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Topic: Rebuilding Aqua Hot (Read 7036 times) previous topic - next topic

Rebuilding Aqua Hot

I finally got a start on the Aqua Hot rebuild this afternoon. I only had a couple of hours today, so not too much progress. I did get the burner removed. I had serviced the unit last year so I was familiar with it. I didn't want to miss anything so I've take lots of pictures and have labeled some of the lines. I'm not sure how well the stickers will stay, but time will tell. I also got the boiler drained. I can't believe how much water/antifreeze came out. I ran out of containers quickly. I estimate that I have close to 15 gallons of antifreeze out of the boiler unit. I wanted to get that done today with the good weather. Rain is supposed to move in tonight and I don't really want to lay on the wet ground if I don't have to.

As I progress, I will update this topic. Hopefully it will be of benefit to some others. I'm following the lead of others (Matthew, Hawkeye, Cubesphere, Craneman and the expert advice from Rudy) to name just a few. I've had comments and recommendations from others giving me their advice. My sincerest thanks for all your help.

Join the ride. Hopefully it won't be to bumpy.

Larry

Re: Rebuilding Aqua Hot

Reply #1 –
Was guessing 18 gal with all the lines on the inside... its a lot of liquid either way.. Good luck..

Re: Rebuilding Aqua Hot

Reply #2 –
I hadn't read anywhere what to expect, boy was I surprised. Probably surprise #1 out of 300 by the time I get done. While the AH is out of the coach, I'm planning on changing the fuel lines.

Larry

Re: Rebuilding Aqua Hot

Reply #3 –
Might as well (if you can afford) to replace the motors and all the shut off ball valves.. If you think you had any one way valves sticking go ahead and replace those also.. New tempering valve (mine had gunk on the inside I couldnt get out) and I pulled every fitting off and resealed them.. Only think I kinda think I should have down was provide a shut off for each motor so it can be changed without draining the whole system.

Re: Rebuilding Aqua Hot

Reply #4 –
If you think your labels might come off then buy a pack of colored zip ties and use those to mark your lines. 

Re: Rebuilding Aqua Hot

Reply #5 –
David, I'm planning on going thru the entire unit and seeing what looks good and what is kinda iffy. I am a firm believer that it needs fixed right the first time. I'm sure that I don't want to have to remove this again down the road.

Foliver, Thanks for the idea. That is excellent. I was thinking of getting those paper tags with strings attached, but I really like the tie wrap idea better. ^.^d

The rain has set in for the day, I will see how much I can get done. Unfortunately, I don't have a building, just the driveway.

Larry

Re: Rebuilding Aqua Hot

Reply #6 –
OK, the rain let up a little bit. I was able to get out there for an hour or so. I went back on the lines that I had labeled yesterday and replaced the stickers with tie wraps and labeled paper key tags. I also unwired the main bundle of wires going to the relays, power, ground and the different control and thermostat wires. Then the rains came back and the DW is fixing supper. Hopefully tomorrow will be a full day.

BTW, for those who have done this, when the coolant lines are disconnected how much coolant should I expect from each line. The AH manual says that there should be about 2 quarts. I assume this means each line. I just want to be prepared better for this than I was for the boiler. I was scrambling to find containers to hold the antifreeze in yesterday. I bought buckets at Home Depot today. The boiler released 15 gallons of coolant. Yep, I was surprised.

Larrty

Re: Rebuilding Aqua Hot

Reply #7 –
Be sure to pinch off the engine coolant loop. I didn't and had way more buckets of coolant than I expected.

Re: Rebuilding Aqua Hot

Reply #8 –
Thanks Craneman, that is the type of insight I need.  ^.^d

Larry

Re: Rebuilding Aqua Hot

Reply #9 –
Quote from: craneman –
Be sure to pinch off the engine coolant loop. I didn't and had way more buckets of coolant than I expected.

The engine coolant loop is circulated directly with the aquahot coolant?  I figured they'd be separate loops with a heat exchanger.

Re: Rebuilding Aqua Hot

Reply #10 –
It is separate, but to drain the Aqua Hot to remove it, the hoses have to be pinched off or they drain also.

Re: Rebuilding Aqua Hot

Reply #11 –
OK, for today's update.

I decided to remove the exhaust system before the AH was loose. I started the coach, travel light went on and it got to travel height, but no other HWH lights. Wouldn't level, raise, dump, nothing. Time to panic. Went on a search on the forum. What more praises can I express for those who post their issues and resolutions for those of us to follow up on in a time of crisis. End result............old timers disease. I forgot to turn on the salesman switch.

Raised the coach, put my safety stands under it and removed the exhaust system. A little PB blaster, air impact and dirt in the eyes and it was off. Only lost one bolt to, not bad start for the day. I'm going to have a new exhaust system rebuilt. As per Rudy's suggestion I plan on having it made from 2" pipe instead of the 1 1/2".

Thanks to Craneman's advice, I went to the tractor store and bought 4 more 5 gallon buckets for removing the engine coolant lines. Sure glad that I did. I pinched the lines and the coolant still keeps on coming. I ended up with around 8 gallons of engine coolant. I think that I had so much because my drive slopes to the front of the coach, therefore I was lower than a lot of the engine. That being said, I plan on draining out the rest of the engine coolant and putting in new antifreeze in both the AH boiler and the engine coolant system.

Got all the lines disconnected and discovered to my chagrin that with my coach they installed the AH first and then built the rest of the coach around it. At least it seemed like it. I was able to use a couple of crowbars and get a 3" board under it. I then slid the unit forward and worked the back corner around, rinse and repeat. When it reached it's maximum point, I didn't have 1/16" clearance on the front corner with the left side dragging the edge of the opening. With a little persistence, I worked the unit onto a small 4 wheel furniture  cart, rolled it to the edge and slid it down to the driveway. Got the two wheel dolly and into the garage where it awaits tomorrow and the tear down process.

I do believe that I may get a good nights sleep tonight :))

Questions or comments are appreciated.

Larry

Re: Rebuilding Aqua Hot

Reply #12 –
What's involved with changing out the exhaust to 2 in? is it a 2-in exhaust from the unit? Or are you going from a one and a half inch to a 2-in?
Sounds like something I would do forgetting the salesman switch was off!

Re: Rebuilding Aqua Hot

Reply #13 –
Yes it is 1 1/2" nipple to a 1 1/2" elbow to another 1 1/2" nipple to the straight pipe out. I will have to flare up somewhere along the way.

Larry

Re: Rebuilding Aqua Hot

Reply #14 –
Quote from: ohsonew –
Yes it is 1 1/2" nipple to a 1 1/2" elbow to another 1 1/2" nipple to the straight pipe out. I will have to flare up somewhere along the way.

Larry
What is the point in making it bigger? what does it help? Or in other words..What is the benefit?

Re: Rebuilding Aqua Hot

Reply #15 –
The 2 inch exhaust currently used by Aqua Hot on new installs breaths better and is a little quieter.  I would not remove a working exhaust to step up to 2 inch but if you are doing something requiring the exhaust removal, then I would with a stainless steel straight out tip.

Re: Rebuilding Aqua Hot

Reply #16 –
Got up early this morning (2:30) couldn't sleep. After coffee and weather started on the AH. Got the cover removed. Had to chisel the rivets. Every one was loose and just spun in the drill. Found the reason for the water leak. 5 ruptures about 1" each. Took my time removing everything and making sure it was tagged and photographed. Had to sweat off 3 lines, cut 1 and unscrewed 2 others.

Disconnected thermostat wires and electric element wire as needed to remove the front inside cover. A lot of the mastic had crumbled off of the unit and was inside the compartment. I am not certain, but it looks like someone has done work on this unit before. The ball valves were newer, the layout was slightly changed from what the AH manual showed and I found a 1/4" deep well socket buried in the debris.

I put a micrometer on the old copper and it showed an outside dimension of .510" . I plan on taking a piece to the local plumbing supply show to match it up for size. I ordered 2 gallons of Thermax 300 heat transfer mastic. Should be here on Monday. I know there was more to tell about the day, but the early morning start has caught up with me and my fried brain. I think I will take a nap now. That's what retired folks do isn't it?

Larry

Re: Rebuilding Aqua Hot

Reply #17 –
1/4" size or 1/4" drive 10 mm?

Re: Rebuilding Aqua Hot

Reply #18 –
1/4" deep well socket on a 1/4" drive

Larry

Re: Rebuilding Aqua Hot

Reply #19 –
Strange 1/4" doesn't match any metric size, and the Aqua Hot is all metric unless some parts were modified.