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  #1  
Old 1 Week Ago
Flyfisher Flyfisher is online now
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Default Aqua Hot 12VDC Controller Mod

Replaced the original Webasto controller and igniter with 12 VDC units made by Beckett. The replacements have tested satisfactorily the last couple of days, but time will tell if they are the right choice. I wired them into the Aqua Hot and the Wesbasto burner exactly like the instruction schematic described. The only change I made to the control circuit was the addition of a Bosch relay in the dash light circuit to receive an alarm signal from the controller and break ground so it goes out when controller senses a fault and turns off the burner. The dash light functions as original, being lit when hydronic heat switch is closed and off when the switch is open or a fault occurs. The relay circuit can be left out if you want the dash light on all the time the switch is closed with or without a fault. The B zone recirculation pump circuit is still powered from the burner motor circuit, just from a new terminal strip point instead of locally at the motor connections.

In my WB there is a shelf attached to the bay ceiling just at the north end of the Aqua Hot. This made a perfect mounting spot for the controller and the igniter and all wires drop straight down into the Aqua Hot in an area where nothing is stored that might impact the wiring. I left plenty of slack wire so removing and servicing the burner will be easy. I found that when I opened up the burner all the original wiring insulation was brittle, cracked and bare in spots, so I completely rewired it with long wire back to my terminal strip with no butt splices. You can also reuse your Webasto igniter if you choose, but I decided to go ahead and complete the swap out rather than later when it fails.

I attached a schematic I drew for review and anyone interested. Also, Clint if you're interested, maybe you could make a nice one from it (hint). Hand drawing it wore me out, I made so many errors that had to be corrected.

The Beckett controller comes with preset factory settings that can only be changed with a programming tool, which they sell for about $60. You can choose the settings you want by the part number though and not worry about change.

Here are the Beckett components I used:

Controller: P/N 7556P152MU
https://www.beckettcorp.com/product/...urner-control/

Igniter: P/N 5218301U
https://www.beckettcorp.com/product/...-oil-igniters/

Total cost of Becket components $240.00. The 22C Bosch relay came with the bus was removed from my Jake brake circuit to make it function correctly, so its been looking for a home, I won't talk about how much it has cost me!

There will be a Webasto controller and igniter for sale soon, too!
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Attached Files
File Type: pdf Aqua Hot Schematic.pdf (40.4 KB, 54 views)
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Randy Dupree Randy Dupree is offline
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Very interesting!
Thanks for posting and giving up the part numbers etc.
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Jim Brookshire Jim Brookshire is offline
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Great find Andy. Where are you buying the parts?
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Jim Brookshire Jim Brookshire is offline
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forget my previous post, I found several vendors on line.
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Flyfisher Flyfisher is online now
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I can't take credit for sourcing, that belongs to another. Patriot Supply had the best price, but I didn't meet the minimum order for shipping, so that was another $13.
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rshrimp rshrimp is offline
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Very Nice! Your work is very clean. That install looks factory (If it was built in a Ferrari factory)
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This is great info, one of the first projects on my new WB is addressing a messed up Aqua Hot. Thanks Andy.
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Andy, you did an expert installation on the Beckett 12 VDC controller and igniter...looks better than factory! All the original functionality was retained and more importantly the replacement parts are available at many distributors nationwide for a reasonable cost. You are to be commended.

https://www.beckettcorp.com/product-category/controls/

https://www.beckettcorp.com/contact/distributors/
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Old 6 Days Ago
Flyfisher Flyfisher is online now
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Thank you all for the generous commendations. This job took several days to complete, although it should have been done in less, but it was one of my typical first time jobs with many trips to NAPA, Home Depot, etc. and not to mention rework due to bad judgement, it was a PITA! In the end though I believe it will have been worth it.
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1996 WB42
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Randy Dupree Randy Dupree is offline
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Andy,what did you use for ignition wires?
From the new coil/igniter?
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