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Aqua-Hot 250D - User Manual

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SERVICE MANUAL
200SERIES
250P and 250D

Table of Contents

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Summary

Introduction and Cautions

About the Aqua-Hot 250 D and 250 P

Hydronic heating systems providing interior heat and continuous hot water.

Caution Notes

Explains the meaning of NOTICE, CAUTION, WARNING, and DANGER symbols.

Safety Instructions and Precautions

General Safety Warnings

Covers fire/explosion risks, pressure, and hot exhaust warnings.

Operating Safety Guidelines

Key safety points for operation and gas smell procedures.

Operating Instructions and Safety Labels

Appliance Operation Notes

Appliance operates on AC/DC power; use specific antifreeze.

Safety and Operational Procedures

Key safety points for operation and turning off gas.

System Operation

Operational Flowchart

Diagram illustrating the heating system's operation sequence.

Relay Control Board Components

Relay Control Board Functions

Details the functions and components of the relay control board.

Interior Switch Panel Operation

Burner and Electric Switches

Operation and reset procedure for burner/electric switches.

Exhaust System Requirements

Exhaust System Installation Guidelines

Guidelines for safe installation and routing of the exhaust system.

Carbon Monoxide Hazard Warning

Warning about Carbon Monoxide (CO2) from heater exhaust.

Component Troubleshooting - Interlock Switch

Interlock Switch Function

Safety switch preventing operation without the access cover.

Interlock Switch Replacement

Steps to replace the interlock switch.

Component Troubleshooting - Expansion Bottle Sensor

Expansion Bottle Fluid Sensor

Monitors fluid level in the expansion bottle.

Component Troubleshooting - Control Thermostat

Control Thermostat Function

Monitors boiler tank temperature for heating control.

Component Replacement - Control Thermostat

Control Thermostat Replacement Procedure

Steps to replace the control thermostat.

Component Troubleshooting - High-Limit Thermostats

AC High-Limit Thermostat

Safety measure for the electric heating element.

Component Replacement - AC High-Limit Thermostat

AC High-Limit Thermostat Replacement Procedure

Steps to replace the AC high-limit thermostat.

Component Troubleshooting - Burner High-Limit Thermostats

Burner High-Limit Thermostats

Safety measure for the burner operation.

Component Troubleshooting - Low-Temperature Cutoff Thermostat

Low-Temperature Cutoff Thermostat

Prioritizes domestic hot water over interior heat.

Component Replacement - Low-Temperature Cutoff Thermostat

LTCO Thermostat Replacement Procedure

Steps to replace the low-temperature cutoff thermostat.

Component Troubleshooting - 3-Way Valve

3-Way Valve Function

Controls coolant priority between hot water and interior heat.

Component Replacement - 3-Way Valve

3-Way Valve Replacement Procedure

Steps to replace the 3-way valve.

Component Troubleshooting - Tempering Valve

Tempering Valve Function

Mixes hot and cold water for consistent output temperature.

Component Replacement - Tempering Valve

Tempering Valve Replacement Procedure

Steps to replace the tempering valve.

Component Troubleshooting - Circulation Pump

Circulation and Stir Pump

Circulates fluid for heating and stirs tank contents.

Component Replacement - Circulation Pump

Circulation Pump Replacement Procedure

Steps to replace the circulation pump.

Burn Hazard Warning

Warning about hot coolant and surfaces.

Component Troubleshooting - AC Electric System

AC Electric System Function

Provides supplementary heat using an electric element.

Component Troubleshooting - AC Electric System (Continued)

Component Replacement - AC Electric System

AC Electric Element Replacement Procedure

Steps to replace the electric heating element.

Propane System Features Overview

Propane Burner Specifications

Technical specifications for the propane burner.

Propane Burner (250 P) Details

Propane Burner Overview and Components

Details the function and components of the propane burner.

Propane Burner Operation

Propane Burner Operational Flow-Chart

Illustrates the propane burner's operational sequence.

Propane Switch Panel

Jumper Wire Installation Warning

Warning about incorrect jumper wire installation.

Fenwal Control Card

Fenwal Control Card Function and Purpose

Purpose of the Fenwal card in controlling the propane burner.

Fenwal Control Card Troubleshooting

Steps to troubleshoot the Fenwal control card.

Propane Burner Removal

Detaching the Propane Burner Procedure

Instructions for safely removing the propane burner.

Propane Burner Re-installation

Re-install the Propane Burner Procedure

Instructions for reinstalling the propane burner.

Propane Burner Components - Mounting Gasket

Gas Supply Caution

Caution to shut off gas supply before replacement.

Propane Burner Components - Hot Surface Igniter

Hot Surface Igniter Function and Purpose

Functions to ignite the propane/air mixture.

Hot Surface Igniter Handling Caution

Caution regarding the hot surface igniter.

Propane Burner Components - Hot Surface Igniter (Continued)

Hot Surface Igniter Replacement Procedure

Steps to replace the hot surface igniter.

Propane Burner Components - Refractory Insulation

Power Disconnect Danger

Danger of electric shock from power supplies.

Propane Burner Components - Refractory Insulation (Continued)

Propane Burner Components - Dual-Stage Gas Valve

Propane Burner Components - Dual-Stage Gas Valve (Continued)

Propane Burner Components - Combustion Blower Fan

Propane Burner Components - Air Shutter Adjustment

Propane Burner Components - Exhaust Back Pressure Switch

Propane Burner Components - Fan Validation Switch

Propane Burner Components - Buck-Boost Converter (Blower Fan)

Propane Burner Components - Buck-Boost Converter (Igniter)

Propane Burner Components - Buck-Boost Module Replacement

Propane Burner Components - Flame Sensor

Propane Burner Components - Flame Sensor Replacement

Diesel System Features Overview

RV;Marine Antifreeze Warning

Warning not to use RV/Marine antifreeze in the system.

Diesel Burner Operation

Diesel Burner System Schematic

Diesel Burner Components - Burner Controller

Diesel Burner Controller Troubleshooting

Diesel Burner Controller Troubleshooting (Continued)

Diesel Burner Components - Burner Head Disassembly

Diesel Burner Components - Burner Head Re-assembly

Diesel Burner Removal and Re-installation

Power Disconnect Warning

Warning about disconnecting power before service.

Diesel Burner Re-installation

Diesel Burner Components - Igniter Module

Diesel Burner Components - Ignition Coil

Electric Hazard Danger

Danger of electric shock during testing.

Diesel Burner Components - Fuel Delivery System

Diesel Burner Components - Fuel Pump Troubleshooting

Diesel Burner Components - Combustion Blower Fan

Blower Fan Orientation Warning

Warning about correct blower fan orientation.

Diesel Burner Components - Combustion Blower Fan Replacement

Diesel Burner Components - Buck-Boost Converter (Blower Fan)

Diesel Burner Components - Buck-Boost Module Replacement

Diesel Burner Components - Photo Eye

Diesel Burner Components - Photo Eye Replacement

Diesel Annual Service

Diesel Annual Service - Re-assembly

Solution Fill and Purge Procedures

Winterization and De-winterization

Troubleshooting - General Issues

Troubleshooting - Specific Unit Issues

Troubleshooting - Smoke Issues

Troubleshooting - Interior Heat Issues

Troubleshooting - Burner Issues

Troubleshooting - Burner Issues (Continued)

Antifreeze Heating Solution - Selection and Properties

Propylene Glycol Safety Warning

Danger of using non-GRAS propylene glycol.

Antifreeze Heating Solution - Terms and Properties

Antifreeze Measurement

Aqua-Hot 250D Specifications

General IconGeneral
Model250D
TypeHydronic Heating System
Fuel TypeDiesel
Heating Capacity25, 000 BTU/hr
BTU Output (Burner)25, 000 BTU/hr
Number of Zones3
Electrical Requirements12V DC
Voltage12V DC
Hot Water CapacityContinuous

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