Aqua Hot controller extension 3D printing

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Aqua Hot controller extension 3D printing

January 28, 2023, 10:38:18 am

So I've been planning on relocating my aqua hot controller outside of the stainless fireproof box. I believe that the controller life is shortened by being inside the hot box environment. Some operate there aqua hot with the access cover removed so it runs cooler. Personally I wish to retain the integrity of the fireproof housing. So there are two ways to do it.
1 Cut the wires and add a extension.
2 Build a extension cord for it with both male and female plugs
Im going to initially just extend the wires, but still would like a simple plug and play alternative, not for myself but everyone else that like to follow this path.
Both will need a fireproof transition thru the firewall.
Sourcing connectors is a unknown and I suspect they are not in production or available. I understand that they can be 3D printed but out of my skill set. Also would be concerned of material operating temperature range?
Any ideas would be appreciated on the connectors.
Scott

Re: Aqua Hot controller extension 3D printing

Reply #1 – January 28, 2023, 11:21:51 am

Scott, I don't think thermal wires would be needed. The connector plug I made for the thermostats is regular wire and I see no hardening of the wires. The new controller made by Aqua Hot has pigtails and it is standard wire. It will take a few years to see if the new solid state controller eliminates the problems of the old metal one. The only thing that gets real hot is the collar that bolts the burner to the swirller. I can touch all the other parts after running and don't feel any major heat. I left the cover off for 3 days here at the Q to make sure I had solved the intermittent no fire issue and put it back on yesterday. I like your idea to be able to switch the controller first before removing the cover and trouble shooting the rest. Obviously the connector will have to be mounted at the front so as not to interfere with the cover.

Re: Aqua Hot controller extension 3D printing

Reply #2 – January 28, 2023, 01:00:41 pm

Quote from: craneman – January 28, 2023, 11:21:51 am

Scott, I don't think thermal wires would be needed. The connector plug I made for the thermostats is regular wire and I see no hardening of the wires. The new controller made by Aqua Hot has pigtails and it is standard wire. It will take a few years to see if the new solid state controller eliminates the problems of the old metal one. The only thing that get real hot is the collar that bolts the burner to the swirller. I can touch all the other parts after running and don't feel any major heat. I left the cover off for 3 days here at the Q to make sure I had solved the intermittent no fire issue and put it back on yesterday. I like your idea to be able to switch the controller first before removing the cover and trouble shooting the rest. Obviously the connector will have to be mounted at the front so as not to interfere with the cover.

Yes no issues with wire temps. Just the 3D printed plugs have me second guessing something I know little about. Ill cut and splice my wires for now. Upsize one size also for the added length. Sorry to hear you were climbing in on your on the road.
Scott

Re: Aqua Hot controller extension 3D printing

Reply #3 – January 28, 2023, 01:06:21 pm

I had trouble with my controller I haven't had any more trouble but lengthening the wires sounds
like a good idea.

Re: Aqua Hot controller extension 3D printing

Reply #4 – January 28, 2023, 10:58:16 pm

The connectors probably could be 3D printed, but you'd have to have a good scan or model drawing of the originals to print from. That's the harder part. Probably easier to try to identify the connectors from a manufacturer and buy them, or get "samples".

Re: Aqua Hot controller extension 3D printing

Reply #5 – January 28, 2023, 11:05:20 pm

My kid 3d prints stuff for me all the time. In fact the bushing for the ball socket on my broken mirror was about the best thing ever. Handed him the broken one and he handed me a brand new part a couple hours later!

If anyone has a spare connector and wants to send it to me I'll see what he can do. He prints with abs or nylon.

Re: Aqua Hot controller extension 3D printing

Reply #6 – January 29, 2023, 09:23:49 am

Quote from: nbluesky – January 28, 2023, 11:05:20 pm

My kid 3d prints stuff for me all the time. In fact the bushing for the ball socket on my broken mirror was about the best thing ever. Handed him the broken one and he handed me a brand new part a couple hours later!

If anyone has a spare connector and wants to send it to me I'll see what he can do. He prints with abs or nylon.

What would be the operating temperature on the nylon or abs?

Re: Aqua Hot controller extension 3D printing

Reply #7 – January 29, 2023, 09:55:43 am

Rethinking the issue of mounting, the cover could have a plasma cut window and the existing wires could be mounted to a slightly larger piece of stainless which could be mounted on the outside of the cover and unscrewed and pushed back through the hole to remove the cover. The existing wires are long enough.

Re: Aqua Hot controller extension 3D printing

Reply #8 – January 29, 2023, 10:57:37 am

Quote from: craneman – January 29, 2023, 09:55:43 am

Rethinking the issue of mounting, the cover could have a plasma cut window and the existing wires could be mounted to a slightly larger piece of stainless which could be mounted on the outside of the cover and unscrewed and pushed back through the hole to remove the cover. The existing wires are long enough.

Just to be clear. 2001 coaches with slides and have a truss that hangs down 14"? I slide the Joey bed out then shimmy under the Truss. Its a pain to Climb in there and well worth putting a extension for me because I would like to use my Coach aqua hot as a test bed for controllers. If I lost 60 lbs and was younger it wouldnt be a issue. Would only need to be outside of the box for most. I wasn't sure if there was enough length to mount outside? I will be installing extensions this week so will for sure have a update. I also was planning on adding a access panel as you had described. I have plenty of stainless sheet

Re: Aqua Hot controller extension 3D printing

Reply #9 – January 29, 2023, 11:12:58 am

I am not familiar with slide coaches, sounds much more difficult. No joey bed in that compartment on my coach just a big carpeted bay. Very easy for me to get in and out. I see why you would want to make the controller easier to access.

Re: Aqua Hot controller extension 3D printing

Reply #10 – January 29, 2023, 12:26:52 pm

We are at Q and had our 600 Aquahot serviced. Tech said there us a recall to remove that small hose on the air intake. He also recommended removing the top/ side cover to keep the heat from killing the controller. I have not checked but I think the "box" is just sheet metal. Not in a Foretravel.

Re: Aqua Hot controller extension 3D printing

Reply #11 – January 31, 2023, 11:55:52 pm

Quote from: dsd – January 29, 2023, 09:23:49 am

What would be the operating temperature on the nylon or abs?

I'm not sure, Google would.prob know more on that .

Re: Aqua Hot controller extension 3D printing

Reply #12 – February 01, 2023, 09:01:26 am

Quote from: moisheh – January 29, 2023, 12:26:52 pm

We are at Q and had our 600 Aquahot serviced. Tech said there us a recall to remove that small hose on the air intake. He also recommended removing the top/ side cover to keep the heat from killing the controller. I have not checked but I think the "box" is just sheet metal. Not in a Foretravel.

Wish I could picture the hose you mentioned? I do agree with wanting the controller to be cooler but will maintain the manufactures original design providing fire box protection. They did it for some reason. DWMYH. Please retain to facilitate reinstalling if you ever want to

Re: Aqua Hot controller extension 3D printing

Reply #13 – February 01, 2023, 09:24:23 am

Quote from: moisheh – January 29, 2023, 12:26:52 pm

We are at Q and had our 600 Aquahot serviced. Tech said there us a recall to remove that small hose on the air intake. He also recommended removing the top/ side cover to keep the heat from killing the controller. I have not checked but I think the "box" is just sheet metal. Not in a Foretravel.

What coach do you have? I did not see you have it listed. You can add this in your signature line.

Re: Aqua Hot controller extension 3D printing

Reply #14 – February 07, 2023, 11:40:17 am

Plugs

Re: Aqua Hot controller extension 3D printing

Reply #15 – February 07, 2023, 12:52:29 pm

The easiest option would be to cut, splice, and extend. The wires in your unit are over 20 years old so are likely getting hard and brittle with every day and risk eventually breaking. I ended up replacing all of my wiring with high temp wiring when changing to a Beckett controller and igniter. The igniter wires were also brittle and cracked while removing, so I replaced that as well. My controller and igniter are now on the driver's side wall of the AH. I was able to also extend the wires enough to remove the burner a little easier.

So, my recommendation would be to also replace the wiring if you're up for the task.

Re: Aqua Hot controller extension 3D printing

Reply #16 – February 07, 2023, 01:23:45 pm

Quote from: Zach – February 07, 2023, 12:52:29 pm

I was able to also extend the wires enough to remove the burner a little easier.

So, my recommendation would be to also replace the wiring if you're up for the task.

If doing all of that. Just take existing harness connectors and make one with new longer wires

Re: Aqua Hot controller extension 3D printing

Reply #17 – February 07, 2023, 01:52:26 pm

Quote from: Zach – February 07, 2023, 12:52:29 pm

The easiest option would be to cut, splice, and extend. The wires in your unit are over 20 years old so are likely getting hard and brittle with every day and risk eventually breaking. I ended up replacing all of my wiring with high temp wiring when changing to a Beckett controller and igniter. The igniter wires were also brittle and cracked while removing, so I replaced that as well. My controller and igniter are now on the driver's side wall of the AH. I was able to also extend the wires enough to remove the burner a little easier.

So, my recommendation would be to also replace the wiring if you're up for the task.

My harness is in great shape and I did extend for my project BUT there are many who would just want a plug and play harness which also could be removed if desired. So I'm completely happy with what I have , just was hoping to make an option for those that can't/won't replace or cut up their harness. Few have the advanced skill set such as yours but still would like to have the benefits and are able to pay for components and shipping. Labor from me is free till I'm retired then it will be a catch me if you can scenario.
Scott

Re: Aqua Hot controller extension 3D printing

Reply #18 – February 07, 2023, 02:19:11 pm

Quote from: turbojack – February 07, 2023, 01:23:45 pm

If doing all of that. Just take existing harness connectors and make one with new longer wires

👍👍 Yep

Re: Aqua Hot controller extension 3D printing

Reply #19 – February 07, 2023, 02:55:22 pm

Quote from: dsd – February 07, 2023, 01:52:26 pm

My harness is in great shape and I did extend for my project BUT there are many who would just want a plug and play harness which also could be removed if desired. So I'm completely happy with what I have , just was hoping to make an option for those that can't/won't replace or cut up their harness. Few have the advanced skill set such as yours but still would like to have the benefits and are able to pay for components and shipping. Labor from me is free till I'm retired then it will be a catch me if you can scenario.
Scott

Ahhh, I see. Just don't let Aqua Hot see this because they may start making a harness extender for a couple hundred dollars.

(For reference a new harness is $200)

Re: Aqua Hot controller extension 3D printing

Reply #20 – February 07, 2023, 03:06:41 pm

I did look up some 6 and 8 pin space connectors. The problem is that I don't know the exact size and spacing of the AH connectors.

Connectors - Vintage Connections Has both latching and non-latching connectors and may need to be filed down to fit correctly.

6 Terminal Wiring Harness Electrical Connector for Vintage Honda Motorcycles|... This appears to be a set of latching connectors but may also work.

Re: Aqua Hot controller extension 3D printing

Reply #21 – February 07, 2023, 03:50:48 pm

Quote from: Zach – February 07, 2023, 03:06:41 pm

I did look up some 6 and 8 pin space connectors. The problem is that I don't know the exact size and spacing of the AH connectors.

Connectors - Vintage Connections Has both latching and non-latching connectors and may need to be filed down to fit correctly.

6 Terminal Wiring Harness Electrical Connector for Vintage Honda Motorcycles|... This appears to be a set of latching connectors but may also work.

I don't see them happening if I have to modify connectors to make them work. It could end up being three or four connectors. I see no reason the large connector couldn't be split into two, to duplicate the controller plug that has two plugs connecting to it. Hopefully someone can come up with plug numbers to build. My son-in-law says he can Copy this summer when we are at his house and produce a 3D print program so that will resolve sourcing, above my pay grade and skill set.

Re: Aqua Hot controller extension 3D printing

Reply #22 – February 13, 2023, 02:02:51 am

Aqua Hot Hydro Hot Burner Control Life Extender Cables | eBay

Re: Aqua Hot controller extension 3D printing

Reply #23 – February 13, 2023, 09:34:45 pm

Quote from: dsd – February 01, 2023, 09:01:26 am

Wish I could picture the hose you mentioned? I do agree with wanting the controller to be cooler but will maintain the manufactures original design providing fire box protection. They did it for some reason. DWMYH. Please retain to facilitate reinstalling if you ever want to

According to Rudy the covers are there just to make it pretty and he suggests leaving them off.

Keith

Re: Aqua Hot controller extension 3D printing

Reply #24 – February 13, 2023, 11:43:44 pm

Does leaving the cover off significantly reduce the heat reaching the controller?
And if so, but putting the carpeted cover back on for aesthetics does that also make it pointless to take of and leave off the metal case?

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