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Old 01-05-2022, 09:51 AM   #1
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Aqua Hot 250D control thermostat- Strike Two!

In a previous post, I described the repair of our Aqua Hot 250D ("Balloon Fest Aqa Hot Challenge"). The problem was a failed control thermostat. The solution was to replace it with a newly engineered part that should be more reliable. Unfortunately, we only got 4 months from the newly engineered part, while we got nine months from the first faulty part.

The bad news is it failed. The good news is I had ordered a spare the last time this happed. I have since replaced the part this morning and all is running straight and normal. Aqua Hot is sending me a new part, so I will have a backup.

I provided great deal of detail in my previous post on the first failure. As the saying goes, practice makes perfect. I did change one thing about the install that made it easier. Rather than using a 7/8 socket to remove and replace the thermostat, I used a 7/8in ratchet wrench instead. It worked much better in the tight space.

Long story short, if you have a similar unit, and are reasonably good with a wrench, it would be in your best interest to carry a spare. See details below from my initial post, that I hope you find helpful:

"Our Aqua Hot is the 250D. As for the control thermostat part number, it is ELE-015-011. I was told that this is a new part number and is supposed to be more reliable than the original. Time will tell, but I now have a spare.

The following are dos and don'ts:
Dos:
1.Do need a 7/8in deep socket and/or an open-end wrench to remove the thermostat. Small hands also help, but these were not available in my case.

2. Do need an adapter that screws into the exit port for fluid on Aqua Hot. This allows for connection of clear plastic hose for draining a couple gallons of Hydronic fluid into a clean container prior to removing the thermostat.

3. Do need a hand pump from an auto parts store to pump fluid back into the system after thermostat is replaced. It is important to pump back in bottom up rather than through the reservoir to avoid air bubbles. I found the best way to avoid air was to prime the hand pump by placing both suction tube and exit tube into the gallon of hydronic fluid and fill all tubing before connecting to the Aqua Hot for filling.

4. Do need to watch Utube channel "Our Next Adventure"- Troubleshooting and Fixing the Aqua Hot in our RV". This video provides a visual view of the process and parts needed above.

Don'ts:
1. Though the Aqua Hot will run using a 10-amp fuse to bypass the thermostat, I would not recommend it. Aqua Hot Technical service said we could run it for short bursts to get showers. I watched it really close and it only takes a couple minutes before hot hydronic fluid begins to bubble back up into the reservoir. If not cut off quickly, this will soon be bubbling out the overflow and has potential to damage or melt your reservoir.

2. When pumping fluid back into the Aqua Hot, be careful not to suck air back into the system. Air will cause the system to fault out and requires going through a stir process to remove air. Fortunately, we did not have to do that.

I hope this additional detail helps should anyone out there have a similar issue. Glad to respond to additional questions, should anyone have those.
Thanks,
Wayne
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Old 01-05-2022, 09:54 AM   #2
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Any response from Aqua Hot about WHY/WHAT thermostat failures??

Old design vs new engineered design??
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Old 01-05-2022, 11:03 AM   #3
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Quote:
Originally Posted by Old-Biscuit View Post
Any response from Aqua Hot about WHY/WHAT thermostat failures??

Old design vs new engineered design??
Good questions. No real answers as to what is causing the defect, nor what was changed on the new engineered part. Main comment was it was thought that the new part would address the issues. Secondly, it was mentioned that only now are they beginning to experience a few failures on the new part. Guess we are just one of the few unlucky ones.

Given our experience, I must believe there are many with similar issues.
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Old 01-07-2022, 09:50 PM   #4
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I just had Carol from rvinspectionspecialists.com who is also an Aqua hot certified tech out of PA. While my control thermostat was not bad she did explain that the issue with the bad ones was a function of the epoxy used and it not able to stand up to the heat. I think she said it was yellow vs back on the new version

My AC thermostat had broken wires so she replaced that and I bought from her a spare high limit sensor and control thermostat. If your near PA and need a knowledgeable and professional person I cannot recommend her high enough.
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Old 11-21-2022, 06:41 PM   #5
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Originally Posted by Kyle M View Post
I just had Carol from rvinspectionspecialists.com who is also an Aqua hot certified tech out of PA. While my control thermostat was not bad she did explain that the issue with the bad ones was a function of the epoxy used and it not able to stand up to the heat. I think she said it was yellow vs back on the new version

My AC thermostat had broken wires so she replaced that and I bought from her a spare high limit sensor and control thermostat. If your near PA and need a knowledgeable and professional person I cannot recommend her high enough.
I second the motion that Carol at RV Inspection Specialist is a rare find. After paying a highly recommended Aqua Hot Diesel Service Shop in Red Bay Alabama in June to perform my annual service, even though it was working fine, it started emitting dense white smoke that he assured me would just burn off and that it was just a little excessive diesel fuel from changing the filter. We really didn’t use our Aqua Hot much until the Hershey PA RV Show September 16th to heat our water while we were dry camping. By then the white smoke was much worse, and it was dripping diesel fuel. The Tiffin Aqua Hot Rep advised me to let it run for 15 minutes to try to burn off excessive fuel, and if that didn’t work, he highly recommend Carol, and stated that she was without a doubt one of the best, if not the best Aqua Hot Technicians there is. After 12 minutes, our neighbors were banging on our door because they thought our coach was on fire. I then called Carol and explained our situation and she worked me into her schedule the very next day, even though she had to work late. She made a very quick diagnosis, and not only fixed the excessive fuel issue, she also found a water leak caused by a worn out seal. I will definitely plan an annual trip to Litiz, PA to see Carol for my Annual Service
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Old 01-29-2023, 09:13 AM   #6
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How is the new part # control thermostat holding up for you? I just recently installed one in my 250D and wondering how long I should expect it to last.
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Old 01-30-2023, 03:32 AM   #7
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Originally Posted by DockmasterAK View Post
How is the new part # control thermostat holding up for you? I just recently installed one in my 250D and wondering how long I should expect it to last.
Can't speak for others, but in our case, we get 3-6 months out of each control thermostat.

Wayne
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Old 01-30-2023, 06:39 AM   #8
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Wow, that really stinks.
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Old 01-30-2023, 09:12 AM   #9
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I saw another post where someone indicated they change the T-stat by using hose pliers and don’t have to drain/fill. If this works, it would be like 10 minutes or less to change a T-stat.
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Old 01-30-2023, 09:59 AM   #10
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I saw a video that looked a little more involved. I wonder if you could'nt put a shut off valve between the aquahot and thermostat? That way you would have minimal loss of fluid. Just shut the valve and replace
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Old 01-30-2023, 12:56 PM   #11
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I saw another post where someone indicated they change the T-stat by using hose pliers and donít have to drain/fill. If this works, it would be like 10 minutes or less to change a T-stat.
This is true and what the Aqua-Hot techs do...Aqua-Hot actually sells the hose clamps on their website....I have done that operation twice ... last time replaced with the new black epoxy version and so far holding up longer than the yellow epoxy version....recommend using a powered pump instead of hand pump to refill the fluid, lot easier.
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Old 01-30-2023, 03:40 PM   #12
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FYI. I searched the forum and apparently Entegras had this problem in 2018. If you pinch the top line you can quickly swap the control thermostat with minimal loss of fluid and no need to bleed the system. Hope this helps anyone in need.
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