 Reston VA 20195 0999 Arrows indicate directional flow of domestic water To Cold Water Faucets INLET To Hot Water Faucets Page 116 Page 117 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i Aqua Hot HYDRONIC HEATING SYSTEM 600 Series SERVICE MANUAL eA 15549 East Highway 52 Fort Lupton CO 80621 Aq ua Ton free 800 685 4298 phone 303 659 8221 fax 303 857 7881 HEATING SYSTEMS INC www aquahot com
46. 3 1V3H i i Te OL 90 2010 Aqua Hot 600 003 Hydronic Heating System Service Manual Rev WIRING DIAGRAM FOR AHE 675 D03 MANUFACTURED AFTER JANUARY 2011 APPENDIX A 8 A33 977 201 301 NYO AlddNsS OL T M 9 OQAZL 00Sr 0002 OWA 02 snj 1504 WO 1V3H 3Hd IH 3NION3 2 122714 Opn1o313 T3NVd HOLIMS 735310 j Lt L IWISOWRBHL 3NOZ ONILW3H wooudas AHE 675 D03 202 OL 3NOZ SNILV3H O XVW SLLVM 92 SH39NYHOX3 LV3H s AZOO 01 o ms 61 LJ qaa 0 Ti 12 rambu i zz m E 69220 Ema sls IVISOWGORI INOZ ONILW3H 21 1 iiid L 1 WOO Hive I TBA 2 bd N35 OL ND OL I n 39O33INI P zu lll mun me O z aor m e DT I anes INOZ ONILV3H HM Cm U vamu 3NV1 H 4 HS333 I I ga 2O0 ZL XV S LLVM 72 2 SYSONVHOXS 1V3H onns uogng yasay ga 0 3NOZ ONILV3H N3HO1I3 WOOd ONIAIT IVISOWASHI 7 BL 1N3W313 PIMOS URIS su3oSNVHOXS IVAH ANENG NG penn el i ine si pi mes sap 22 380 z 202 OL vv ainbi4 Page 91 2010 Aqua Hot 600 D03 Hydronic Heating System Service Man
47. 38b 2 The eye bolt nuts can then be tightened by using a 10mm socket wrench with a 10 inch long exten sion Use extreme caution when tightening down the eye bolt nuts over tightening of the eye bolt nuts can cause the aluminum blower casing to crack Torque Specifications Approximately 20 40 in Ibs Page 60 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 2 Reattach the fuel lines to the Aqua Hot Figure 39a 1 Align the fuel lines on the diesel burner with the fittings on the Aqua Hot and using a 7 16 inch wrench tighten down both the supply and return fuel fittings CAUTION Be sure to remove the clamps off of the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to starting the diesel burner or serious damage will occur to the diesel burner s fuel pump Step 3 Plug in the diesel burner s controller and mount Figure 40 3 Locate the Diesel Burner s Controller and connect both plugs Page 61 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 4 Reinstall the Access Cover NOTE The access cover must be installed prior to operation as a safety switch exists which will prevent the Aqua Hot from operating whenever the access cover is not properly installed Figure 41a paves
48. 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 1 INTRODUCTION TO THE AQuA HoT 600 SERIES This service and parts manual is designed to aid trained and qualified service technicians with the process of troubleshooting and servicing the Aqua Hot 600 series Hydronic heating system The Aqua Hot 600 heating system features a 12 Volt DC powered diesel burner and two AC powered electric heating element These two heating sources are used in conjunction with an FDA approved GRAS Generally Recognized as Safe propylene glycol based boiler antifreeze and water heating solution in order to provide a continuous supply of domestic hot water interior fresh water tank heating inde pendent interior zone heating and engine preheating Be sure to reference Figures 3 through 5 for a complete compo nent overview Please note that all Danger Warning Caution and Note box es appearing as needed throughout this manual must be reviewed and adhered to during any service procedure in order to avoid potential hazards which could result in injury product damage or property damage Should additional assistance be needed please contact the technical support department at 1 800 685 4298 Monday through Friday between the hours of 7 00 AM and 4 00 PM Mountain Standard Time Danger Warning Caution and Note Boxes Danger Warning Caution and Note boxes appear through out this manual as a means of alerting the servic
49. AC Control Thermostat is call ing for heat will the Motor 2 begin to operate After approximately 10 25 se conds the Fuel Solenoid Valve 6 opens and fuel is sprayed into the Combustion Chamber 11 through the Fuel Nozzle 9 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Operational Flow Chart Simultaneously the Ignition Coil 3 produces a high voltage spark which is transferred across the Ignition Electrodes 8 The in coming air fuel mixture is then ignited creating combustion 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 combustion process will con tinue to operate in this manner until one of the following occurs A The VDC VAC Control Thermostat which senses cool ant temperature reaches the pre set temperature of approximately 190 5 F NOTE If process A occurs the Aqua Hot Heating Status Light on the Electronic Controller will go OFF B the Aqua Hot s Diesel Burn er Switch is turned OFF NOTE If process B occurs the Diesel Burner switch s Indicator Light on the Switch Panel will go OFF along with the Heating Status and Diesel Burner Status lights on the Electronic Control ler SECTION 8 DIESEL BURNER Once the heater switches OFF thermostatically or manua
50. CE OPERATES ON BOTH AC AND DC POWER USE COPPER CONDUCTORS ONLY Use a 25 Amp fuse for over current protection for the DC power supply Use a circuit breaker that cuts power at 20 Amps maximum for over current protection for the 120 VAC power supply Mount the Heater near a bay storage door so that the Access Cover can be easily removed for service WARNING DO OPERATE APPLIANCE WITH ACCESS COVERS REMOVED Minimum Heater Clearances Front Open Access Back inch Top 3 inches Sides 3 inches Install in strict compliance with local codes NFPA 1192 and the manufacturer s instructions ATER Tek Certified for use in a Recreational Vehicle ONLY US Listed Direct Vent Appliance 3069328 Maximum Tank Watts DC Watts AC Pressure 35 60 12 VDC 120 VAC 60 Hz Nozzle Size Angle Volts Volts 56 000 BTU 16 4 kWh 145 PSI 10 0 bar Input Firing Rate Pump Pressure WEBASTO DIESEL Diesel Burner Diesel Burner Fuel Type Model Number Serial Number Model Number Serial Number Manufactured Date 15549 East Highway 52 Fort Lupton CO 80621 1 800 685 4298 www aqua hot com Page 10 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Interlock Switch Zone 1 Circulation Zone 3 Circulation Circulation Pump Engine Pre heat Pump SECTION 2 AQUA HoT 600 SERIES OVERVIEW Thermostat V A C Wiring Access Panel Access Panel WARNING
51. ECTION 10 DiESEL BURNER COMPONENTS Be sure to remove the jumper wire that was used to make the connection from the C 1 location to the C 7 location Failure to do so will result in an overheating condition during normal operation Replacement Procedure 1 Remove both the B plug and the C plug from the diesel burner controller Gently pry away each side of the diesel burner controller bracket from the die sel burner controller s locking posts with a flat head screw driver Once the locking posts have been released pull on the diesel burner controller to re move it from the diesel burner head 2 Slide the new diesel burner controller into the diesel burner controller bracket Push down on the diesel burner controller until the locking posts snap into the bracket slots 3 Reconnect the B plug and the C plug NOTE Be sure to install the diesel burner controller with it s 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 diesel burner controller s internal circuitry Figure 60 Bracket Slot Locking Post Diesel Burner Controller Controller Mounting Bracket Diesel Burner Controller Page 83 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A 1 Black Smoke 1 Isthe heater experiencing a low voltage condition 8 A Fire up the generator or plug the coach into shore power
52. Instructions for Checking Fuel Pressure A fuel pressure gauge is used to properly check the fuel pump s pressure setting The fuel pump is preset to 145 PSI Perform the following procedures to check for a proper fuel pressure setting NOTE In order to perform the following procedure it is necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching instructions Step 1 Remove the diesel burner Figure C1 1 Refer to the section on detaching reattaching the diesel burner to detach the diesel burner Step 2 Install fuel line bypass fittings onto the diesel burner Figure C2 1 4 Fuel Tube unions 1 Locate the 1 4 fuel tube unions on the bottom side of diesel burner Page 94 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 2 Install fuel line bypass fittings onto the diesel burner continued Figure C3 2 Using a 13mm and a 9 16 wrench remove Steel Fuel lines from the diesel Burner Figure C4 Page 95 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 3 Installing the fuel pressure gauge Figure C5 Figure C6 2 Using a 5 8 and a 3 4 wrench install the fuel pressure gauge
53. Manual Rev i APPENDIX E AQUA HOT MAINTENANCE Step 5 Clean and Inspect the Combustion Chamber and Heat Transfer Tabs Combustion Chamber Fig ure E7 Back side of air Assembly swirler Outer ring that the photo disc seats against 3 Inspect the Combustion Chamber Assembly and Air Swirler for damage or signs of warping 1 Remove and Inspect the aluminum Air Swirler for signs of warping If any part of the Air Swirler is warped the Air Swirler must be replace A Inspect the outer ring that the photo disc seats against for signs of warping B Inspect the back side of the Air Swirler for signs of warping between screws Page 107 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX E AQUA HoT MAINTENANCE Step 6 Reinstall the Combustion Chamber CAUTION Failure to reinstall the combustion chamber will result in serious damage to the diesel burner is bok Combustion Chamber S Assembly iB Pally sevi 1 Reinstall the Combustion Chamber Assembly and the Air Swirler into the Aqua Hot Please note It will be necessary to replace the combustion chamber gasket anytime the combustion chamber is removed Page 108 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HoT MAINTENANCE Step 6 Inspect Diesel Burner Fuel Nozzle _ C E _ i Photo Disc L Inspect the following
54. NISA OT 552 asana gaga daa NI aaa aaa aa DIU due eiie ars ite Dod Ves E 18 5 H x 18 5 W x 36 75 L Weight approximately 186 Ibs Wet l approximately 303 Ibs NOTE All vehicle installations must comply with the requirements listed the Recreational Vehicle Industry Associ ation s RVIA ANSI NFPA 1192 Handbook for Recreational Vehicle Standards To receive a copy of this handbook and other pertinent RVIA Standards write to Recreation Vehicle Industry Association 1896 Preston White Drive P O Box 2999 Reston VA 22090 0999 call them at 703 620 6003 or visit them online at www tvia org Page 9 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev 5 SECTION 2 AQUA HoT 600 SERIES OVERVIEW Each Aqua Hot heating system possesses an I D label on the heater to what standard it has been tested and important unit itself This I D label details the specifications of the safety notices s2Aqua Hot HYDRONIC HEATING SYSTEM For installation only in a compartment that is completely closed off from living quarters and accessible only from the outdoors The Exhaust System MUST NOT terminate beneath the vehicle or under an openable window or vent Combustion Air MUST BE supplied from outside the vehicle A CAUTION THIS APPLIAN
55. OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Turn the motor home s water pump off 2 Drain the water pressure by opening the faucets and allowing the water to drain 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS 10 11 12 13 14 15 Remove both the Domestic Water access panel and the Thermostat Access Panel Disconnect the motor home s water lines from the tempering valve assembly Loosen and Remove the Bulk Head Fitting Nut Located on the top of the heater for the Hot output water Disconnect both the Hot and Cold Pex pipe fittings from the boiler tank Remove the tempering valve assembly from the Aqua Hot by sliding it out the thermostat access cover area Remove all fittings from the defective tempering valve and clean to be reused Wrap the threads of the brass fittings with a thread seal tape on the side that screws into the tempering valve and Install the brass fittings onto the replacement tem pering valve Install the replacement tempering valve onto the Aqua Hot by sliding in through the thermostat access cover Reconnect the Pex pipe fittings on the tempering valve assembly to the Aqua Hot Be sure to inspect the rubber seals and replace if necessary Reconnect the motor home s water lines to the temper ing valve assembly Turn the motor home s water pump
56. UA HOT COMPONENTS C Locate the Left AC relay and check pin 1 for 12VDC If no 12VDC is present on the left relay but there is 12VDC on the right relay troubleshoot the High Low switch Locate the switch panel inside the motor home Remove the switch panel Locate the wires for the High Low Switch Using a Voltmeter Verify 12VDC on pin 1 If voltage is present turn the switch on and verify 12VDC on pin 2 If no voltage is pre sent on pin 2 with the High Low switch in the High position the switch will need to be replaced g O gt D Locate the AC wires connected to the AC relay pins 6 and 8 and remove the AC wires from the relay E Using an ohmmeter check the relay AC pins 6 and 8 for continuity If no continuity exists follow the instructions in this section to replace the AC relay Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIUOS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed 2 Also ensure that the motor home is not connected to shore power and that a generator is not connected during this replacement procedure 3 Remove the Thermostat Access cover 4 Release the wires from the defective AC relay by removing the corresponding screw terminals 5 Remove the defective relay by dri
57. a 10 mm socket tighten the retaining clamp bolt 5 Remove the electrode adjustment gauge and reat tach to the diesel burner head Replacement Procedure 1 Using a 10mm socket loosen and remove the taining clamp bolt and the retaining clamp 2 Slide the electrode out of the photo disc 3 remove the electrode hold onto the orange electrode boot and pull firmly on the electrode 4 Once the electrode has been removed Inspect inside the orange electrode boot for the retaining clip which holds the electrode in place If it is missing replace the electrode boot Electrode Adjustment Gauge Ignition Electrodes Electrode Adjustment Gauge Properly Positioned Fuel Nozzle Fuel Nozzle Manifold 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Page 70 SECTION 10 DiESEL BURNER COMPONENTS Ignition Electrodes Replacement Procedure continued 5 Insert the new electrode into the orange electrode boot and snap into place Pull firmly on the elec trode to make sure the retaining clip has secured the electrode in place 6 Slide the electrode into the photo disc 7 Install retaining clamp and retaining clamp bolt and finger tighten 8 Follow steps 1 4 to properly adjust the electrodes Fuel Nozzle The fuel nozzle 1s simply a fuel atomizer It reduces the diesel fuel into a fine spray which is mixed with incom ing combustion air and is ignited
58. an issue with the wiring or the Engine Preheat Pump Pump 1 This indicator light shows the status of the Circulation Pump that controls the fluid for Heating Zone 1 by illuminating green for on red for fault and by turning off when the sys tem is off The system is functioning properly if the motor home s inte rior room thermostat is calling for heat the pump 15 operat ing and the light is green The system is also functioning properly if the pump and light are off and the interior room thermostat is not calling for heat If the light is red under any condition then there is either an Issue with the wiring or the circulation pump Pump 2 This indicator light shows the status of the circulation pump that controls the fluid for Heating Zones 72 3 and 4 by illuminating green for on red for fault and by turning off when the system is off Pump 2 18 also the Stir Pump and will be activated anytime the Diesel Burner is operating and heating up the antifreeze solution 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A The system is functioning properly if the motor home s inte rior thermostat is calling for heat the circulation pump is active and the indicator light is green The system is also functioning properly if the circulation pump and indicator light are off and the thermostat is not calling for heat If the light is red under any condition there is either an issue with t
59. ars on the diesel burner and securely tighten using a 10mm socket with a 10 inch long extension Use extreme caution when tightening down the eye bolt nuts over tightening of the eye bolt nuts can cause the aluminum blower casing to crack Torque Specifications Approximately 20 40 in Ibs Page 113 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX E AQUA HOT MAINTENANCE Step 12 Reconnect the Fuel Lines 1 Align the fuel lines on the diesel burner with the fittings on the Aqua Hot and using a 7 16 inch wrench tighten down both the supply and return fuel fittings CAUTION Be sure to remove the clamps off of the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to start ing the diesel burner or serious damage will occur to the diesel burner s fuel pump Step 13 Plug in the diesel burner s controller and mount 1 Locate the Diesel Burner s Controller and connect both plugs NOTE The Diesel Burner s Controller might have to be mounted onto the side of the diesel burner before the plugs are inserted into the control unit otherwise it might not be possible to mount the control unit Page 114 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX E AQUA HoT MAINTENANCE Step 14 Re Install the Aqua Hot Access Cover NOTE The access cover must be installed prior to operation as a safety switc
60. at When the Heating Zone Status indicator light illuminates on the electronic controller the corre sponding Pump 1 and or Pump 2 and or Pump 3 indicator light should illuminate as well 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A If the indicator light illuminates red complete the fol lowing A Disconnect the circulation pump s wires If the indicator light turns green with the circulation pump disconnected follow the instructions in this section to replace the circulation pump If the indicator light remains red with the circulation pump disconnected check the wiring for damage If no damage is found follow the instructions in this manual to replace the electronic controller Page 32 SECTION 5 AQUA HOT COMPONENTS Replacement Procedure FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR 6 5 Remove the hoses from the defective circulation pump Release the pump from the mounting bracket by pulling TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY on each Nylatch plunger then remove the defective pump from the Aqua Hot Ensure that the Aqua Hot has been completely shut 7 Slide the hoses back onto the replacement pump and set down and that all power sources have been disconnect the constant tension clamps back into place ed Also because this replacement procedure will in
61. ating element from the Aqua Hot s boiler tank 7 Install the replacement 2000 4500 watt electric heating 4 Check the electric heating element for functionality by element into the boiler tank ensuring that the up letter completing the following ing on the element is installed in the up position A Disconnect all power supplies 8 Connect the wires removed from the defective electric heating element to the replacement electric heating ele B Remove the Electric Element access cover ment and tighten the screw terminals C Remove all wires from the electric heating element Sy ReinstallalieBlacttio Element access caver D Using an ohmmeter check the electric heating ele 10 Follow the Directions for reattaching the diesel burner in ment for proper ohm reading 120 VAC 2000 Watt 8 9 ohms 240 VAC 4500 Watt 12 5 13 ohms section 9 11 Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution If no continuity exists follow the instructions in this section to replace the electric heating element Page 39 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 5 AQUA HOT COMPONENTS Left Electric Right Electric Element Element Page 40 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev AC Relay Right The AC relay 15 an electrical device where the DC circuit from the electronic controller determines wheth
62. calling for Heat Exchangers in heat the Zone calling for heat Page 14 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 2 AQuA HoT 600 SERIES OVERVIEW Antifreeze and Water Heating Solution As the antifreeze type and mixture ratio is essential to the Aqua Hot s performance and ability to comply with reg ulations the following information is being supplied to understand various types of antifreeze the quality of wa ter necessary and the mixture ratio Aqua Hot Heating Systems Inc recommends CAMCO s Boiler Antifreeze 100 Antifreeze Types The following information addresses the necessary usage of a propylene glycol based boiler type antifreeze in the Aq ua Hot Propylene glycol is a safer alternative to the more toxic ethylene glycol antifreeze however as mandated by IAPMO International Association of Plumbing and Mechan ical Officials only those propylene glycol based boiler type antifreezes deemed Generally Recognized as Safe GRAS by the FDA should be utilized Because of the significant impact various types of antifreeze can have on a Hydronic heating system including the level of safety provided it has been recognized that there is a need to provide an explanation regarding two additional promi nent types of antifreeze coolant available The following information should be utilized as an educational means of ensuring that the proper type of pr
63. ck the relay AC pins 2 and 4 for continuity If no continuity exists follow the instructions in this section to replace the AC relay Replacement Procedure DANGER FAILURE DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIUOS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed 2 Also ensure that the motor home is not connected to shore power and that a generator is not connected during this replacement procedure 3 Remove the Thermostat Access Cover 4 Release the wires from the defective AC relay by re moving the corresponding screw terminals 5 Remove the defective relay by drilling the rivets that hold the defective relay in place 6 Rivet the replacement AC relay to the AC access cover 7 Using the wiring diagram in Appendix A connect the wires previously removed to the replacement AC relay 8 Reinstall the Thermostat Access cover Page 41 AC Relay Left The AC relay is an electrical device where the DC circuit from the electronic controller determines whether the AC power is permitted to flow to the electric heating element This allows the electronic controller to switch the electric heating element on and off in conjunction with the interior switch panel and control thermostat even though the electric heating element is on a se
64. ctric heating element for functionality by 8 Reinstall the Electric Element access cover completing the following 9 Refill the Aqua Hot s boiler tank with the antifreeze and A Disconnect all power supplies water heating solution B Remove the Electric Element access cover C Remove all wires from the electric heating element D Using an ohmmeter check the electric heating ele Right Electric Left Electric ment for the proper ohms reading 8 9 ohms Element Terminal Element Terminal Block Block If the ohms reading is not within spec follow the instructions in this section to replace the electric heating element Replacement Procedure A DANGER A TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut Figure 20 Page 37 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i Electrical AC Electric Heating Element Left CAUTION There are two different Models in the Aqua Hot 600 Series The Aqua Hot 600 has 2 2000 Watt 120 VAC electric heat ing elements The Aqua Hot 675 has 1 2000 Watt 120 VAC electric heating element Right and 1 4500 Watt 240 VAC electric heating element Left The electric heating element uses AC power as an alternate power source for heating the Aqua Hot s boiler tank Troubleshoot the left electric heating element if the follow ing conditi
65. ctric heating element in approximately 1 to 2 hours The electric element alone will not be able to provide continu ous hot water HYDRONIC HEATING SYSTEM Engine Preheat Diesel Burner 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Electric Element Page 17 AHE 600 D03 Electric Element s 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 7 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 in approximately 1 2 hours 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 two 120 VAC 2000 Watt Electric Heating Ele ments will heat the Aqua Hot System to the maximum oper ating temperature 190 F 5 in approximately 0 5 1 hour SECTION 3 INTERIOR SwiTCH PANEL AHE 675 D03 Electric Element s Functi
66. d avoid any leaks NOTE adjustment of the ignition electrodes may be necessary after replacing the fuel nozzle Follow the igni tion electrode adjustment procedure found in the ignition electrode section of this manual 3 After replacing the fuel nozzle reattach the diesel burner head Be sure to reattach the diesel burner head prior to switching the heater ON Failure to do so may result in ignition of the diesel burner and serious bodily injury 4 Turn ON the diesel switch for 5 seconds then turn it OFF This will activate the diesel burner s prime cycle and flush the fuel system of any potential contaminants Perform this procedure twice 5 Test for normal operation Ignition Electrodes Fuel Nozzle Fuel Nozzle Fuel Nozzle Manifold Hex Page 72 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 10 DiESEL BURNER COMPONENTS Fuel Solenoid The fuel solenoid allows the flow of diesel fuel to the diesel burner s fuel nozzle NOTE If a long after smoking condition exists during the diesel burner s purge cycle the fuel solenoid valve kit may need to be replaced NOTE order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching instructions Fuel Solenoid Component Test NOTE Ifthe fuel solenoid is not working troubleshoot the di
67. d on the interior switch panel the DC power from the electronic con troller is permitted to flow to the AC relay which activates the relay in order to allow AC power to flow to the electric heating element When the electric heating element receives power it becomes active and supplies heat to the boiler tank until operating temperature is reached NOTE The Aqua hot 600D is equipped with 2 2000 watt 120 Volt A C electric heating elements The Aqua Hot 675D is equipped with 1 2000 watt 120 Volt A C Electric element along with 1 4500 watt 240 Volt A C electric heating element To operate both electric elements simulta neously the motor home must be plugged into a 50 amp circuit Therefore when there is less than 50 amp service provided there is a Hi Low switch where only one electric element can be activated by switching the switch to low Page 7 SECTION 1 INTRODUCTION TO THE AQUA HoT 600 SERIES Aqua Hot Model Differentiation 600 series Aqua Hot Heating Systems Inc Manufactures two individual models of the Aqua Hot 600 series Hydronic Heating Systems The varying factor between these two models is the output of the Electric Heating Elements featured In order to determine which of the following Aqua Hot models has been employed locate the Marking Plate on the Heating System reference Figure 2 For Marking Plate information and view the Model number AHE 600 D03 This model features two 120Volt A C 2000
68. e fluid level sensor s wires by releasing the clip securing the plug to the sensor and pulling the plug away from the sensor Reference Figure 11 for location 5 Using a 7 8 wrench unscrew the fluid level sensor from the Aqua Hot s boiler tank It may be necessary to use a 7 8 Crow s Foot wrench 6 Add a liquid thread sealant such as Loctite to the threads of the replacement fluid level sensor 7 Screw the replacement fluid level sensor into the port on the Aqua Hot s boiler tank and tighten with a wrench 8 Plug the fluid level sensor s wires into the replacement sensor and secure with the clip 9 Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution 10 Reinstall the Thermostat Access Panel Page 22 SECTION 5 AQUA HOT COMPONENTS Fluid Level Sensor Thermostats If the Heating Status indicator light is not illuminated check the following Control Thermostat Verify that the temperature of the boiler tank has fallen below the 158 F minimum operating temper The control thermostat is installed into the Aqua Hot s boiler ature by checking with a digital thermometer tank and monitors the temperature of the antifreeze and wa ter heating solution to determine when it is at operating tem B perature and when it requires heat The Aqua Hot is consid ered to be at operating temperature between 158 F and 190 F Disconnect the control thermostat s wires from
69. e supply inlet of the fuel pump for dirt particles Clean and or replace if necessary A plugged screen filter will restrict fuel from entering the fuel pump Also be sure to inspect for cracked or loose fittings on the supply line cracked or loose fitting on the supply line will allow air to enter into the fuel system 7 If fuel does flow through the fuel pump when ran off an external source inspect the following in the motor home A Check the motor home fuel tank for fuel If the fuel level is below 1 4 the Aqua Hot diesel burner will not operate B Inspect the supply fuel line for kinks which would prohibit fuel flow C Inspect the supply fuel line for cuts which would cause the diesel burner to suck air D Inspect the fuel filter to make sure all fittings are tight including hose clamps Also make sure the fuel filter is tight E Inspect the Aqua Hot for loose or cracked fittings F Inspect the supply fuel system for loose hose clamps throughout G Inspect the fuel pick up tube in the tank for loose connection and pin holes in the pick up tube Fuel Pump Cleaning and Maintenance 1 2 Check all fuel connections for tightness Check the screen filter located in the fuel supply inlet of the fuel pump for dirt particles Clean and or replace if necessary To adjust the fuel pressure refer to Appendix C Fuel pressure check and adjustment FUEL PUMP OVERVIEW Fuel Nozzle Air
70. e technician to important information A DANGER A INDICATES THAT PERSONAL INJURY IS LIKELY OR IMMINENT WARNING Indicates that serious damage to the heater will occur and personal injury is possible as well CAUTION Indicates that damage to the heater is possible NOTE Indicates information that requires special atten tion by the service technician 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Understanding the Aqua Hot 600 s Major Svstems The basis for the Aqua Hot heating system s functionality is the antifreeze and water heatng solution which is comprised of water that is distilled de ionized or soft as well as FDA approved GRAS propylene glycol based boiler antifreeze Through this solution s ability to maintain and transfer heat the Aqua Hot s three major systems the domestic water system engine preheat system and interior heating system are able to function effectively This antifreeze and water heating solution is contained within the Aqua Hot s boiler tank and is heated by the diesel burner when its operating criteria are met and or the electric heating element when its operating criteria are met In order for the diesel burner to be considered as a heating source by the Aqua Hot it must have an adequate fuel supply receive power from the elec tronic controller and be selected as a heating source from the interior switch panel In order for the
71. eck Check valves are installed into the zone outlet ports for each valvcund wait ive minutes to YE intertor beats heating loop to ensure that the antifreeze and water heating now present solution only flows in one direction If the heating solution attempts to backflow into the boiler tank the check valve it heat de presen alter tipping the check valve Preven ahat om happening the check valve was stuck closed and no further action is 2 necessary Troubleshoot the check valves if the following condition has occurred NOTE Storing the motor home for an extended period of time can cause the check valves to stick If after the initial There is a lack of interior heat in a particular zone release of the stuck check valve it continues to stick follow the instructions in this section to replace the check valve Troubleshooting 1 Verify that the heating zone is operating properly by 3 Check the Aqua Hot s antifreeze and water heating solu checking the following tion s ratio of water to propylene glycol The mixture ratio should be approximately 50 50 If the solution is A Check the electronic controller to insure that both comprised fully of antifreeze 100 the check valves the Heating Zone Status and corresponding pump status Pump 1 Pump 2 or Pump 3 indi will continue to stick cator lights are illuminated green B Check the circulation pump for operation by
72. ed and wire 25 is connected to the terminal labeled COM 4 Using a digital volt meter set to check for continuity check the interlock switch for continuity while the button is pushed in 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev SECTION 5 AQUA HOT COMPONENTS If continuity is not present with the button pushed in follow the instructions in this section to replace the Interlock Switch Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Disconnect the Interlock Switch s wires by pulling the quick connectors from the switch s spade terminals 2 Release the Interlock Switch from the Aqua Hot cabinet by pushing in on the locking tabs and pulling the Interlock Switch 3 Remove the defective Interlock Switch from the Aqua Hot 4 Install the replacement Interlock Switch onto the Aqua Hot ensuring that the locking tabs snap into place 5 Connect the Aqua Hot s wires to the replacement Interlock Switch with yellow wire 24 connected to the terminal labeled NO and yellow wire 25 connected to the terminal labeled COM NOTE If the Interlock Switch s wires are reversed the Interlock Switch will only allow the diesel burner to operate when the access cover is removed and the button on the switch is released Interlock
73. er and the diesel burner controller s B Plug which is the diesel burner motor power wire A Using a volt meter check for 12 Volt DC on the JP4 plug on the B4 pin red wire 3 If no power is present verify the electronic controller is Component Test receiving power from the batteries 1 Locate the diesel burner controller s C Plug and insert i Locate the main power terminals on the the probes of a DC voltmeter into the C 2 and the C bottom of the electronic controller 5 locations ii Using a volt Meter check for 12 Volt A Turn the diesel switch ON and verify both the diesel D C on the JP 8 terminal If no voltage is burner status light and the heating status lights are present verify that either the jumper is in illuminated on the electronic controller If either place that connects pins JP5 and JP8 together light is not illuminated follow the trouble shooting or if there is a power wire hooked up to the guide for that particular component JP8 terminal verify that it is receiving 12 Volt D C from the Motor home s batteries B Observe the voltage level If a normal voltage regis ters on the voltmeter and the motor is not operating If the JP8 pin does have 12 Volt D C inspect the C Plug Harness for loose or damaged but pin 3 on the JP4 terminal does not have wire connections If the C Plug harness and con power replace the electronic controller nections are in good condition but the motor
74. er the AC power is permitted to flow to the electric heating element This allows the electronic controller to switch the electric heating element on and off in conjunction with the interior switch panel and control thermostat even though the electric heating element is on a separate circuit Troubleshoot the Right AC relay if the following condition has occurred e The Right electric heating element fails to operate Troubleshooting 1 Disconnect the AC power source to the motor home unplugging from shore power or shutting off the gener ator 2 Turn the electric element switch on the interior switch panel on and check the electronic controller to ensure that the Electric Heating Element Status and the Heating Status indicator lights are illuminated 3 Using a voltmeter check pins 11 and 12 Relay and on the JP3 plug for 12 Volts DC If 12 Volts of DC power are not present while the Electric Heating Element Status and Heating Status indicator lights on the electronic controller are illuminat ed follow the instructions in this manual to replace the electronic controller If 12 Volts of DC power are present complete the fol lowing 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS A Locate the AC wires connected to the AC relay pins 2 and 4 and remove the AC wires from the relay B Using an ohmmeter che
75. esel burner s hi limit thermostats If they are tripped they will not allow the fuel solenoid to operate 1 Locate and detach the C plug harness violet and Brown wires from the fuel solenoid 2 Connect the lead of a 12 volt DC power supply to the fuel solenoid s electrical terminal 3 Intermittently apply the lead of the power sup ply to the fuel solenoid s electrical terminal 4 Listen for the fuel solenoid to click 1 e open and close 5 If the fuel solenoid does not click it must be re placed Fuel Solenoid Replacement Procedure 1 Disconnect the C plug harness violet and brown wires from the fuel solenoid 2 Using an 8mm wrench remove the lock nut and flat washer from the end of the fuel solenoid shaft and then pull the fuel solenoid away from the nozzle 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev stand approximately 1 2 Remove the fuel sole noid shaft from the nozzle manifold using a 16mm wrench Discard the shaft and valve kit as replace ments are provided with the new fuel solenoid as sembly 3 Insert the contents of the new fuel solenoid valve kit into the new fuel solenoid shaft Slide the new fuel solenoid onto the fuel solenoid shaft Thread the new fuel solenoid shaft with fuel solenoid to the fuel nozzle manifold and tighten Secure the fuel solenoid in place with the new flat washer and lock nut 4 Connect the C plug ha
76. eshooting and or replacement in the event of a malfunction The diesel burner and its components are detailed in Section 10 of this manual Replacement parts can be ordered through Aqua Hot s Web site at www aquahot com or by calling 1 800 685 4298 If additional assistance is needed the Technical Support Team can also be reached Monday through Friday from 7 00 AM to 4 00 PM Mountain Standard Time at 1 800 685 4298 Sensors Switches Interlock Switch The Interlock Switch is a safety device designed to ensure that the Aqua Hot s access cover is securely installed before allowing the diesel burner to operate Troubleshoot the Interlock Switch if the following condition has occurred e diesel burner fails to operate e diesel burner switch light does not illuminate Troubleshooting NOTE The interlock switch will prevent the diesel burner from operating without the access cover intact therefore the switch will need to be manually pressed during testing for the switch s functionality 1 Turn the diesel burner switch on from the interior switch panel and ensure that the boiler tank has sufficiently cooled in order to require heat from the diesel burner 2 Verify that the Heating Status and Diesel Burner Status indicator lights are illuminated on the electronic controller 3 Disconnect the two yellow wires from the interlock switch noting that wire 24 is connected to the terminal label
77. ffect the combustion process of the diesel burner Fuel Filter Page 102 APPENDIX E AQUA HOT MAINTENANCE Aqua Hot Maintenance Procedure 3 Replace fuel filter with proper replacement Note Before performing an annual canister maintenance it is recommended to test run NOTE It is recommended that the replacement fuel filter be filled with clean diesel fuel prior to installation the Diesel Burner While testing inspect exhaust for smoke 4 R h inch off pliers Step 1 Test Run the Diesel Burner dtd S a 1 Turn the Diesel Burner Switch to the on Step 3 Run the Diesel Burner position 2 After the Diesel Burner has ignited inspect 1 Turn the Diesel Burner Switch to the on po the exhaust for smoke sition 3 Shut the Diesel Burner off and wait for unit 2 After the Diesel Burner has ignited let it to completely shut off burn for 1 2 minutes to purge the old fuel out of the nozzle holder to prevent contami NOTE The diesel burner can either be shut off by 1 Turning the Diesel Burner switch to the off position nation of the replacement nozzle 2 Disconnecting the control thermostat wires 3 Shut the Diesel Burner off and wait for unit 3 Unplugging the diesel burner controller Reference Figure E3 to completely shut off NOTE The diesel burner can either be shut off by Step 2 Replace the Fuel Filter 1 Turning the Diesel Burner switch to the off position 2 Disconnecti
78. freeze and water heating solu tion is transferred to the motor home s engine coolant The heated engine coolant is then transported back to the engine where it transfers the heat to the engine to gradually warm it Additionally the Aqua Hot 600 includes a Motoraide fea ture which uses the circulation of the motor home s engine to transport the engine s coolant from the Aqua Hot s boiler tank to the motor home s warm engine and back to the boiler tank Through this process the boiler tank is kept heated which reduces the time required to bring the tank to operat ing temperature for interior heat and continuous domestic hot water This Motoraide feature is part of the engine preheat ing feature and plumbing system and requires no action on the user s behalf to function Interior Heating System The interior heating system is responsible for providing heat to the motor home s interior in order to maintain the temper ature at a comfortable level For interior heating it is the room thermostats that trigger the Aqua Hot s interior heating system When a thermostat rec ognizes that heat 1s required in a particular area it sends a signal to the Aqua Hot s electronic controller calling for heat The Aqua Hot responds by activating the circulation pump for that zone which sends the heated antifreeze and water heating solution through the Heating Loop correspond ing to the zone requesting heat The fans on the heat ex changers in the zo
79. g and rust anti corrosive protection A 50 50 mixture ratio is recommended which will result in a freeze point of approximately 28 F and a boil point of approxi mately 222 F The following information should be utilized for the purpose of clarifying some terms commonly associated with anti freeze Page 15 SECTION 2 AQUuA HoT 600 SERIES OVERVIEW Freeze Point and Burst Point Antifreeze lowers the freezing point of any liquid to which it has been added by preventing the formation of ice crystals however as the ambient temperature continues to decline the water the solution will attempt to attain a solid state The point in which the water begins to solidify is termed the Freeze Point Although the water in the solution has be gun to freeze producing a slushy consistency the anti freeze in the solution will continue to combat the normal expansion of the solution as it freezes The point in which the solution can begin to expand due to colder temperatures is called the burst point Once the solution reaches the burst point the potential is present for ruptured pipes to ex ist The burst point of the antifreeze and water heating solu tion is dependent upon the brand of propylene glycol em ployed Boiling Point The Aqua Hot utilizes the antifreeze and water heating solu tion as a transportation means for the heat produced from the internal processes The antifreeze absorbs the heat created
80. g ig agan anganaki Page 19 Interlock SWitCh aa TTC PM Aa an a Page 21 Fluid Level SeriSOR 22 23 Control Themis db orate Sono SA S Sa oe Sera bns Page 23 24 AC High Limit Thermostat Right rrr anapi gan ahi p ran pera Page 25 A C High Limit Thermostat Left 26 D C High Limit eee eee Page 27 28 Check WAVES Ee aski Page 28 29 I us zuibud T Page 30 31 Circulation Pumps 1 2 amp asso Frater pria Donner tutae enr nin p debi eo Page 32 33 Engine Pre Hestb PUMP oui turae urea audio iure ase emt ure e Dee a aeu Page 34 35 Electric Heating Element Right Page 36 37 Electric Heating Element u u uuu u Page 38 40 A C Relay Right niga napa nina naa nda naa nai naa nda naa tees ue napa nini naka nda aii Page 41 Relay Miri Page 42 43 Page 3 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Section 6 Electronic Controller General cr cc EN Page 44 Secondary 12 Volt DC battery Connection
81. h exists which will prevent the Aqua Hot from operating whenever the access cover is not properly installed Figure E17a F Aqua Hot 600 D Cover Combustion Air Sleeve Tray Flange Mounting Tray 1 Reinstall the Aqua Hot s access cover 2 Securely tighten the four screws securing the access cover in place Step 15 Test for Normal Operation A Turn the Diesel Burner switch on and let the diesel burner run for a complete cycle until it shuts off on it s own B After the Diesel Burner has shut off turn on the interior heat run hot water until the Diesel Burner cycles back on When the diesel burner cycles back on check the exhaust for signs of smoke Page 115 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A WARNING Not winterizing the Aqua Hot when freezing temperatures are present will result in serious damage to the Aqua Hot s domestic water heating system Also be sure to use an FDA approved GRAS rated antifreeze for winterization NOTE The Aqua Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized The Aqua Hot s domestic water heating system must be com pletely drained of domestic water any time the heater is stored where freezing temperatures may be experienced Winterizing the Domestic Water Heating System Please follow these instruct
82. he wiring or the circulation pump Pump 3 This indicator light shows the status of the circulation pump that controls the fluid for Heating Zone 5 by illuminating green for on red for fault and by turning off when the sys tem is off The system 18 functioning properly if the motor home s inte rior room thermostat is calling for heat the pump is operat ing and the light is green The system is also functioning properly if the pump and light are off and the interior room thermostat is not calling for heat If the light is red under any condition then there is either an Issue with the wiring or the circulation pump Diesel Burner Status This indicator light shows the status of the diesel burner by illuminating green when the diesel burner switch is on red for fault and by turning off when the diesel burner switch is turned off If the diesel burner switch on the interior switch panel is in the on position then the indicator light should be illuminat ed green When the Diesel Burner switch on the interior switch panel is in the off position the indicator light will not be illuminat ed Page 49 SECTION 7 ELECTRONIC CONTROLLER INDICATOR LiGHTS Diesel Burner Status continued If the indicator light turns red there is either a short in the wiring or the diesel burner is in need of servicing When checking the wiring be sure to verify that the diesel burner controller s harness connectors are comp
83. ies they should never be used in the Aqua Hot s Hydronic Heating System Antifreeze Mixture Water Quality In order to ensure maximum performance and longevity of an Aqua Hot heating system s boiler tank and associated components it has been determined that there is a need to use distilled de ionized or soft water in combination with concentrated propylene glycol for the Aqua Hot s antifreeze and water heating solution Please note that this is only nec essary when mixing concentrated propylene glycol antifreeze with water suppliers of pre mixed antifreeze are responsible for the use of high quality distilled de ionized or soft wa ter when preparing their antifreeze for sale Hard water possesses a high level of calcium and magnesium ions which deplete the propylene glycol antifreeze s corro sion inhibitors This in turn causes the antifreeze and water heating solution to begin turning acidic which can corrode the Aqua Hot s boiler tank and associated components prem aturely Therefore concentrated propylene glycol should be diluted with distilled de ionized or soft water that is 80 PPM or less in total hardness The local water agency should have up to date water quality reports that should indicate if the local tap water is within this guideline Antifreeze Terms and Mixture Ratio The following information addresses the process of selecting an antifreeze and water mixture ratio that provides adequate freeze boilin
84. ing a voltmeter check for 12 volts of DC power I on the JP3 plug pins corresponding to the pump not e The Engine Preheat Pump is not operating and the Engine Preheat Switch on the Switch Panel inside the motor Home is in the ON position and the Low operating If 12 volts of DC power are not present follow the Temp Cutoff Status indicator light is illuminated instructions in this manual to replace the electronic onthe electronic controller controller 1 Verify that the Low Temp Cutoff Status indicator light on the electronic controller is illuminated as it will be continuously with the 600 Series Aqua Hot B Disconnect the engine preheat circulation pump s wires from the wiring harness then using a voltme ter check the wires on the wiring harness for 12 RENE volts of DC power 2 Verify that the Engine Preheat Switch is in the ON posi tion on the interior switch panel inside the motor home 2 VS SHOWS ies ame If 12 volts of DC power are present at the wiring Either the diesel burner switch or the electric element f f harness follow the instructions in this section to switch must also be activated in order for the engine 7 replace the engine preheat circulation pump preheat feature to function 3 Onthe electronic controller verify that the engine NOTE The engine preheat circulation pump can be tested by connecting it to an external 12 Volt DC so
85. ions when winterizing the Aqua domestic water heating system 1 Completely drain the fresh water storage tank Disconnect the domestic water demand pump s suction line from the fresh water storage tank 3 Attach an adequate piece of hose onto the suction side of the domestic water demand pump 4 Place the opposite end of the hose into an adequate supply of FDA approved GRAS RV Antifreeze RV Fresh Water Storage Tank DOMESTIC WATER PORTS COLD WATER INLET HOT WATER OUTLET 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Antifreeze Domestic Cold Water Domestic Hot Water OUTLET APPENDIX F WINTERIZATION 5 Open and close all interior and exterior water faucets one at a time until only pure RV Antifreeze is present Perform this procedure for both the hot and cold faucets 6 Remove the hose and reconnect the domestic water demand pumps suction line to the fresh water storage tank Wi IP ic Wa For de winterization completely fill the fresh water storage tank Open and close all interior and exterior water faucets oneata time until only clear water is present visible If disinfecting the potable water system after de winterizing be sure to follow RVIAs Instructions for Disinfection of Potable Water Systems on Recreation Vehicles These in structions can be obtained by contacting the Recreational Vehicle Industry Association at 7
86. is not operational the motor must be replaced 12 Volt D C from coach house batteries 20A Fast Blow Fuse Fuse for Webasto Blower Motor Page 64 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 10 DiESEL BURNER COMPONENTS Diesel Burner Motor continued RPM Test 1 Disconnect the ignition cables from the ignition electrodes 2 Remove the four ignition coil screws that secure the ignition coil to the protection cap 3 Lift the ignition coil and disconnect its wires from the C Plug harness wires prior to removing 4 Remove the protection cap from the diesel burner so that the motor and clutch halves are exposed NOTE It may be necessary to remove the diesel burner to remove the bottom two screws securing the protection cap in place Follow the direction on detaching and reattaching the diesel burner in section 9 5 Place a few wraps of black electrical tape around the clutch halves and then place a small piece of reflective tape over the black tape 6 Disconnect the motor s black and brown wires from the C plug harnesses black and brown wires Figure 44 WARNING 7 Connect the motor s wires directly to a 12 volt DC power supply 8 Turn the power supply ON and use a photo tachometer to test for a proper RPM reading 9 At approximately 12 volts DC the RPM reading should be 4500 RPM s 300 RPM s If the
87. isconnect the ignition cables on the defective burner and test for proper operation ignition coil from the ignition electrodes Figure 58 Ignition Coil Ignition Cable Brown Wire to Diesel Burner TORON IB ie to Diesel Burner Page 81 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 10 DiESEL BURNER COMPONENTS Diesel Burner Controller The diesel burner controller operates all the compo nents of the diesel burner head and safely shuts the heater OFF in the event of an overheat flameout and low voltage condition It also receives diesel burner operation status signals from the flame sen sor VDC control thermostat and VDC high limit thermostat Component Test The following conditions must exist prior to per forming the diesel burner controller circuit tests on the following page If one of the conditions below does not exist please contact our technical support department at 1 800 685 4298 for additional assis tance Condition 1 A battery voltage level between 11 5 to 14 0 volts DC must be present at the diesel burner controller 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 diesel burner controller s B plug and insert the probes of a DC voltmeter into the B 4 and B 2 loca tions Condition 2 A voltage level of between 11 5 to 14 0
88. ler ter heating solution in tank the Boiler Tank 10 20 minutes 1 2 Hours Boiler Tank heats to 190 F Zone Thermostat The Engine Preheat A hot water faucet e g calls for heat switch on the Interior kitchen sink shower Switch Panel of the Mo etc calls for hot water tor Home is activated Heat is transferred to the Engine Preheat System NOTE The Diesel s DA NE Burner and or Electric Upnp acuvates dob h hich Heat is transferred to Heating Element as the Zone whic the Domestic Water System switched ON will auto galled Tue matically begin reheat heated antifreeze ing the antifreeze and waler heating solution is trans water heating solution ported throughout crops below L60 E the plumbing lines the that zone The engine s coolant is circulated through the Aqua hot s internal En gine Preheat System where the heat from the Boiler Tank is trans ferred to the engine s coolant Continuous hot water is supplied to the faucet The cooled antifreeze and water heating solu Heat Exchanger tion is returned to the fans activate Boiler Tank to be re The antifreeze and water heated heating solution within the Boiler Tank is re heated as needed and continues warming the engine s coolant as it circulates through the Aqua hot s internal En gine Preheat System Antifreeze and wa ter heating solution moves through the Heat is transferred into the Zone
89. letely locked togeth er Also verify the Photo Eye Wires have not been pinched Reference section 10 of this manual for additional diesel burner information Overload Fault This indicator light shows the status of the DC voltage ap plied to the electronic controller and the Aqua Hot Under normal operating conditions this indicator light is off This light illuminates red when the Aqua Hot is shut down due to excessive DC voltage over 14 8 Volts and or the electronic controller has overheated Once the excessive voltage issue is resolved the electronic controller will reset itself This light may also illuminate red if one or more of the heat er components has a direct short i e the diesel burner mo tor the interior heat exchanger fans the zone circulation pump etc Page 50 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 8 DIESEL BURNER Diesel Burner Overview The Aqua Hot s diesel burner is a device that ignites a mix from the flame is transferred to the antifreeze and water heat ture of diesel fuel and air within a controlled setting to serve ing solution where it can be used for each system of the Aq as a heat source The flame is established in a combustion ua Hot domestic hot water interior heat and engine pre chamber within the Aqua Hot s boiler tank and the heat heat Diesel Burner LD Plate V Jebasto Assembled in USA Ive Vn Heater Model
90. lling the rivets that hold the defective relay in place 6 Rivet the replacement AC relay to the AC access cover Page 42 SECTION 5 AQUA HOT COMPONENTS AC Relay Left Continued 7 Using the wiring diagram in Appendix A connect the wires previously removed to the replacement AC relay 8 Secure the Thermostat Access cover in place Left A C Relay Page 43 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Electronic Controller Overview The electronic controller is an electronic circuit board that controls the electrical functions of the Aqua Hot heating system All wiring for the switch panel is connected to the electronic controller as well as the wiring circuitry from the Electric Heating e Element Status Low Voltage 8 Reset SECTION 6 ELECTRONIC CONTROLLER Aqua Hot unit Indicator lights on the front panel will illu minate red if there is a short circuit overload or fault condi tion within the system It also will indicate when circuits are functioning properly with a green indicator light Aqua Hot HYDRONIC HEATING SYSTEM Low Tank Level Cutoff Heating Status Engine Preheat Pump Low Battery Voltage Fault e Diesel Burner Status utoff Status Overload Fault ELECTRONIC CONTROLLER Electronic Controller General Facts Nominal input voltage range 10 6V to 15V Idle curtent hee
91. lly the Fuel Solenoid Valve 6 closes which interrupts the supply of die sel fuel to the Fuel Nozzle 9 The Motor 2 will continue to run for approximately three 3 addi tional minutes This process is re ferred to as the Purge Cycle which cools the heater s internal compo nents and purges the Combustion Chamber 11 of any residual exhaust gases NOTE When the Aqua Hot s Diesel Burn er is switched OFF by the VDC VAC Control Thermostat the following process will take place 1 The Motor 2 will shut off once the three 3 minute Purge Cycle has expired THEN 2 The Aqua Hot s Diesel Burner will automatically turn back ON once the coolant reaches the preset temperature of approximately 160 5 F Summary The Aqua Hot s Diesel Burner is operational anytime the operator moves the Diesel Burner Switch to the ON position The Diesel Burner will then automatically maintain the coolant temperature in the Aqua Hot s Boiler Tank with out additional involvement from the operator Page 53 SECTION 8 DIESEL BURNER Diesel Burner Operations The following sequence illustrates how the Diesel Burner as a diagnostic tool to determine at what point in the diesel operates once it is activated Also 1f diesel burner malfunc burner s operation the malfunction is occurring Use the tions are experienced use this sequence of operating events KEY provided to understand each symbol
92. lowing 7 Is the Photo Disc bent or tight A The photo disc must be free floating If it is bound up it will not seat against the combustion chamber 11 the following What are the RPM s of the Combustion Blower Motor A The RPM s should be 4500 rpm at 12 VDC B If the motor 15 running slow inspect the bearings before replacing the blower motor Are the bearings faulty A The bearings should spin freely and sound smooth B Bearings that are bad will slow the motor down Is the Impeller fan gapped properly A The impeller fan should be gapped between 018 020 thousands NOTE Anything that throws off the air fuel mixture in the combustion chamber is a possible cause of black smoke Page 84 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 11 TROUBLE SHOOTING 2 Blue White Smoke 1 Ifthe heater is smoking blue white smoke 2 If the heater is smoking blue white smoke during during the start up or shut down cycle A Is the Fuel Solenoid functioning properly i Test the fuel solenoid and make sure it engages as soon as power is put to it Any delay in the fuel solenoid may cause blue white smoke ii Remove the fuel solenoid and inspect the plunger for any damage or debris that may interfere with the fuel shutting down B Is the Nozzle Tower Damaged i Inspect the area where the nozzle screws in for cracks in the brass ii Remove the fuel s
93. manual for troubleshooting tips Page 99 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A APPENDIX D ExTREME COLD WEATHER OPERATION Diesel Burner When storing the Motorhome Not winterizing the Aqua Hot when freezing temperatures are present will result in serious damage to the Aqua Hot s Domestic Water Heating 1 If the Diesel burner Fails to operate System Also be sure to use an FDA approved GRAS rated antifreeze for winterization A Is the Diesel Fuel in the motor home winter fuel or summer fuel B Is the Diesel Fuel liquid or Jelled NOTE The Aqua Hot can continue to be used for interior C Are the electrodes properly adjusted zone heating once the domestic water heating system D When was the last time an Annual Service has been drained and winterized was performed 120 Volt A C Electric Heating Element Please note that the 120 Volt AC Electric Heating Element is the Aqua Hot s secondary heat source for heating both the interior and or the domestic hot water during low heating de mand situations such as when moderate ambient temperatures exist and or when there is a low demand for domestic hot wa ter If the 120 Volt AC Electric Heating Element is not providing enough heat turn the Diesel Burner on in conjunction with the 120 Volt AC Electric Heating Element Aqua Hot High e HYDRONIC HEATING SYSTEM ON ON Engine Preheat Ele
94. ment Page 100 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i Front APPENDIX D ExTREME COLD WEATHER OPERATION If there is a lack of interior Heat Note The 120 Volt AC Electric Heating Element is the Aqua Hot s secondary heat source for heating both the interior and or the domestic hot water during low heat ing demand situations such as when moderate ambient temperatures exist and or when there 15 a low demand for domestic hot water If the ambient temperature 15 ex 1 Is the Diesel Burner activated 2 Is the Diesel Burner operating Properly 3 What is the antifreeze concentration inside of the Aqua Hot Boiler Tank 4 Was the heating system properly installed following the 600 installation manual A Are there at least 5 heat exchangers installed in the Interior of the motor home B Are there cold air returns installed for every heat exchanger Reference Figure D3 C Are the heat exchangers mounted as close to the hot air outlet grill as possible Reference Figure D2 Return Air Return Ai Indicates generally recommended locations for the Cozy eat Exchangers 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev Page 101 Monthly Maintenance Check the antifreeze and water heating solution to ensure that it is at the proper level by visually checking the solution level in the expansion ta
95. mostats individual wires If an individual wire does not have continuity that wire must be replaced If a thermostat with the wires removed that has been reset does not have continuity follow the instruc tions in this section to replace the high limit ther mostat NOTE Ifthe high limit thermostats continue to trip trou bleshoot the control thermostat and verify the boiler tank 1s full of the antifreeze water solution Replacement Procedure A DANGER FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnected 2 Remove the Thermostat Access Panel 3 Remove the two wires from the defective high limit thermostat by pulling firmly on the wires 4 Using a 5 8 wrench or socket remove the defective high limit thermostat from the Aqua Hot s boiler tank 5 Install the replacement high limit thermostat into the port on the Aqua Hot s boiler tank and finger tighten only 15 in Ibs 6 Connect the wires removed from the defective high limit thermostat to the replacement high limit thermostat 7 Secure the Thermostat Access Panel in place Page 27 SECTION 5 AQUA HOT COMPONENTS 215 F D C High Limit Thermostat Valves Check Valve 2 With the circulation pump operating tap on the ch
96. n air blower s move the motor and flange assembly along with the shaft and allows the blower to turn smoothly clutch halves Disconnect the motor s black and brown wires from the C plug harness wires NOTE order to perform the following procedures it is 6 Remove the four blower housing screws that secure necessary to detach and reattach the diesel burner head Be the blower housing to the blower casing Remove the blower housing so that the combustion air blower is exposed sure to review section 9 for detaching and reattaching the diesel burner instructions Bearing Test 7 Spin the combustion air blower by hand Placing one of the clutch halves to the end of the shaft as 1 In order to perform the following procedure it is sists with the spinning of the bearings necessary to detach and reattach the diesel burner head Be sure to review the detaching and reattach 8 Ifthe combustion air blower rotates smoothly with ing section for detaching and reattaching instruc out any friction or noise the bearings are in proper tions working condition If the combustion air blower does not rotate smoothly and or produces noise the 2 Locate and disconnect the C plug harness wires that bearings are worn and must be replaced connect to the flame sensor and fuel solenoid Also disconnect the ignition cables from the ignition electrodes Replacement 3 Remove the four nozzle stand plate screws that se 1 In order to perfo
97. n chamber for leaks NOTE It might be necessary to cut away some of the 2 On the Top Side of Aqua Hot insulation around the tank ports to locate the leak A Expansion Tank Connection B Control Thermostat i Cracked expansion tank tubing ii Loose air release valve NOTE It might be necessary to cut away some of the iii Brass hose barb fitting defective or loose insulation around the tank ports to locate the leak B Supply Return Ports i Defective fitting Drai 1 ing to th i Drain Valve and Hose going to the drain i Lesung e valve D Electric element E Circulation Pump i Hoses ii Tank ports NOTE It might be necessary to cut away some of the insulation around the tank ports to locate the leak iii Pump Page 87 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A WIRING DIAGRAM FOR AHE 600 D03 MANUFACTURED BEFORE JANUARY 2011 AHE 600 D03 APPENDIX A A33 9 001 301 M91 DAA ZL MO000ZZ OVAOZL zoa oo930H enby umda uoy ATOL xg cael kanang ON SINSISAB ENILV3H 30H enby s 1504 VOZ yanyna AV3H33d lN3W313 SNISNS Ohil2313 1 ana pr MM UN o d T3NVd HOLIMS
98. n in this manual Side B Side A Blower Casting Rubber Grommets Blower Casing O Ring Wave Page 79 SECTION 10 DiESEL BURNER COMPONENTS Ignition Coil The ignition coil produces a high voltage ignition spark approx 8000 volts which is released across the metal tips of the ignition electrodes during the initial diesel burner start up Use extreme care when testing the ignition coil as a High Voltage Shock may result NOTE order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review the section for detaching and reattaching the diesel burner Component Test 1 Remove the four ignition coil screws that secure the ignition coil in place 2 Disconnect the ignition coil s black and brown wires from the C plug harness yellow and brown wires Figure 57 Ignition Coil Brown Wire Brown Wire to Diesel Burner 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A 3 Connect the ignition coil wires directly to a 12 volt DC power supply i e black wire to lead and brown wire to lead 4 Turn the power supply ON and watch for a spark to appear across the metal tips of the ignition elec trodes If a spark does not appear the ignition coil must be replaced NOTE Some ignition coils are intermittent and will need to be tested
99. n of the aforemen tioned functions If excess propylene glycol exists within an antifreeze and water heating solution the water s heat ab sorption properties are compromised which could ultimately inhibit the Aqua Hot from providing adequate domestic hot water and interior heating Additionally if the antifreeze and water heating solution contains over 70 percent antifreeze the freezing point is tually raised resulting in less freeze protection Page 16 The interior switch panel is used to control the two potential heating sources for the Aqua Hot s boiler tank as well as to control the engine preheat feature When a switch is activat ed the indicator light on the switch will illuminate Diesel Burner Switch When the diesel burner switch is in the on position and any time the control thermostat tells the electronic controller that heat is needed for the boiler tank the diesel burner will re spond by firing up and providing heat A cold boiler tank can expect to be brought to operating temperature by the diesel burner in approximately 10 to 20 minutes In order to obtain continuous hot water the diesel burner switch must be activated NOTE If the diesel burner fails to ignite the diesel burner status light will go out indicating to the customer the burn er has gone into a default To reset the default the diesel burner switch must be turned off for 5 seconds and then turned back on Additionally
100. n valve 9 Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution 3 Remove the Thermostat Access Panel 21 10 Re install the Thermostat Access Panel 4 Disconnect the defective control thermostat s wires by separating the quick disconnect terminals Reference 12 dot locate 11 Test the Aqua Hot for normal operation 185 F Control Thermostat Page 24 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A AC High Limit Thermostat Right Electric ement The AC high limit thermostat serves as a safety measure in the event that the electric heating element continues to oper ate after the maximum operating temperature is reached The high limit thermostat allows the current for the heating element to pass through it until the boiler tank reaches a tem perature of 215 F Should this temperature be reached the high limit thermostat blocks the current to the element which prevents it from continuing to provide heat to the boil er tank Troubleshoot the AC high limit thermostat for the right elec tric element if the following condition has occurred e The right electric heating element fails to operate Troubleshooting 1 Disconnect all power supplies 2 Remove the Thermostat Access Panel 3 Verify that the boiler tank s temperature is below 215 F 4 Locate the AC high limit thermostat for the Right Elec tric element and remove its
101. ne calling for heat are also activated there fore as the heated solution flows over the heat exchanger s fins the heat is transferred to those fins and dispersed into the interior of the motor home by the fans Until the thermo stat signals that heat 1s no longer required the Aqua Hot will continue to send the heated antifreeze and water solution through the loop which returns the cooled solution to the Aqua Hot s boiler tank to be re heated before being sent back through the loop again This process continues until the pre set temperature of the interior is reached and the interior room thermostat signals the electronic controller that heat is no longer required 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A AC Circuit Although the diesel burner is the primary heating source for the Aqua Hot and is necessary for providing continuous do mestic hot water an alternate heat source exists for moderate temperatures which functions with an AC circuit Whenever the motor home is connected to an AC power source plugged into shore power or using a generator the Aqua Hot s electric heating elements 2 have the ability to func tion in order to provide heat for the boiler tank When the antifreeze and water heating solution falls below operating temperature as determined by the control thermo stat a signal is sent to the electronic controller requesting heat Because the electric element switch is activate
102. ner After approx 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 Figure 49 Page 71 SECTION 10 DiESEL BURNER COMPONENTS Fuel Nozzle 6 Remove the B plug from the diesel burner control ler 7 Ifthe cone shaped spray pattern did not appear fol low the troubleshooting guides for the following components and verify they are operating properly A Fuel Solenoid B Fuel pump C D C High Limit thermostats 8 If the components listed above are operating proper ly and there is still no fuel coming out of the nozzle replace the fuel nozzle Fuel Nozzle Cleaning and Maintenance The fuel nozzle is a precision calibrated part and cannot be cleaned or serviced A replacement of the fuel nozzle is recommended annually Fuel Nozzle Replacement Procedure 1 Use a 3 4 in wrench to hold the fuel nozzle stand hex while loosening the fuel nozzle with a 5 8 in wrench and remove 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 partially plugged orifice will restrict fuel flow which will affect the combustion process of the diesel burner Diesel Burner Head 2 When replacing the fuel nozzle be sure to tighten the nozzle loosen it a 1 4 turn and then firmly re tighten This will establish a seated fit an
103. 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 2 When replacing the fuel nozzle be sure to tighten the nozzle loosen it a 1 4 turn and then firmly retighten This will estab lish a seated fit and avoid any leaks A DANGER A Be sure to reattach the diesel burner head prior to switching the heater ON Failure to do so may result in ignition of the diesel burner and serious bodily injury Page 111 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HoT MAINTENANCE Step 9 Adjust Ignition Electrodes Electrode Adjustment Gauge Igniton 4 Retaining metal tips Electrode on Ignition Photo Disc Electrodes Retaining Ignition Clamp Cables Electrode Adjustment Gauge Properly Positioned Fuel Electrical Insulators Nozzle Fuel Nozzle Manifold 1 Using a 10mm socket slightly loosen the retaining clamp bolt 2 Place the electrode adjustment gauge on the nozzle manifold hex and insert the metal tips of the ignition electrodes into the appropriate notches of the electrode adjustment gauge 3 Using 10 mm socket tighten the retaining clamp bolt Be sure not to over tighten the retaining clamp bolt when readjusting the ignition electrodes
104. ng the control thermostat wires 3 Unplugging the diesel burner controller Reference Figure Connector A 1 Locate Fuel Filter 2 Using hose pinch off pliers clamp off both fuel lines going to the fuel filter Reference figure E2 Figure E3 10 Micron Fuel Filter Diesel Burner Controller Plugs 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Page 103 APPENDIX E AQUA HOT MAINTENANCE Aqua Hot Maintenance Procedure Step 4 Remove The Diesel Burner CAUTION Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to beginning this replacement procedure Figure E4b Diesel Burner Controller 1 Locate the Diesel Burner s Controller and dis 2 Using an 7 16 wrench loosen the nuts securing connect both plugs each fuel line to the Aqua Hot Figure E4d 3 The Diesel Burner is secured to the Aqua Hot with two nuts that can be loosened and swung out of the way by using a 10mm socket wrench with a 10 inch long extension Page 104 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX E AQUA HoT MAINTENANCE Aqua Hot Maintenance Procedure Step 4 Remove The Diesel Burner continued Diesel Burner s white Thermostat Plug 4 Carefully pull the Diesel Burner away from the Aqua Hot 4 to 5 inches before rotating the burner and then
105. nk The level of the antifreeze and water heating solution within the expansion tank should only be checked when the Aqua Hot is at maximum operating temperature If additional antifreeze and water heating solution is re quired fill the expansion tank to the level mark Be sure to reference Section 2 of this manual to ensure that the proper type of antifreeze is selected and mixed with high quality water at the correct mixture ratio Additionally it is recommended that the diesel burner be fired and allowed to run monthly to keep it in good working order Fuel Nozzle 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev APPENDIX E AQUA HOT MAINTENANCE Annual Maintenance A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY To keep the Aqua Hot running smoothly it is recommended 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 To ensure maximum diesel burner performance always use the recom mended fuel nozzle and fuel filter when replacing these parts NOTE Be sure to use care when handling the fuel nozzle Oils and or small dust or dirt particles from the hands may plug the nozzle s small orifice A par tially plugged orifice will restrict fuel flow which will a
106. nt following i 9 Wording Properly i Stuck Check Valve ii Inspect for a Kinked plumbing line 11 15 there a Lack of antifreeze in the boiler tank B Is the Heater up to operating temperature C Is the Interior Room Thermostat Calling for heat D Is the Zone Circulation Pump operating G Is the Low Temperature Cutoff Thermostat light on the electronic controller out E Are the Heat Exchanger fans operating H Isthe Electronic Control Board working properly 4 Lack of Domestic Hot Water C Has the Internal Washing Machine Valve gone bad 1 Things to keep in mind when trouble shooting a heater for a lack of hot water i If both the internal washing machine valve has gone bad it acts like a secondary A The Diesel Burner must be on for continuous mixer valve and the remaining hot water hot water faucets will only produce warm water NOTE The Electric Element is designed to be used D What is the Antifreeze concentration during low heat demand situations and will not supply continuous hot water i The proper antifreeze concentration should be between 30 50 antifreeze If the concentration is over a 50 B The Heater is only rated for a water flow of L5GPM antifreeze concentration the antifreeze does not transfer the heat properly and t here will be a lack of domestic hot water C The heater is only rated for a 55 F Temperature rise on the cold water coming in E Whatis the ope
107. of the blower casing Push all the contents of the bearing kit out of the blower casing s bore bearing cavity Discard the retaining nut steel drive gear snap rings bear ings spacer tube and washers as replacements are provided in the new bearing kit 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A NOTE Be sure to inspect the blower casing s bore bearing cavity for signs of damage due to potentially seized bear ings If damage is present the blower casing must be re placed 9 Install a new snap ring into side A of the blower casing Once the snap ring is in place insert the remaining contents of the new bearing kit into side B of the blower casing starting with the wave washer Secure the bearing kit assembly in place with the remaining snap ring 10 Inspect the combustion air blower for warping and or damage If warping or damage is visible the combustion air blower must be replaced 11 Reference Figure 55 for exact placement of the three washers that slide over the threaded end of the combustion air blower s shaft prior to installation 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 12 Slide the combustion air blower s shaft with the three washers up through the bearing kit assembly until the threaded portion appears on side A of the blower casing Place the new thick flat wa
108. olenoid and inspect the plunger seat for poorly machined brass C Is the Diesel Burner short cycling turning off and on more frequently than normal i Test the control thermostat to ensure it is operating within the proper range Ensure someone has not turned the heater off and on several times the Burn Cycle A Are the electrodes adjusted properly i Use the gauge on the side of the diesel burner to properly adjust the ignition electrodes B Are the air bubbles in the fuel system i If the fuel pump is sucking air at any point on the supply fuel system the heater will continuously puff out blue white smoke C Is the Fuel Nozzle Bad D Is the Fuel Pressure Adjusted properly i The fuel pressure should be 145psi E Is the Fuel Pump Leaking i If the fuel pump is leaking it will need to be replaced F Is the Ignition Coil igniting every time i An intermittent Ignition Coil will allow fuel to spray into the combustion chamber NOTE Webasto says it is normal for there to be a short puff of smoke after the flame has shut down due to the nozzle tow without igniting it every time er emptying the fuel out Page 85 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 11 TROUBLE SHOOTING 3 Lack of Interior Heat F If the Heat Exchanger Fans and the Zone Circulation Pumps are operating check for the A Is the Diesel Burner Electric Heating Eleme
109. ombustion s flame is detected by the Flame Sensor and the Ignition Coil is then automatically switched off no more spark across the gnition Electrodes V Hot Exhaust Sensor Gases Page 55 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 8 DIESEL BURNER KEY 5 Diesel Fuel Spray Combustion Air gt The particular component begins to operate 1 The component is currently operating Diesel Burner Operation continued 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 Aqua Hot 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 Djesel 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 Page 56 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Instructions for Detaching the Diesel Burner WARNING Be sure to mo
110. on 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 7 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 2000 Watt Electric Heating Ele ment 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 approximately 1 2 hours 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 2000 Watt and the 240 VAC 4500 Watt Electric Heating Elements to supply heat to the Aqua Hot s Boiler Tank The 120 VAC 2000 Watt and the 240 VAC 4500 Watt Electric Heating Elements will heat the Aqua Hot System to the maximum operating temperature 190 F 5 in approximately 0 5 1 hour s Aqua Hot HYDRONIC HEATING SYSTEM ON Diesel Engine Burner Preheat Diesel Burner Switch must be ON to obtain a continuous supply of hot water 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Electric Element l 1 Activate the electric element switch and place the high low switch on HIGH for maximum hot water capacity
111. on has occurred e There is a lack of hot domestic water and interior heat when the electric element is selected as the heating source Troubleshooting NOTE For continuous domestic hot water to be present the diesel burner must be selected also as a heating source 1 Verify that the motor home is either plugged into shore power or that the generator is running to provide AC power 2 Verify that both the Electric Heating Element Status and the Heating Status indicator lights on the electron ic controller are illuminated If the Electric Heating Element Status indicator light on the electronic controller is not illuminated complete the following A Verify that the electric element switch on the interi or switch panel is on B Install a jumper wire on the JP2 plug between pins 52 and 53 and ELECT I on the electronic controller to bypass the electric element switch 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS If the Electric Heating Element Status indicator light illuminates on the electronic controller with the jumper wire installed check the Electric Ele ment Switch on the interior switch panel for func tionality If the Electric Heating Element Status indicator light does not illuminate on the electronic controller with the jumper wire installed follow the instruc tions in this manual to replace
112. onding to the pump not operating If the indicator light illuminates green complete the following A Using a voltmeter check for 12 volts of DC power on the JP3 plug pins corresponding to the pump not operating If 12 volts of DC power are not present follow the instructions in this manual to replace the electronic controller B Disconnect the circulation pump s wires from the wiring harness then using a voltmeter check the wires on the wiring harness for 12 volts of DC pow er If 12 volts of DC power are present at the wiring harness follow the instructions in this section to replace the circulation pump 2 Turn on the interior room thermostat corresponding to NOTE The circulation pump can be tested by connecting the circulation pump not operating heating zone 1 oper ates with circulation pump 1 heating zones 2 3 and 4 it to an external 12 Volt DC source to verify that the pump is defective operate with circulation pump 2 and heating zone 5 operates with circulation pump 3 Check the corre sponding Heating Zone Status indicator lights on the electronic controller for illumination If the Heating Zone Status indicator light does not illuminate complete the following A Install a jumper wire on the JP1 plug between the pins corresponding to the room thermostat operating the circulation pump that is not operating Refer ence the wiring diagram in Appendix A This will bypass the room thermost
113. onnect the defective engine preheat pump s wires by separating the quick disconnect terminals Using constant tension pliers loosen and slide back the constant tension clamps securing the hoses to the engine preheat pump Remove the hoses from the defective engine preheat pump Release the pump from the mounting bracket by pulling on each Nylatch plunger then remove the defective pump from the Aqua Hot Slide the hoses onto the replacement pump and set the constant tension clamps back into place Install the replacement pump onto the mounting bracket by aligning the Nylatch plungers to their respective holes and pushing the plungers in to secure the pump to the bracket Reconnect the wires on the replacement pump to the wire harness on the heater by uniting the red quick disconnect terminals Remove the hose pinch off pliers previously installed on both hoses Test the Aqua Hot for normal operation WARNING RISK OF SHOCK ATTENTION RISQUE Dt CHOC ELECTRIQUE Page 35 Electrical AC Electric Heating Element Right CAUTION There are two different Models in the Aqua Hot 600 Series The Aqua Hot 600 has 2 2000 Watt 120 VAC electric heat ing elements The Aqua Hot 675 has 1 2000 Watt 120 VAC electric heating element Right and 1 4500 Watt 240 VAC electric heating element Left The electric heating element uses AC power as an alternate power source for heating the Aqua Hot s boiler tank Tr
114. opylene glycol based anti freeze is selected RV amp Marine Antifreeze These types of propylene glycol based antifreeze products are formulated specifically for winterizing applications only Although RV amp Marine antifreeze is often Generally Recognized as Safe by the FDA it should never be used in the Aqua Hot s Hydronic Heating System This type of anti freeze is not formulated to transfer heat which is essential to the heating system s functionality and does not contain rust inhibitors Please note however that RV amp Marine anti freeze can be utilized to winterize the Aqua Hot s domestic water heating system Automotive Antifreeze Coolant These types of propylene glycol based antifreeze products are formulated specifically to protect automotive engines against corrosion freezing temperatures and overheating They also have excellent heat transfer and thermal conduc 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A tivity characteristics Although these types of antifreeze products are considered less toxic and safer than ethylene glycol for people pets and the environment they are not Generally Recognized as Safe GRAS rated by the FDA Therefore they must be marked with a harmful if swal lowed warning This additional warning is required be cause these types of antifreeze products contain high levels of chemical inhibitors Due to their potentially hazardous propert
115. oubleshoot the electric heating element if the following condition has occurred e There is a lack of hot domestic water and interior heat when the electric element is selected as the heating source Troubleshooting NOTE For continuous domestic hot water to be present the diesel burner must be selected also as a heating source 1 Verify that the motor home is either plugged into shore power or that the generator is running to provide AC power 2 Verify that both the Electric Heating Element Status and the Heating Status indicator lights the electron ic controller are illuminated If the Electric Heating Element Status indicator light on the electronic controller is not illuminated complete the following A Verify that the electric element switch on the interi or switch panel is on B Install a jumper wire on the JP2 plug between pins 52 and 53 and ELECT I on the electronic controller to bypass the electric element switch 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS If the Electric Heating Element Status indicator light illuminates on the electronic controller with the jumper wire installed check the Electric Ele ment Switch on the interior switch panel for func tionality If the Electric Heating Element Status indicator light does not illuminate on the electronic controller with the jumpe
116. parate circuit Troubleshoot the Left AC relay if the following condition has occurred e The Left electric heating element fails to operate Troubleshooting CAUTION There are two different Models in the Aqua Hot 600 Series The Aqua Hot 600 has 2 2000 Watt 120 VAC electric heat ing elements The Aqua Hot 675 has 1 2000 Watt 120 VAC electric heating element Right and 1 4500 Watt 240 VAC electric heating element Left 1 Disconnect the AC power source to the motor home unplugging from shore power or shutting off the gener ator 2 Turn the both the electric element switch on the interior switch panel on and turn the High Low Switch to the High position and check the electronic controller to ensure that the Electric Heating Element Status and the Heating Status indicator lights are illuminated 3 Using a voltmeter check pins 11 and 12 AC Relay and AC Relay on the JP3 plug for 12 Volts DC If 12 Volts of DC power are not present while the Electric Heating Element Status and Heating Status indicator lights on the electronic controller are illuminat ed follow the instructions in this manual to replace the electronic controller If 12 Volts of DC power are present complete the fol lowing A Locate the AC relay for the Right electric heating element B Check pins 1 for 12VDC 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQ
117. r the diesel burner controller must be replaced If voltage is present proceed to the next circuit test Motor Circuit Test Locate the diesel burner controller s B plug and C plug Use a jumper wire to make a connection from the C 1 location to the C 7 location Turn the diesel switch ON and insert the probes of a DC voltmeter into the C 2 and C 5 locations If no voltage reading registers on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test Be sure to remove the jumper wire that was used to make the connection from the C 1 location to the C 7 location A fail ure to do so will result in an overheating condition during normal operation Ignition Coil Circuit Test Turn the diesel switch OFF and locate the diesel burner controller s C plug Also locate the VDC high limit thermostat and disconnect it s 2 way male plug from the white plastic 6 way female connector Insert the probes of a DC voltmeter into the C 8 and C 5 locations and turn the diesel switch ON Ifa voltage reading does not register on the voltmeter 18 25 seconds after the initial start up the diesel burner controller must be replaced NOTE sure to reconnect the VDC high limit thermo stat s 2 way male plug to the 6 way female plug The diesel burner will not ignite during normal operation if the VDC high limit thermostat is left disconnected Page 82 S
118. r Tank exists When illuminated red only four possible issues exist the antifreeze and water heating solution level is inadequate and must be refilled there 1s a short in the wiring to the Fluid Level Sensor the Fluid Level Sensor is not operating properly or Circulation Pump 3 is shorted out Heating Status This indicator light will illuminate green only when the diesel burner and or the electric heating element switch on the interior switch panel is on and the control thermostat in the Aqua Hot Boiler Tank is calling for heat If the heater is functioning and the light is not illuminated or the heater is not functioning and the light is illuminated there is an issue with the wiring or one of the components Page 48 SECTION 7 ELECTRONIC CONTROLLER INDICATOR LiGHTS Engine Preheat Pump This indicator light shows the status of the Engine Preheat Pump by illuminating green for on red for fault or by turn ing off when the Engine Preheat Pump 15 not operating The system is functioning correctly when the indicator light is green while the Engine Preheat Switch on the interior switch panel is on the Electric Element and or Diesel Burner switch is on and the Engine Preheat Pump is operating The system is also functioning correctly when the engine preheat switch is off and the engine preheat pump is not op erating If the light illuminates red when the pump should be func tioning then there is either
119. r wire installed follow the instruc tions in this manual to replace the electronic con troller If the Heating Status indicator light on the electronic controller is not illuminated complete the following A Check the temperature of the Aqua Hot s boiler tank If the boiler tank temperature is below 158 F trou bleshoot the control thermostat If the boiler tank is above 158 F the Aqua Hot is at operating temperature and requires no heat 3 Verify the Electronic Controller is sending 12 Volt DC to the A C Relay A Using a volt meter check pins 11 amp 12 REL and REL for 12 Volt D C on the JP3 plug If 12 Volts of DC power are not present while the Electric Heating Element Status and Heating Status indicator lights on the electronic controller are illuminat ed follow the instructions in this manual to replace the electronic controller 4 If 12 Volts of DC power are present at the relay com plete the following follow the troubleshooting section for the Right A C Relay in this section 5 Verify that the electric heating element is receiving ade quate AC power by completing the following A Remove the AC access cover B Plug the Coach into shore power turn generator on Page 36 SECTION 5 AQUA HOT COMPONENTS C Using an AC voltmeter verify that 110 volts of AC down and that all power sources have been disconnect power are present at the terminal block
120. rating range of the control 2 Check the following if there is a lack of domestic thermostat hot water A Is the heater bypassed i 155 F to 185 F B Has the Outside water faucet been left on BW bas AG Water Pow GEM i The water flow must be 1 5GPM or less ii Test the water flow where the customer is complaining about lack of hot water i e shower sink etc i If both the cold and hot valves are left in the on position the outside water faucet acts like a secondary mixer valve and the remaining hot water faucets will only produce warm water Page 86 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A 3 Lack of Domestic Hot Water Continued G Is the Mixer Valve functioning properly i The mixer valve s adjustment knob should turn freely If the adjustment knob does not have free movement the mixer valve must be replaced 4 Antifreeze Leak F Domestic Water Engine Preheat copper NOTE To find an antifreeze leak the system must pipe be Hot up to operating temperature or pressurized to 15 PSI i The copper pipes come out of the boiler tank and are possible leak points Inspect the following components on the Aqua Hot Heating System for Leaks G Burn Chamber Leak 1 On the Front Side of Aqua Hot i If Antifreeze is running out of the tip of the exhaust pipe remove the burner and A Fluid Level Sensor combustion chamber and inspect inside the bur
121. reference ed Also because this replacement procedure will in figure 20 If there is not 110 VAC present at the volve the boiler tank and the potential for hot coolant be terminal block for the right electric element there is sure the heater has adequately cooled a problem inside the motor home 2 Drain the antifreeze and water heating solution from the D Using an amp meter verify that approximately 17 Aqua Hot s boiler tank using the drain valve amps are present at the element s wires 3 Remove the Electric Element access cover E Check the electric element s wires for continuity by completing the following 4 Remove the two wires secured to the defective electric heating element by releasing the screw terminals Disconnect the motor home from shore power shut off generator 5 Using 1 1 2 inch socket remove the defective electric heating element from the Aqua Hot s boiler tank b Disconnect the wires from the electric heating element 6 Install the replacement 2000 watt electric heating ele ment into the boiler tank ensuring that the up lettering c Disconnect the wires from the AC terminal on the element is installed in the up position block 7 Connect the wires removed from the defective electric d With the wires disconnected check each indi heating element to the replacement electric heating ele vidual wire for continuity ment and tighten the screw terminals 6 Check the ele
122. rm the following procedure it is cure the nozzle stand plate in place Remove the necessary to detach and reattach the diesel burner nozzle stand plate by pulling on the nozzle stand head Be sure to review the detaching and reattach until the plate releases from the cast aluminum ing section for detaching and reattaching instruc blower casing tions 4 Remove the four ignition coil screws that secure the 2 Locate and disconnect the C plug harness wires that ignition coil to the protection cap Lift the ignition connect to the flame sensor and fuel solenoid Also coil and disconnect its black and brown wires disconnect the ignition cables from the ignition from the C plug harness wires prior to removing electrodes Remove the protection cap from the diesel burner so that the motor and clutch halves are exposed Protection Blower Housing Housing Flange Page 77 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 10 DiESEL BURNER COMPONENTS 3 Remove the four nozzle stand plate screws that se cure the nozzle stand plate in place Remove the nozzle stand plate by pulling on the nozzle stand until the plate releases from the cast aluminum blower casing NOTE It is recommended to mark the internal components of the diesel burner prior to disassembling of the burner Make a mark between the motor flange and the blower housing and also between the blower housing and the blow
123. rness violet and brown wires to the fuel solenoid s and electrical terminals Retaining Clamp Ignition Cable Violet wire Brown wire Photo Disc Retaining Clip Fuel Solano Valve Lock Nut Electrical Terminals 1 Fuel Solenoid Shaft Fuel Solenoid Valve Kit Fuel Solenoid Valve Assembly Page 73 SECTION 10 DiESEL BURNER COMPONENTS Fuel Pump The fuel pump draws diesel fuel from the vehicle s fuel tank and creates a preset pressure of 145 PSI which is required for proper fuel atomization Ref erence the illustration below for a basic overview and understanding of how the fuel pump functions Fuel Pump Testing Procedure A DANGER A Do not remove the diesel burner at this time Failure to do so may result in serious bodily injury 1 Clamp off and remove the fuel return and fuel sup ply lines coming into the Aqua Hot unit 2 Attach a short piece of fuel line to both the inlet and outlet fuel ports 3 Submerse the opposite end of the temporary fuel supply line in a container of diesel fuel 4 Place the opposite end of the temporary fuel return line in an empty container 5 Turn the diesel switch ON to activate the diesel burner and wait ten seconds 6 If fuel does not flow out of the return line into the empty container the fuel pump must be replaced NOTE Prior to replacing the fuel pump be sure to in spect the screen filter in th
124. s 2 serve as a safety measure in the event that the diesel burner continues to operate after the maximum operating temperature is reached The high limit thermostats allow the current for the diesel burner to pass through them until the boiler tank reaches a temperature of 215 F Should this temperature be reached the high limit thermostat blocks the current to the diesel burner s fuel sole noid valve which prevents the diesel burner from operating Troubleshoot the DC high limit thermostat if the following condition has occurred e fuel solenoid on the diesel burner fails to operate Troubleshooting 1 Remove the Thermostat Access Panel 2 Place a jumper wire between the blue and purple wires on the diesel burner s wire harness to bypass the high limit thermostats Check the Aqua Hot for normal operation NOTE Bypassing the high limit thermostats is for testing only and must not be used for the Aqua Hot s normal functioning 3 Disconnect the DC high limit thermostats wires then using an ohmmeter check each thermostat for continui ty If there is no continuity complete the following A Press the white reset button on the high limit ther mostat then re check for continuity 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS B Disconnect the wires from each thermostat and re check each thermostat for continuity as well as each of the ther
125. s section to replace the AC high limit thermostat 215 F A C High Limit Thermostat 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS NOTE If the high limit thermostats continue to trip trou bleshoot the control thermostat and verify the boiler tank is full of the antifreeze water solution Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power supplies have been disconnect ed 2 Remove the AC access cover 3 If applicable remove the heat shrink insulation covering the wires and terminals on the defective high limit ther mostat 4 Remove the two wires from the defective high limit thermostat by pulling firmly on the wires 5 Using a 5 8 wrench or socket remove the defective high limit thermostat from the Aqua Hot s boiler tank 6 Install the replacement high limit thermostat into the port on the Aqua Hot s boiler tank and finger tighten only 15 in Ibs 7 Connect the wires removed from the defective high limit thermostat to the replacement high limit thermostat 8 Secure the Thermostat Access Panel back into place 9 Test for proper operation Page 26 DC High Limit Thermostats The DC high limit thermostat
126. s up to run off of the external fuel source WARNING A spark will appear across the ignition electrodes 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 In some installations it may be necessary to shine a light on the flame sensor to simulate a flame condition to shot of the ignition coil Figure C9 HYDRONIC HEATING SYSTEM Diesel Engine Electric Burner Preheat Element 2 Turn the diesel burner switch to the on position pressure will register on the fuel pressure gauge once the fuel solenoid opens after approx 10 20 seconds Page 98 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 2 Adjust the Fuel pressure to 145 PSI 5 Figure C10 Fuel Pressure Gauge D Fuel Pump 9 Pressure Regulator decrea Screw Adjustment 1 Once the fuel solenoid has been activated and the fuel pressure gauge is registering a pressure the fuel pressure can be adjusted To increase the fuel pressure turn the pressure adjustment screw clock wise and to reduce the fuel pressure turn the pressure adjustment screw counter clockwise NOTE Ifthe fuel pressure cannot be adjusted refer to the fuel pump section in section 10 of this
127. s2Aqua Hot HYDRONIC HEATING SYSTEM 600 Series ib da Eres 4 Aqua Hot 600 0 600 003 675 003 SERVICE MANUAL 2010 Aqua Hot Heating Systems Inc Page 2 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Table of Contents Section 1 Introduction to the Aqua Hot 600 D03 ARCET RE uu 6 8 Danger Warning Caution and Note Box Definitions Page 6 Model Differentiation NES T Page 8 Technical Informations m Page 9 I D Label Sample ac sui ear eius encantan vif ub Page 10 Component OVerVIBW i aeter a Page 11 13 Aqua Hot Operational Page 14 Antifreeze amp Water Heating solution Page 15 16 Section 3 Interior Switch Panel Diesel Burner sasaran ana aana NGGEN races Abend veut E Page 17 Engine Preheat Switch suba 17 Electric Element SWIICT Sua Siena qu acci qe diosa qe Page 17 High Low Switch Electric Element Page 18 Pin rasanan E pa Teng aa a ia agan a
128. sher and steel drive gear on the threaded end of the combu stion air blower s shaft Thread the new retaining nut on the combustion air blower s shaft until it is finger tight DO NOT TIGHTEN Dished Surface Washer Dished Surface Washer Flat Washer Page 78 SECTION 10 DiESEL BURNER COMPONENTS 12 Place a feeler gauge between the combustion air blower and the flat surface of the blower casing Slowly tighten or loosen the retaining nut holding the combustion air blower until a 018 020 gap is achieved Remove feeler gauge 13 Spin the combustion air blower to ensure a friction free rotation NOTE If the combustion air blower 1s rubbing loosen the retaining nut slightly and lightly tap on the combustion air blower s shaft opposite side then readjust the gap 14 Reattach the blower housing to the blower casing using the four blower housing screws Reinstall the clutch half on both the motor s shaft and the com bustion air blower s shaft Attach the motor and flange assembly with the recessed edge of the mo tor flange in line with the wiring access slot of the blower casing to the blower housing with the three hex head screws the black and brown wires of the motor to the C plug harness black and brown wires Feed the C plug harness yellow and brown wires back through the wiring access hole in the protection cap Blower Housing Combustion Air
129. t 600 will have 120 VAC present at the terminal block for the left electric element while the TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Aqua hot 675 will have 240 VAC present at the terminal block for the left electric element 1 1 Ensure that the Aqua Hot has been completely shut D Using an amp meter verify that amps are present at down and that all power sources have been disconnect the element s wires 120VAC 2000 Watt Approximately 17 amps 240V AC 4500 Watt Approximately 17 amps ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be sure the heater has adequately cooled E Check the electric element s wires for continuity by 2 Drain the antifreeze and water heating solution from the completing the following Aqua Hot s boiler tank using the drain valve a Disconnect the motor home from shore power 3 Follow the instructions for detaching the diesel burner in shut off generator section 9 b Disconnect the wires from the electric heating As Reeve id Electric El ment access Cover element 5 Remove the two wires secured to the defective electric c Disconnect the wires from the AC terminal block heating element by releasing the screw terminals 6 Using a 1 1 2 inch socket remove the defective electric d Check the black and white wires at the terminal block for continuity he
130. t the motor s black and brown wires from the C plug harness wires NOTE Inspect the clutch halves for cracks and also en sure that the flat portion in each shaft hole is free of wear and tear Too much play on the shaft produces a loud clack ing noise If any cracks or wear are detected the clutch half must be replaced 4 Detach the motor from the motor flange by removing the two Phillips heads screws that fasten the two parts together 5 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 This will ensure a proper protection cap fit 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A NOTE 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 6 Reinstall a clutch half on both the new motor s shaft and the combustion air blower shaft Attach the mo tor and flange assembly with the recessed edge of the motor flange in line with the wiring access slot of the blower casing to the blower housing with the three hex head screws NOTE Inspect the blower casing s O ring for damage or wear prior to reinstalling the diesel burner head s protection cap If damage or wear exists replace the O ring 7 Connect the black and the brown wires of the new motor to the C Plug harness
131. talled follow the instructions in this manual to replace ever the Aqua Hot is below the operating temperature the electronic controller range of 158 F NOTE If the Control Thermostat is intermittent it may result in the Heating status light flickering off and on which would cause the diesel burner to blue white smoke Page 23 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev SECTION 5 AQUA HOT COMPONENTS Control Thermostat Replacement Procedure 5 Using a 7 8 socket unscrew the control thermostat from DA G R A the Aqua Hot s boiler tank FAILURE TO DISCONNECT ALL POWER SUPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD 6 Wrap the threads of the replacement control thermostat CAUSE SERIOUS DAMAGE OR PERSONAL INJURY sealing tape 7 Screw the replacement control thermostat into the port on the Aqua Hot s boiler tank and tighten securely with a 7 8 socket 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be 8 Connect the replacement control thermostat s wires in sure the heater has adequately cooled the same configuration as the removed control thermo stat s wires 2 Drain the antifreeze and water heating solution from the boiler dani heme ule drai
132. the electronic con troller If the Heating Status indicator light on the electronic controller is not illuminated complete the following A Check the temperature of the Aqua Hot s boiler tank If the boiler tank temperature is below 158 F trou bleshoot the control thermostat If the boiler tank is above 158 F the Aqua Hot 15 at operating temperature and requires no heat 3 Verify the Electronic Controller is sending 12 Volt DC to the A C Relay A Using a volt meter check pins 11 amp 12 REL and REL for 12 Volt D C on the JP3 plug If 12 Volts of DC power are not present while the Electric Heating Element Status and Heating Status indicator lights on the electronic controller are illuminat ed follow the instructions in this manual to replace the electronic controller 4 If 12 Volts of DC power are present at the relay com plete the following follow the troubleshooting sections for both the right and the Left A C Relays in this sec tion 5 Verify that the electric heating element is receiving adequate AC power by completing the following A Remove the VAC access cover B Plug the Coach into shore power turn generator on Page 38 SECTION 5 AQUA HOT COMPONENTS C Using an AC voltmeter verify the presence of AC Replacement Procedure A DANGER FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR voltage at the terminal NOTE The Aqua Ho
133. the interior switch tor light on the electronic controller will illuminate Reset panel for approximately 30 seconds then turning the switch the electronic controller by pressing the low voltage reset back on Figure 25 Electronic Controller Board E tcc was on Reset Button MEM rU a 5 Y S RS 1 t c 9c 010 unim 4 oiuoJp H s 5 i qi 2 gt 3 k ise A Secondary Power Source 12 Volt DC Screw Terminal Primary Power Source 12 Volt DC Screw Terminal Ground Wire Screw Terminal Page 46 2010 Aqua Hot 600 003 Hydronic Heating System Service Manual Rev SECTION 6 ELECTRONIC CONTROLLER Replacement Procedure DANGERI FAILURE DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed 2 Remove the faceplate from the electronic controller by removing the four screws securing it to the mounting bracket 3 Disconnect the positive negative and secondary power if applicable wires from the electronic controller 4 Disconnect the four terminal strips plugs from the elec tronic controller by loosening the screws on each strip plug and pulling each strip plug away from the electron ic controller 5
134. to an ohmmeter Check resistance by placing a shop rag over the flame sensor s glass surface to simulate a no flame condition and then remove the rag and expose to a light source to simulate a flame condition If the flame sensor is operating properly the ohm meter should register high resistance over 100K when the glass surface is covered and less than 200 when exposed to a light source If these resistance numbers cannot be obtained ver ify the flame sensor s glass surface is clean If the flame sensor is clean and the resistance numbers cannot be obtained the flame sensor must be re Component Test Ohms placed NOTE Be sure to calibrate your ohmmeter prior to check ing the flame sensor to proper resistance values Flame Sensor Maintenance In order to perform the following procedures it is necessary to detach the diesel burner Be sure to review the detaching attaching instructions in sec tion 9 Once the diesel burner has been removed Locate and detach the flame sensor s green and blue wires from the C plug harness wires 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev For light dirt dust and or carbon deposits simply wipe off the flame sensor with a soft cloth Should heavy carbon deposits be present complete ly remove the flame sensor from the photo disc and clean with brake cleaner Figure 46 Le gt Page 68 SECTION 1
135. ua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 5 Remove the Diesel Burner from the Aqua Hot Figure 37a Figure 37b 1 The Diesel Burner is secured to the Aqua Hot with two nuts that can be loosened and swung out of the way by using a 10mm socket wrench with a 10 inch long extension Figure 37c 2 Carefully pull the Diesel Burner away from the Aqua Hot 4 to 5 inches before rotating the burner and then remove Page 59 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Reattaching the Diesel Burner to the Aqua Hot CAUTION When reattaching the diesel burner be sure to properly align the diesel burner before tightening the eye bolt nuts Also visually inspect all of the rubber grommets on the top and bottom of the diesel burner s cast aluminum blower casing to ensure they are in place DO NOT over tighten the eye bolt nuts Torque specifi cations are approx 20 40 in lbs An improper alignment and or over tightening of the eye bolt nuts can cause damage to the diesel burner s cast aluminum blower casing Step 1 Reattaching the Diesel Burner to the Aqua Hot Figure 38a 1 The Diesel Burner is secured to the Aqua Hot with two eye bolt nuts that can be swung into place after the diesel burner has been properly aligned and set in place Figure
136. ual Rev A APPENDIX B WiRE GAUGE INFORMATION Because all Aqua Hot heating systems are designed to operate only when there is an adequate supply of DC Direct Current voltage it is imperative that the proper wire gauge be determined and used for the DC power supply and ground wires This bulletin address es how to determine the DC amperage draw of the heating system including heat exchangers then how to determine the proper wire gauge based upon those findings for a specific application Aqua Hot Base DC Model Amp Draw Aqua Hot 375 D 26 Amps Aqua Hot 450 DM 19 Amps Figure B1 Aqua Hot 450 DE 19 Amps Aqua Hot 525 D 26 Amps Aqua Hot 675 D excludes heat exchangers Determining the DC Amperage Draw of the Heating System 1 Review the chart above for the amperage draw of each Aqua Hot heater excludes heat exchangers 2 Determine the number of heat exchangers installed with the Aqua Hot Heating System 3 Consult the heat exchanger s manufacturer for amp draw information NOTE Each Aqua Hot Cozy heat exchanger draws 23 amps of direct current Each Aqua Hot Whisper heat exchanger draws 38 amps of direct current 4 Determine the total amperage draw for all heat exchangers installed For example if six Aqua Hot Cozy heat exchangers have been installed multiply the amperage draw of each heat exchanger 23 amps by the number of heat exchangers 6 The total amperage draw in this scenario would be 1 38 amps
137. until its boiling point 1s reached it 18 at this point that the liquid turns to a gas and is expelled to prevent the heating system from overheating Each time the boiling point is reached a loss of efficiency occurs because the heat pro duced is expelled rather than used for the function of the heating system Therefore a higher boiling point 1s desired in order to combat the loss of efficiency which allows the antifreeze to transport the heat created from the internal pro cess throughout the motor home where it can be used pro ductively rather than dissipating due to its change from a liquid to a gas Rust and Anti Corrosive Inhibitors Another major function of antifreeze 15 to provide protection to the internal metal components of the Aqua Hot Hydronic heating system from corrosion and rust Antifreeze 1s able to perform this function by the addition of rust and anti corrosive inhibitors which are designed specifically to acti vate in a water solution 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A Summary Antifreeze has three basic functions freeze protection boil over protection and anti corrosion and rust protection Antifreeze is also primarily responsible for heat transfer characteristics Therefore as water is an excellent heat con ductor it is added to the mixture A 50 50 solution of pro pylene glycol antifreeze and water 1s recommended to pro vide the best performance combinatio
138. urce to verify preheat pump light is illuminated that the pump 18 defective If the Engine preheat pump indicator light does not illu minate complete the following Page 34 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i The Engine Preheat Pump indicator light illuminates red on the electronic controller A Disconnect the engine preheat circulation pump s wires If the indicator light turns green with the engine preheat circulation pump disconnected follow the instructions in this section to replace the engine preheat circulation pump If the indicator light remains red with the circulation pump disconnected check the wiring for damage If no damage 15 found follow the instructions in this manual to replace the electronic controller Replacement Procedure FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnected Also because this replacement procedure will involve the potential for hot coolant be sure the heater is adequately cooled 2 Using hose pinch off pliers clamp both hoses attached to the engine preheat pump closed Engine Preheat Pump 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A 10 11 Disc
139. ve the Diesel Burner switch on the Interior Switch Panel to the OFF position and disconnect the Diesel Burner s power supply before detaching the Diesel Burner from the Aqua Hot Failure to turn off the Diesel Burner and disconnect power could result in serious bodily injury CAUTION Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to beginning this procedure Step 1 Turn Off the Diesel Switch HYDRONIC HEATING SYSTEM Electric Preheat Element 1 Move the Interior Switch Panel s Diesel Burner switch to the OFF position Figure 34b Step 2 Remove the Access Cover Combustion Air Sleeve Aounting Tray Mounting Tray gt Flange 1 Remove the Aqua Hot s access cover by locating 2 Unscrew the bolt and screws securing the cover in the screws securing it in place place Page 57 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A i SECTION 9 DETACHING AND REATTACHING THE DiESEL BURNER Step 3 Disconnect the Diesel Burner s Controller 1 Locate the Diesel Burner s Controller and disconnect both plugs Step 4 Disconnect the fuel lines from the Aqua Hot Figure 36a Figure 36b k 1 Locate where the fuel lines on the diesel burner 2 Using an 7 16 wrench loosen the nuts securing connect to the Aqua Hot Bulkhead fittings each fuel line to the Aqua Hot Page 58 2010 Aq
140. visual ly inspecting it for rotation of the pump Page 28 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS Replacement Procedure 6 Remove the hose barb and the 1 2 inch coupler from the N G E ye A defective check valve FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING 7 Clean the hose barb and coupler then wrap the hose COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY barb and the 1 2 meh coupler pipe threads with Teflon tape 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect 8 Install the hose barb and 1 2 inch coupler on the replace ed Also because this replacement procedure will in ment check valve ensuring that they are installed volve the boiler tank and the potential for hot coolant be properly with the hose barb n the arrow side ot the sure the heater has adequately cooled check valve 2 Drain the antifreeze and water heating solution from the 9 Install the replacement check valve onto the Aqua Hot s Aqua Hot s boiler tank using the drain valve boiler tank The arrow on the check valve must point away from the boiler tank 3 Using constant tension pliers loosen and slide back the constant tension clamp securing the hose to the defective 10 Slide the hose back onto the replacement pump and set didt salve
141. wires 5 Using an ohmmeter check the thermostat for continuity If there is no continuity press the white reset button on the thermostat and re check for continuity If continuity is still not present after the reset button has been pressed follow the instructions in this section to replace the AC high limit thermostat 215 F A C High Limit Thermostat 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS NOTE If the high limit thermostats continue to trip trou bleshoot the control thermostat and verify the boiler tank is full of the antifreeze water solution Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power supplies have been disconnect ed 2 Remove the AC access cover 3 If applicable remove the heat shrink insulation covering the wires and terminals on the defective high limit ther mostat 4 Remove the two wires from the defective high limit thermostat by pulling firmly on the wires 5 Using a 5 8 wrench or socket remove the defective high limit thermostat from the Aqua Hot s boiler tank 6 Install the replacement high limit thermostat into the port on the Aqua Hot s boiler tank and finger tighten only 15 in Ibs
142. zzle stand until the plate releases from the cast aluminum blower casing 5 Remove the two pump mounting screws that secure the fuel pump in place Turn the nozzle stand plate over and remove the snap ring from the fuel pump shaft using snap ring pliers Remove the nylon drive gear and then the fuel pump 6 Attach the new fuel pump to the nozzle stand plate with the two pump mounting screws Turn the noz zle stand plate over to install the nylon drive gear on the fuel pump s shaft and secure in place with the snap ring Dab the teeth of the nylon drive gear with white lithium grease Isoflex LDS 18 is recom mended NOTE Do not adjust the fuel pressure regulator of the new fuel pump as it has been factory preset 2010 Aqua Hot 600 D03 Hydronic Heating System Service Manual Rev A ing may be necessary Leaking fuel could cause bearing seizure resulting in potential damage to the internal bore bearing of the blower casing 7 Fit the nozzle stand plate inside the cast aluminum blower casing and secure in place with the four noz zle stand plate screws Install the grommets on the fuel return and supply banjo pipes and secure the pipes to the fuel pump with the new banjo bolts and gasket rings NOTE Failure to use the new gasket rings or the correct order placement could result in a fuel leak 8 Reconnect the C plug harness violet and brown wires to the fuel solenoid s and electrical

SERVICE MANUAL - Aqua-Hot Heating Systems, Inc.

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