PARTS MANUAL Model Numbers: AHE-100-03S - 12 VDC AHE-120-03X - 12 VDC AHE-130-03X - 12 VDC (SN: 03-675 TO 04-533) May 2014 Table Of Contents Heater Overview Webasto Diesel Burner ...........................................................................................Page 5-8 Heating Zone Plumbing ...........................................................................................Page 9 Engine Preheat Plumbing........................................................................................Page 10 Domestic Water Plumbing .......................................................................................Page 11 Electronic Controller and Switch Panel (AHE-100-03S ONLY). ..............................Page 12 Electrical Components, Internal (AHE-100-03S ONLY) ..........................................Page 13 Electronic Controller and Switch Panel (AHE-130-03X & AHE-120-03X ONLY) .....Page 14 Electrical Components, Internal (AHE-130-03X & AHE-120-03X ONLY) ................Page 15 Misc. Parts Misc. Parts ..............................................................................................................Page 16 Tools __________________________________________________________ Tools .......................................................................................................................Page 17 В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 3 Webasto Diesel Burner 5 Key Part Number Description 2 3 4 5 6 7 8 10 11 12 14 22 24 25 26 27 28 WPX-287-962 WPX-362-107 WPX-470-562 WPX-101-838 WPX-404-918 WPX-178-624 WPX-176-494 WPX-350-427 WPX-432-377 WPX-152-269 WPX-436-216 WPX-147-834 WPX-425-05A WPX-432-377 WPX-152-269 WPX-425-060 WPX-350-516 Controller, Diesel Burner, 12 VDC Bracket, Controller Mounting Screw, Coil Mounting Coil, Ignition, 12 VDC Boot, Ignition Wire Wire, Ignition Boot, Ignition Wire, Elbow Shutter, Combustion Air Intake Screw, Protection Housing Washer, Star, Protection Housing Cap, Protection, Motor Screw, Flange, Blower Housing Plate, Motor Mounting Screw, Motor Plate Washer, Star, Motor Plate Motor, Combustion Air/Fuel Pump, 12 VDC Clutch, Half, 6mm В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 5 Webasto Diesel Burner Key Part Number Description 35 38 39 40 41 42 43 44 45 46 WPX-434-795 WPX-148-210 WPX-152-552 WPX-301-841 WPX-373-001 WPX-378-313 WPX-412-244 WPX-225-67A WPX-298-964 WPX-299-995 Harness, C-Plug Screw, Blower Casting Washer, Lock, Blower Casting Housing, Blower Blower, Wheel, w/Shaft Bearing Kit O-Ring, Blower Casting Casting, Blower Grommet, Blower Casting, Left Grommet, Blower Casting, Right Page 6 В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Webasto Diesel Burner 68 78 69 78 Key Part Number Description 50 51 53 54 55 56 58 59 60 61 62 65 66 67 68 69 70 71 72 73 74 75 76 77 78 WPX-322-083 WPX-386-650 WPX-267-279 WPX-152-560 WPX-278-971 WPX-274-313 WPX-147-699 WPX-638-78A WPX-453-048 WPX-887-71A WPX-503-03A WPX-665-49A WPX-150-754 WPX-151-157 WPX-661-002 WPX-661-001 WPX-277-282 WPX-152-544 WPX-886-41A WPX-412-198 WPX-277-150 WPX-102-861 WPX-371-289 WPX-152-390 FLE-FUL-100 Valve, Fuel Solenoid, 12 VDC Valve, Fuel Solenoid, Kit Bolt, Electrode Washer, Lock, Electrode Clamp, Electrode Electrode, Ignition Screw, Flame Sensor Sensor, Flame Clip, Retaining, Photo Disc Disc, Photo Pump, Fuel, Kit Tube, Fuel, High Pressure Bolt, Banjo Gasket, Ring, Copper Pipe, Fuel, Banjo, Supply, DBW 2010 (w/Straight Tube) Pipe, Fuel, Banjo, Return, DBW 2010 (w/Straight Tube) Screw, Mounting, Fuel Pump Washer, Lock, Fuel Pump Nozzle, Fuel, 0.35 GPH Stand, Fuel Nozzle, Brass Screw, Plate, Nozzle Stand Plate, Manifold Gear, Fuel Pump, Nylon Snap, Ring, Gear Fuel Kit, JIC, Male, w/Nut & Ring, Complete В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 7 Webasto Diesel Burner 8 9 7 6 3 10 5 4 2 1 12 5 14 Key Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PLX-105-800 FLX-751-CVL FLX-FL1-022 FLX-038-204 FLE-FUL-200 FLE-FUL-100 WPX-310-646 WPX-461-555 WPX-420-565 WPX-363-618 PLE-688-002-FRU WPX-265-53A FLX-131-280 WPE-905-834 Page 8 11 13 Description Fitting, Bulkhead, 3/4 (M) NPST x 1/4 in (F) NPT, Brass Valve, Check, Fuel 1/4 in (M) NPT Fitting, Elbow, 1/4 in (F) NPT Fitting #6 (M) JIC x 1/4 in (M) NPT Hose, Fuel, Supply/Return Kit w/Clamps Fitting, Fuel Line, Hose Barb x Compression Gauge, Adjustment, Electrode Bolt, Eye Pin, Eye Bolt Nut, Eye Bolt Valve, Ball Assembly Chamber, Combustion Fitting, Elbow, #6 (M) JIC x 1/4 in (M) NPT Burner, Diesel, 12 VDC В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Heating Zone Plumbing 3 4 5 2 1 Key Part Number 1 2 3 4 5 PLE-100-811 PLX-699-330 PLX-2A1-300 PLE-100-500 PLX-A65-800 Description Pump, Circulation, Kit Fitting, 1/2 in Hose Barb x 1/2 in (M) NPT Valve, Check, 1/2 in (F) NPT Manifold, Zone Return Fitting, Elbow 45В°, 3/4 in Hose Barb x 1/2 in (M) NPT В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 9 Engine Preheat Plumbing 2 3 2 1 Key Part Number 1 2 3 PLX-105-810 PLX-699-330 PLE-100-811 Page 10 Description Fitting, Bulkhead, 3/4 in (M) NPST x 1/2 in (F) NPT Fitting, 1/2 in Hose Barb x 1/2 in (M) NPT Pump, Circulation, Kit В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Domestic Water Plumbing 3 2 1 4 3 Key Part Number 1 2 3 4 5 6 PLX-09P-100 PLX-99D-90A PLX-803-000 PLX-111-123 PLX-0X1-07D PLX-M10-1DA 6 5 Description Valve, Tempering Fitting, 90В°, Elbow, Brass, 1/2вЂќ M, NPT Fitting, Straight 1/2 Pex x 1/2 (F) NPT PSF Valve, Pressure Relief Fitting, tee, 1/2вЂќ NPT, Brass, Male, Female Fitting, Tee, Forged, 1/2вЂќ Male NPT В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 11 Electronic Controller and Switch Panel (AHE-100-03S Only) 4 5 1 2 3 6 7 8a 9a 8b 9b Key Part Number 1 2 3 4 5 6 7 8a 8b 9a 9b SME-200-501 ELX-312-491 ELX-312-499 ELE-PC4-010-AA ELE-100-453 ELE-100-422 SME-EN4-008 ELE-000-507 ELE-000-509 ELX-283-284 ELX-283-283 Page 12 Description Faceplate, Electronic Controller, Assembly, Enclosure Plug, Electronic Controller, 20-Position Plug, Electronic Controller, 8-Position Controller, Electronic w/Time Delay, 12 VDC Harness, Control Harness, B-Plug Back, Electronic Controller, Enclosure Panel, Switch, Assembly, 12 VDC (Discontinued) Panel, Switch, Assembly, 12 VDC Switch, Rocker, w/LED (Discontinued) Switch, Rocker, w/LED В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Electrical Components, Internal (AHE-100-03S ONLY) 5 6 4 3 2 7 1b* 1a* 9 Key Part Number 1a 1b 2 3 4 5 6 7 8 9 ELX-630-001 ELE-630-001-FRU ELE-ASY-300-FRU ELE-HLT-322 ELE-014-005 ELE-800-002 ELX-002-100 SME-200-200 ELX-2E7-540 SME-200-301 8 Description Relay, Electromechanical, 30 Amp Relay, Electromechanical Retrofit Kit Thermostat, High-Limit, VAC, Kit, w/Connector Thermostat, High-Limit, VDC Thermostat, Control, 185В°F, 1/2 (M) NPT Switch, Float, Assembly Meter, Hour, Quartz Cover, Access, Junction Box Element, Heating, 120 VAC, 1650 Watts Cover, Access, Heating Element. * Originally a вЂњwhite Solid StateвЂќ relay was used for the Electric Element. If the heater has the original вЂњWhite Solid StateвЂќ relay, you must replace it with ELE-630-001-FRU. If the original вЂњWhite Solid StateвЂќ relay has already been replaced with the вЂњBlack MechanicalвЂњ relay, you may order just the Relay, ELX-630-001. В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 13 Electronic Controller and Switch Panel (AHE-130-03X & AHE-120-03X ONLY) 4 5 1 2 3 6 7 8a 9a 8b 9b Key Part Number 1 2 3 4 5 6 7 8a 8b 9a 9b SME-200-501 ELX-312-491 ELX-312-499 ELE-PC4-010-AA ELE-100-463 ELE-100-422 SME-EN4-008 ELE-000-907 ELE-000-908 ELX-283-284 ELX-283-283 Page 14 Description Faceplate, Electronic Controller, Assembly, Enclosure Plug, Electronic Controller, 20-Position Plug, Electronic Controller, 8-Position Controller, Electronic w/Time Delay, 12 VDC Harness, Control Harness, B-Plug Back, Electronic Controller, Enclosure Panel, Switch, Assembly, 12 VDC (Discontinued) Panel, Switch, Assembly, 12 VDC Switch, Rocker, w/LED (Discontinued) Switch, Rocker, w/LED В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Electrical Components, Internal (AHE-130-03X & AHE-120-03X ONLY) 1b* 6 1a* 5 4 7 3 2 10a or 10b 9 Key Part Number 1a 1b 2 3 4 5 6 7 8 9 10a 10b ELE-630-000 ELE-630-001 ELE-ASY-300-FRU ELE-HLT-322 ELE-014-005 ELE-800-002 ELX-002-100 SME-200-200 ELX-G12-07L SME-200-301 ELX-G12-07L ELX-2E7-600 8 Description Relay, Electromechanical Retrofit Kit Relay, Electromechanical, 30 amp Thermostat, High-Limit, VAC, Kit, w/Connector Thermostat, High-Limit, VDC Thermostat, Control, 185В°F, 1/2 (M) NPT Switch, Float, Assembly Meter, Hour, Quartz Cover, Access, Junction Box Element, Heating, 120 VAC, 2000 Watts Cover, Access, Heating Element. Element, Heating 120 VAC, 2000 Watts (AHE-130-03X ONLY) Element, Heating 240 VAC, 4500 Watt (AHE-120-03X ONLY) * Originally a вЂњwhite Solid StateвЂќ relay was used for the Electric Element. If the heater has the original вЂњWhite Solid StateвЂќ relay, you must replace it with ELE-630-001-FRU. If the original вЂњWhite Solid StateвЂќ relay has already been replaced with the вЂњBlack MechanicalвЂњ relay, you may order just the Relay, ELX-630-001. В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 15 Misc. Parts 4 1 2 5 3 6 9 10 7 8 Key Part Number Description 1 2 3 4 5 6 7 8 9 10 MSX-300-275 MSX-300-270 FLX-R12-TRA FLE-120-100 FLX-120-000 WPX-265-53A WPX-302-651 WPX-303-050 PLX-102-229 PLE-GAS-FLL Antifreeze, Boiler, P.G., 1 qt, Concentrate, (Camco) Antifreeze, Boiler, P.G, 1 Gallon (Camco) Filter, Fuel, Racor Spin-On, 10 Micron Filter, Canister, Replacement, Garber Filter, Fuel, Garber Combustion Chamber, DBW 2010 Air Swirler, DBW 2010 Tube, Combustion Chamber, DBW 2010 Cap, Radiator, 13 lb Gasket, Rubber, Filler Neck Page 16 В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Tools 1 2 3 4 Key Part Number Description 1 2 3 4 WPX-440-280 WPE-600-190 MSX-907-162 WPX-310-646 Tester, Controller Gauge, Fuel Pressure Tester, Refractometer, Battery/Coolant Gauge, Adjustment, Electrode В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 17 PARTS MANUAL Model Numbers: AHE-100-03S - 12 VDC AHE-120-03X - 12 VDC AHE-130-03X - 12 VDC (SN: 03-675 TO 04-533) 7501 Miller Drive | Frederick, CO 80504 Toll free: 800.685.4298 | phone: 303.651.5500 | fax:303.651.5699 www.aquahot.com В© May 2014 Aqua-HotВ® AHE-100-03S, AHE-120-03X, AHE-130-03X Hydronic Heating System Parts Manual - Rev. D Page 20