Aqua-Hot AHE-100-02S-12 VDC Service Manual Page 1

SERVICE MANUAL © 2011 Aqua-Hot Heating Systems Inc. AHE-100-02S

— Page 10 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Figure 3

— Page 100 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 12: Inspect Photo

— Page 101 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 14: Plug in the

— Page 102 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 15: Re-Install t

— Page 103 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX F: WINTERIZATION PROCCESS Not winterizing the

— Page 104 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B

— Page 105 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B

15549 East Highway 52 | Fort Lupton, CO 80621 Toll free: 800.685.4298 | phone: 303.659.8221 | fax:303.857.7881 www.aquahot.com SERVICE MANUAL AHE-100-

— Page 11 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B “Diesel Burner” Switch Turned On SECTION 2: AQUA-HOT AHE

— Page 12 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 3: INTERIOR SWITCH PANEL Diesel-Burner Switch:

— Page 13 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 4: EXHAUST SYSTEM REQUIREMENTS Because the Aqu

— Page 14 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Thermostats Control Ther

— Page 15 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Control Thermostat Replac

— Page 16 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Thermostats Control Ther

— Page 17 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Control Thermostat Repla

— Page 18 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS AC High-Limit Thermostat:

— Page 19 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS DC High-Limit Thermostat:

— Page 2 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B

— Page 20 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Valves Check Valve: Che

— Page 21 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Replacement Procedure: (c

— Page 22 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Tempering Valve: The tem

— Page 23 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Tempering Valve: Thermost

— Page 24 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Pumps Circulation Pumps

— Page 25 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS 11. Install the replac

— Page 26 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Stir Pump / Circulation P

— Page 27 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS SECTION 5: AQUA-HOT COMP

— Page 28 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 12. Reinstall the bulk head fitting. Be sure to u

— Page 29 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Zone Relay: Interior Heat Exchanger Fans/Zone Pump

— Page 3 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Section 1: Introduction to the Aqua-Hot AHE-100-02S

— Page 30 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Terminal Strip Fuse Block

— Page 31 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS Electrical - AC Electric

— Page 32 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 5: AQUA-HOT COMPONENTS 2. Drain the antifreeze

— Page 33 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B from the flame is transferred to the antifreeze and water

— Page 34 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 6: DIESEL-BURNER OVERVIEW Figure 23

— Page 35 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 6: DIESEL-BURNER OVERVIEW Operational Flow-Chart

— Page 36 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 6: DIESEL-BURNER OVERVIEW Diesel-Burner Operatio

— Page 37 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 6: DIESEL-BURNER OVERVIEW Figure 25

— Page 38 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 6: DIESEL-BURNER OVERVIEW Figure 26 The Diesel-B

— Page 39 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER In

— Page 4 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Section 6: Diesel-Burner Overview ...

— Page 40 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER 1.

— Page 41 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER St

— Page 42 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER St

— Page 43 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER Re

— Page 44 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 7: DETACHING AND REATTACHING THE DIESEL BURNER 3.

— Page 45 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Turn the Control Switch ON. Is the indicator light illumi

— Page 46 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1. Turn the Control Switch Off. 2. Remove the fuel-line

— Page 47 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Does a spark appear across the Ignition Elec-trodes? With

— Page 48 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Does the spark reappear? 1. Turn the Control Switch OFF.

— Page 49 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1. Check “Fuel Solenoid Valve” wires for continuity. Re

— Page 5 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B This Page Left Blank Intentionally

— Page 50 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Diesel-Burner Motor: The motor drives the combustion

— Page 51 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Diesel-Burner Motor (continued) - RPM Test: 1. Dis

— Page 52 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Motor Replacement Procedure: 1. Follow the directio

— Page 53 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Motor Replacement Procedure: (continued) Figure 39 SECT

— Page 54 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Flame Sensor: The flame sensor is a photo resisti

— Page 55 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Flame Sensor Replacement Procedure: 1. In order to

— Page 56 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Ignition Electrodes The diesel-burner’s ignition c

— Page 57 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Failure to connect a jumper wire across the ignition ele

— Page 58 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Fuel Nozzle: 5. Remove the B-plug from the diesel-b

— Page 59 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Fuel Solenoid: The fuel solenoid allows the flow

— Page 6 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 1: INTRODUCTION TO THE AQUA-HOT AHE-100-02S This

— Page 60 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Fuel Pump: The fuel pump draws diesel fuel from the

— Page 61 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Fuel Pump Replacement Procedure: 1. Locate and disconn

— Page 62 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Fuel Pump: (continued) Figure 47 SECTION 8: DIESEL-BURNE

— Page 63 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Bearings: The bearings support the combustion ai

— Page 64 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 3. Remove the four nozzle stand plate screws that se

— Page 65 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 12. Place a feeler gauge between the combustion a

— Page 66 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Ignition Coil: The ignition coil produces a high

— Page 67 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Ignition Coil: Replacement Procedure: 1. Disconnect th

— Page 68 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Diesel-Burner Controller: The diesel-burner controll

— Page 69 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Be sure to remove the jumper wire that was used to make t

— Page 7 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 1: INTRODUCTION TO THE AHE-100-02S Engine Prehea

— Page 70 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1. Things to check before opening up heater 1. Low Vol

— Page 71 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1. If The Heater Smokes on Start up/Shut down. a. F

— Page 72 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1. General Problems A. Diesel/Electric not operatin

— Page 73 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1: General information 1. The heater is only rated fo

— Page 74 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B 1. On the Front-Side of Aqua-Hot - 1. Electric elem

— Page 75 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 9: GENERAL TROUBLESHOOTING IF THERE IS ANTIFREEZ

— Page 76 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX A: WIRING DIAGRAM

— Page 77 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX A: WIRING DIAGRAM

— Page 78 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATI

— Page 79 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATI

— Page 8 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Diesel-Burner, H

— Page 80 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATI

— Page 81 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX B: BLEEDING THE INTERIOR HEATING ZONE CIRCULATI

— Page 82 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Coolant System Tester Pressurize System up to 15 psi Usin

— Page 83 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT A fuel p

— Page 84 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instruct

— Page 85 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instruct

— Page 86 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX C: FUEL PRESSURE CHECK AND ADJUSTMENT Instruct

— Page 87 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B When storing the Motorhome: Not winterizing the Aq

— Page 88 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX D: EXTREME COLD WEATHER OPERATION If there is a

— Page 89 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B Annual Maintenance: FAILURE TO DISCONNECT ALL POWER

— Page 9 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B SECTION 2: AQUA-HOT AHE-100-02S OVERVIEW Figure 2

— Page 90 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 1: Test Run

— Page 91 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Aqua-Hot Maintenance Pr

— Page 92 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE 4. Carefully pull the

— Page 93 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 6: Clean and Insp

— Page 94 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE 3. Inspect the combust

— Page 95 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 7: Reinstall the

— Page 96 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 8: Inspect Diesel

— Page 97 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 9: Clean Ignition

— Page 98 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 10: Replace The F

— Page 99 — © 2011 Aqua-Hot® AHE-100-02S Hydronic Heating System Service Manual—Rev. B APPENDIX E: AQUA-HOT MAINTENANCE Step 11: Adjust Igniti