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SERVICE MANUAL - Aqua-Hot Heating Systems, Inc.

1. Prenat O renes Preto foires Engine Preheat Switch to ps omoro E Electronic Controller connections Diesel Burner Switch to Electronic Controller connections Essen scene Electric Element Switch to Electronic Controller connections Page 16 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Fluid Level Sensor The fluid level sensor monitors the level of antifreeze and water heating solution within the Hydro Hot s boiler tank to ensure that an adequate volume exists Troubleshoot the fluid level sensor if one of the following conditions has occurred diesel burner and or electric heating element fails to operate e Hydro Hot fails to operate and the Low Tank Level Cutoff indicator light on the electronic controller is illuminated Troubleshooting 1 Verify that the Hydro Hot s boiler tank is full of the antifreeze and water heating solution 2 Verify that the harness wire connectors are securely plugged into the fluid level sensor 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 electronic controller 4 Verify the functionality of the fluid level sensor by com pleting the following A Remove the faceplate from the electronic controller B Install a jumper wire on the JP
2. Does a spark appear across the Ignition Elec trodes Turn the Control Switch OFF Remove shop rag from the Flame De Check Flame Detection Photocell for tection Photocell exposing it to a light proper operation by Removing both source The spark should disappear wires from the Photocell and covering with a shop rag When dark Photocell wire leads should read 300 000 ohms or greater of electrical resistance Remove shop rag and expose to light electrical resistance should be 200 ohms or less Does a spark disappear after the Photocell is exposed to Does the Photocell operate Properly Replace the Flame Detection Photocell Reconnect Fuel Solenoid Valve Reattach Diesel Burner Head and attempt heater restart Replace Control Unit Reconnect Flame Detection Photocell wires and Fuel Sole noid Valve wire Reattach Diesel Burner Head and attempt heater restart Cover Flame Detection Photocell Replace Control Unit again with a shop rag The spark Reconnect Flame Detection should reappear and continue for Photocell wires Fuel Solenoid approx 15 seconds and then switch Valve wire and C plug off Reattach Diesel Burner Head and attempt heater restart April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Does a spark appear across the Ignition Elec trodes Turn the
3. AC LEE SE Secondary _ Power Source 12 Volt DC Screw Terminal Primary Power Source 12 Volt DC Screw Terminal Ground Wire Screw Terminal Page 40 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev 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 Hydro 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 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 Hydro will not function properly 2 Ifthe 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 ap
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5. Ajddns 20 uon e104d gt 10 dwy oz esp TKINO SYOLDINONOS 934400 3511 WaMOd 2 ANY H108 S31V1340 5 1 P1YAA perddns 38 ISW uen 40 a qeuado ue sapun 10 azeu TON 1SnW WeIshs 1sneux3 eut 400pjno juo 41558226 pue ssayenb pasop 51 ye puawyedwo AJUO 1 61501 104 Heating Zone Wiring Harness Heating Zone 1 Outlet Port amp Harness Port 2 Outlet Port Diesel Fuel Supply and Return Ports Drain Valve Assembly Circulation Circulation Page 9 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 2 HYDRO HOT OVERVIEW e Interior Heating Domestic Cold Water Inlet Engine Preheat Inlet from engine Engine Preheat Outlet to engine Engine Preheat Circulation Pump Domestic Hot Water Outlet Tempering Valve April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Page 10 SECTION 2 HYDRO HOT OVERVIEW AC Wiring Cable Clamp Heating Zone Outlet Ports Supply 13 LB Radiator Cap 1 0 Label Location Diesel Fuel Supply Return Ports 2 3 o Page 11 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev
6. April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Bracket Slot Locking Post Diesel Burner Controller Controller Mounting Bracket ne Sa Diesel Burner Controller Page 82 SECTION 10 TROUBLESHOOTING IF THE HYDRO HOT is BLACK SMOKING 1 Things to check before opening up heater 1 Low Voltage Fire up generator plug coach into shore power 2 Damaged or Restricted exhaust pipe Inspect exhaust pipe for damage 2 Access cover must be removed to check the following Air Intake Closed off on the bottom of the burner is the air adjustment set at the half way point Broken Protection Cap Check cap for cracks or missing pieces Worn OUT Grommets run hands over grommets on top and bottom and feel for excessive air Burner not seated properly or Loose run hands along the seal of the burner and check for excessive air Air Intake Sleeve collapsed BW ND Re 3 Diesel Burner must be removed to check the following 1 Photo Disc Bent or Tight The photo disc must be loose so it will seal on the combustion chamber properly 2 Combustion Chamber Warped Melted Inspect for signs of warping melted aluminum 3 Bad Nozzle If nozzle is spraying poorly it must be replaced 4 Fuel Pressure not at 145 PSI check fuel pressure with fuel pressure gauge 4 Diesel Burner must be torn down to check the following 1 Slow Motor Less Than 4500rpms at 12v a sl
7. Circuit us Wire Diesel Bumer Page 63 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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 8 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 Connect the motor s wires directly to a 12 volt DC power supply Turn the power supply ON and use photo tachometer to test for a proper RPM reading At approximately 12 volts DC the RPM reading should be 4500 5 300 RPM s If the motor s RPM reading is not within the above specs the motor must be replaced Test the diesel burner s bearings prior t
8. nates Green the problem is in the motor Home Either a loose wire bad switch etc Is the Diesel Burner If the Diesel Burner Status Status Light on the Light Does not Illuminate on Electronic Controller the Electronic Controller Illuminated Green ensure that the JP2 plug is securely plugged in If it is then the Electronic Controller will need to be replaced NOTE It is possible for the Is the Diesel Burner s Is the Heating Status Plug to be defective It is rec Motor Operating Light Illuminated ommended to remove the Plug Green and check the pins on the elec tronic controller for power using a digital volt meter Locate the JP8 Power Terminal NOTE The heating status light will also labeled B4 in on the bot Remove the Hydro Hot s Access only illuminate green when either the tom of the Electronic Controller Cover Diesel or Electric switch is in the on Using a Digital Volt Meter Remove the Thermostat Access Position and the Control Thermostat is verify that 12 VDC is present Panel calling for heat on the JP8 terminal If 12VDC Check the Diesel Burner s VDC 1 j 222 not presen Either High Limit Thermostat for conti jumper between terminals B4 in nuity and 12V is not secure or there is a fuse blown in the Motor Is the Heater up to operatin Home NOTE This thermostat protects p Remove the Hydro Hot s Ac against overheating temperatures cess cover Check th
9. Connect the wires removed from the defective electric heating element to the replacement electric heating ele ment and tighten the screw terminals Reinstall the AC access cover Refill the Hydro Hot s boiler tank with the antifreeze and water heating solution Page 36 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A AC Relay 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 separate circuit Troubleshoot the AC relay if the following condition has occurred e The electric heating element fails to operate Troubleshooting 1 Disconnect the AC power source to the motorhome 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 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 an
10. Electrical Terminals Fuel Solenoid Shaft Fuel Solenoid Valve Kit Fuel Solenoid Valve Assembly Page 72 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Fuel Pump 7 If fuel does flow through the fuel pump when ran 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 uel 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 Clamp off and remove the fuel return and fuel sup ply lines coming into the Hydro Hot unit Attach a short piece of fuel line to both the fuel re turn and fuel supply ports Submerse the opposite end of the temporary fuel supply line in a container of diesel fuel Place the opposite end of the temporary fuel return line in an empty container Turn the diesel switch ON to activate the diesel burner and wait ten seconds 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 Hydro Hot diesel burner will not operate B Inspect the supply fuel line for kinks which would prohibit fuel flow C Inspect the
11. 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 AAA AAA AAA AR A 222774 0909090 QU ll all hc Page 39 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 5 ELECTRONIC CONTROLLER Low Voltage Reset Feature reset button on the electronic controller use thin straight Whenever the Hydro Hot s DC power is interrupted for nonmetallic object to access the button through the faceplate longer than 5 minutes the low battery voltage fault red or by turning off the diesel burner switch on the interior indicator light on the electronic controller will illuminate switch panel for approximately 30 seconds then turning the Reset the electronic controller by pressing the low voltage switch back on Electronic Controller Board Reset Button 2 Terminal Strip Plug Lx PA o d lt 5 3 PE 52 9 o 3 00 000 al To Motorhome Pin Jumper
12. calls for hot water The Engine Preheat switch on the Interior Switch Panel is activated Heat is transferred to the Domestic Water System Heat is transferred to the Engine Preheat System Continuous hot water is supplied to the faucet The engine s coolant is circulated through the Aqua Hot s internal Engine Preheat System where the heat from the Boiler Tank is transferred to the engine s coolant The antifreeze and water heating solution within the Boiler Tank is reheated as needed and contin ues warming the engine s coolant as it circulates through the Aqua Hot s internal Engine Heat is transferred into the Zone calling for heat Heat Exchangers in the Zone calling for heat Preheat System April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Page 12 Antifreeze and Water Heating Solution As the antifreeze type and mixture ratio is essential to the Hydro Hot s performance and ability to comply with regulations the following information is being supplied to understand various types of antifreeze the quality of wa ter necessary and the mixture ratio Hydro 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 Hy dro Hot Propylene glycol is a safer alternative to the more toxic ethylene glycol antifre
13. s diesel burner is a device that ignites a mix ture of diesel fuel and air within a controlled setting to serve as a heat source The flame is established in combustion chamber within the Hydro Hot s boiler tank and the heat Figure 26 Fuel Nozzle Diesel Fuel Return Banjo April 2012 SECTION 7 DIESEL BURNER OVERVIEW from the flame is transferred to the antifreeze and water heat ing solution where it can be used for each system of the Hy dro Hot domestic hot water interior heat and engine pre heat Diesel Burner LD Plate 52000154 Assembled in USA _ i nenie Heater Model DBW2010 75 Voltage Power 12V 60W Output 13 2kW 45000Btu h Fuel Type Diesel No 1 No 2 and Artic ratin 2 bar 29PS No 90915 Vers Serial No Year of installation 08 09 10 12 Webasto Diesel Burner Diesel Fuel Supply Banjo Air Intake Page 44 Hydro Hot Hydronic Heating System Service Manual Rev Diesel Burner Controller Motor Ignition Coil Clutch Combustion Air Blower Fuel Solenoid Valve Electrode Boots Ignition Electrodes Fuel Nozzle SECTION 7 DIESEL BURNER Heat Exchanger n Combustion Exhaust Port Flame Sensor Fuel Pump Fuel Tubes Supply Return Combustion Air Intake Port with Adjustable Shutter Page 45 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Operation sequence once
14. 190 F Water Flow is too fast a Must be 1 5 GPM or Less Mixer Valve is stuck knob does not turn freely Low Temperature Cut off Thermostat is not functioning properly a Needs to trip within 1 2 Minutes when running hot water b Needs to turn the stir pump on if the diesel burner switch is on as well Stir Pump is not functioning properly a Needs to be running when the diesel burner switch is on and the Low Temperature Cut Off thermostat is Tripped b Hold onto both upper and lower hose to make sure both get hot 1 Page 86 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 10 1 On the Front Side A Fluid Level Sensor Float Switch B Control Thermostat C Drain Valve Assembly may be plastic D Electric Heating Element E Circulation Pump s Stir Pump i When checking the circulation pumps be sure to inspect all of the plumbing Hoses the Tank Ports and the Circulation Pump F Combustion Burn Chamber leak i When the Combustion Burn Chamber leaks the antifreeze will run out the tip of the exhaust pipe NOTE The burner will need to be removed 2 On the Top of The Unit A Radiator Cap i bad seal ii Loose B Expansion Tank Tubing i Cracked ii Loose C Filler Neck i Bent ii Broken nipple Bad solder joint NOTE Newer model heaters do not have a radiator cap They will have a brass hose barb fitting which the expansion t
15. A Disconnect the stir pump s wires SECTION 4 HYDRO HOT COMPONENTS If the Pump 3 indicator light turns green when the stir pump is disconnected follow the instruc tions in this section to replace the stir pump If the Pump 3 indicator light remains red when the stir pump is disconnected check the wiring for damage If no damage is found follow the instruc tion in this manual to replace the electronic control ler If the indicator light is illuminated green complete the following A Using a voltmeter check for 12 Volts of DC power on the JP3 plug between pins 1 and 2 PUMP 3 and PUMP 3 on the electronic controller If 12 Volts of DC power are not present follow the instructions in this manual to replace the electronic controller 3 Disconnect the stir pump s wires from the wiring har ness then using a voltmeter check the wires on the wiring harness for 12 Volts of DC power If 12 Volts of DC power are not present inspect and test the wires going from the electronic controller to the pump If 12 Volts of DC power are present at the wiring har ness complete the following A Verify that the pump is operating by placing a hand on the pump to feel for vibrations If no vibrations are felt follow the instructions in this section to replace the stir pump B Once it is determined that the pump is active verify that the pump is operating properly by checking both connected ho
16. April 2012 Hydro Hot Hydronic Heating System Service Manual Rev APPENDIX F FILLING DRAINING THE HYDRO HOT WITH HEATING SOLUTION Zone 1 Zone 2 Circulation Pump Circulation Pump Red positive wire will not be disconnected for the purging procedure Spade Terminal 244 Alligator Clip to be connected to the Blue disconnected from the Wire s Spade Terminal opposing wire Opposite end of the Alligator Cable to be connected to a ground source Page 114 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev APPENDIX F FILLING DRAINING THE HYDRO HOT WITH HEATING SOLUTION WARNING Only propylene glycol based boiler type antifreeze deemed GRAS Generally Recognized as Safe by the FDA shall be used in the Hydro Hot s Hydronic heating system Failure to use the above specified antifreeze type could result in serious injury or death CAUTION Ensure that the overflow tube is connected from the Hydro Hot s expansion tank connection to the expansion tank s bottom connection and from the expansion tank s top con nection through the overflow tube hole in the motor home s bay floor prior to beginning this antifreeze and water heating solution fill procedure Failure to do so could result in an antifreeze spill in the motor home s bay In order to provide the best freeze protection boil over pro tection and anti corrosion and rust protection a
17. Too much play on the shaft produc es a loud clacking noise If any cracks or wear are detected the clutch half must be replaced 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 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 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 Follow the instructions for reattaching the diesel burner in the detaching reattaching section in Section 8 of this manual Blower Casting Blower Housing Rubber Blower Casing Grommets O Ring Combustion Air Blower w shaft Blower Housing Screws Dished Surface Washer Dished Surface Washer Flat Wave Washer Bearing Snap Retaining Ring Flat Drive Nut 1 4 Washer Gear 006 002 inch M Tube Ring Bearing 015 05 mm Bearing Kit Page 78 April 2012 Hydro Hot Hydronic Heating System Serv
18. 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 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 Hydro Hot s electric heating element has the ability to function 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 activated 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 Page 7 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 2 HYDRO HOT OVERVIEW Hydro Hot Technical Specifications Diesel Butner Heat Input F
19. Fuel Nozzle Retest Fuel Nozzle spray pattern fine mist of fuel present Reconnect Ignition wires to Ignition Elec trodes or remove jumper wire Reattach Diesel Burner Head and attempt heater restart Is a mist of fuel Cone Shaped present Turn the Control Switch Off Turn the Control Switch Off Reconnect ignition wires to 2 Remove Fuel Nozzle Ignition Electrodes or re Turn the Control Switch ON move jumper wire After approx 20 seconds fuel Reattach Diesel Burner should flow freely from the Head and attempt heater fuel nozzle port restart Turn the Control Switch OFF Check Fuel Solenoid Valve for proper operation Does the Solenoid by Removing both wires Valve operate from the Solenoid Valve and Does fuel flow properly click applying VDC Power and freely from the ground to the Solenoid port Valve electrical terminals Fuel Solenoid Valve should click when VDC power is applied Page 61 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Check Fuel Solenoid Valve Turn the Control Switch OFF wires for continuity Replace 2 Replace Fuel Nozzle wires if necessary Retest Fuel Nozzle spray pattern Replace Control Unit if wires fine mist of fuel present indicate continuity Reconnect ignition wires to Retest fuel flow
20. Hydro Hot s boiler tank 5 Wrap the threads of the replacement Fluid Level Sensor with a thread seal tape 6 Screw the replacement Fluid Level Sensor into the port on the Hydro Hot s boiler tank and tighten securely with a 7 8 socket ensuring the N O stamp in on top 7 Connect the replacement Fluid Level Sensor s wires in the same configuration as the removed Fluid Level Sen sors wires 8 Refill the Hydro Hot s Boiler tank with the proper water antifreeze mixture Reference Section 5 in this manual for instructions on filling and draining the Hydro Hot unit 9 Test for proper operation CAUTION Be sure to install the replacement float switch with the N O stamp on top failure to do so will allow the diesel electric to come on with no antifreeze in the boiler tank Page 17 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Thermostats Control Thermostat The control thermostat is installed into the Hydro Hot s boil er tank and monitors the temperature of the antifreeze and water heating solution to determine when it is at operating temperature and when it requires heat The Hydro Hot is considered to be at operating temperature between 158 F and 190 F Troubleshoot the control thermostat if one of the following conditions has occurred There is a lack of hot domestic water and interior heat The heating Status light does not illuminate on the elec tron
21. 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 element status indicator light follow the instructions in this manual to replace the electronic controller e The Engine Preheat Pump indicator light illuminates green on the electronic controller but the pump is not running 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 engine preheat circulation pump s wires from the wiring harness then using a voltme ter check the wires on the wiring harness for 12 volts of DC power If 12 volts of DC power are present at the wiring harness follow the instructions in this section to replace the engine preheat circulation pump NOTE The engine preheat circulation pump can be tested by connecting it to an external 12 Volt DC source to verify that the pump is defective Page 32 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A e 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
22. Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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 Ifthe 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 Be sure to use care when handling the new fuel nozzle Oils and or small dust or dirt particles from your hands may plug the nozzle s small orifice A partially plugged orifice will restrict fuel flow which will affect the combustion process of the diesel burner Diesel Burner 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 and avoid any leaks An adjustment of the ignition electrodes may be necessary after replacing the fuel nozzle Follow the ignition electrode adjustment procedure
23. able to provide continu ous hot water 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 NOTE The Engine Preheat is an option on the Hydro Hot Heating system If you have model number HHE 500 09M the heater does not have the engine preheat feature but it does have the Motor Aide feature Current Switches 8 Aqua Hot 800 685 4298 o o o gt 9 Electric Engine Preheat 15 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 3 INTERIOR SWITCH PANEL Discontinued Switches Engine Electric Diesel Preheat Element Burner Pin 1 PREHEATO Pint ELECTRICO Pint DIESELI Pin2 PREHEAT Pin2 ELECTRIC Pin2 DIESELO Pin4 Jump to Pin2 Pin4 Jump to Pin2 Pin4 B3INDIC Pin 6 Chassis Ground Engine Preheat Pins 6 6 Engine Preheat Electric Element Jumper Wire Jumper Wire Controle switch
24. be replaced Attempt Heater Restart Note Test the motor several times to find a flat spot Apply power and take it away to test Is there continuity across the thermostat Turn the Control Switch Off Remove the fuel line from the Aqua Hot s Diesel Fuel Return and place a short piece of fuel line in its place Put the opposite end of the fuel line in a container Place the probes of a DC Multi meter into plug locations 1 and B 2 of the Diesel Burner s Control Unit Also measure the voltage across B 2 and B 4 Turn the Control Switch ON Observe the fuel flow Flow should be consistent without air bubbles Check the Electronic 1 Replace Thermostat Controller for loose or damaged wires NOTE Hydro Hot operat Inspect the Hydro Hot s ing temperature must be wire Harness for loose below 155 F when checking or damaged wires the VDC Control Thermo If nothing is found with stat for continuity the wiring the Electron ic Controller will Need 2 Attempt Heater Restart to be replaced Check for fuel leaks in the Diesel Burner s Diesel Fuel Supply Is the fuel flow line Repair if necessary consistent with Check the Hydro Hot s b bbles Fuel Filter for clogging Replace if necessary Reattach Diesel Fuel Return line Attempt heater restart Page 58 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev SECTION 9 DIESEL
25. connected to the heater by uniting the red quick disconnect terminals 9 Refill the Hydro Hot s boiler tank with the antifreeze and water heating solution and check for leaks 10 Reinstall the Diesel Burner NOTE be necessary to remove the air intake sleeve and discard If the air intake sleeve is discarded it is recommended to install a wire mesh screen over the air intake hole underneath the die sel burner It is recommended to use a 1 4 hole wire mesh screen If the Diesel Burner Does not align properly it may Page 30 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 4 HYDRO HOT COMPONENTS Page 31 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Engine Preheat Pump The Engine Preheat circulation pump draws the cold anti freeze and water heating solution from the motor home s 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 dition has occurred 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 Temp Cutoff Status indicator light is illuminated on the electronic controller Engine Preheat Pump indicator light illuminates red on the electronic controller Troubleshooting NOTE Either the diesel
26. found in the ignition electrode section of this manual 3 After replacing the fuel nozzle reattach the diesel burner head 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 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 poten tial contaminants Perform this procedure twice 5 Test for normal operation Figure 49 Ignition Electrodes Fuel Nozzle Fuel Nozzle Fuel Nozzle Manifold Hex Page 71 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Fuel Solenoid The fuel solenoid allows the flow of diesel fuel to the diesel burner s fuel nozzle If a long after smoking condition exists during the diesel burner s purge cycle the fuel solenoid valve kit may need to be replaced 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 in section 8 Fuel Solenoid Component Test NOTE If the fuel solenoid is not working troubleshoot the diesel burner s hi limit thermostat If it is tripped it will not allow the fuel solenoid to operate 1 Locate and detach the
27. freezing temperatures and overheating They also have excellent heat transfer and thermal conduc SECTION 2 HYDRO HOT OVERVIEW 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 properties they should never be used in the Hydro Hot s Hydronic Heating System Antifreeze Mixture Water Quality In order to ensure maximum performance and longevity of an Hydro 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 Ethylene glycol for the Hydro Hot s antifreeze and water heating solution Please note that this is only nec essary when mixing concentrated Ethylene 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
28. heater and only the pump should be re moved Therefore to detach the defective pump re move the three screws on the back of the attached mounting bracket Slide the defective pump out of the bracket and set aside The replacement pump will arrive complete with a mounting bracket however because the existing bracket remains mounted to the heater the new mounting brack et must be removed by detaching the three screws secur ing it to the replacement pump Slide the replacement pump into the existing mounting bracket and secure with the three screws previously re moved from the replacement pump Slide the hoses back onto the replacement pump and set the constant tension clamps back into place Reconnect the wires on the replacement pump to the wire harness on the heater by uniting the red quick disconnect terminals Refill the Hydro Hot s boiler tank with the antifreeze and water heating solution Test the Hydro Hot for normal operation Page 27 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 4 HYDRO HOT COMPONENTS Page 28 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev Stir Pump Circulation Pump 3 The stir pump circulates the antifreeze and water heating solution within the Hydro Hot s boiler tank in order to en sure even heating of the solution To accomplish this the stir pump draws the solution from the bottom of the
29. is below 90 F which is necessary for the indicator light to extinguish B Inspect the wiring to ensure that the Hydro Hot is wired properly and that the low temperature cutoff thermostat has not been bypassed via jumper wires C Disconnect the low temperature cutoff thermostat s wires from the Hydro Hot s wiring harness 1 If the Low Temp Cutoff Status indicator light on the electronic controller extinguishes follow the instructions in this section to replace the low temperature cutoff thermostat 2 If the light remains illuminated with the low temperature cutoff thermostat s wires discon nected verify that the jumper pins on the elec tronic controller are properly positioned Ref erence Section 7 for the proper pin jumper con figuration 3 If the jumper pins are properly positioned follow the instructions in this manual to replace the electronic controller Page 22 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 4 HYDRO HOT COMPONENTS Low Temperature Cut Off Replacement Procedure 5 Install the replacement low temperature cutoff thermostat tightening only to 15 in Ibs Do not overtighten DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR 6 Connect the replacement low temperature cutoff thermostat s TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY wires in the same configuration as the removed thermo
30. 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 2 3 and 4 by illuminating green for on red for fault and by turning off when the system is off The system is functioning properly if the motor home interi or thermostat is calling for heat the circulation pump is ac tive 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 the wiring or the circulation pump Pump 3 Stir Pump This indicator light shows the status of the stir pump by illu minating green for on red for fault and by turning off when either the Low Temp Cut Off Status light is illuminated with the Diesel Burner Switch on or the Diesel Burner Switch is turned off The system is functioning if the Stir Pump is operating when the Diesel Burner Status light is illuminated and the Low Temp Cut Off light is extinguished i e running hot water The system is also functioning properly if the stir pump and indicator light are off when the Diesel Burner Status light and the Low Temp Cut Off status lights are illuminated or the Diesel Burner Switch is turned off If the light is red under any condition then there is an issue with either the wiring
31. or the stir pump Diesel Burner Status This indicator light shows the status of the diesel burner by illuminating green when the diesel burner 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 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 completely locked togeth er Also verify the Photo Eye Wires have not been pinched Reference section 9 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 Hydro Hot Under normal operating conditions this indicator light is off This light illuminates red when the Hydro 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 Page 43 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Diesel Burner Overview The Hydro Hot
32. pering valve assembly SECTION 4 HYDRO HOT COMPONENTS 4 Disconnect the pex pipe and fittings from the tempering valve assembly 5 Remove the pressure relief valve assembly from the tempering valve assembly as the tempering valve cannot be removed from the Aqua Hot with the pressure relief valve still attached 6 Using a back up wrench unscrew the tempering valve from the Hydro Hot CAUTION A back up wrench must be used for loosening and removing the tempering valve from the Hydro Hot Failure to use the back up wrench will cause the copper domestic water coil to twist and kink which will render the domestic water feature unusable 7 Remove the brass fittings from the defective tempering valve NOTE Be sure to wrap a thread seal tape around the threads of the brass fittings to prevent domestic water from leaking 8 Install the brass fittings onto the replacement tempering valve 9 Install the replacement tempering valve onto the Hydro Hot using a back up wrench to tighten 10 Install the pressure relief valve onto the replacement tempering valve 11 Reconnect the Pex pipe and fittings to the tempering valve and Hydro Hot Be sure to inspect the rubber seals and replace if necessary 12 Reconnect the motor home s water lines to the temper ing valve assembly 13 Turn the motor home s water pump back on and check for leaks and the presence of hot domestic water 14 Verify that the re
33. pressure gauge is registering a pressure the fuel pressure can be adjusted To increase the fuel pressure turn the pressure adjustment screw clockwise and to reduce the fuel pressure turn the pressure adjustment screw counter clockwise Page 93 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX EXTREME COLD WEATHER OPERATION WARNING Diesel Burner When storing the Motor home Not winterizing the Hydro Hot when freezing temperatures are present will result in serious damage to the Hydro Hot s Domestic Water Heat 1 If the Diesel burner Fails to operate ing 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 Hydro 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 Hydro 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 Hea
34. removing the two Phillips heads screws that fasten the two parts together 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 Page 65 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Motor Replacement Procedure continued Electrode Adjustment Gauge Flange Protection Housing Figure 44 ED 4 Page 66 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Flame Sensor 3 Connect the flame sensor s green and blue wires to The flame sensor is a photo resistive device which an ohmmeter supplies the diesel burner s controller with a DC voltage signal when it detects a flame When the 4 Check resistance by placing a shop rag over the flame sensor senses the light of the flame it will flame sensor s glass surface to simulate a no flame shut the ignition coil off and send a signal to the condition and then remove the rag and expose to a diesel burner controller indicating that everything is light source to simulate a flame condition working properly If the flame sensor does not sense the flame it will shut the diesel burner down 5 Ifthe flame sensor is operating proper
35. 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 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 106 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Page 107 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev APPENDIX D HYDRO HOT MAINTENANCE Step 11 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 12 Re Install Diesel Burner Figure D14a 5 27 NOTE When reinstalling the diesel burner be careful not to damage the photo disc bend the elect
36. room thermostat e The Zone Pump indicator light illuminates red on the When the Heating Zone Status indicator light illuminates on the electronic controller the corre sponding Pump 1 and or Pump 2 indicator electronic controller Troubleshooting light should illuminate as well 1 Verify that the Low Temp Cutoff Status indicator B With the jumper wire installed check the indicator light on the electronic controller is illuminated as it will light corresponding to the pump not operating be whenever the boiler tank is at operating temperature and domestic hot water is not being used If the indicator light illuminates green complete the following 1 Page 26 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A A Using 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 If the indicator light illuminates red complete the fol lowing A Disconnect the circulation pump s wires If the indicato
37. 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 Hydro 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 Check all fuel connections for tightness If fuel does not flow out of the return line into the empty container the fuel pump must be replaced 2 Check the screen filter located in the fuel supply inlet of the fuel pump for dirt particles Clean and Prior to replacing the fuel pump be sure to inspect or replace if necessary the screen filter in the supply inlet of the fuel pump for dirt particles Clean and or replace if necessary 3 To adjust the fuel pressure refer to Appendix B A plugged screen filter will restrict fuel from enter ing the fuel pump Fuel pressure check and adjustment FUEL PUMP OVERVIEW Fuel Nozzle Air Relief Bore Fuel Supply Line Fuel Return Line Fuel Pressure Regulator Fuel Solenoid Page 73 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Fuel Pump Replacement Procedure NOTE To perform the following procedur
38. 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 B1 1 Refer to the section on detaching reattaching the diesel burner to detach the diesel burner Step 2 Installing the fuel pressure gauge ba Figure B2 1 Using a 5 8 and a 3 4 wrench remove the fuel nozzle 90 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev APPENDIX FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 3 Installing the fuel pressure gauge Figure B3 1 Using a 5 8 and 3 4 wrench install the fuel pressure gauge 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 amp Aqua Hot Figure B4 800 685 4298 8 5 3 4 ki Electric Engine Preheat e 2 Turn the diesel burner switch to the on position A pressure will register on the fuel pres su
39. the Hy dro 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 14 will begin to operate NOTE If the Hydro Hot s coolant tem perature 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 VAC 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 Operational Flow Chart 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 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 NOTE If process A occurs the Aqua Hot Heating Status Light on the Electronic Contr
40. the burner and then remove NOTE To remove the diesel burner it may be necessary to disconnect the control and hi limit thermostats from the diesel burner s white thermostat plug Page 99 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Step 5 Clean and Inspect the Combustion Chamber and Heat Transfer Tabs 4 DANGER Use caution when handling the combustion chamber it may be extremely hot and serious burns could result from touching a hot combustion chamber Figure D5a me dicbus 2 1 Remove the combustion chamber by pulling Once the combustion chamber has been re it straight out approximately 16 inches moved Use a long handled wire brush and brush the heat transfer tabs to loosen soot deposits Failure to do so will reduce the Hydro 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 100 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Step 5 Clean and Inspect the Combustion Chamber and Heat Transfer Tabs continued Figure D5d Back side of air swirler Outer ring tha
41. 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 Page 6 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 1 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 is activated via the interior switch panel the motor home s engine coolant is circulated through a dedicated copper coil in the Hydro Hot s boiler tank where heat from the antifreeze 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 Hydro Hot includes a Motor aide feature which uses the circulation of the motor home s engine to transport the engine s coolant from the Hydro 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 Motor aide feature is part of the engine preheat ing feature and plumbing sys
42. the pump to the heater 8 Using constant tension pliers loosen and slide back the constant tension clamps securing the hoses to the heater 9 Remove the hoses from the heater Installing the replacement Stir Pump Hydro Hot amp Aqua Hot 450DE1 DM1 1 Using the Pump Adapter Bracket Align the two holes in the middle of the bracket in between the existing holes on the sheet metal where the defective stir pump was mounted NOTE The Mitered side of the Pump Adapter Bracket must be facing towards the front of the heater Away from the Boiler tank SECTION 4 HYDRO HOT COMPONENTS 2 Mark the holes and drill them out using an 11 32 drill bit 3 Using the Constant Tension pliers install the 3 4 hose clamps Size 27 onto the 3 4 side of the replacement hoses and the 23 32 Size 20 hose clamps onto the 1 2 side of the replacement hoses NOTE The hoses may need to be cut to fit properly 4 Slide the new replacement hoses on the new replacement pump and set the constant tension clamps into place on the pump 5 Slide the new replacement hoses onto the fittings in the boiler tank and set the constant tension clamps into place 6 Install the Pump Bracket onto the pump aligning the mounting tabs with the holes previously drilled in step 7 Removing the Defective Stir Pump 7 Secure the pump to the side of the heater 8 Plug the Cooper pump wire harness into the pump and connect the wires to the wires
43. up the diesel burner controller must be replaced Be 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 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 NOTE Ifthe Control Box is replaced and the Ignition Coils still will not operate it is possible the Electronic Con troller is defective 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 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 Reconnect the B plug and the C plug 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
44. without Fuel Ignition Electrodes or remove Nozzle jumper wires Install Fuel Nozzle Reattach Diesel Burner Head Retest Fuel Nozzle spray pattern and attempt heater restart fine mist of fuel present Reattach Diesel Burner Head and attempt heater restart NOTE If an improper fuel spray is still observed a normal spray pattern should be observed as a coned shaped mist the Diesel Burner s Fuel Pump should be calibrated for the proper fuel pressure setting End of Troubleshooting Flow Chart For additional troubleshooting information please contact Aqua Hot Heating System s Service Department at 303 659 8221 Mon Fri 7 00 a m 4 00 p m Page 62 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING If there is no 12 Volts D C present on the C 2 pin con tinue Diesel Burner Motor The motor drives the combustion air blower and the fuel pump In order to perform the following proce 2 Verify the Electronic Controller is sending power dures it may be necessary to detach the diesel burner head NOTE The motor may have a flat spot and will cause the burner to work intermittently When testing the motor be sure to test it multiple times to find the intermittent problem Component Test 1 Locate the diesel burner controller s C Plug and insert the probes of a DC voltmeter
45. 2 Low Tank Level Cutoff Indicator Light Page 42 Heating Status Indicator Light Red Page 42 Engine Preheat Pump Indicator Elglhil aiii inire ennenen Page 42 43 Circulation Pump 1 Indicator Light Page 43 Circulation Pump 2 Indicator Ligas irren tn remedia en eee iu Page 43 Stir Pump 3 Indicator Light repere Hei oi res Ero Page 43 Diesel Burner Status Indicator Eight eee eee ean eaae Page 43 Overload Fault Indicator Light iii Page 43 Section 7 Diesel Burner Overview OVE VIEW iato sat estet mnie heh AA lta a LA CaL ees Page 44 Moe Page 44 Diesel Burner Overview SA AM Au AM SA ANS Page 45 Diesel Burner Operational Flow 5 55485 i 445 484 445 444848 4144 431413 Page 45 Diesel Burner Operational Overview ses Page 47 49 Section 8 Detaching and Reattaching the Diesel Burner Detaching the Diesel Burner 2 2 2 Page 50 52 Reattaching the Diesel Burner 1 1 1 21 1 cerca 53 55 Section 9 Diesel Burner Components and Repair Information Diesel Burner Component 2 2 2 2 1 1 111 ccce 56 Tr
46. 2 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 7 DIESEL BURNER Diesel Burner Operations The following sequence illustrates how the Diesel Burner as diagnostic tool to determine at what point in the diesel operates once it is activated Also if 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 shown Diesel Fuel Spray Combustion Air gt Exhaust Gases The particular component begins to operate I The component is currently operating When the Diese switch is turned ON the Motor and Combustion Air Blower begin to operate This Combustion process is referred to as the prime cycle 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 Fuel Solenoid Valve After approximately 10 25 seconds the Fuel Solenoid Valve opens and fuel is released into the Fuel Nozzle then sprayed into the Combustion Chamber Fuel Nozzle Fuel Solenoid Valve Combustion Diesel Fuel Chamber Fuel Pump Supply and Return Page 47 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 7 DIESEL BURNER Diesel Fuel Spray Combustion Air gt Exhaust Gases NE The particular
47. 3 plug between pins 15 and 16 between LWCO I 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 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 SECTION 4 HYDRO HOT COMPONENTS Replacement Procedure 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 Hydro Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will involve 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 Hydro Hot s boiler tank using the drain valve Approxi mately 1 2 gallons will need to be drained 3 Disconnect the Fluid Level Sensor s wires by separating the quick disconnect terminals 4 Using a 7 8 socket remove the defective Fluid Level Sensor from the
48. 50 50 mix ture of GRAS approved propylene glycol boiler antifreeze and water is recommended Reference Section 1 Antifreeze and Water Heating Solution for additional information regarding the antifreeze and water heating solution Be sure to use a GRAS boiler type pro pylene glycol based antifreeze rather than an RV and Marine antifreeze or an automotive antifreeze coolant If assistance is needed in selecting an appropriate antifreeze please contact the Aqua Hot Heating Systems Product Appli cation Department at 1 800 685 4298 TO DRAIN THE AQUA HOT 1 Connect a piece of 1 2 inch PEX type tubing or rubber hose to the drain valve This piece should be long enough to transport the antifreeze and water heating solution from the Hydro hot to a bucket 2 Open the Hydro Hot s drain valve located at the front of the heater Reference Figure F5 Note The Hydro Hot holds approximately 5 gallons of the antifreeze and water heating solution Page 115 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A 200 9 HHE 500 09M SERVICE MANUAL Sens aS 15549 East Highway 52 Fort Lupton CO 80621 DS Aq ua OT free 800 685 4298 phone 303 659 8221 fax 303 857 7881 HEATING SYSTEMS INC www aquahot com
49. 8 405 584 565 24 45 524 444 54425 22 Low Temperature Cut Off Thermostat Page 22 23 Check Valves siot wate aah wat tt Page 23 24 TY GING TAA AS Page 25 26 CirCulation PUMPS c 25 R EREA A Page 27 28 SU EOIN At hr et A an a eed Page 29 31 Engine Preheat Pump nn NN ne Page 32 34 Heating EIS Meni acer cie o AR AN At at Page 35 36 AC Relay 37 Section 5 Electronic Controller General M Page 38 Secondary 12 Volt DC battery Connection 39 Terminal Strips with Screw Type Page 39 Low Voltage Reset Feature MONA M M Page 40 Replacement Procedure 41 Proper Jumper Pin Formation Page 41 Page 3 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev Table of Contents Section 6 Electronic Controller Indicator Lights Electric Heating Element Status Indicator Light VV Page 42 Heating Zones Status Indicator Lights 1 5 Page 42 Low Battery Voltage Fault Indicator Light Page 42 Low Temp Cutoff Status Indicator Light Page 4
50. A i Diesel Burner Switch Turned ON Diesel Burner heat source selected by Diesel Burner switch Diesel Burner fires into the Combustion Chamber which heats the antifreeze and water heating solution in the Boiler Tank 10 20 Minutes Zone Thermostat calls for heat The Circulation Pump activates for the Zone which called for heat The heated antifreeze and water heating solution is trans ported throughout the plumbing lines in that zone Heat Exchanger fans activate NOTE The Circula tion Pumps and Heat Exchangers will not operate until the Boiler Tank reaches a minimum of 150 F NOTE The Diesel Burner and or Electric Heating Element as switched ON will automatically begin reheating the antifreeze and water heating solution when the Boiler Tank drops below 160 F The cooled antifreeze and water heating solution is returned to the Boiler Tank to be reheated Antifreeze and water heating solution moves through the selected from the Interior Switch Panel Boiler Tank heats to SECTION 2 HYDRO HOT OVERVIEW AQUA HOT OPERATIONAL Heat Source is FLOW CHART Electric Element Switch Turned ON Electric Heating Element heat source selected by Electric Element switch Electric Heating Element activates which heats the antifreeze and water heating solution in the Boiler Tank 1 2 Hours 190 F A hot water faucet e g kitchen sink shower etc
51. Aqua Hot HHE 200 09E HHE 500 09M SERVICE MANUAL NOTE This Service Manual will also work with model numbers HHE 200 08E HHE 500 08M AHE 450 DE1 and AHE 450 DMI 2012 Aqua Hot Heating Systems Inc Table of Contents Section 1 Introduction to the Hydro Hot ligu gere CK Kc C ten Page 6 7 Danger Warning Caution and Note Box Definitions Page 6 Section 2 Hydro Hot Hydronic Heating System Overview Technical Information 55 285525 TENEO IRE 8 8 La bel Samples T Page 9 Component OvervieW E Page 9 11 Hydro Hot Operational Flow Gbhart ee e e ete ee Page 12 Antifreeze amp Water Heating solution es Page 13 14 Section 3 Interior Switch Panel Di sel Burner SWIIC 034553 053 15 Electric Element SWIICE 5o coe o Page 15 Engine Preheat 15 16 Section 4 Hydro Hot Components blind Level Sensor Page 17 18 Control Themnostal sooo ee 19 20 AC Fight Lat Thermmos al soia es Page 21 Dy Ge right Limit Thermostat 8455552 554525254 445450 4654525
52. BURNER COMPONENTS AND TROUBLESHOOTING 1 Check the voltage level of the DC multi meter NOTE Voltage level should be within 0 5 volts of the system s DC batter voltage Does the DC multi meter indicate ac ceptable system voltage Turn the Control Switch OFF Reattach Diesel Fuel Return line Detach the Diesel Burner Head from the Aqua Hot Disconnect one of the wires from the Fuel Solenoid Valve Inspect the Flame Detection Photocell for dust and or sooty carbon deposits Clean if necessary Completely cover the Flame Detection Photocell with a shop rag Turn the Control Switch ON After approx 20 seconds of A DAN G operation a bright blue arc spark should appear across the Ignition Electrodes NOTE Do not remove or cut any of the external wires attached to the Diesel Burner Head Do not attempt to restart the Hydro Hot when the Diesel Burner Head is detached An open flame can result and cause serious personal injury To prevent a fire hazard be sure to disconnect one of the Fuel Solenoid Valve wires Page 59 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Within 15 seconds after turning ON the Control Switch disconnect one of the two wires from the Flame Detection Photocell A spark should now appear across the Ignition Electrodes
53. 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 i 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 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 harness violet and brown wires to the fuel solenoid s and electrical terminals Retaining Clamp Brown wire Photo Disc Retaining Clip Fuel Solenosd Valve Lock Nut
54. Control Switch OFF Check Ignition Coil for proper operation by Removing C plug from Control Unit Apply DC power to C 8 plug yellow wire and ground to C 5 plug brown wire A spark should now appear across the Ignition electrodes Does the Ignition Coil operate Properly Replace Ignition Coil Reconnect Flame Detec tion Photocell wire Fuel Solenoid Valve wire and C plug Reattach Diesel Burner Head and attempt heater restart Page 60 SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Turn the Control Switch OFF Reconnect Fuel Solenoid Valve wire Remove both ignition wires from the Ignition Electrodes or connect a jumper wire across the Electrodes Does the spark reappear To prevent a HIGH VOLTAGE shock and or a fire hazard be sure to remove both Ignition Electrodes tape the ends and separate the wires or connect a jumper wire across the Electrodes Turn the Control Switch Off Replace the Control Unit Reconnect Fuel Solenoid Valve wire Reattach Diesel Burner Head and attempt heater restart 4 Turn the Control Switch ON After approx 20 seconds the Fuel Solenoid Valve should receive power from the Control Unit A fine mist of fuel should appear from the Fuel Nozzle Replace Fuel Solenoid Valve Retest fuel flow without Fuel Nozzle Install
55. ET HOT 1 General Problems A Diesel Electric not operating antifreeze cold Heater is Not up to operating Temperature antifreeze is cold Interior Zone Thermostat Not calling for heat Zone Circulation Pump Not Operating Heat Exchanger Fans Not Operating The Low Temp Cut Off status light is not illuminated on the Electronic Control Board The Electronic Control Board is wired wrong 1 the fans for the bedroom come on but the pump for the living room comes on Not enough Heat Exchangers installed Heat Exchangers improperly installed 2 If Fans and Pumps are Running A B Stuck Check Valve Kinked Line No Antifreeze in system Page 85 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 10 TROUBLESHOOTING IF THERE Is A LACK OF DOMESTIC HOT WATER 1 General information 1 2 The heater is only rated for water flow of 1 5 The heater is only rated for 55 F temperature Rise on the cold water coming into the unit The diesel burner must be on for continuous hot water the electric element is for lim ited use only 2 Things to test for a lack of hot water problem 1 2 Hydro Hot Heater Bypassed Outside Water Faucet is left on Washing Machine Valve has gone bad Antifreeze Concentration is incorrect a 30 50 antifreeze concentration Operating Range of the heater I E Control Thermostat 15 incorrect a 160 F
56. Step 4 Remove the fuel lines from the Hydro Hot 1 Locate where the fuel lines on the diesel burner 2 Using an 11 16 wrench loosen the nuts securing connect to the Hydro Hot Bulkhead fittings each fuel line to the Hydro Hot Page 51 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 8 DETACHING AND REATTACHING THE DIESEL BURNER Step 5 Remove the Diesel Burner from the Hydro Hot 1 The Diesel Burner is secured to the Hydro 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 exten sion 2 Carefully pull the Diesel Burner away from the Hydro Hot 4 to 5 inches before rotating the burner and then remove Page 52 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev SECTION 8 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 Dies
57. ake sure the retaining clip has secured the Failure to connect a jumper wire across the ignition elec electrode in place trodes or to remove the ignition cables from the ignition electrodes will result in a HIGH VOLTAGE shock and 6 Slide the electrode into the photo disc or a fire If the ignition cables are removed be sure to place a piece of electrical tape on the end of each cable 7 Install retaining clamp and retaining clamp bolt and finger tighten 3 Remove the B plug from the diesel burner head s 8 Follow steps 2 5 to properly adjust the electrodes controller 4 Turn the diesel switch ON and then plug the B plug back into the diesel burner controller to activate the ES diesel burner 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 Fuel Nozzle pattern The fuel nozzle is simply a fuel atomizer It reduces the diesel fuel into a fine spray which is mixed with incoming combustion air and is ignited within the combustion chamber 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 instructions Fuel Nozzle Component Test 7 Figure 48 1 Follow the directions for detaching the diesel burner in section 8 of this manual Ignition Cable April 2012 Hydro Hot Hydronic Heating System Service
58. ank tubing connects to There is also an air release valve on the brass fitting that may leak D Supply and Return interior zone heat ports i tubing hose ii Brass fittings TROUBLESHOOTING ANTIFREEZE LEAK NOTE On the Hydro Hot Models the interior zone heat return ports are located on the Back of the unit Page 87 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 10 TROUBLESHOOTING ANTIFREEZE LEAK 3 Onthe Back A Domestic Water and Coach Engine copper plumbing 1 The copper coils are in the antifreeze solution and where they come through the steal tank 15 a possible point of leakage for each pipe B Interior Zone Heat Return ports i Either the coach manufacturer s fitting could be leaking or the brass fitting on the back of the Hydro Hot supplied by Hydro Hot could be leaking The brass fitting may need to be removed to inspect for cracks NOTE On some of the AHE 450 models the return ports are on the top of the heater and do not utilize the brass fitting supplied by aqua hot Domestic Water amp Coach Engine Copper Plumbing NOTE If no leaks are found on the Aqua Hot it is possible the leak is on the interior of the motor home It could be an interior heat exchanger or the plumbing for the interior heat exchangers Page 88 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A WIRING DIAGRAM APPENDIX A
59. as 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 Drain the antifreeze and water heating solution from the Hydro Hot s boiler tank using the drain valve Disconnect the defective control thermostat s wires by separating the quick disconnect terminals Using a 7 8 socket unscrew the control thermostat from the Hydro Hot s boiler tank Wrap the threads of the replacement control thermostat with Teflon tape Screw the replacement control thermostat into the port on the Hydro Hot s boiler tank and tighten securely with a 7 8 socket Connect the replacement control thermostat s wires in the same configuration as the removed control thermo stat s wires Refill the Hydro Hot s boiler tank with the antifreeze and water heating solution Test the Hydro Hot for normal operation Page 19 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A AC High Limit Thermostat 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 220 F Should this temperature be r
60. burner switch or the electric ele ment switch must also be activated in order for the engine preheat feature to function 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 Temp Cutoff Status indicator light is illuminated on the electronic controller 1 Verify that the Low Temp Cutoff Status indicator light on the electronic controller is illuminated 2 Verify that the Engine Preheat Switch is in the ON posi tion on the interior switch panel inside the motor home Either the diesel burner switch or the electric element switch must also be activated in order for the engine preheat feature to function 3 the electronic controller verify that the engine preheat pump light is illuminated If the Engine preheat pump indicator light does not illu minate complete the following SECTION 4 HYDRO HOT COMPONENTS A Verify that the low temperature cutoff light and the diesel burner electric heating element status lights are illuminated on the electronic controller B Using a jumper wire bypass the engine preheat switch on the JP3 plug by connecting pins Preheat O and Preheat I together If the engine preheat pump indicator light illuminates with the jumper installed inspect for loose wires If no loose wires are found replace the engine preheat switch on the interior switch panel inside the motor home
61. cement canister NOTE It is recommended that the replacement fuel filter be filled with clean diesel fuel prior to installation 4 Remove hose pinch off pliers Step 3 Run the Diesel Burner 1 Turn the Diesel Burner Switch to the on po sition 2 After the Diesel Burner has ignited let it burn for 1 2 minutes to purge the old fuel out of the nozzle holder to prevent contami nation of the replacement nozzle 3 Shut the Diesel Burner off and wait for unit to completely shut off NOTE The diesel burner can either be shut off by 1 Turning the Diesel Burner switch to the off position 2 Disconnecting the control thermostat wires Reference Figure D3 Page 97 APPENDIX D HYDRO HOT MAINTENANCE Hydro Hot Maintenance Procedure Step 4 Remove The Diesel Burner Figure D4a 1 Locate the Diesel Burner s Controller and disconnect both plugs Failure to do so may result in the Diesel burner igniting F 3 The Diesel Burner is secured to the Hydro Hot with two 10mm nuts that can be loosened and swung out of the way by using a 10mm socket wrench with a 10 inch long extension Page 98 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev APPENDIX D HYDRO HOT MAINTENANCE Hydro Hot Maintenance Procedure Step 4 Remove The Diesel Burner continued Figure D4d i 4 Carefully pull the Diesel Burner away from the Hydro Hot 4 to 5 inches before rotating
62. 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 22 Ignition Coil Ignition Electrodes Combustion The combustion s flame is detected by the Flame Sensor and the gnition Coil is then automatically switched off no more spark across the gnition Electrodes Flame Hot Exhaust Sensor Gases Page 48 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 7 DIESEL BURNER Semet Diesel Fuel Spray Combustion Air gt The particular component begins to operate ZT 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 Diese Burner is switched off by the VDC VAC Control Thermostat it will automatically be reactivated once the Aqua Hot Boiler 5 coo
63. d 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 SECTION 4 HYDRO HOT COMPONENTS A Locate the AC wires connected to the AC relay pins 6 and 8 and remove the AC wires from the relay B 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 AC 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 AC access cover Page 37 April 2012 Hydro Hot Hyd
64. dix D Aqua Hot Annual Page 96 110 Appendix E Winterization Page 111 Appendix F Filling Draining the Page 112 115 Page 5 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 1 This service manual is designed to aid trained and qualified service technicians with the pro cess of troubleshooting and servicing the Hydro Hot Hydronic heating system The Hydro Hot heating system features a 12 Volt DC pow ered diesel burner and a 120 Volt AC 1650 Watt electric heating element These two heating sources are used in con junction with an FDA approved GRAS Generally Recog nized as Safe propylene glycol based boiler antifreeze and water heating solution in order to provide a continuous sup ply of domestic hot water interior fresh water tank heating independent 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
65. e Washer Flat Washer Page 77 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A 12 13 14 SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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 006 002 inch gap is achieved Remove feeler gauge Reference Figure 55 Spin the combustion air blower to ensure a friction free rotation If the combustion air blower is rubbing loosen the retaining nut slightly and lightly tap on the combus tion air blower s shaft opposite side then readjust the gap 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 Reconnect 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 NOTE Inspect the clutch halves for cracks and also ensure 15 16 17 18 that the flat portion in each shaft hole is free of wear and tear
66. e Figure F4 All air is bled from the heating system when both plumbing lines are free of air and there is fluid in 8 Connect an alligator clip to the spade terminal on the expansion tank the circulation pump s blue negative wire and clip the opposite end of the cable to a ground source 13 Continue to fill the Hydro Hot Heating System until the fluid level remains at the top of the filler neck The circulation pump will activate as soon as the pump is connected to a ground source 14 Securely tighten the radiator cap 9 Allow the circulation pumps to operate for the re 15 Fill the Expansion Tank bottle to the cold mark mainder of the purging process in order to purge all the air out of the heating loops and boiler tank 16 Once the systems have been purged reconnect the pump s wires as originally configured Reference NOTE Once the Purging Process has begun it will be nec Figure F4 essary to refill the Hydro Hot s Boiler tank with the appro priate antifreeze and water heating solution 17 Ensure that each circulation pump s wiring has been returned to its original configuration Reference 10 Open the drain valve and Turn the fluid transfer Figure F4 pump on and fill the Hydro Hot with the 50 50 mixture of antifreeze and water heating solution until the Low Tank Level Cutoff Light on the Electronic Control Board is extinguished reference Figure F2 13LB Radiator Cap Page 113
67. e Motor s in line fuse for continuity Replace if neces sary Temperature LE above 155 F The Heater is Functioning NOTE The Indicator light will illu Properly minate for only 30 seconds if the motor fuse is blown open circuit 4 Attempt heater restart 1 Page 57 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 5 Using a digital volt meter Check both the C7 1 and the C1 O Termi Is there continuity nals for 12 VDC on the JP4 plug on across the the Electronic Controller If either thermostat wire does not have 12 VDC the Elec tronic Controller will need to be re placed Check the Diesel Burner s VDC Control Thermo stat for continuity NOTE The only time both the C7 and the wires will have 12VDC is when 1 Reset the Thermostat by both the Diesel Burner Status Light pushing on the reset button and the Heating Status Lights are illu in between the two wires minated on the Electronic Controller NOTE Hydro Hot operating 6 The motor may either be bad or temperature must be below have a flat spot Hot wire the mo 220 F when checking the High tor by locating the C plug and put Limit Thermostat for continui power to the C 5 pin and a ty or attempting a reset ground to the C 2 If the motor does tot rib the motoris Dad 2 Ifthe Thermostat cannot be reset it will need to
68. e it will be nec essary to remove the diesel burner Follow the section on detaching and reattaching the diesel burner section 8 of this manual 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 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 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 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 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 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 wi
69. eached 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 if the following condition has occurred e The electric heating element fails to operate Troubleshooting 1 Disconnect all power supplies 2 Remove the AC access cover 3 Verify that the boiler tank s temperature is below 220 F 4 Locate the AC high limit thermostat 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 is still not present after the reset button has been pressed follow the instructions in this section to replace the AC high limit thermostat NOTE Ifthe High Limit Thermostat is tripped it is recom mended to test the control thermostat for proper operation and verify the boiler tank is full of antifreeze A C High Limit Thermostat SECTION 4 HYDRO HOT COMPONENTS 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 Hydro 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 termi
70. el Burner to the Hydro Hot Figure 36a 1 The Diesel Burner is secured to the Hydro Hot with two eye bolt nuts that can be swung into place after the diesel burner has been properly aligned and set in place 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 53 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 8 DETACHING AND REATTACHING THE DIESEL BURNER Step 2 Reattach the fuel lines to the Hydro Hot Figure 37 1 Align the fuel lines on the diesel burner with the fittings on the Hydro Hot and using 11 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 Hydro Hot prior to start ing 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 3 Locate the Diesel Burner s Controller and connect both plugs Figure 38 Page 54 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 8 DETACHING AND REATTACHING THE DIESEL BURNER Step 4 Reinstall the Access Cove
71. el burner to be considered as a heating source by the Hydro 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 electric heating ele ment to be considered as a heating source by the Hydro 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 Hydro 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 Priority System The Hydro Hot is a Hot Water Priority System Meaning that the Hydro Hot cannot heat the interior of the motor home and produce continuous hot water simultaneously When Domestic Hot Water is being used the interior heating system will shut down until no more Domestic Hot Water is called for The domestic hot water priority system is responsible for providing hot water whenever a hot water faucet is opened such as with a shower or sink When hot water is requested domestic water from the motor home s fresh water tank is transported through a copper coil in the Hydro Hot s boiler tank where heat is transferred from the heated antifreeze and water heating solution to the do mestic water flowing through
72. electric heating element for functionality by completing the following A Disconnect all power supplies B Remove the AC access cover C Remove all wires from the electric heating element D Using an ohmmeter check the electric heating ele ment for the proper ohms The Ohms reading should be between 8 5 9 5 ohms If the ohms reading is not between 8 5 9 5 ohms follow the instructions in this section to replace the electric heating element 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 SECTION 4 HYDRO HOT COMPONENTS Ensure that the Hydro 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 Drain the antifreeze and water heating solution from the Hydro Hot s boiler tank using the drain valve Remove the AC access cover Remove the two wires secured to the defective electric heating element by releasing the screw terminals Using a 1 1 2 inch socket remove the defective electric heating element from the Hydro Hot s boiler tank Install the replacement 1650 watt electric heating ele ment into the boiler tank ensuring that the up lettering on the element is installed in the up position
73. 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 complete the following 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 check the relay AC pins 2 and 4 for continuity If no continuity exists follow the instructions in this section to replace the AC relay 5 Verify that the electric heating element is receiving adequate AC power by completing the following A Remove the AC access cover B Plug the Coach into shore power turn generator on Page 35 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A C Using an voltmeter verify that 110 volts of AC power are present at the terminal block reference figure 20 If there is not 110 VAC present at the terminal block for the electric element there is a problem inside the motor home D Using a digital clamp meter verify the electric ele ment s amp draw is between 11 2 to 13 amps E Check the electric element s wires for continuity by completing the following a Disconnect the motor home from shore power shut off generator b Disconnect the wires from the electric heating element c Disconnect the wires from the AC terminal block d Check the black and white wires at the terminal block for continuity 4 Check the
74. emove the hose from the defective check valve 5 Disconnect the Motor Home s interior plumbing line from the Hydro Hot s bulk head fitting NOTE When the interior heating zone line is disconnected from the bulkhead fitting approximately 2 quarts of anti freeze will leak out of the interior heating zone line Zone Check Valve SECTION 4 HYDRO HOT COMPONENTS 10 11 12 13 Unscrew the defective check valve from the Hydro Hot s bulkhead fitting Remove the hose barb and the 1 2 inch coupler from the defective check valve Clean the hose barb and coupler then wrap the hose barb and the 1 2 inch coupler pipe threads with a thread seal tape Install the hose barb and 1 2 inch coupler on the replace ment check valve ensuring that they are installed properly with the hose barb on the arrow side of the check valve Install the replacement check valve onto the Hydro Hot s bulkhead fitting The arrow on the check valve must point away from the circulation pump Connect the interior heating zone line to bulkhead fitting Slide the hose back onto the check valve and set the con stant tension clamp back into place Refill the Hydro Hot s boiler tank with the antifreeze and water heating solution Page 24 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Tempering Valve The tempering valve for the Hydro Hot mixes the heated domestic water from the boiler tank w
75. 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 affect the combustion process of the diesel burner Fuel Nozzle Page 96 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Hydro Hot Maintenance Procedure Note Before performing an annual maintenance it is recommended to test run the Diesel Burner While testing inspect exhaust for smoke Step 1 Test Run the Diesel Burner 1 Turn the Diesel Burner Switch to the on po sition 2 After the Diesel Burner has ignited inspect the exhaust for smoke 3 Shut the Diesel Burner off and wait for unit to completely shut off NOTE The diesel burner can either be shut off by 1 Turning the Diesel Burner switch to the off position 2 Disconnecting the control thermostat wires Reference Figure E3 Step 2 Replace the Fuel Filter 1 Locate Fuel Filter 2 Using hose pinch off pliers clamp off both fuel lines going to the fuel filter Reference figure D2 10 Micron Fuel Filter April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE 3 Replace fuel filter with proper repla
76. erior switch panel is on the system is also functioning correctly If the light is red and the electric element switch on the inte rior switch panel is on then there is 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 These lights indicate the status of each motor home 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 functioning 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 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 shuts the interior heat off when domestic hot water is being used and activates the stir pump in conjunction with the diesel burner switch When
77. etach and reattach the diesel burner head Be sure to review the detaching and reattach ing section for detaching and reattaching instruc tions Locate and disconnect the C plug harness wires that connect to the flame sensor and fuel solenoid Also disconnect the ignition cables from the ignition electrodes 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 Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition 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 Protection Housing Electrode Adjustment Motor Flange 5 6 Te 8 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 Remove the four blower housing screws that secure the blower housing to the blower casing Remove the blower housing so that the combustion air blower is exposed Spin the combustion air blower by hand Placing one of the clutch halves to the end of the shaft assists with the s
78. eze 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 propylene 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 Hydro Hot s Hydronic Heating System This type of antifreeze is not formulated to transfer heat which is essen tial to the heating system s functionality and does not contain rust inhibitors Please note however that RV amp Marine antifreeze can be utilized to winterize the Hydro Hot s do mestic water heating system Automotive Antifreeze Coolant These types of propylene glycol based antifreeze products are formulated specifically to protect automotive engines against corrosion
79. hat the domestic hot water is not being used 2 Ifthe Low Temp Cut Off Status indicator light on the electronic controller is not illuminated after it has been determined that it should be complete the following A Install a jumper wire on the JP3 plug between pins 9 and 10 and LTCO I on the elec tronic controller If the indicator light does not illuminate once the jumper wire is installed follow the instructions in this manual to replace the electronic controller B Using a temperature sensor verify that the low temperature cutoff thermostat is above 90 F If the thermostat is below 90 F verify that the Aqua Hot is up to operating temperature and that a hot water faucet is not leaking SECTION 4 AQUA HOT COMPONENTS C Disconnect the Low Temperature Cut Off thermo stat s wires from the Hydro Hot s wiring harness then jump the wiring harness wires for the thermo stat together to bypass the thermostat If the Low Temp Cutoff Status indicator light illuminates on the electronic controller with the thermostat bypassed follow the instructions in this section to replace the low temperature cutoff ther mostat 3 Ifthe Low Temp Cutoff Status indicator light does not extinguish when domestic hot water is being used or when the Hydro Hot falls below operating temperature complete the following A Using a temperature sensor verify that the low temperature cutoff thermostat
80. he 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 If the ignition electrode s electrical insulator is cracked or damaged the ignition electrode must be replaced The electrode adjustment gauge is used to set the gap between the ignition electrodes The electrode adjustment gauge is located on the outside surface of the diesel burner head on the left hand side Ignition Electrode Adjustment Procedure 1 Follow the directions for detaching reattaching the diesel burner in section 9 of this manual Using a 10mm socket slightly loosen the retaining clamp bolt 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 metal tips Retaining Clamp Ignition Cables Electrical Insulators Retaining Clamp Bolt NOTE Be sure not to over tighten the retaining clamp bolt 4 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 combustion and result in a smoky exhaust A bent retaining clamp can be re straightened with a punch and hammer Lay the c
81. hermostat s wires by separating the quick disconnect terminals 3 Using a 5 8 wrench or socket remove the defective high limit thermostat from the Hydro Hot s boiler tank 4 Install the replacement high limit thermostat into the port on the Hydro Hot s boiler tank and finger tighten only 15 in Ibs 5 Connect the wires removed from the defective high limit thermostat to the replacement high limit thermostat Page 21 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Low Temperature Cut off Thermostat The Low Temperature Cut Off thermostat operates the do mestic hot water priority system by blocking the interior heating feature when domestic hot water is being used This ensures that even heat is provided for domestic hot water which avoids the possibility of cold water pockets during showers Troubleshoot the Low Temperature Cut Off thermostat if the following conditions have occurred e There is a lack of interior heat e There is a lack of hot water and the Low Temp Cutoff Status indicator light on the electronic controller con tinuously remains illuminated which does not allow the stir pump to operate Troubleshooting 1 Determine if the conditions are right for the Low Tem perature Cutoff Status indicator light on the electronic controller to be illuminated A Verify that the Hydro Hot is at operating tempera ture between 158 F and 190 F B Verify t
82. hite Drive P O Box 2999 Reston VA 22090 0999 call them at 703 620 6003 or visit them online at www rvia org Page 8 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A B HYDRO HOT OVERVIEW SECTION 2 8629 589700871 12908 vo1dm 3104 25 3573 6551 12qunn s qwu ny LC CD DH jenas JOqUINN adj jen Jauing jasaiq jeuang Jeserq 135310 OLSVIIM 4 4 ynduy 1 4 0701 ISd SPL UMY 791 NLA 000 95 SYA SHOA 215 2 ZZON 09 2102 __oGAz 09 5 aunssaidg Dv SREM 2 SREM yue wnwixew s 822690 lt IN o iAINO 10 suon najsui 5 pue 2611 VdAN sapoo eo uedo 15035 eysu enue A 0 19193 48 28 uinuuluny 83AOD 55322 1144 31 8340 LON OQ ONINUVM 40 1580 ue 48A0 55822 243 184 OS 100p eBv10 s eq IL JUNOW Addins JYA OZL 10 uonp ejoad 10 sduiy oz SINI jeu UNNI
83. ic controller when the Hydro Hot is below 158 F Excessive Blue or white smoke is expelled from the ex haust Troubleshooting 1 Turn the diesel burner and electric element switches on the interior switch panel on and check the electronic controller to ensure that the Electric Heating Element Status and Diesel Burner Status indicator lights are illuminated Verify that the Heating Status indicator light on the electronic controller is illuminated as it should be when ever the Hydro Hot is below the operating temperature range of 158 F SECTION 4 HYDRO HOT COMPONENTS If the Heating Status indicator light is not illuminated check the following A Verify that the temperature of the boiler tank has fallen below the 158 F minimum operating temper ature by checking with a digital thermometer B Disconnect the control thermostat s wires from their connections and using an ohmmeter check for continuity If there is no continuity follow the instructions in this section for replacing the control thermostat If continuity exists complete the following a Inspect the control thermostat s wiring and connections b Install a jumper wire on the JP3 plug between pins 13 and 14 and TSTAT O on the electronic controller in order to bypass the control thermostat The diesel burner and or electric element switch must be in the on position also for the Hea
84. ice Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Ignition Coil 3 Connect the ignition coil wires directly to a 12 volt DC power supply 1 black wire to lead and The ignition coil produces a high voltage ignition brown wire to lead spark approx 8000 volts which 15 released across the metal tips of the ignition electrodes during the 4 Turn the power supply ON and watch for a spark to initial diesel burner start up appear across the metal tips of the ignition elec trodes If a spark does not appear the ignition coil Use extreme care when testing the ignition coil as a High must be replaced Voltage Shock may result NOTE In order to perform the following procedures it is necessary to detach and reattach the diesel burner NOTE Some ignition coils are intermittent and will need to be tested numerously If the Ignition Coils tests good and it still will not operate it is possible the Electronic Controller is defective CAUTION head Be sure to review the section for detaching and reattaching the diesel burner Component Test Before replacing the ignition coil 1 AE Verify the ignition electrodes are not cracked or broken Remove the four ignition coil screws that secure the Verify that the ignition electrodes are adjusted properly ignition coil in place Ensure the electrode boots are securely holding the electrodes in place Ensure the e
85. 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 is found follow the instructions in this manual to replace the electronic controller 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 Hydro 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 and motor home Engine is adequately cooled 2 Using hose pinch off pliers clamp both hoses attached to the engine preheat pump closed SECTION 4 HYDRO HOT COMPONENTS 10 11 Disconnect the defective circulation pump s wires by sepa rating 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 6 Remove the defective pump from the heater by drill ing out the rivets securing the pump to the heater Then remove the defective pump from the Hydro Hot Slide the hoses onto the replacement pump and set the constant tension clamps back into place Secure the replacement pump to the heater using rive
86. ine 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 is 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 Page 42 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 6 ELECTRONIC CONTROLLER INDICATOR LIGHTS If the red light illuminates when the pump should be func tioning then there is either an issue with the wiring or the engine preheat pump NOTE The Low Temp Cut Off light must be illuminated for the Engine Preheat pump to be activated Pump 1 This indicator light shows the status of the circulation pump that controls the fluid for Heating Zones 1 and 5 by illumi nating green for on red for fault and by turning off when the system is off The system is functioning properly if the coach thermostat is calling for heat the pump is operating and the light is green The system is also functioning properly if the pump and light are off and the thermostat is not calling for heat If the light is red under any condition then there
87. into the C 2 and the 5 locations A Turn the diesel switch ON and verify both the diesel burner status light and the heating status lights are illuminated on the electronic controller If either light is not illuminated follow the trouble shooting guide for that particular component B Observe the voltage level If a normal voltage registers on the voltmeter and the motor is not operating inspect the C Plug Harness for loose or damaged wire connections If the C Plug harness and connections are in good condition but the motor is not operation the motor must be replaced 12 Volt D C from coach house batteries to the diesel burner motor 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 receiving power from the batteries i Locate the main power terminals on the bottom of the electronic controller ii Using a volt Meter check for 12 Volt D C on the JP 8 terminal If no voltage is present verify that either the jumper is in place that connects pins JP5 and JP8 together or if there is a power wire hooked up to the JP8 terminal verify that it is receiving 12 Volt D C from the Motor home s batteries iii If the JP8 pin does have 12 Volt D C but pin 3 on the JP4 terminal does not have power replace the electronic controller C 2
88. into the C 2 and 5 locations If no voltage reading registers on the voltmeter the diesel burner controller must be replaced If voltage is present Motor Circuit Test tions A voltage level of between 11 5 to 14 0 volts must Ms be present at the diesel ON OFF switch circuit of proceed to the next circuit test 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 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 Page 81 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A 8 SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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
89. ion cap Lift the ignition 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 Be sure to observe the placement of the three wash ers of the bearing kit To ensure proper tension the same order and direction of the dished surfaces of the washers must be followed when reassembling 8 With a pair of snap ring pliers remove the snap rings from both side A and side B 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 i
90. ith brake cleaner 072 La 2 Page 67 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Flame Sensor Replacement Procedure 1 In order to perform the following procedures it is 3 Slide the tab of the new flame sensor into the pro necessary to detach diesel burner head Be sure to vided slot in the photo disc and secure in place with review the detaching attaching instructions in sec the screw Connect the flame sensor s green wire to tion 8 the green C plug harness wire and the blue wire to the C plug harness violet wire 2 Remove the screw that fastens the flame sensor to the photo disc and detach the sensor s green and 4 Follow the directions for reattaching the diesel blue wires from the C plug harness green and vio burner in section 8 of this manual let wires and remove flame sensor Figure 46 Flame Sensor Green Wire Green Wire to Diesel Burner NOTE This screw is used to fasten the Flame Sensor to Blue the Photo Disc Remove Wire when replacing the Flame Sensor Violet Wire to Diesel Burner 1 Page 68 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Ignition Electrodes The diesel burner s ignition coil produces a high voltage ignition spark across the ignition electrodes which ignites t
91. ith cold domestic wa ter 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 10 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 NOTE Ifthe Hot water pipe coming into the mixer valve is hot but the Mix water coming out of the mixer valve can non be adjusted the mixer valve will need to be replaced 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 Turn the motor home s water pump off 2 Drain the water pressure by opening the faucets and al lowing the water to drain 3 Disconnect the motor home s water lines from the tem
92. iting Rate 56 000 BTU hr Diesel Burner Fuel Consumption Continuous Operation nine 0 40 gal hr Heater Voltage Maximum Power Consumption rennes 12 Volt DC 60 watts Electric Heating 120 Volt AC 1650 watts Zone Heat Circulation Pump specifications ses 2 12 Volt DC 21 watts each Number of Heating ZONES tidie eadein maximum of 5 plus Engine Preheat optional Domestic Water Heating nn nete cbe ennemie ne een en een tty continuous on demand Antifreeze Used Generally Recognized as Safe by the FDA Propylene Glycol Boiler luc san 12 x 18 5 W x 3071 Diy suum approximately 127 lbs Wet Welo ee ee ee ee ee ee EE approximately 184 lbs NOTE All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Association s RVIA ANSI NFPA 1192 Handbook for Recreational Vehicle Standards To receive a copy of this handbook and other perti nent RVIA Standards write to Recreation Vehicle Industry Association 1896 Preston W
93. lamp 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 re turns to proper form Using 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 Ignition Electrodes Fuel Nozzle Manifold Fuel Nozzle Using a 10mm socket loosen and remove the re taining clamp bolt and the retaining clamp Slide the electrode out of the photo disc To remove the electrode hold onto the orange elec trode boot and pull firmly on the electrode 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 Electrode Adjustment Gauge Properly Positioned Page 69 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Ignition Electrodes 2 Remove both the ignition cables from the ignition Repl ment Proc dure continued electrodes or connect a jumper wire with alligator Replacement Procedure continued clips across the metal tips of the electrodes 5 Insert the new electrode into the orange electrode boot and snap into place Pull firmly on the elec A DANGER A trode to m
94. lant reaches the preset temperature of approximately 160 5 degrees Fahrenheit Page 49 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 8 DETACHING AND REATTACHING THE DIESEL BURNER Instructions for Detaching the Diesel Burner WARNING Be sure to move 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 Hydro 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 Hydro Hot prior to beginning this replacement procedure Step 1 Turn Off the Diesel Switch pem www aquahot com 800 685 4298 Electric Engine Preheat 1 Move the Interior Switch Panel s Diesel Burner switch to the OFF position Step 2 Remove the Access Cover 1 Remove the Hydro Hot s access cover by locating 2 Unscrew the four screws securing the front of the the screws securing it in place cover in place Page 50 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 8 DETACHING AND REATTACHING THE DIESEL BURNER Step 3 Disconnect the Diesel Burner s Controller Locking Post Controller Mounting Bracket 1 Locate the Diesel Burner s Controller and disconnect both plugs
95. leaks 6 Rubber Grommets hard brittle 3 Photo disc rubber has been cut out warped right left bent 7 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 103 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A S APPENDIX D HYDRO HOT MAINTENANCE tep 8 Clean Ignition Electrodes and Flame Sensor Electrode Tips Figure D8 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 104 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Step 9 Replace The Fuel Nozzle Figure D9 APPENDIX D HYDRO HOT MAINTENANCE Ignition Electrodes P 4 Fuel Nozzle d 3 lt f Diesel Burner Fuel Nozzle Head Fuel Nozzle Manifold Hex NOTE It is recommended to check fuel pressure any time the fuel nozzle is replace 1 Use a 3 4 in wrench to hold the fuel nozzle manifold hex while loosening the fuel nozzle with a 5 8 i
96. lectrode boots are not broken inside the igni tion coil wires Disconnect the ignition coil s black and brown wires from the C plug harness yellow and brown wires Ignition Coil Ignition Cable Brown Wire to Diesel Burner Yellow Wire to Diesel Burner Page 79 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Ignition Coil 2 Connect the new ignition coil s black and brown wires to the C plug harness yellow and brown wires Attach the ignition coil to the pro tection cap with the four ignition coil screws then reconnect the ignition cables to the ignition elec trodes NOTE In 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 Replacement Procedure NOTE If the new ignition coil does not function check wire connections and ensure they are properly connected 1 Disconnect the ignition cables from the ignition electrodes Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil and disconnect its wires from 3 Follow the instructions for reattaching the diesel the C plug harness wires prior to removing burner and test for proper operation Figure 57 Igni
97. lete 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 ELECT O and on the electronic controller to bypass the electric element switch 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 SECTION 4 HYDRO HOT COMPONENTS with the jumper 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 Hydro 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 Hydro 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 AC REL and AC REL for 12 Volt D C on the JP3 plug If 12 Volts of DC power is not present while the Electric Heating Element Status and Heating Status indicator lights on the
98. ly the ohm in a default after 20 seconds meter should register high resistance over 100K when the glass surface is covered and less than 200 In order to perform the following procedures it is Q when exposed to a light source necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching 6 Ifthese resistance numbers cannot be obtained ver instructions in Section 8 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 NOTE When connecting the flame sensor wires to the 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 8 Once the diesel burner has been removed Locate Webasto Harness be sure the Green harness wire goes to the green flame sensor wire and the violet harness wire goes to the blue flame sensor wire Flame Sensor Maintenance and detach the flame sensor s green and blue wires 1 For light dirt dust and or carbon deposits simply from the C plug harness wires wipe off the flame sensor with a soft cloth 2 Should heavy carbon deposits be present complete Green Wire ly remove the flame sensor from the photo disc and clean w
99. max Electric Element switch Approx 4mA Engine preheat pump eee 2 0A max Engine Preheat switch Approx 4mA AGTelay iate o deep 500mA max Low level cutoff switch Approx 10mA B4 burner Webasto 6 0A max Control 2 8mA B1 burner master control 2 0A max Low temperature cutoff switch Approx 5mA C1 C7 burner thermostat control 1 0A max Page 38 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 5 ELECTRONIC CONTROLLER Electronic Controller Features Secondary 12 Volt DC Battery Connection The electronic controller is equipped with two 12 Volt DC ensure that the Hydro Hot will be protected in the event that power source connections which allow for a secondary 12 the primary power is interrupted while the diesel burner is Volt DC battery connection This 12 Volt DC battery con operating e g during a burn cycle This secondary 12 Volt nection is a product safety feature that should be utilized DC battery connection will ensure completion of the re whenever the Hydro Hot s main 12 Volt DC power supply is quired 3 minute purge cycle of the Hydro Hot s diesel connected to a battery disconnect switch This feature will burner Optional connection to the Negative Ground house battery disconnect Screws 2 per Plug
100. mp and pump the antifreeze into the Boiler Tank thru the drain valve on the Hydro Hot 1 Locate the Hydro Hot s Drain Valve located at the front of the heater Reference Figure F1 2 Connect a piece hose to the drain valve This piece should be long enough to trans port the antifreeze and water heating solution from its source to the Hydro Hot 3 Connect the other end of the hose to the fluid transfer pump 4 Open the Hydro Hot s Drain Valve and turn the fluid transfer pump on and fill the Hydro Hot with the 50 50 mixture of antifreeze and water heating solution until the Low Tank Level Cutoff Light on the Electronic Con trol Board is extinguished reference Figure F2 This will take approximately four gallons Turn the fluid transfer pump off and close the drain valve Low Tank Level Cutoff YEXACINIC HEATING ELECTRONIC CONTROLLER Page 112 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX F FILLING DRAINING THE HYDRO HOT WITH HEATING SOLUTION 6 Locate the heating zone circulation pumps Refer 11 Turn the fluid transfer pump off and close the drain ence Figure F3 valve 7 Take the circulation pump s blue negative wire 12 Repeat steps 10 and 11 until all air has been com and disconnect it from the connector of the oppos pletely bled from the entire heating system ing wire Be sure to purge both circulation heating loops simultaneously Referenc
101. n 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 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 105 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Step 10 Adjust Ignition Electrodes Figure D10 Igniton AC Retaining metal tips Clamp Bolt Electrode Adjustment Gauge Electrode lt Ignition Photo Disc 4 Electrodes Retaining Electrode Ignition Clamp Adjustment Gauge Cables Properly Positioned Electrical Insulators 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
102. nals on the defective high limit ther mostat 4 Disconnect the High Limit Thermostat from the A C Relay and the Electric Heating element by removing the screws securing them in place 5 Using a 5 8 wrench or socket remove the defective high limit thermostat from the Hydro Hot s boiler tank 6 Install the replacement high limit thermostat into the port on the Hydro Hot s boiler tank and finger tighten only 15 in Ibs 7 Connect the wires previously removed from the A C Relay and Electric Heating Element 8 Secure the AC access cover back into place 9 Test for proper operation Page 20 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A DC High Limit Thermostat The DC high limit thermostat 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 thermostat allows the current for the diesel burner to pass through them until the boiler tank reaches a temperature of 220 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 Place a jumper wire between the blue and purple wires on the diesel burner
103. ngs spacer tube and washers as replacements are provided in the new bearing kit 10 11 12 Be sure to inspect the blower casing s bore bearing cavity for signs of damage due to potentially seized bearings If damage is present the blower casing must be replaced 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 Inspect the combustion air blower for warping and or damage If warping or damage is visible the combustion air blower must be replaced Reference Figure 54 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 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 washer 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 Surfac
104. o 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 func tion test section Photo Tachometer Reflective Ss Wire Wire Black Electrical Tape on Clutch Halves Page 64 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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 6 NOTE Be sure to test the diesel burner s bearings prior to reinstalling the motor Worn bearings can cause lower than normal RPM readings and premature motor wear Reinstall a clutch half on both the new motor s shaft and the combustion air blower shaft Attach the motor and flange assembly with the recessed edge of the motor flange in line with the wiring access 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 slot of the blower casing to the blower housing with the three hex head screws 1 Follow the directions for detaching the diesel burner in section 8 Inspect the blower casing s O ring f
105. oller 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 7 DIESEL BURNER Once the heater switches OFF thermostatically or manually 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 Hyro 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 Hydro Hot s Diesel Burner will automatically turn back ON once the coolant reaches the preset temperature of approximately 160 5 F Summary The Hydro 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 Hydro Hot s Boiler Tank with out additional involvement from the operator Page 46 April 201
106. or damage or wear prior to reinstalling the diesel burner head s 2 Remove the four ignition coil screws that secure the protection cap If damage or wear exists replace ignition coil to the protection cap Lift the ignition the O ring coil to disconnect its wires from the C plug harness wires prior to removing Remove the protection cap 7 Connect the black and the brown wires of the from the diesel burner so that the motor clutch new motor to the C Plug harness yellow and halves are exposed brown wires Feed the C plug harness yellow and brown wires back through wiring access hole in 3 Remove the three hex head screws that secure the the protection cap motor and flange assembly to the blower housing Remove the motor and flange assembly along with 8 Reinstall the protection cap Reconnect the black the clutch halves Disconnect the motor s black and brown wires and brown wires from the C plug harness wires 9 Reinstall the ignition coil and secure to the protec Inspect the clutch halves for cracks and also ensure tion cap with the four ignition coil screws that the flat portion in each shaft hole is free of wear and tear Too much play on the shaft produc 10 Follow the directions for reattaching the diesel es a loud clacking noise If any cracks or wear are burner in section 8 detected the clutch half must be replaced 11 Test for proper operation 4 Detach the motor from the motor flange by
107. oubleshooting ture ratio should be approximately 50 50 If the solution is comprised fully of antifreeze 100 the check 1 Verify that the heating zone is operating properly by checking the following 1 NOTE Storing the motor home for an extended period of A Check the electronic controller to insure that both 1 1 time can cause the check valves to stick If after the Heating Zone Status and corresponding pump status Pump 1 or Pump 2 indicator lights are illuminated green the initial release of the stuck check valve it contin ues to stick follow the instructions in this section to replace the check valve Page 23 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A 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 Hydro 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 Hydro Hot s boiler tank using the drain valve 3 Using constant tension pliers loosen and slide back the constant tension clamp securing the hose to the defective check valve 4 R
108. oubleshooting Flow Chartes hits LR nil beni eni 57 62 MOOR eras nn ures Veoh Nr em en een Page 63 66 OTIS Ole wm Page 67 68 lnition 17 69 70 Hel AUI AIME d d Page 70 71 EU SONO ea TIC Page 72 1311 D 73 75 tee Page 76 78 tr 79 80 COMPONGN ec S Page 81 82 Page 4 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Table of Contents Section 10 Troubleshooting If the Hydro Hot is Black Smokin tle aiu cae olea acne chee cove li ette Page 83 If the Hydro Hot is Blue White Smoking 11 84 If one of the Hydro Hot s Heating Zones will Page 85 If there is a lack of domestic continuous hot Page 86 If there is antifreeze leaking se Page 87 88 Appendix A gt Wiring ex x ie ek ee ns ce ox x Cw OR CR Page 89 Appendix B Fuel Pressure check and 2 2 11 1 Page 90 93 Appendix C Extreme Cold Weather Operation Page 94 95 Appen
109. ough the water in the solution has begun to freeze producing a slushy consistency the antifreeze 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 exist The burst point of the antifreeze and water heating solution is dependent upon the brand of propylene glycol employed Boiling Point The Hydro 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 until its boiling point is reached it is at this point that the liq uid 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 produced is expelled rather than used for the function of the heating system There fore a higher boiling point is desired in order to combat the loss of efficiency which allows the antifreeze to transport the heat created from the internal process throughout the motor home where it can be used productively rather than dissipating due to its change from a liquid to a gas SECTION 2 HYDRO HOT OVERVIEW Rust and Anti Corrosive Inhibitors Another major function of antifreeze is to provide protec
110. ow motor acts the same as low voltage Check motor rpm with an rpm tester under full load 2 Bearings worn Out Bearings should spin freely and sound smooth If they are starting to seize up they will slow the motor down 3 Impeller Fan Not Gapped Properly The impeller needs to be gapped at 3 5 thousands or tighten fan down until it rubs back it off turn 1 Page 83 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 10 TROUBLESHOOTING THE HYDRO HOT is BLUE WHITE SMOKING 1 If The Heater Smokes on Start up Shut down a Fuel solenoid plunger worn out plastic metal in the way of plunger fuel solenoid intermittent b Nozzle Tower cracked poorly machined c Short cycling control t stat bad someone turned heater off on repeatedly d Return Fuel Check Valve heaters manufactured before 2001 NOTE It is normal for the heater to blue white smoke for 3 5 seconds on start up and shut down 2 If The Heater Smokes During The Burn Cycle a Electrodes out of adjustment b Air in the fuel system c Bad nozzle d Fuel pressure e Fuel Pump f Intermittent Ignition Coil Ifthe coil doesn t turn on the fuel sprays for 20 seconds before the photo eye shuts the fuel off Page 84 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 10 TROUBLESHOOTING IF ONE OF THE HYDRO HOT HEATING ZONES WILL NOT G
111. pinning of the bearings If the combustion air blower rotates smoothly with out any friction or noise the bearings are in proper working condition If the combustion air blower does not rotate smoothly and or produces noise the bearings are worn and must be replaced Replacement 1 2 In order to perform the following procedure it is necessary to detach and reattach the diesel burner head Be sure to review the detaching and reattach ing section for detaching and reattaching instruc tions Locate and disconnect the C plug harness wires that connect to the flame sensor and fuel solenoid Also disconnect the ignition cables from the ignition electrodes Blower Housing Page 76 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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 hous ing and also between the blower housing and the blower casing If the burner is assembled improperly the protection cap will not go on 4 Remove the four ignition coil screws that secure the ignition coil to the protect
112. placement 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 Page 25 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev SECTION 4 HYDRO HOT COMPONENTS Tempering d Valve Knob IE Pumps 2 Turn on the interior room thermostat corresponding to the circulation pump not operating heating zones 1 and 5 operate with circulation pump 1 and heating zones Circulation Pumps 1 and 2 sign 2 3 and 4 operate with circulation pump 2 Check the corresponding Heating Zone Status indicator lights on The circulation pumps first draw the heated antifreeze and the electronic controller for illumination water heating solution from the Hydro Hot s boiler tank then propel it through the Hydronic heating system s interior If the Heating Zone Status indicator light does not heat plumbing illuminate complete the following the circulation pumps if the following condi salle jumper wate on die IPL plug beton the tion has occurred 1 pins corresponding to the room thermostat operating the circulation pump that is not operating Refer e The circulation pump is not operating and the Low Temp Cutoff Status indicator light is illuminated on the electronic controller ence the wiring diagram in Appendix A This will bypass the
113. propriately as per the illus tration SECTION 5 ELECTRONIC CONTROLLER Snap the replacement electronic controller into the mounting bracket Ensure that the pin jumpers are properly configured for a Hydro Hot reference information in this section for proper pin jumper configuration Install each terminal strip plug back onto the electronic controller and tighten the screws on the terminal strips plugs to secure them to the board NOTE Check the terminal strips plugs for loose wires and tighten 1f loose 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 Page 41 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 6 ELECTRONIC CONTROLLER INDICATOR LIGHTS Electric Heating Element Status 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 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 int
114. r NOTE The access cover must be installed prior to operation as a safety switch exists which will prevent the Hydro Hot from operating whenever the access cover is not properly installed Figure 39a Figure 39b 1 Reinstall the Hydro Hot s access cover 2 Securely tighten the four screws securing the ac cess cover in place Page 55 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A 1 2 3 4 6 T 8 9 SECTION 9 Diesel Burner Controller Motor Ignition Coil Clutch Combustion Air Blower Fuel Solenoid Valve Electrode Boots Ignition Electrodes Fuel Nozzle DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Figure 40 Heat Exchanger Combustion Chamber Exhaust Port Flame Sensor Fuel Pump Fuel Tubes Supply Return Combustion Air Intake Port with Adjustable Shutter Page 56 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Trouble Shooting Flow Chart Chart 3 Check DC power supply at the Electronic Controller Verify DC power at the Diesel light illuminated Switch 0 terminal on the JP2 Plug on the electronic Controller Turn the Burner Control Switch ON Using a Jumper Wire Jumper the Diesel I and the Diesel o Terminals together on the JP2 plug on the Electronic Controller If the Diesel burner Status Light Illumi
115. r 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 Ifno damage is found follow the instructions in this manual to replace the electronic controller NOTE The circulation pump can be tested by con necting it to an external 12 Volt DC source to verify that the pump is defective Replacement Procedure 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 Hydro Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the potential for hot coolant be sure the heater is adequately cooled SECTION 4 HYDRO HOT COMPONENTS 10 11 12 13 Drain the antifreeze and water heating solution from the Hydro Hot s boiler tank using the drain valve Disconnect the defective circulation 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 circu lation pump Remove the hoses from the defective circulation pump For ease of replacement pump installation the defective circulation pump s mounting bracket should remain fas tened to the
116. re gauge once the fuel solenoid opens after approx 10 20 seconds Page 91 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 1 Follow the directions for Checking the Fuel Pressure in this section 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 B5 8 Aqua Hot e bs 5 9 3 800 685 4298 Electric Engine Preheat e 1 Turn the diesel burner switch to the on position A pressure will register on the fuel pressure gauge once the fuel solenoid opens after approx 10 20 seconds Page 92 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 2 Adjust the Fuel pressure to 145 PSI 40 Figure 6 Fuel Pressure Gauge E 22 Oe AL 9e increase Fuel gt 4 Pressure Regulator decrease Screw Adjustment 2 Once the fuel solenoid has been activated and the fuel
117. rodes Also be careful to not pinch any wires between the burner and the Hydro Hot Tank 1 Align the Diesel Burner with the Hydro Hot using the alignment tabs welded on the Hydro Hot 2 Swing the Eye Bolts around the Ears 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 108 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Step 14 Plug in the diesel burner s controller and mount Figure D15b Figure D15a 1 Locate the Diesel Burner s Controller and connect both plugs Page 109 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D AQUA HOT MAINTENANCE Step 15 Re Install the Hydro Hot Access Cover 1 Reinstall the Hydro Hot s access cover 2 Securely tighten the four screws securing the ac cess 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 exhau
118. ronic Heating System Service Manual Rev A Electronic Controller Overview The electronic controller is an electronic circuit board that controls the electrical functions of the Hydro 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 Low Voltage Reset Element Status SECTION 5 ELECTRONIC CONTROLLER Hydro 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 bd Voltage Fault e Low Temp Cutoff Status Diesel Burner Status Overload Fault ELECTRONIC CONTROLLER Electronic Controller General Facts Nominal input voltage range 10 6V to 15V Idle current eiiie ient en Approx 15mA Low voltage cutoff threshold 10 0V Low voltage lockout delay Approx 5 minutes Input Load Currents Output Current Capacity Zone thermostats Approx 4mA Zone fans each 2 0A max Diesel Burner switch Approx 12mA Circulation pumps 2 0A
119. ropylene glycol based boiler type antifreeze deemed GRAS Generally Recognized as Safe by the FDA shall be used in the Hydro Hot s hydronic heating system Failure to use the above specified antifreeze type could result in serious injury or death CAUTION that the overflow tube is connected from the Hydro Hot s expansion tank connection to the expansion tank s bottom connection and from the expansion tank s top con nection through the overflow tube hole in the motor home s bay floor prior to beginning this antifreeze and water heating solution fill procedure Failure to do so could result in an antifreeze spill in the motor home s bay Filling The Hydro Hot Heating System with Boiler Antifreeze In order to provide the best freeze protection boil over pro tection anti corrosion and rust protection a 50 50 mixture of GRAS approved propylene glycol boiler antifreeze and water is required Reference the owners manual for additional information re garding the antifreeze and water heating solution Be sure to use a GRAS Boiler Type Propylene Glycol based anti freeze rather than an RV and Marine antifreeze or an auto motive antifreeze coolant If assistance 1s needed in selecting an appropriate antifreeze please contact the Aqua Hot Heating Systems Product Appli cation Department at 1 800 685 4298 NOTE To Fill the Hydro Hot it is recommended to use a fluid transfer pu
120. s wire harness to bypass the high limit thermostats Check the Hydro Hot for normal op eration NOTE Bypassing the high limit thermostats is for testing only and must not be used for the Hydro Hot s nor mal functioning 2 Disconnect the DC high limit thermostats wires then using an ohmmeter check the thermostat for continuity 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 B Disconnect the wires from each thermostat and re check each thermostat for continuity as well as each of the thermostats individual wires D C High Limit Thermostat SECTION 4 HYDRO HOT COMPONENTS 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 thermostat continues 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 Hydro Hot has been completely shut down and that all power sources have been disconnect ed 2 Disconnect the defective control t
121. ses for heat If both hoses are hot the pump is working properly If only one hose is hot or neither hose 1s hot check the cold hose for a blockage If no blockage exists follow the instructions in this section to replace the stir pump Page 29 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A 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 Removing the Defective Stir Pump NOTE The original Stir Pump is no longer available When replacing an original Stir Pump part number PLE 100 830 FRU This is a retrofit kit that will include all necessary items to use the new style Stir Pump 1 Ensure that the Hydro Hot has been completely shut down and that all power sources have been disconnected Also because this replacement procedure will involve the poten tial for hot coolant be sure the heater has adequately cooled 2 Drain the antifreeze and water heating solution from the Hydro Hot s boiler tank 3 Remove the Diesel Burner 4 Disconnect the defective stir pump s wires by separating the quick disconnect terminals 5 Using constant tension pliers loosen and slide back the constant tension clamps securing the hoses to the stir pump 6 Remove the hoses from the defective stir pump 7 Remove the defective pump from the heater by drilling out the rivets securing
122. st for signs of smoke Page 110 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX E WINTERIZATION PROCCESS WARNING Not winterizing the Hydro Hot when freezing temperatures are present will result in serious damage to the Hydro Hot s Domestic Water Heating System Also be sure to use an FDA approved GRAS rated antifreeze for winteriza tion NOTE The Hydro Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized 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 Turn off Demand Water pump and remove the hose and re connect the domestic water demand pump s suction line to the fresh water storage tank WARNING An FDA approved GRAS rated winterization antifreeze must be used YOU CANNOT BLOW DOMESTIC WATER COIL OUT WITH AIR TO WINTERIZE AQUA HOT The Hydro Hot s Domestic Water Heating System must be completely drained of domestic water and properly winterized any time the heater is stored where freezing temperatures may be experienced Winterizing the Domestic Water Heating System Please follow these instructions when winterizing the Hydro Hot s Domestic Water Heating System Completely drain the fresh water storage tank 2 Disconnect the domestic wa
123. stat s wires 1 Ensure that the Hydro Hot has been completely shut down and that all power sources have been disconnect ed 2 Locate the low temperature cutoff thermostat on the cold domestic water inlet pipe at the back of the Hydro Low Temperature Cut Off Thermostat Hot 3 Disconnect the defective low temperature cutoff thermo stat s wires by separating the quick disconnect termi nals 4 Using a 5 8 wrench or socket remove the defective low temperature cutoff thermostat from the Hydro Hot Valves Check Valve B Check the circulation pump for operation by visual ly inspecting it for rotation of the pump Check valves are installed into the zone outlet ports for each heating loop to ensure that the antifreeze and water heating 2 With the circulation pump operating tap on dis Check solution only flows in one direction If the heating solution y 8 i valve and wait five minutes to evaluate if interior heat is attempts to backflow into the boiler tank the check valve now present closes to prevent that from happening If interior heat 1s present after tapping the check valve Troubleshoot the check valves if the following condition has the closed and no further action is occurred necessary There is a lack of interior heat i 1 3 Check the Hydro Hot s antifreeze and water heating solution s ratio of water to propylene glycol The mix Tr
124. 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 service 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 INTRODUCTION TO THE HYDRO HOT Understanding the Hydro Hot Major Systems The basis for the Hydro Hot heating system s functionality is the antifreeze and water heating 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 Hydro 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 Hydro 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 dies
125. t Hydronic Heating System Service Manual Rev C EXTREME COLD WEATHER OPERATION Figure C2 COLD AIR REGISTER HOT AIR V OUTLET BASE BOARD TOE KICK AREA Return Ai Figure C3 Page 95 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 tank The level of the antifreeze and water heating solution within the expansion tank should only be checked when the Hydro Hot is at maximum operating temperature If additional antifreeze and water heating solution is re quired fill the expansion tank to the HOT 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 Filter APPENDIX D HYDRO 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 Hydro Hot running smoothly it is recommended to have the diesel burner tuned up annually tune up should consist of a new fuel nozzle and fuel filter along with a thorough cleaning of the combustion chamber To
126. t the photo disc seats against 3 Inspect the Combustion Chamber 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 combustion chamber 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 Note If the Aluminum on the combustion chamber is melted or warped it is recommended to replace the Flame Sensor along with the Combustion Chamber Page 101 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Step 6 Reinstall the Combustion Chamber CAUTION Failure to reinstall the combustion chamber will result in serious damage to the diesel burner Figure D6 99 1 Li 277 NT 1 Reinstall the Combustion Chamber into the Hydro Hot Be sure to install the combustion chamber Seam in the 12 00 position Failure to do so may cause a crack to appear along the seam Page 102 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX D HYDRO HOT MAINTENANCE Step 7 Inspect Diesel Burner Grommet Photo Disc Ear Inspect the following Flame Sensor 1 Electrodes cracked damaged overheated purple color improperly adjusted melted wires dirty 2 Fuel Pump
127. tank and immediately deposits it back into the top of the tank Troubleshoot the stir pump if the following condition has occurred e There is a lack of hot domestic water e Pump 3 indicator light illuminates red Troubleshooting NOTE In order for the stir pump to operate the diesel burner switch must be on and the indicator light for the Low Temp Cutoff Status on the electronic controller must be extinguished NOTE Verify the Electronic Controller Proper Jumper Pin formation Reference Section 6 Electronic Controller for the proper jumper pin formation 1 Verify that the Pump 3 indicator light on the elec tronic controller is illuminated If the indicator light is not illuminated check the follow ing A Verify that the diesel burner Status Light is Illumi nated indicating the switch is on B Verify that the Low Temp Cutoff Status indicator light on the electronic controller is not illuminated If the diesel burner switch is on the Low Temp Cutoff Status indicator light is not illuminated the jumper pins on the electronic controller are properly positioned and the stir pump is not operating follow the instructions in this manual to replace the elec tronic controller 2 Check the color of the illuminated Pump 3 indicator light on the electronic controller If the indicator light 1s illuminated red the stir pump 1s experiencing a short therefore complete the following
128. tem and requires no action on the user s behalf to function NOTE The Engine Preheat is an option on the Hydro Hot Heating system If you have model number HHE 500 09M the heater does not have the engine preheat feature but it does have the Motor Aide feature 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 Hydro Hot s interior heating system When a thermostat recognizes that heat is required in a particular area it sends a signal to the Hydro Hot s electronic controller calling for heat The Hydro 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 zone calling for heat are also activated there fore as the heated solution flows over the heat exchanger s INTRODUCTION TO THE HYDRO HOT 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 is no longer required the Hydro Hot will continue to send the heated antifreeze and water solution through the loop which returns the cooled solution to the Hydro Hot s boiler tank to re heated before being sent
129. ter 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 and turn on the demand water pump RV Fresh Water Storage Tank Domestic Hot Water OUTLET Antifreeze De Winterizing the Domestic Water Heating System For de winterization completely fill the fresh water storage tank Turn on demand water pump and open and close all interior and exterior water faucets one at a time until only clear water is present visible If disinfecting the potable water system after de winterizing be sure to follow RVIA s Instructions for Disinfection of Potable Water Systems on Recreation Vehicles These instructions can be obtained by contacting the Recreational Vehicle Industry Association at 703 620 6003 www rvia com or writing to them at the following address visiting them online at 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 Domestic Cold Water INLET To Hot Water Faucets Page 111 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A APPENDIX F FILLING DRAINING THE HYDRO HOT WITH HEATING SOLUTION WARNING Only p
130. th the snap ring Dab the teeth of the nylon drive gear with white lithium grease Isoflex LDS 18 is recom mended Do not adjust the fuel pressure regulator of the new fuel pump as it has been factory preset 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 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 8 9 10 11 12 13 order placement could result in a fuel leak Reconnect the C plug harness violet and brown wires to the fuel solenoid s and electrical terminals Insert both the ignition cables into the rubber grom met and slide into the appropriate notch on the blower casing Reconnect the ignition cables to the ignition elec trodes Reinstall the photo disc and secure it in place with the retaining clip Reconnect the flame sensor s green wire to the green C plug harness and the blue wire
131. the indicator light is green it indicates that the heater is up to operating temperature and hot water is not being used It also indicates that the interior heating zones will op erate When the indicator light is off it indicates there is a demand for domestic hot water or the heater is not up to operating temperature and the interior heat will not operate Low Tank Level Cutoff The Low Tank Level Cutoff senses the level of antifreeze in the boiler tank and will shut the Diesel Burner and the Elec tric Heating element 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 Hydro Hot s boiler tank exists When illuminated red only four possible issues exist the antifreeze and water heating solution level is inadequate and must be refilled there is a short in the wiring to the fluid level sensor or the fluid level sensor is not operating proper ly or the Electronic Controller is defective 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 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 Eng
132. ting Element is not providing enough heat turn the Diesel Bumer on in conjunction with the 120 Volt AC Electric Heating Element Figure C1 8 Aqua Hot t 5 Electric Engine Preheat e Page 94 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Front APPENDIX If there is a lack of interior Heat Note The 120 Volt AC Electric Heating Element is the Hydro 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 is a low demand for domestic hot water If the ambient temperature is ex tremely cold the Diesel Burner must be utilized 1 Is the Diesel Burner activated 2 Is the Diesel Burner operating Properly 3 What is the antifreeze concentration inside of the Hydro Hot Boiler Tank 4 Was the heating system properly installed following the Hydro Hot 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 C2 C Are the heat exchangers mounted as close to the hot air outlet grill as possible Reference Figure C2 Return Air Indicates generally recommended locations for the Cozy eat Exchangers April 2012 Hydro Ho
133. ting Sta tus indicator light on the electronic controller to illuminate If the Heating Status indicator light on the elec tronic controller does not illuminate with the jumper wire installed follow the instructions in this manual to replace the electronic controller Page 18 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A If the Heating Status indicator light is illuminated But the diesel burner fails to come on check the following 1 Verify the diesel burner s control thermostat wires are properly connected and that there are no loose wires both at the diesel burner and at the JP4 plug on the Electronic Controller 2 Using a DC Voltmeter Verify both the Orange 22 and the C7 White 23 Wires on the Electronic Controller s JP4 Plug have 12VDC If the C7 White 23 Wire does not have 12VDC and both the Diesel Burner Status Light and the Heating Sta tus lights are illuminated the electronic controller will need to be replaced If the C1 Orange 22 wire does not have 12VDC Re fer to the Webasto Diesel Burner Controller Trouble shooting in section 9 Control Thermostat Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 190 Control Thermostat SECTION 4 HYDRO HOT COMPONENTS Ensure that the Hydro Hot h
134. tion Coil Ignition Cable Brown Wire Brown Wire to Diesel Burner IB PH to Diesel Burner Page 80 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Diesel Burner Controller Ground Circuit Test NOTE Before troubleshooting the Diesel Burner Control ler verify that the Hydro Hot s Electronic Controller has Locate the diesel burner controller s B plug and C voltage at both the C1 orange amp C7 white wires on the JP4 plug Insert the probes of a DC voltmeter into the B Plug Both the C1 amp C7 wires will only have power when 4 and C 5 locations and turn the diesel both the Diesel Burner Status Light and the Heating Status switch ON Ifa voltage reading does not register on Light are illuminated the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test 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 plug Insert the probes of a DC voltmeter into the C thermostat 1 and B 2 locations and turn the diesel switch ON Ifa voltage reading does not register on the vol
135. tion to the internal metal components of the Hydro Hot Hydronic heat ing system from corrosion and rust Antifreeze is able to per form this function by the addition of rust and anti corrosive inhibitors which are designed specifically to activate in a water solution 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 charac teristics Therefore as water is an excellent heat conductor it is added to the mixture A 50 50 solution of propylene glycol an tifreeze and water is recommended to provide the best perfor mance combination of the aforementioned functions If excess propylene glycol exists within an antifreeze and water heating solution the water s heat absorption properties are compro mised which could ultimately inhibit the Hydro Hot from providing adequate domestic hot water and interior heating Additionally if the antifreeze and water heating solution con tains over 70 percent antifreeze the freezing point is actually raised resulting in less freeze protection Page 14 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A The interior switch panel is used to control the two potential heating sources for the Hydro 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
136. tmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test VDC VAC Control Thermostat Circuit Test Locate the diesel burner controller s B plug and C 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 VDC High Limit Thermostat Circuit Test does not exist please contact our technical support department at 1 800 685 4298 for additional assis 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 Condition 1 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 tance 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 Locate the diesel burner controller s B plug and C a DC voltmeter into the B 4 and B 2 loca 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 Conan
137. 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 Follow the directions for reattaching the diesel burner in section 8 of this manual Page 74 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING 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 75 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 9 DIESEL BURNER COMPONENTS AND TROUBLESHOOTING Bearings The bearings support the combustion air blower s shaft and allows the blower to turn smoothly In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review section 8 for detaching and reattaching the diesel burner instructions Bearing Test 1 In order to perform the following procedure it is necessary to d
138. ts Reconnect circulation pump s wires by uniting the quick disconnect terminals Be careful to connect the wires properly Reference the wiring schematic in Appendix A Remove the hose pinch off pliers previously installed on both hoses Test the Hydro Hot for normal operation Page 33 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A SECTION 4 HYDRO HOT COMPONENTS Engine Preheat Pump W Bracket TN x Page 34 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Electrical Electric Heating Element The electric heating element uses AC power as an alternate power source for heating the Hydro Hot s boiler tank Troubleshoot the electric heating element if the following condition has occurred 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 comp
139. turn causes the antifreeze and water heating solution to begin turning acidic which can corrode the Hydro Hot s boiler tank and associated components prematurely 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 indi cate 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 boiling and rust anti corrosive protection A 50 50 mixture of propylene glycol water ratio is recommended which will result in a freeze point of approximately 28 F and a boil point of approximately 222 F The following information should be utilized for the purpose of clarifying some terms commonly associated with anti freeze Page 13 April 2012 Hydro Hot Hydronic Heating System Service Manual Rev A Antifreeze and Water Heating Solution continued 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 in the solution will attempt to attain a solid state The point in which the water begins to solidify is termed the Freeze Point Alth
140. will illuminate Diesel Burner Switch When the diesel burner switch is in the on position any time the control thermostat tells the electronic controller that heat is needed for the boiler tank the diesel burner will respond by firing up and providing heat A cold boiler tank can ex pect 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 acti vated 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 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 Original Switches vehicle systems 9 SECTION 3 INTERIOR SWITCH PANEL Electric Element Switch 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 electric heating element in approximately 1 to 2 hours The electric element alone will not be

SERVICE MANUAL - Aqua-Hot Heating Systems, Inc.

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