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Aqua-Hot 200 Series Service Manual

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SERVICE MANUAL
200
SERIES
250P and 250D

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Summary of Contents for Aqua-Hot 200 Series

  • Page 1 SERVICE MANUAL SERIES 250P and 250D...

  • Page 3: Table Of Contents

    Adjustment of the Propane Air Shutter ..... 45 Exhaust High Back Pressure Switch ......46 Fan Validation Switch ..........47 Combustion Blower Fan Buck-boost Module .... 48 Hot Surface Igniter Buck-boost Module ....49 Flame Sensor.............. 51 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 1...

  • Page 4: Introductions And Cautions

    As you read this information, take particular note of the NOTICE, CAUTION, WARNING and DANGER symbols The Aqua-Hot 250D, and 250P are hydronic (water when they appear. This information is important for safe and based) heating systems that provide interior heat and tank- efficient use of the Aqua-Hot system.
  • Page 5 • Read this service manual before installing or using the ly, a fire or explosion may result causing property damage, Aqua-Hot System to reduce the risk of injury to persons or personal injury, or death. damage to the equipment •...
  • Page 6 Section #: Title Safety Instructions and Precautions ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 4...

  • Page 7: Cross Section

    10. 3-Way Valve 11. Diesel Burner Assembly 12. Boiler Tank 13. Tempering Valve 14. Diesel Burner Controller 15. Drain Valve 16. Zone Circulation Pump 17. Access Cover Screw Figure 1 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 5...

  • Page 8: Cross Section

    9. Propane Burner Assembly 10. Tempering Valve 11. Boiler Tank 12. 3-Way Valve 13. Propane Burner Controller 14. Interlock Switch 15. Drain Valve 16. Zone Circulation Pump 17. Access Cover Screw Figure 2 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 6...

  • Page 9: Operational Flowchart

    Heat Ex- ers will not operate until changers in the Zone the Boiler Tank reaches a calling for heat minimum of 155°F ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 7...

  • Page 10: Relay Control Board

    Fuse Functions, Locations, and Ratings There are three fast-blow fuses included with this re- The relay control board at use in your Aqua-Hot 200 lay board, and may need to be replaced if they cease to func- series unit is designed to function in conjunction with the Fen- tion.
  • Page 11 When this light is on, it indicates that there is either a demand for hot water, or the Aqua-Hot is not yet up to operat- ing temperature. ©Aqua-Hot®...

  • Page 12: Interior Switch Panel

    The interior switch panel is used to control the two switch is “ON,” the electric heating element will be used to potential heating sources for the Aqua-Hot’s boiler tank. When provide heat to the boiler tank if the need arises. A cold boiler...

  • Page 13: Exhaust System Requirements

    Exhaust Requirements The exhaust must be able to freely exit away from the ve- hicle without any obstructions The Aqua-Hot’s exhaust is hot and must be kept away from • Use standard two-inch automotive type exhaust piping any heat-sensitive material. Therefore, the exhaust system and avoid bends if possible.

  • Page 14: Aqua-Hot Components

     Release the interlock switch from the Aqua-Hot cabinet by Replacement parts can be ordered online through pushing in on the locking tabs and pulling the interlock Aqua-Hot’s webstore.

  • Page 15: Expansion Bottle Fluid Sensor

    +1 (800) 685-4298. Troubleshooting  Using a hose clamp, clamp off the connection between  Verify that the Aqua-Hot’s expansion bottle is full of anti- the expansion bottle and the fluid return port as depicted freeze and water heating solution below. ...

  • Page 16: Control Thermostat

    The Aqua-Hot is the control thermostat. considered to be at operating temperature between 155°F and 188°F.
  • Page 17 Failure to disconnect all power supplies and/or allow the thermostat unit to cool before servicing could cause serious damage 8. Refill the Aqua-Hot’s boiler tank with anti-freeze and water and/or personal injury. heating solution. 9. Refill the Aqua-Hot using an external fill pump, filling 1.

  • Page 18: Ac High Limit Thermostat

    2. Ensure that the unit has been shut down, and cooled completely before continuing. 3. Shut off the coach-side power breaker to the Aqua-Hot 4. Disconnect the 3-pin AC Molex plug from the AC relay en- closure. Leave the DC power supply connected.
  • Page 19 8. Butt-splice a new AC high-limit thermostat to the stripped wire 1. Shut off gas, electric and water supply to the Aqua-Hot. 9. Re-install the AC high-limit thermostat using a 5/8” sock- 2. Disconnect the domestic water inlet and outlet line fittings et or crow’s foot...

  • Page 20: Burner High Limit Thermostats

    Replacement Procedure tion by interrupting the power signal (left thermostat,) and the  Ensure that the Aqua-Hot has been completely shut down, fan validation signal (right thermostat.) all power sources disconnected, and the unit is allowed to cool completely before continuing...

  • Page 21: Low Temperature Cutoff Thermostat

    If the LTCO indicator light does not illuminate when do- heating feature when domestic hot water is being used. This mestic water is being used, or when the Aqua-Hot falls ensures that even heat is provided for domestic hot water, below operating temperature, complete the following;...
  • Page 22 1. Ensure that the Aqua-Hot has been completely shut down, and that all the power sources have been disconnected 2. Locate the low-temperature cutoff thermostat on the Aqua -Hot 3.

  • Page 23: 3-Way Valve

    Aqua-Hot Components 3-Way Valve Scope The Aqua-Hot has a 3-way directional valve to control coolant priority within the Aqua-Hot. This ensures that there will be a supply when heated water is being called, but can provide interior heating when the need arises.
  • Page 24 Connect to wire and/or personal injury. #21 “Faston” connector.  Ensure that the Aqua-Hot has been completely shut down, Crimp a female 22-18AWG “Faston” connector to the that all power sources have been disconnected, and that green/black wire of the three way valve.

  • Page 25: Tempering Valve

    Using a back-up wrench, unscrew the tempering valve a lack of hot water and may result in scalding. Do NOT at- from the Aqua-Hot. Failure to use a back-up wrench could tempt to adjust the tempering valve without assistance from result in damage to the cold water inlet pipe.

  • Page 26: Stir Pump

    - If the pump operates with 12V DC applied, begin diagnosing the relay control board. - If the pump does not operate with 12V DC directly applied to it, the pump will need to be replaced. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 24...
  • Page 27 9. Connect the wires to the replacement pump 1. Ensure that the Aqua-Hot has been completely shut down, 10. Refill the boiler tank with a 50/50 mixture of propylene- all power sources have been disconnected, and that the...

  • Page 28: Ac Electric System

    1. Switch both the electric, and burner switches to the “OFF” position. If the boiler tank is above 155°F, the Aqua-Hot is up at 2. Allow the unit to cool completely. operating temperature, and will not request heat.
  • Page 29 Aqua-Hot molex terminal. 9. Refill the Aqua-Hot boiler tank with a 50/50 mix of anti- - Resistance should be between approximately 11 freeze and distilled water heating solution.

  • Page 30: Aqua-Hot 250P System Features

    Recreational Vehicle Industry Association’s (RVIA) ANSI/NFPA 1192 Handbook for Recreational Vehicle Standards. To receive a Note: The product label attached to each Aqua-Hot pro- copy of this handbook and other pertinent RVIA Standards, write to: vides a ready reference to specifications, test standards, Recreation Vehicle Industry Association, 1896 Preston White Drive, and important safety notices.

  • Page 31: Propane Burner Overview

    The propane burner operates on standard, readily available propane found at a local propane store. The Aqua-Hot’s propane burner is the heart of the Aqua-Hot The burner itself contains six user-serviceable components unit. The propane burner is the device which ignites, and sus- that can be repaired, or replaced as part of standard service, tains the combustion of a propane-air mixture.

  • Page 32: Propane Burner Operational Flow Chart

    8. The Flame Sensor verifies that a 13. The Dual-Stage Gas Valve is flame is present. 10 seconds deactivated. 14. A 90-second Purge Cycle takes place. 9. Hot surface igniter is de-activated. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 30...

  • Page 33: Propane Switch Panel

    8-pin Harness Plug 2-pin AC Control Switch Plug Manufacturer: TE Connectivity Manufacturer: TE Connectivity Mating Part No: 163007 Mating Part No: 180907 Common name: 8-Way Fastin Receptacle Common Name: Fastin-Faston Series ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 31...

  • Page 34: Propane Fenwal Control Card

    The purpose of the Fenwal card is to control the pro- 9. Move the burner switch, located on the interior switch pane burner. Please note that the Aqua-Hot 250P units are panel to the “ON” position. absent a unified “controller” as it is traditionally known, and...

  • Page 35: System Schematic

    Section #: Title 250P System Schematic Figure 32 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 33...

  • Page 36: Detaching The Propane Burner

    “PWR.” burner from the Aqua-Hot. Failure to do so before service 12. Set the Fenwal control card and the steel enclosure aside. may lead to unit damage and/or personal injury.
  • Page 37 16-pin connector from its mate on the relay control board. 14. Carefully remove the clear tubing from the pressure switch located on the right side of the Aqua-Hot cabinet. Figure 38 15. Continue to carefully remove the diesel burner from the Aqua-Hot cabinet.

  • Page 38: Re-Attaching The Propane Burner

    11. Using a 1/2” socket and extension, re-secure the propane these replacement gaskets and prep them to be installed. burner to the mounting studs on the Aqua-Hot tank face. 2. Slide the combustion chamber, and the old gaskets for- It may be necessary to use a swivel fitting to gain access ward until they are completely removed from the Aqua- to all mounting hardware.
  • Page 39 24. Secure these ground wires with the previously removed 3/16” nuts atop the propane burner sub-assembly. Figure 43 25. Reconnect the Aqua-Hot to a propane source to check for leaks in the propane fittings. 26. Open the propane ball valve on the Aqua-Hot, and open any propane shut-off valves present within the coach.

  • Page 40: Propane Burner Mounting Gasket

    Section #: Title Propane Burner Components Mounting Gasket The Aqua-Hot operates on both AC and DC power. Be sure to disconnect the 120V AC power supply from the Aqua-Hot Mounting prior to servicing. Failure to do so could result in serious Gaskets personal injury, electrical shock, or even death.

  • Page 41: Hot Surface Igniter

    - If the amp-draw is less than 1.5A, replace the hot surface igniter. The Aqua-Hot operates on both AC and DC power. Be sure to disconnect the 120V AC power supply from the Aqua-Hot prior to servicing. Failure to do so could result in serious personal injury, electrical shock, or even death.
  • Page 42 1. If not done so already, shut off all power sources to the Aqua-Hot 2. Turn off the propane at the ball valve atop the Aqua-Hot. 3. Remove the access cover of the Aqua-Hot to gain access to internal components.

  • Page 43: Refractory Insulation

    30 ft/lbs. 11. Test the Aqua-Hot for proper operation The Aqua-Hot operates on both AC and DC power. Be sure to disconnect the 120V AC power supply from the Aqua-Hot prior to servicing. Failure to do so could result in serious personal injury, electrical shock, or even death.

  • Page 44: Dual Stage Propane Gas Valve

    - If voltage is not present at the gas valve, inspect the wiring harness for damage. 6. If voltage is present, but the gas valve is non-functioning replace the dual-stage gas valve. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 42...
  • Page 45 Backing Wrench Here Tighten Fitting Figure 52 12. Tighten the bulkhead fitting to the Aqua-Hot cabinet. Figure 50 Backing Wrench Here 7. Remove the fittings present at the top and bottom of the dual-stage propane gas valve as shown below.

  • Page 46: Propane Combustion Blower Fan

    9. Using a 3/8” socket, secure the now repaired assembly to the top of the propane burner. 10. Reconnect the wires of the blower fan to the buck-boost module. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 44...

  • Page 47: Adjustment Of The Propane Air Shutter

    3. While holding the bit in place, tighten the set screw. 4. Remove the drill bit and ensure that the air shutter is se- cure. Set Screw 0.275” Figure 57 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 45...

  • Page 48: Exhaust High Back Pressure Switch

    “back-flows” 3. Remove the defective switch into the cabinet of the Aqua-Hot, or if there is an obstruction or 4. Secure the replacement switch to the side of the propane damage to the exhaust system.

  • Page 49: Fan Validation Switch

    5. Remove the defective switch. 6. Secure the replacement switch to the side of the Aqua-Hot NOTE: The interlock switch will inhibit the operation of the cabinet in place of the defunct component.

  • Page 50: Combustion Blower Fan Buck-Boost Module

    NOTE: There are two buck-boost converters at use within the propane units of the 200 series. Reference figures 62 and 64 to ensure that you are troubleshooting the correct mod- ule.

  • Page 51: Hot Surface Igniter Buck-Boost Module

    - If the buck-boost converter does not output approximately 12.5V DC if the supply voltage is between 11V DC and 15V DC, the buck-boost will need to be replaced. Figure 65 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 49...
  • Page 52 1. Move all switches on the interior switch panel to the “OFF” module. position. - Connect the Hot Surface Igniter wires to the 2. Disconnect the Aqua-Hot from any power source. side labelled “OUT.” 3. Locate the buck-boost module which is to be replaced. Blower Fan 4.

  • Page 53: Flame Sensor

    0.7µA or higher while a flame is established. NOTE: If the multi-meter reads below “0” on scale, the meter Figure 68 leads have been reversed. Disconnect power, and reconnect the meter leads to record the proper polarity. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 51...
  • Page 54 Procedure: 1. Disconnect the Aqua-Hot from any and all electric sources. 2. Ensure that the Aqua-Hot has had adequate cool-down time if the unit has been recently run.

  • Page 55: Aqua-Hot 250D System Features

    Section #: Title Diesel System Features Note: The product label attached to each Aqua-Hot provides a ready reference to specifications, test standards, and im- portant safety notices. Diesel Burner Heat Input (Firing Rate) ....55,000 BTU/hr ± 10% Continuous Fuel Consumption ......0.40gal/hr Electric Heating Element Specifications ..........

  • Page 56: Diesel Burner Overview

    The diesel burner serves as the primary heating source for the er will also possess a unique identifying label with information Aqua-Hot 250D. The diesel burner is responsible for mixing such as specifications, and a serial number. and igniting diesel fuel within the combustion chamber. Heat 1.

  • Page 57: Diesel Burner Operational Flow Chart

    Continuous hot heating loop. to be reheated. water is supplied to the faucet Heat exchanger fans Zone thermostat activate. calls for heat ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 55...

  • Page 58: Diesel Switch Panel

    12- Pin Mate-N-Lock receptacle, differing from the 250P. Receptacle Housing Information Mfg: TE Connectivity Mating Part No: 1-480709-0 Common Name: Mate-N-Lock Wire Insertion View Shown ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 56...

  • Page 59: System Schematic

    Section #: Title Diesel Burner Figure 72 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 57...

  • Page 60: Diesel Burner Controller

    Aqua-Hot. Thermostat Input (White) Replacement Procedure Thermostat Output (Orange) 1. Disconnect the Aqua-Hot from any and all power sources. Block C 2. Using a 3/8” socket, remove the two bolts on the left side Function...
  • Page 61 Test for continuity page, Section A to con- Replace this controller across pins C4 and C9 at the controller. If con- tinue. tinuity exists, replace this controller. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 59...
  • Page 62 Is voltage present at pin C2 This controller will need to be as described above? replaced. Begin troubleshooting the Can you hear the fuel sole- solenoid on page 68. noid opening? ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 60...

  • Page 63: Disassembly Of Burner Componentry

    1. Disconnect the Aqua-Hot from any and all electrical sources. 8. Remove the remaining two nuts from the right side of the 2. Remove the access cover from the front of the Aqua-Hot. diesel burner assembly. 9. Disconnect the blower fan by separating the wires at the 3.

  • Page 64: Re-Assembly Of Burner Componentry

    Take care to ensure that wires are correctly reconnected to the Aqua-Hot harness. Failure to correctly reconnect these wires may result in damage to the Aqua-Hot and/or the en- closed components. 6. Reconnect the plugs to of the diesel burner controller to the wiring harness present within the Aqua-Hot.

  • Page 65: Detaching The Diesel Burner

    Scope: This section details how to safely remove, and re- install the diesel burner found on the Aqua-Hot 250D. It may be necessary to perform this procedure for repair and mainte- nance. Be sure to move the Burner switch on the interior switch panel to the “OFF”...
  • Page 66 Reference figure 82 below. Figure 82 13. Disconnect wires #2 and #8 from the high-limit thermo- stats 14. Carefully remove the diesel burner assembly from the Aqua-Hot cabinet. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 64...

  • Page 67: Re-Attaching The Diesel Burner

    9. Re-install the heater cover and test for normal operation. Figure 84 4. Reconnect wires #6 and #8 to the left and right high-limit thermostats. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 65...

  • Page 68: Diesel Igniter Module

    Figure 89 10. Follow the instructions on page 62 to re-insert and re- secure the diesel burner head. Figure 88 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 66...

  • Page 69: Ignition Coil

    Purpose: The ignition coil functions as a voltage transformer to provide adequate voltage to the igniter electrodes thereby igniting the diesel fuel cone within the Aqua-Hot’s combustion chamber. Troubleshooting Procedure: 1. Move the burner switch, located on the interior switch Figure 90 panel to the “OFF”...

  • Page 70: Diesel Fuel Delivery System

    - The motor operates with excessive noise - The motor operates with excessive heat 3. Follow the directions on page 61 to remove the diesel- - The in-line fuse of the Aqua-Hot continually burns burner head 4. Using a 7/16” wrench, and an additional backing wrench The fuel pump must be replaced if it meets any of the follow- of the same size, remove the fuel nozzle.

  • Page 71: Diesel Combustion Blower Fan

    Failure to correctly orient the blower fan will result in com- 6. Disconnect the blower fan from the buck-boost module, bustion exhaust venting into the Aqua-Hot cabinet, and and apply 12V DC directly to the fan. It should reach full could result in serious personal injury.

  • Page 72: Adjustment Of The Diesel Air Shutter

    Follow the steps below in order to correctly set the diesel air shutter. 1. Remove the access cover from the Aqua-Hot to gain ac- cess to the air shutter. 2. Using a Philips head screwdriver, loosen, but do not re- move the adjustment screw located at the top of the air shutter.

  • Page 73: Combustion Blower Fan Buck-Boost Module

    11V DC and 15V DC. - If the buck-boost converter does not output approximately 13.5V DC if the supply voltage is between 11V DC and 15V DC, the buck-boost will Figure 97 ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 71...
  • Page 74 Procedure: 15. Test the unit for normal operation. 1. Before removing the defunct buck-boost module from the Aqua-Hot, the replacement buck-boost must first be set to the correct output voltage. Voltage IN 2. Locate the new buck-boost, and a multi-meter. Set the meter to measure for voltage.

  • Page 75: Photo-Eye

    11. Using a 5/32” Allen wrench, secure the photo-eye to the tions under the correct conditions, it will need to be re- fuel tower on the burner head sub-assembly as shown on placed. the next page ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 73...
  • Page 76 13. Using a 1/4” wrench or socket, re-secure the blower fan and the air shutter in place. 14. Follow the instructions on page 62 to re-install the diesel burner head into the Aqua-Hot. 15. Test the unit for normal operation. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 74...

  • Page 77: Diesel Burner Annual Service

    Purpose: nance, it may be necessary to scrub excess carbon buildup from the air swirler and/or the combustion cham- Every Aqua-Hot 250D is equipped with a diesel burner ber. which serves as the primary heat source. This burner will need to be serviced annually in order to ensure optimal perfor- mance.
  • Page 78 Reference the figure below to properly position the igniter in place. Figure 107 3. Follow the directions on page 62 to reinstall the diesel burner head. 4. Test for unit operation. ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 76...

  • Page 79: Filling The Aqua-Hot

    3-way valve Procedure: • Fluid expansion bottle 1. Attach an external fill pump and hose to the Aqua-Hot at • Control thermostat the ball valve located just above the 3-way valve. Ensure that the hose is of adequate length to allow the easy •...

  • Page 80: Winterizing And De-Winterizing The Aqua-Hot

    Purpose: the coach. During winter months it is highly recommended that the Aqua-Hot be winterized due to the possibility of freezing 2. Ensure that all of the interior faucets have been re- temperatures causing damage to the Aqua-Hot. Damage re- opened.

  • Page 81: Troubleshooting

    Once these components have been diagnosed, restart searching for any damaged, or disconnected wires. Recon- the Aqua-Hot and allow it to heat itself to operating tempera- nect, or repair any damaged wires found. ture. Once that’s been done, draw hot water to determine if •...

  • Page 82: 250D Unit Smoke

    - Damaged wiring Black Smoke Troubleshooting Procedure: - A malfunctioning control thermostat 1. Ensure that the Aqua-Hot is receiving 12V DC power from 2. Diagnose the control thermostat by testing for continuity. the coach. Reference page 13 for detailed instructions. Test the unit after this is complete.
  • Page 83 8. Diagnose the fuel delivery system. Reference page 66. 9. Visually inspect the inside of the combustion chamber for any warping or apparent heat damage. 10. Remove the diesel burner from the Aqua-Hot with the di- rections found on page 61. Ensure that all of...

  • Page 84: Lack Of Interior Heat

    17 to diagnose, and if necessary, re- outline common reasons for overall unit non-function which pair it exist outside of the Aqua-Hot. Stage 2 will diagnose common • Test for unit operation. issues within the Aqua-Hot, including lack of burner operation.

  • Page 85: Burner Troubleshooting

    As always, if you require additional assistance in diag- place one or both of them. nosing problems with your Aqua-Hot, please contact our tech- 11. Verify the functionality of the diesel fuel delivery system by nical support department at +1 (800) 685-4298.

  • Page 86: Propane Burner Troubleshooting

    47. 13. Troubleshoot the Fenwal Control Card referencing page 14. Follow the instructions on page 33 to remove the propane burner from the Aqua-Hot. This will grant access to compo- nents for troubleshooting. Figure 112 ©Aqua-Hot®...

  • Page 87: Anti-Freeze Heating Solution

    Although RV and Marine antifreeze is often “GRAS” transport medium for the Aqua-Hot, transferring heat from the approved by the FDA, it should never be used in the Aqua-Hot internal heating sources to the heat exchangers at use within hydronic heating system.
  • Page 88 Another major function of antifreeze is to provide pro- Antifreeze Terms and Mixture Ratio: tection to the internal metal components of the Aqua-Hot hy- The following information addresses the process of dronic heating system from corrosion and rust. Antifreeze is...

  • Page 89: Measuring Propylene Glycol Concentration

    Application of Propylene Glycol Boundary Line Adjust to 32°F Lower White Field Poor Poor Good ©Aqua-Hot® 200 Series Propane and Diesel Service Manual p. 87...
  • Page 90 SERVICE MANUAL SERIES Aqua-Hot Heating Systems, Inc. 7501 Miller Drive, Frederick, CO 80504 Visit us on line at www.aquahot.com Call us at (800) 685-4298 or (303) 651-5500 ©2018 Aqua-Hot Heating Systems Inc. Printed In U.S.A.

This manual is also suitable for:

250p250d

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