Truma AquaGo LP Gas Instant Water Heater Model: Truma AquaGo basic (AquaGo60B) * Truma AquaGo comfort (AquaGo60C) * Truma AquaGo comfort plus (AquaGo60CP) * * Patent Pending If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death. Do not store or use gasoline or other flaz. B.able vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS Evacuate all persons from the vehicle. Shut off the gas supply at the gas container or source. Do not touch any electrical switch, or use any phone or radio in the vehicle. Do not start the vehicle s engine or electric generator. Contact the nearest gas supplier or certified service technician for repairs. If you cannot reach a gas supplier or certified service technician, contact the nearest fire department. Do not turn on the gas supply until the gas leak(s) has been repaired. Installation and service must be performed by a certified service technician, service agency, or the gas supplier. Exchange Spare Parts Note: Only the spare parts described here can be replaced; if other components are affected, the complete appliance must be replaced. Note: When all the repair and maintenance work has been carried out, the functions of the complete system must be tested. The installation and operating instructions enclosed with the appliance must be observed. Conforms to ANSI Std Z21.10.3 Certified to CSA Std 4.3 Certified to AS4552
Troubleshooting Problem Potential cause Resolution No hot water at the tap Gas supply is turned off or interrupted. Gas tank is empty. Check and/or turn on gas supply. Refill/replace the gas tank. Boiling noises Hot water temperature too low. Water escaping at pressure relief valve. Water escaping at the water inlet filter The appliance is switched off. Fresh water supply is turned off. Power supply to the appliance is switched off. Defect in the appliance. Too much lime scale in the Truma AquaGo instant water heater. Gas flow to the appliance is too low (gas inlet pressure < 2,62 kpa. Volume flow of hot water is too high and/or the temperature of cold water reaching the appliance is too low. Too much lime scale in the appliance. Water pressure in water system too high. Water cannot expand in the water system. Lime or dirt under the pressure relief valve seat. Lime or dirt under the O-ring seats. Switch on the appliance according to instructions Open the fresh water supply. Switch on power supply to the appliance. LED 2 blinks red and contact a certified service technician if necessary. The appliance must be decalcified. Consult vehicle documentation to determine if gas supply is capable of providing the necessary volume of gas for the appliance. Contact a service technician to verify a suitable gas installation. Turn down hot water at the tap or in the shower in order to reduce volume flow. Potentially retrofit a volume flow throttle into the water system. This must be performed only by a certified service technician. The appliance must be decalcified. Adjust the water pump pressure to a maximum of 450 kpa. If the water system is connected to a central water supply higher than 450 kpa (4.5 bar) (rural or urban connection), a pressure reducer must be used. Install a pressure reducer (e.g. Truma pressure reducer) at the fresh water supply. Contact the vehicle manufacturer about retrofitting a pressure compensation element. Allow the appliance to cool and then slowly raise the test lever to flush the water system and attempt to force dirt or foreign matter out of the pressure relief valve seat. Replace pressure relief valve. This must be performed only by a certified service technician. Clean the O-rings and their corresponding sealing surfaces with clean water. AquaGo comfort / AquaGo comfort plus The yellow LED 3 is off although an operating mode was selected. Power switch is OFF. Power supply to the appliance is switched off. The power supply was interrupted. Switch ON the appliance at the POWER switch. Switch on power supply to the appliance. Reset by switching OFF at the control panel, waiting 2 seconds and then switching on again. 2
APPENDIX A Error Codes* If the appliance malfunctions LED 2 ( Overview / Designation of parts on Page 5) will flash to indicate the malfunction. There are short and long intervals of flashing. The flashing will repeat every 3 seconds. 1. Write down the flashing intervals and check the list below. * for more information, please observe 2. Reset the appliance: the installation and operating instructions enclosed with the appliance Switch off the appliance. / Wait 5 seconds. / Switch the appliance on again. 3. If an error code is still displayed, contact an authorised Truma service center. Error code Flash code s =short = 0 l = long = 1 Error Description 1 s,s,s,s,s,s,s,l Flame not detected There is a flame-detection error at the burner because the flame was not detected after release of gas and ignition. Important: The system indicates this error only after three attempts at intervals of approximately 30 seconds. 2 s,s,s,s,s,s,l,s Error at over temperature switches (EOS, BOS) The exhaust over temperature switch (EOS) or burner over temperature switch (BOS) is open/unplugged. 3 s,s,s,s,s,s,l,l Error at exhaust pressure switch (EPS) 4 s,s,s,s,s,l,s,s Error at water over temperature switch (WOS) 5 s,s,s,s,s,l,s,l Flame detected at incorrect time 6 s,s,s,s,s,l,l,s Error in the safety circuit for gas valve 7 s,s,s,s,s,l,l,l Error of burner MCU internal RAM 9 s,s,s,s,l,s,s,l Malfunction of water outlet temperature sensor WOT The EPS did not close when the flue fan was actuated because the fan did not push enough air through the exhaust channel. A cause could be, e.g., blocking of the exhaust channel or a faulty switch. OR The EPS is closed even though the flue fan is not running. Cause is a defective EPS or flue fan. The WOS opened at a water temperature of over 185 F (85 C). There is an error in flame detection of the burner because the flame was detected before ignition or before the release of gas or after the gas was switched off. There is a heating request but gas cannot be released. One of the switches WOS, EOS, BOS, EPS is open/unplugged. Error detected in the burner MCU s internal safety monitoring feature (safety variables are no longer correct or RAM/STACK was overwritten by mistake). Water outlet temperature sensor WOT has a short circuit or is open/unplugged. 10 s,s,s,s,l,s,l,s Error in the safety circuit There is a heating request but gas is not released because a valve-actuation signal was not activated. 11 s,s,s,s,l,s,l,l Error of MCU watchdog gas release There is a heating request but the MCU watchdog does not release the gas path. 12 s,s,s,s,l,l,s,s Internal error 13 s,s,s,s,l,l,s,l Short circuit shut-off valve Short circuit detection in the gas valve (shut-off part) detected a current > 1000 ma and shut off. 16 s,s,s,l,s,s,s,s Malfunction of the MCU Internal error of the control unit. 20 s,s,s,l,s,l,s,s Malfunction of water inlet temperature sensor WIT Water inlet temperature sensor WIT has a short circuit or is open/unplugged or the temperature of the sensor is colder than 14 F (-10 C). 21 s,s,s,l,s,l,s,l Malfunction of circulation line temperature sensor WCT 22 s,s,s,l,s,l,l,s Malfunction of gas valve, modulation section Circulation line temperature sensor WCT has a short circuit or is open/unplugged or the temperature of the sensor is colder than 14 F (-10 C). Error at gas valve, modulation level, because - the modulator has a short circuit or - is open/unplugged. 23 s,s,s,l,s,l,l,l Voltage is too high The main power supply s voltage detector measured a voltage level of >16.4 V. 24 s,s,s,l,l,s,s,s Voltage is too low The main power supply s voltage detector measured a voltage level of <10 V. 25 s,s,s,l,l,s,s,l Flue fan current consumption error The current detector for the flue fan has measured a current outside the permitted limits. 26 s,s,s,l,l,s,l,s Circulation pump current consumption error The current detector at the circulation pump has measured a current outside the permitted limits. 27 s,s,s,l,l,s,l,l Water circulation pump is running dry. The circulation pump does not generate water flow. The water system may not be filled or not sufficiently vented. The circulation pump tries (20 times) to generate a water flow every 30 s (if successful, the error is reset). 28 s,s,s,l,l,l,s,s Too low gas pressure. Gas supply (in vehicle) to the appliance insufficient. 29 s,s,s,l,l,l,s,l Too high heat power required. You are trying to use more hot water than the appliance can supply. 30 s,s,s,l,l,l,l,s Risk of freezing. Temperature in the appliance below 37 F (3 C). 31 s,s,s,l,l,l,l,l Decalcification finished. 32 s,s,l,s,s,s,s Current too low. Current in the antifreeze kit too low (e.g. cable break). 33 s,s,l,s,s,s,s,l Current too high. Current in the antifreeze kit too high (e.g. short circuit). 3
Contents Page Spare parts Truma AquaGo dismantle/install 8 Housing open/close 12 Exhaust pressure switch replace 77000-90100 13 Fan replace 77000-90200 15 Control unit assembly replace 77000-00113 17 Burner assembly replace 77000-90400 19 Flow sensor replace 77000-90500 23 Circulation pump replace 77000-90600 26 Non-return valve replace 77000-90700 28 Filter assembly replace 77000-90800 30 Electrodes replace 77000-91300 31 Access door standard replace 77001-01 33 Access door XS replace 77201-01 33 Access door adapter replace 77101-01 33 Spare parts Front Side Robustness, a long service life, and simplicity of service were very high priorities during development of the Truma AquaGo instant water heater. Should service or replacement of components be necessary, this can be completed without removing the entire appliance, unlike many other products of this type. Some appliance components can be easily maintained or replaced from the front side of the appliance. 4
Spare parts 1 37 28 2 28 3 4 5 6 38 27 29 7 8 26 30 36 24 9 25 10 23 35 20 17 15 22 19 16 18 Item Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part no. 77000-90100 77000-90200 77000-00113 77000-91300 77000-90400 77000-90800 Component Flue Duct Assembly Flue Duct gasket Air Overheat Switch Exhaust Pressure Switch Flue Fan Assembly Heat Exchanger Lower housing Assembly Grommet Control Unit Assembly Electrodes Flame rectification Access Door Venting Grid Slide latch Burner Assembly Lever Spacer Set Filter Assembly Temperature stabilizer Assembly Item Ref. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Part no. 77000-90500 77000-90600 77000-90700 77001-01 77201-01 77101-01 77000-00089 Component Relief Valve Upper housing Assembly Water temperature sensor Flow Sensor Assembly Water connector Piping "Basic Piping "Comfort Piping "Comfort Plus Circulation Pump Non-Return Valve Assembly Water overtemperature switch Cable harness 1 (not shown) Cable harness 2 (not shown) Small parts (not shown) Access Door Standard Access Door XS Access Door Adapter Control panel incl. cable 5
Serial numbers of the spare parts Some spare parts have an individual serial number. This number is printed on a sticker. Truma Gerätetechnik GmbH & Co KG needs this serial number if the appliance has to be repaired. The following photos show where the sticker is located on the spare part. Circulation pump Burner assembly Control unit assembly 6
Serial numbers of the spare parts Flow sensor Truma AquaGo Truma AquaGo 7
1. Dismantling/installing Truma AquaGo Required tools: Screwdriver, suitable for the available screws Scraper, knife Switch the Truma AquaGo off and wait until the water inside the appliance has cooled. 8
1. Dismantling/installing Truma AquaGo Open the access door. Top Disconnect the power supply from the Truma AquaGo. + red 12 V DC black Cable tie Close the gas system. Disconnect the gas supply from the Truma AquaGo. Grommet 2 3 Top Close the water supply to the water system. Drain the water system (open the filter valve). Disconnect the water supply from the Truma AquaGo. 1 9
1. Dismantling/installing Truma AquaGo Undo the 8 screws around the frame of the access door. 1 8 x Cover plate Remove the access door with frame. Undo the 14 screws around the Truma AquaGo housing. 90 degrees 14 x Carefully remove or separate the sealing or adhesive material between the Truma AquaGo and the installation wall with a scraper or a knife. 10
1. Dismantling/installing Truma AquaGo Top Pull the Truma AquaGo forward out of the installation opening. Make sure that it does not catch on gas pipes, water connections or electrical connections, etc. Install in the reverse order. If necessary, use new sealing material and new screws. Check the gas system for leaks. Vent the water system. More information can be found in the installation and operating instructions. 11
2. Opening/closing the housing Required tools: Torx screwdriver T10 or T15 Place the Truma AquaGo on a flat surface. Undo the 6 screws (5 x 9.5 mm Torx 10 or Torx 15) on the top of the cover. Undo the 6 screws (5 x 9.5 mm Torx 10 or Torx 15) on the side of the cover. Remove the cover. Close the cover in the reverse order. 12
3. Replacing the exhaust pressure switch Exhaust pressure switch Part number: 77000-90100 Required tools: Torx screwdriver T10 or T15 Preparation: Switch the Truma AquaGo off. Disconnect the white and gray cables from the exhaust pressure switch. To do this, grip the plug and do not pull the cables. Undo the 2 screws (5 x 9.5 mm Torx 10) on the left and right side of the metal bracket of the exhaust pressure switch. 13
3. Replacing the exhaust pressure switch Remove the exhaust pressure switch downward from the metal bracket. The exhaust pressure switch is still connected to the fan housing with two transparent silicone tubes. Pull the silicone tubes off the exhaust pressure switch. Replace the defective exhaust pressure switch with a new one. Replace the silicone tubes as shown in the figure. Note: There are marks on the fan housing and the exhaust pressure switch to indicate the positions of the silicone tubes: P1 on P1 P2 on P2 14 Complete the installation in the reverse order.
4. Replacing the fan Flue fan assembly Part number: 77000-90200 Required tools: Torx screwdriver T10 or T15 Preparation: Switch the Truma AquaGo off. Disconnect the white plug with the blue and orange cables from the fan. To do this, press the lock on the plug together. Disconnect the green and purple cables from the temperature sensor. To do this, grip the plug and do not pull the cables. The cable harness can now be put aside from below. Pull the two transparent silicone tubes off the fan. 15
4. Replacing the fan Undo the 3 screws (5 x 9.5 mm Torx 10 or Torx 15) around the fan. Remove the fan towards the front. Replace the defective fan with a new one. Replace the silicone tubes (see Replacing the exhaust pressure switch ). Make sure that the silicone tubes are not kinked. Figure on left = wrong (kinked) Figure on right = right (smooth bend) Complete the installation in the reverse order. 16
5. Replacing the control unit Control unit assembly Part number: 77000-11300 Required tools: Torx screwdriver T10 or T15 Preparation: Switch the Truma AquaGo off. Disconnect the Truma AquaGo from the onboard power supply. Undo the screws (5 x 9.5 mm Torx 10 or Torx 15) on the wire guard* or the housing of the control unit. Remove the wire guard* towards the front. * not on all appliance variants 17
5. Replacing the control unit Disconnect the plug from the upper cable harness. Disconnect the plug from the lower cable harness. Pull the control unit slightly towards the front. Disconnect the remaining 4 cables from the control unit. Replace the defective control unit with a new one. Install in the reverse order. 18
6. Replacing the burner Burner assembly Part number: 77000-90400 Required tools: Torx screwdriver T10 or T15 Torx screwdriver T20 Open-end wrench 11/16 in. (18 mm) Open-end wrench 3/4 in. (19 mm) Required tools: Wire cutter 19
6. Replacing the burner Preparation: Switch the Truma AquaGo off. Close the gas system. Disconnect the gas supply (gas cylinder) from the system. Use the wire cutter to cut the yellow cable tie around the sealing sleeve. Use the open-end wrench (3/4 in.) to open the union nut of the gas supply pipe on the gas valve, using the second wrench (11/16 in.) as a brace. Undo the screws (5 x 9.5 mm Torx 10 or Torx 15) on the wire guard* or the housing of the control unit. Remove the wire guard* towards the front. * not on all appliance variants 20
6. Replacing the burner Remove the control unit towards the front. Disconnect all cables from the control unit. Open the black cable clip on the front left side of the burner assembly. Remove the black cable. Undo the safety screw in the middle of the transparent plug on the orange coil body. Disconnect the plug with the blue and red cables from the orange coil body. Disconnect the plugs with the orange and black cables from the blue coil body. 21
6. Replacing the burner Separate the plug connection with the brown and purple cables to the thermal fuse on the burner. Undo the two screws (Torx 20) on the front bottom of the burner assembly. Remove the complete burner assembly, including gas valve, towards the front. Replace the defective burner with a new one. Disconnect the short black ground cable from the defective burner and connect it to the new burner. Carefully slide the burner into the housing. Make sure that the flame rectification electrode does not touch the copper plate of the heat exchanger and that the burner locks into the guide rails. Complete the installation in the reverse order. When assembly is complete, check the gas system for leaks. 22
7. Replacing the flow sensor Flow sensor assembly Part number: 77000-90500 Required tools: Wrench 15/16 in. Preparation: Remove the Truma AquaGo (see Dismantling/installing Truma AquaGo ). Open the Truma AquaGo (see Opening/closing the housing ). Open the top cable clip on the flow sensor and remove the cable. Open the bottom cable clip on the mixing tank and remove the cable. 23
7. Replacing the flow sensor Separate the plug connection with the two white cables to the water temperature sensor. Separate the plug connection with the blue, red and yellow cables to the flow sensor. The plug connection has a lock. Undo the 15/16 in. union nut from the flow sensor assembly (unscrew completely). Hold the flow sensor with your free hand. Turn the flow sensor slightly to the front. Remove the black rubber seal. 24
7. Replacing the flow sensor Remove the safety clip towards the front. Remove the flow sensor from the mixing tank upward. Remove the flow sensor. Replace the defective flow sensor with a new one. Insert the black rubber seal. Complete the installation in the reverse order. The tightening torque of the union nut is 6 Nm. 25
8. Replacing the circulation pump Circulation pump, including seals Part number: 77000-90600 Required tools: Wrench 15/16 in. Preparation: Remove the Truma AquaGo (see Dismantling/installing Truma AquaGo ). Open the Truma AquaGo (see Opening/closing the housing ). Separate the plug connection of the pump cable (red-black). The plug connection has a lock. Open the lock and pull the plug connection apart. Separated plug connection. 26
8. Replacing the circulation pump Undo the first 15/16 in. union nut from the pump (unscrew completely). Hold the pump with your free hand. Undo the second 15/16 in. union nut from the pump (unscrew completely). Hold the pump with your free hand. Remove the pump. Replace the defective pump with a new one. Insert the two new black rubber seals in the pump body. Complete the installation in the reverse order. The tightening torque of the union nut is 6 Nm. 27
9. Replacing the non-return valve Non-return valve assembly can be white/blue or blue/black Part number: 77000-90700 Required tools: Wrench 15/16 in. Preparation: Remove the Truma AquaGo (see Dismantling/installing Truma AquaGo ). Open the Truma AquaGo (see Opening/closing the housing ). Undo the 15/16 in. union nut from the pump (unscrew completely). Hold the pump with your free hand. Turn the elbow piece slightly away from the pump. 28
9. Replacing the non-return valve Press the bottom black ring from the nonreturn valve upward, using long-nose pliers for example. This releases the clamping system in the valve. Remove the non-return valve with the elbow piece from the mixing tank upward. Non-return valve with elbow piece Press the other black ring from the nonreturn valve inward, using long-nose pliers for example. This releases the clamping system in the valve. Remove the elbow piece from the non-return valve. Replace the defective non-return valve with a new one. Pay attention to the arrow for the flow direction of the non-return valve. When the valve is installed, the arrow must face downward. Insert the black rubber seals in the pump body. Complete the installation in the reverse order. The tightening torque of the union nut is 6 Nm. 29
10. Replacing the filter Filter assembly Part number: 77000-90800 Preparation: Open the access door. Switch the Truma AquaGo off. Close the water supply to the water system. Press the latch upward (I). Press the lever downward (II). Remove the filter towards the front. Replace the defective filter with a new one. Insert the new filter in the filter holder. Fold the lever upward until it locks in place. Close the access door and restart the Truma AquaGo. 30
11. Replacing electrodes Electrodes Part number: 77000-91300 Required tools: Torx screwdriver T10 or T15 Remove the complete burner assembly (see Replacing the burner ). Undo the two screws (2.9 x 19 mm Torx 10 or Torx 15) on the ignition electrode. 31
11. Replacing electrodes Remove the ignition electrode towards the front. Replace the defective ignition electrode with a new one. Install in the reverse order.. 0.16 in. (4 mm) Check the gap between the electrodes. It must be 0.16 in. (4 mm). If necessary, bend the electrodes slightly. Undo the two screws (3.5 x 9.5 mm Torx 10 or Torx 15) on the right and left sides of the exhaust-gas overtemperature switch. Remove the exhaust-gas overtemperature switch. Carefully open the metal strap over the monitoring electrode a little and remove the monitoring electrode towards the front. Replace the defective monitoring electrode with a new one. Install in the reverse order. 32
12. Replacing the access door Access door standard Part number: 77001-01 No picture: Access door XS Part number: 77201-01 No picture: Access door adapter Part number: 77101-01 Required tools: Screwdriver suitable for the available screws 8 x 1 Open the access door and undo the 8 screws around the frame. Remove the access door with frame. Replace the defective access door with a new one. Cover plate Install in the reverse order. 33
Electrical Connection Diagram Flame Ignition Electrode - FIE Flame Rectification Electrode - FRE -t Power ON LED Power Switch Internal Fuse (10 A) -t Water Outlet Temperature Sensor - WOT Water Inlet Temperature Sensor - WIT Water Flow Sensor - WFS (green) ( white) (grey) (blue) (red) Ground Circulation Line Temperature -t Safety Valve Modulator Sensor - WCT * Gas Valve 12 VDC MOT Flue Fan If any of the original wire as supplied with the water heater must be replaced, it must be replaced with wire 18 AWG (** 16 AWG) - 105 C - UL1015, or its equivalent 18 AWG or 1 mm2 MWG (** 16 AWG or 1.5 mm2 MWG) (grey) (white) Exhaust Pressure Switch - EPS Water Over Temperature Switch - WOS (green) Burner Over Temp. Switch - BOS Exhaust Over Temp. Switch - EOS * only AquaGo Comfort and AquaGo Comfort Plus ( red) ( blue) (blue) (red) (red **) (orange) (yellow) (brown) (black) (black) (black) (black) Circulation Pump* (violet) (yellow) (brown) (black **) (orange) (orange) Error Code LED Anti Freeze Element * (optional) Control Panel * / Diagnosis ig. 34 35
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In case you encounter any problems, please contact the Truma Service Center at 855-558-7862 or one of our authorized service partners. For details see www.truma.net. Please have the model number and serial number (on furnace s type plate) handy when you call. In Australia, always notify the Dometic Service Centre if problems are encountered; in other countries the relevant service partners should be contacted (www.truma.com). Having the equipment model and the serial number ready (see type plate) will speed up processing. Manufacturing Truma Gerätetechnik GmbH & Co. KG Wernher-von-Braun-Straße 12 D - 85640 Putzbrunn Germany www.truma.com Sales Truma Corp 825 East Jackson Blvd. Elkhart, IN 46516 USA Toll Free 1-855-558-7862 Fax 1-574-538-2426 service@trumacorp.com www.truma.net Sales Dometic Australia Queensland 1 1 John Duncan Court Varsity Lakes QLD 4227 Australia Phone +61 (0)7 5507 6000 Fax +61 (0)7 5507 6001 Reparaturanleitung Truma AquaGo 23.02.2016 77000-00147 01 Fo 36