Vehicle Systems AHE-100-04S Bedienungshandbuch

Shop Manual Model Numbers AHE-100-04S - 12 VDC AHE-120-04X - 12 VDC AHE-130-04X - 12 VDC Rev. B November - 2012

Electronic 4.4 Low Voltage Reset Controller, continued The Aqua-Hot’s Electronic Controller must be manually reset whenever the Low Battery Vol

Electronic 4.10 Pump #3 Indicator Light Controller, This indicator light will illuminate GREEN whenever Circulation Pump #3 is operating; con

Component 5.1 Component Overview Overview 1. Diesel-Burner Controller 10. Heat Exchanger 2. Motor 11. Combustion Chamber 3. Ignition Coil 1

Operational 5.2 Operational Flow-Chart Flow-Chart The Motor (#2), which turns the Combustion Air Blower (#5) and drives the Fuel Pump (#14), wil

Operational 5.3 Operational Sequence Sequence The following sequence illustrates how the Aqua-Hot’s Diesel-Burner operates once it is ac

SECTION 5: DIESEL-BURNER Operational 5.3 Operational Sequence Sequence, continued KEY Diesel Fuel Spray Combustion Air Exhaust Gases The

Operational 5.3 Operational Sequence Sequence, continued

I.D. Plate 5.4 Identification Plate Fabrikschild-Duplikat gultig nur zusammen mit Original Thermosysteme GmbH MADE IN GERMANY HEIZGERAT Typ DB

Controller 6.1 Diesel-Burner Controller Wiring Figure 8

Troubleshooting This Troubleshooting Section has been separated into various Aqua-Hot Troubleshooting Scenarios, which may be experienced by the he

1.1 Component Overview 1 1.2 Marking Plate 2 Section 2 Model Differentiation 2.1 Aqua-Hot Model Differentiation Section 3 Switch Panel 3.1 I

Section 7.1 After turning the “Diesel” switch ON: TS1 : The Aqua-Hot’s Diesel-Burner fails to operate. Q1 : Is the Electronic Controller’s Low

Section 7.1, continued A: If YES: Check the JP-3 Plug for loose wire connections and/or harness damage If NO: The Electronic Controller mu

Section 7.1, continued NOTE (7.1-C): If no problems were discovered up to this point, the problem most likely lies within the Diesel-Burner Head.

Section 7.1, continued NOTE (7.1-D): If the Aqua-Hot still does not operate after performing all of the listed checks, contact the Technical Sup

Section 7.2, continued Q3 : Is the Diesel-Burner’s Fuel SolenoidValve functioning properly? I. In order to determine if the Fuel Solenoid

Section 7.2, continued I. In order to determine if the Ignition Elec-trodes are in good condition and properly adjusted, reference Section 8.5

Section 7.3, continued Q2 : Is the Diesel-Burner’s Flame Sensor functioning properly? I. In order to determine if the Flame Sensor is fun

Section 7.3, continued Fuel Filter Clear Bowl TOP VIEW: of Fuel Filter Head Plug output to Aqua-Hot’s Fuel "Supply" Port input f

Section 7.3, continued NOTE (7.3-C): Be sure to check that each fitting at the Fuel Filter Head contains thread sealant. A fitting without threa

Section 7.4 After turning the “Diesel” switch ON: TS4: The Aqua-Hot’s exhaust system sputters. NOTE (7.4-A): Before advancing to the follow

Section 8 Diesel-Burner Service, Maintenance, and Repair Information Page 8.7 Fuel Solenoid Valve 53 8.8 Fuel Pump 55 8.9 Bearings 61 8.10 Ig

Section 7.4, continued A: If air bubbles are not visible: Reference “NOTE (7.4-D).” If air bubbles are visible: You will need to inspect

Supply Cover Boiler Tank Diesel Fuel Drain Valve Supply Diesel-Burner Diesel Fuel Controller Return Pressure-Relief Ho

Section 7.5, continued A: If constant white smoke exists: Continue troubleshooting. NOTE (7.5-B): Inspect the clear bowl of the Fuel Filter

Section 7.5, continued 2. Once the potential air leak has been discovered and corrected, reattach the Aqua-Hot’s Fuel Return Line an

Section 7.6, continued II. Reset the Low Voltage Reset (button) on the Electronic Controller (this can be accom- plished either by using a thi

Section 7.6, continued If the Fuel Nozzle is functioning properly: Continue troubleshooting. Q3 : Is the Diesel-Burner’s Motor operating a

Section 7.6, continued 1 Pump the rubber ball 18 times. 2 Release the suction hose from the CO2 Analyzer’s plunger. 3 Turn the CO 2 An

Section 7.7 After turning the “Diesel” switch ON: TS7: The Aqua-Hot is at operating temperature, but an Interior and/or Fresh Water Tank Heatin

Section 7.8 After turning the “Diesel” switch ON: TS8: The Aqua-Hot is at operating temperature; however, the Interior

SECTION 1: GENERAL HEATER INFORMATION Component 1.1 Component OverviewOverview ELECTRONIC CONTROLLER R � Motor Coach Heating Specialists

Section 7.9 After turning the “Diesel” switch ON: TS9: The Aqua-Hot is at operating temperature, but the domestic hot water system is not

Section 7.9, continued The chart below is a graphical representation of how the Aqua-Hot’s Domestic Hot Water System theoretically performs unde

Section 7.10 After turning the “Electric” switch ON: TS10: The Aqua-Hot’s 120 VAC Electric Heating Element does not operate (i.e., lack of

Section 7.10, continued I. Turn the “Diesel” switch ON and allow the Aqua-Hot to reach maximum operating temperature (i.e., until the Diesel-

Section 7.10, continued Q4 : Is the 120 VAC Electric Heating Element functioning properly? I. Disconnect the Motorhome from VAC shore

Section 7.11, continued Does the Electronic Controller’s Engine Preheat Pump light now illuminate? A: If YES: Check for loose wire connectio

Recommended Maintenance Monthly Check the Aqua-Hot’s water and antifreeze solution to ensure that it is at the proper level. Do this by visual

SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Detaching and 8.2 Detaching and Reattaching the Diesel-Burner Head Reattachi

Function: The Motor drives the Combustion Air Blower and the Fuel Pump. NOTE: In order to perform the following procedures, it may be necessary to

Motor, continued Adjustment Procedure: N/A RPM Test: Disconnect the Ignition Cables from the Ignition Electrodes; reference Figure 16. Remove

SECTION 1: GENERAL HEATER INFORMATION Marking 1.2 Marking Plate Plate Model Number Box Serial Number Box Manufactured Date Box Figure 2

Motor, continued Replacement Procedure: 1. Remove the four Ignition Coil Mounting Screws, which secure the Ignition Coil to the Protectio

Motor, continued Ignition Coil Housing Mounting Screws Casting Figure 13 Casting Motor Figure 14 Clutch Halves Black Wire Brown

Sensor Function: The Flame Sensor is a photoresistive device, which supplies the Diesel-Burner’s Controller with a DC voltage signal when it detec

Flame Sensor, continued Ignition Electrodes 8.5 Ignition Electrodes Function: The Diesel-Burner’s Ignition Coil (reference Figure 24) prod

Ignition Electrodes, into the appropriate notches of the Electrode Adjustment Gauge as continued illustrated in Figure 16. 3. Tighten the Reta

Nozzle Function: The Fuel Nozzle is simply a fuel atomizer. It reduces the diesel fuel into a fine spray, which is mixed with incoming combusti

Fuel Nozzle, WARNING: Be sure to reattach the Diesel-Burner Head prior to switching the continued heater ON. Failure to do so may resu

Solenoid Function: The Fuel Solenoid Valve allows the flow of diesel fuel to the Diesel-Burner’s Valve Fuel Nozzle. Component Te

Valve, 7. Fit the Fuel Nozzle Manifold Plate inside the cast-aluminum Blower Casting and continued secure in place with the four Fuel Nozzle Manif

Fuel Pump 8.8 Fuel Pump Function: The Fuel Pump draws diesel fuel from the vehicle’s fuel tank and creates a preset pressure of 145 psi (required f

Aqua-Hot 2.1 Aqua-Hot Model Differentiation Models Vehicle Systems, Inc. manufactures three individual models of the Aqua-Hot Hydronic Heating Syst

SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued Ignition Cable (1) Supply Figure 19

SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued Fuel Pressure Function Test: 1. Remove the

SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Fuel Pump, continued Figure 20 Figure 21

Fuel Pump, continued Replacement Procedure: 1. Locate and disconnect the C-Plug Harness wires, which connect to the Flame Sensor and the Fu

Supply Cover Boiler Tank Diesel Fuel Drain Valve Supply Diesel-Burner Diesel Fuel Controller Return Pressure-Relief Ho

Bearings 8.9 Bearings Function: The Bearings support the Combustion Air Blower’s shaft and allows the blower to turn smoothly. Function Test:

Bearings, continued NOTE: Inspect the Clutch Halves for cracks and ensure that the flat portion in each shaft hole is free of wear and tear.

Bearings, continued through the Bearing Kit assembly until the threaded portion appears on Side-A of the Blower Casting; reference Figure 23.

SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION Bearings, continued Bearing Kit Figure 23

Switch Panel 3.1 Interior Switch Panel The Interior Switch Panel serves as an interior means of controlling the separate heating sources of the Aqu

Ignition Coil 8.10 Ignition Coil Function: The Ignition Coil produces a high voltage ignition spark (approximately 8000 volts), which is releas

Diesel-Burner 8.11 Diesel-Burner Controller Controller Function: The Controller operates all the components of the Diesel-Burner Head and safely sh

Diesel-Burner Controller, continued B-2 ( - ) Battery Circuit (Brown Wire) to JP-4 (Pin 4) COM (-) (+) B-Plug B-1 B-2 B-3 B-4 B-6 B-4 (

Diesel-Burner Controller, NOTE: If, after performing the following circuit tests, the Controller is deter- continued mined to be defective and

Diesel-Burner Controller, Cleaning Tips/Maintenance: N/A continued Adjustment Procedure: N/A Replacement Procedure: 1 Remove both the B-Plug

Controller, continued Diesel-Burner Controller Mounting Bracket Figure 27

WARRANTY INFORMATION -FOR ALL AQUA-HOT MODELS Vehicle Systems, Inc. warrants the AQUA-HOT Heater to be free from defects in material and workmansh

Controller, Diesel-Burner, 12 VDC 2 WPX-287-962 Coil, Ignition, 12 VDC 5 WPX-101-838 Motor, Combustion Air/Fuel Pump, 12 VDC 27 WPX-425-060 Val

Switch Panel, continued High: The process of moving the “High/Low” switch to the “High” position, in conjunction with the activation of the “El

TO COZY + 1-BLK 1 HEAT EXCHANGERS12VDC 8 � � 24 WATTS MAX. - � 6 4 BLK 3-WHT 2 0 LIVING ROOM/ � KITCHEN BLK HEATING ZONE #5 16 RED

RIGHT TO COZY + +1 2 BLK 8 HEAT EXCHANGERS12VDC 6 1-BLK 24 WATTS MAX. 4 � - APPENDIX AWIRING INFORMATION (AHE-120-04X) A2 Aqua-Hot

N.C. RIGHT TOCOZY + +1 2BLK 8 HEATEXCHANGERS 12VDC 24WATTSMAX. - 12 VDC 6 1-BLK ELECTRIC HEATING ELEMENT 4 VAC HIGH LIMIT 120VAC,2000W 2 0

Heating Loop #1 Heating Zone #1 Heating Loop #2 Heating Zone #2 Heating Zone #3 Heating Loop #3 Heating Zone #5 Circulation Pump #1 Circ

Generalized Motorhome HeatingSystem Floorplan Bedroom Engine Heat ExchangerBathroomHeat ExchangerKitchenHeat Exchanger Living RoomHeat Exchanger

� 15549 East Highway 52 Fort Lupton, Colorado 80621 1-800-685-4298 Fax: 303-857-9000 © Copyright 2004 Vehicle Systems, Inc. All

Electronic 4.1 Electronic Controller Controller Figure 5 4.2 Electric Heating Element Status Indicator Light This indicator light will illum