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PARTS MANUAL - Aqua-Hot Heating Systems, Inc.

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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, 90°, Elbow, Brass, 1/2” M, NPT
Fitting, Straight 1/2 Pex x 1/2 (F) NPT PSF
Valve, Pressure Relief
Fitting, tee, 1/2” NPT, Brass, Male, Female
Fitting, Tee, Forged, 1/2” 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 “white Solid State” relay was used for the Electric Element. If the heater has the original “White Solid
State” relay, you must replace it with ELE-630-001-FRU. If the original “White Solid State” relay has already been replaced
with the “Black Mechanical“ 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 “white Solid State” relay was used for the Electric Element. If the heater has the original “White Solid
State” relay, you must replace it with ELE-630-001-FRU. If the original “White Solid State” relay has already been replaced
with the “Black Mechanical“ 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
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