Aqua Hot smoking like a crop duster

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Aqua Hot smoking like a crop duster

November 12, 2021, 08:23:47 pm

I am slowly resurrecting a coach that sat for at least two years. Yesterday I ran the Aqua Hot for the first time just to see what would happen. Lot of smoke.
Today I installed a fresh nozzle and tried it again for 30 minutes with my thermostat set to 98 degrees. The smoke was bad, but got less and less. I let it rest and filled the water tank just see if the hot water worked too. It did and the smoke was almost non-existent. Is this normal?

Re: Aqua Hot smoking like a crop duster

Reply #1 – November 12, 2021, 09:00:14 pm

It takes a while for the excess diesel to get burnt off.

Re: Aqua Hot smoking like a crop duster

Reply #2 – November 12, 2021, 11:12:13 pm

Going forward, be sure to run it 1x per month to keep it happy.

Re: Aqua Hot smoking like a crop duster

Reply #3 – November 13, 2021, 08:03:05 am

Quote from: Bob_B – November 12, 2021, 08:23:47 pm

Today I installed a fresh nozzle and tried it again for 30 minutes with my thermostat set to 98 degrees. The smoke was bad, but got less and less. I let it rest and filled the water tank just see if the hot water worked too. It did and the smoke was almost non-existent. Is this normal?

The AH will smoke a second or two on startup. Other than that, it should burn clear. When installing a new nozzle, the combustion chamber should be removed, cleaned, and the inside of the vessel cleaned. Check and adjust electrodes as needed. Never run the unit without coolant. You can crack the vessel. Very expensive!

TOM

Re: Aqua Hot smoking like a crop duster

Reply #4 – November 13, 2021, 08:21:21 am

I did skip the cleaning of the combustion chamber as well as replacing the fuel filter. Looks like my short-cuts are a problem.
I did see that the coolant level was good.

Re: Aqua Hot smoking like a crop duster

Reply #5 – November 13, 2021, 09:00:05 am

Bob, Many good suggestions have been offered to you. May I add the following:

When installing the nozzle, thighten it up, loosen it 1/4 turn and tighten it a second time. Check flame sensor and clean if needed. Check ignitor point gap as suggested.

The torque for the 10 mm J-bolt nuts is 15 inch/pounds. For most men, that is snug, not tight. Do not break off the ears of the burner as it is a lot of work to fix.

The coolant picture of your over flow bottle is fine if heater is cold. Bring the heater up to temp and fill over flow bottle to the hot line.

Just because the over flow bottle is full does not mean the heater coolant tank is full. Remove the radiator cap, replace if not in excellent condition, and fill coolant tank lipping full. Replace the radiator cap and you are good to go. I have put 4 gallons of coolant in a heater that had an over flow tank at the hot line.

Check the over flow hose at the radiator cap. It should be flexable. Over time they can become stiff and split leaking air back into the tank. You can cut off and inch or so and re-install using a hose clamp.

All the best

Re: Aqua Hot smoking like a crop duster

Reply #6 – November 13, 2021, 10:25:50 am

Rudy had mentioned something to me that was very beneficial to my coolant replacement. He said to pump coolant in threw the drain valve with the radiator cap check valve held open, once fluid started entering overflow tank I removed the wire holding check valve in cap open and filled tank. Assured AH was full. It's like Rudy has been working on these things a couple of months. Rudy thanks for the wise words.
Scott

Re: Aqua Hot smoking like a crop duster

Reply #7 – November 13, 2021, 10:29:48 am

Quote from: Bob_B – November 13, 2021, 08:21:21 am

I did skip the cleaning of the combustion chamber

I had read a note in the manual that mentions placing the combustion liner with the welded seam at the top I think to prevent cracking?
Scott
http://www.aquahot.com/files/service_manual/AHE-100-02S%20Service%20Manual%20Rev.%20B%209-27-2011.pdf

Re: Aqua Hot smoking like a crop duster

Reply #8 – November 13, 2021, 11:03:48 am

Quote from: dsd – November 13, 2021, 10:29:48 am

I had read a note in the manual that mentions placing the combustion liner with the welded seam at the top I think to prevent cracking?
Scott

Something I had missed. I will pull the burner and clean and reposition the liner if not correct. When I first started dealing with Aqua Hot systems in 2012 I had to replace melted swirlers, cracked liners and deal with cracked coolant tubes. There was a company back then called "Bus Service Inc. that sold parts for the AH. The gentleman who owned it was like Rudy always gave me advice on keeping the AH working. He has since passed and the company shut down as his daughters didn't have the knowledge to keep it going. Thank goodness for Rudy for giving his time to me many times.

Re: Aqua Hot smoking like a crop duster

Reply #9 – November 13, 2021, 11:09:18 am

Rudy is the man!

Re: Aqua Hot smoking like a crop duster

Reply #10 – November 13, 2021, 11:39:13 am

Bob,

One other thing to check if smoking continues (which I learned from Rudy) is the two rubber grommets for where the ignition wires enter the housing. They are meant to actually seal the entry hole to prevent the forced combustion air from escaping out the side rather than going into the combustion chamber. If they are leaking (old and dried up) then there is lower air/fuel ratio than required, therefore smoking.

Richard

Re: Aqua Hot smoking like a crop duster

Reply #11 – November 13, 2021, 11:57:58 am

I see that I would do well to get back in there and check it again and do a more thorough job. Thanks again for the advice, especially about the coolant tank. It seems that it would give false security about the actual level in the unit.

Re: Aqua Hot smoking like a crop duster

Reply #12 – November 13, 2021, 01:12:02 pm

Quote from: craneman – November 13, 2021, 11:03:48 am

Thank goodness for Rudy for giving his time to me many times.

X2 You, me and many others.
Scott

Re: Aqua Hot smoking like a crop duster

Reply #13 – November 13, 2021, 09:27:16 pm

Rudy is a gift
Let's clone him

Re: Aqua Hot smoking like a crop duster

Reply #14 – November 14, 2021, 06:01:08 am

Met Rudy yesterday and he serviced my Oasis system in our new to us bus...what a great guy . He came to me in the Lake Conroe KOA as we are on our way to FOT for some work. I thank him for taking the time to explain the working and flows of the system. He is definitely the man when it comes to Aqua Hot and Oasis heating systems...

Re: Aqua Hot smoking like a crop duster

Reply #15 – November 16, 2021, 06:04:30 pm

Today, one step forward and one step back.
Sure enough the overflow tank is inoperable. Pulling the radiator cap reveals that I needed some boiler fluid. It took a half-gallon which is roughly equal to the distance between the hot mark and the cold mark on the overflow tank.
The tank must've been inoperable because of failure of the (probably brittle) hose near the cap. Once the Aqua Hot got up to temperature, it dumped the fluid onto the ground outside where the exhaust poked through the underbelly.
I'll try to attach the overflow hose in a secure fashion tomorrow
The good news, it only smoked for five minutes and then dissipated.

Re: Aqua Hot smoking like a crop duster

Reply #16 – November 16, 2021, 08:47:33 pm

Quote from: Bob_B – November 16, 2021, 06:04:30 pm

The tank must've been inoperable because of failure of the (probably brittle) hose

Seems I recall that fitting is replaceable

Re: Aqua Hot smoking like a crop duster

Reply #17 – November 16, 2021, 09:54:44 pm

Well, Look on the bright side of a smoking AH. If your neighbors are being a pain at 12 Midnight or they have a yapping rat on a rope chained up outside. Then just take a long hot shower. And no mosquitoes for miles either.

Re: Aqua Hot smoking like a crop duster

Reply #18 – November 17, 2021, 04:37:18 pm

Success!
No more smoke and no more leaking coolant.

The coolant overflow hose was completely separated UNDER the clamp near the radiator cap.
I cut the hose a few inches back and reinstalled it with a new clamp. I topped off the coolant and installed the radiator cap. I fired up the AH and watched it like a hawk as it slowly filled the overflow. It didn't spill a drop.

As far as the smoke, I pulled the burner loosened the new nozzle a quarter turn and tightened.
I pulled the burner tube out, then apart and scrubbed it clean in the kitchen sink. The sensor plate also got a good cleaning too.
It all works great now.
I might even take out for Thanksgiving in 24-degree weather. Wish me luck😀

Re: Aqua Hot smoking like a crop duster

Reply #19 – November 17, 2021, 07:37:30 pm

No luck needed. The AH works great in the cold weather. We have been in the 20's over night for about 4 nights now. Fortunately it warms to about 60 for a high temp. The burner fires up quite often during the night. We are also hooked up to 50Amp.

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