Hayward H150FDAU Service & Installation Manual
Hayward H150FDAU Service & Installation Manual

Hayward H150FDAU Service & Installation Manual

Pool and spa/hot tub heaters
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H150FDAU, H250FDAU, & H400FDAU MODELS
SERVICE & INSTALLATION MANUAL
FOR YOUR SAFETY
WARNING: If the information in these
instructions is not followed exactly, a fi re or
explosion may result causing property damage,
injury, or death.
- Do not store or use gasoline or other fl am-
mable vapors or liquids in the vicinity of this
or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.
Do not touch any electrical switch; do not use
any phone in your building.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
If you cannot reach your gas supplier, call the
fi re department.
- Installation and service must be performed by
a qualifi ed installer, service agency, or the
gas supplier.
This product must be installed and serviced by authorized personnel, qualifi ed in pool/
spa heater installation. Improper installation and/or operation can create carbon monoxide gas
and fl ue gases that can cause serious injury, property damage, or death.
See www.haywardpool.com/patent for U.S. and
Canadian patent information
POOL AND SPA/HOT TUB HEATERS
FOR USE IN AUSTRALIA
FOR YOUR SAFETY
1301272601 Rev E 0515

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Summary of Contents for Hayward H150FDAU

  • Page 1: What To Do If You Smell Gas

    POOL AND SPA/HOT TUB HEATERS H150FDAU, H250FDAU, & H400FDAU MODELS FOR USE IN AUSTRALIA SERVICE & INSTALLATION MANUAL FOR YOUR SAFETY WARNING: If the information in these instructions is not followed exactly, a fi re or explosion may result causing property damage, injury, or death.
  • Page 2: Table Of Contents

    Heat exchanger inspection and cleaning ..35 Combustion chamber ........35 Heat exchanger removal ......35 Burner inspection and cleaning ....36 Burner removal and replacement ....36 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 3: Safety Information

    In addition, the licensed electrician must also conform to AS/NZS 3000 Wiring Rules and local electrical codes for bonding requirements. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 4 • Install two or more suction outlets per pump in accordance with AS 1926.3 current edition. Follow all applicable National, State, and Local codes. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 5 WARNING – Failure to install according to defi ned instructions may result in severe personal injury or death. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 6 - An abbreviation of Kilopascal Main Drain – See Suction Outlet PSI – An abbreviation for pounds per square inch. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 7: Section I General Information

    WARNING: Premature Heat Exchanger Damage or Failure The heat exchanger in your Hayward pool heater is made from the highest quality of copper and nickel (Cupronickel) materials. The premium materials and the exacting processes used in the manufacture of the heat exchanger is state of the art in pool heater design and manufacture.
  • Page 8 Refer to pages 19 and 20 for further information. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd.
  • Page 9: Section Ii Installation

    fi tting regulations, municipal building codes, electrical wiring regulations, local water supply regulations, AS 5601.1 (current edition) - Gas Installations and any other statutory regula- tions. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 10 422 MJ/h Natural/Propane 92.7 cm 89 kg 61.0cm 35.2cm WIDTH FRONT 74.8cm 34.6cm 24.8cm 38.3cm 37.7cm 37.3cm 31.9cm 9.5cm 7.8cm 19.1cm 14.5cm LEFT RIGHT USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 11: Uncrating The Heater

    The heater must be installed such that the location of the exhaust gas vent assembly outlet relative to adja- cent public walkways, adjacent buildings, openable windows, and building openings complies with AS/NZS 5601.1 (current edition) Gas Installations and any other statutory regulations. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 12: Flooring

    4.22 MJ/h input rating of all gas appliances in the enclosure. See Table 1. FLOORING: This heater may be installed on either non-combustible or combustible fl ooring. Ultralite™ or equivalent concrete-over-foam HVAC pads are acceptable. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 13: Reversible Water Connections

    14. Reverse the above steps to reassemble the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 14 Water temperature sensor Manual Reset Sensing Bulb Upper Plastic Heater Side Panel Thermostat Control Upper Plastic Heater Circuit Board Side Panel Front Access Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 15: Gas Supply And Piping

    Line Material Iron or Plastic Pipe Iron or Plastic Pipe Iron or Plastic Pipe Gas Valve Inlet 0 to 3 m 3/4” 3/4” 3/4” USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 16 Gas Valve Inlet Line Material Iron Pipe Tubing Iron Pipe Tubing Iron Pipe Tubing 0 to 15 m 1/2” 5/8” 1/2” 3/4” 3/4” 7/8” USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 17: Natural Gas

    If doubt exists as to the meter size, consult the local gas utility for assistance. Hayward will not be responsible for heaters that soot up due to improper meter and gas line sizing resulting in improper gas volume.
  • Page 18: Water Piping

    Make sure that 1st and 2nd stage regulators are large enough to handle the MJ/h input listed for the heater(s) being used. Hayward will not be responsible for heaters that soot up due to improper gas line or propane tank siz- ing resulting in improper gas volume.
  • Page 19 fl ow rates are not maintained as specifi ed in Figure 10 under all operating conditions. The heat ex- changer will fail and this damage will not be covered under the Hayward warranty. Figure 12 illustrates a typical pool piping diagram and layout for the pool equipment.
  • Page 20: Installation Above Pool Surface

    Backsiphoning usually occurs when the pump is shut off and a pressure differential is created. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 21: Electrical Specifi Cations

    CAUTION - This heater must be connected to a bonding grid with a solid copper conductor wire gauge 8 AWG or larger. All Hayward heaters are designed for copper conductors only. Most codes require that all metallic components of a pool structure, including reinforcing steel, metal fi ttings and above ground equipment, be bonded together with a solid copper conductor wire gauge 8 AWG or larger.
  • Page 22: Electrical Connections

    Wiring Terminal Block Remote Connection Terminal Block (junction box cover not shown) (left side shown, right side is similar) Common Pool Spa (RED) (WHITE) (ORANGE) USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 23 Figure 18: Control Panel Layouts H150FDAU Control Panel Assembly (wiring not shown) H250FDAU and H400FDAU Control Panel Assembly (wiring not shown) 1. Direct Spark Ignition Controller 2. Thermostat Control Board 3. Transformer 240V Primary / 24V Secondary 4. Blower Air Pressure Switch 5.
  • Page 24 Figure 19: Wiring connection diagram. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 25: Remote Control Connection

    To deactivate the heating cycle, the user presses the “MODE” button to return to “STANDBY” mode. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 26 Figure 20: Lighting & Operating Instructions label USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 27: Section Iii Check-Out & Start-Up

    Gas supply line must be capped when not connected. After pressure testing, reconnect the gas piping to the gas valve. Turn gas supply “ON” and test all pipe and tubing joints for leaks. Use a soap and water solution. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd.
  • Page 28: Gas Pressure Testing

    “ON” position. The valve must be in the “OFF” position when the screw is removed. Removal of the screw with the gas valve “ON” could cause an explosion resulting in severe injury and/or death. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 29: Water Pressure Switch

    If the pump and piping arrangement are such that the required 6.9 kPa minimum pressure cannot be obtained, do not attempt to operate the heater. Correct the installation. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd.
  • Page 30: Temperature Adjustment

    TEMPERATURE CONTROL OPERATION: This model of Hayward gas fi red pool/spa heater is equipped with a temperature control module (TCM) and a direct spark ignition control module (DSICM) for automatically controlling pool and spa water tem- peratures. The TCM has three components, the Display/Control Board with its attached Keypad and the IO/ Power Supply Board.
  • Page 31: Retry (Failure Of Light)

    Should the gas valve later close completely removing the fl ame signal, the blower will be turned off following the post-purge period. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd.
  • Page 32: Automatic Reset Time

    5. If the heater is operating on propane gas, the tank must not fall below 30% full or damage to the heater may occur. Hayward will not be responsible for heaters that soot up due to improper gas level in the tank resulting in inadequate gas volume.
  • Page 33: Draining The Heat Exchanger

    ATTENTION: A heater damaged by freezing is not covered under the Hayward warranty. REMOVING THE DRAIN PLUG: This procedure applies to installations where the heater is located higher than the pool water level. If it is necessary to drain a pool heater located below the pool water level, you must either partially drain the pool, or isolate the pool heater from the pool using valves.
  • Page 34: Section Iv Technician Service

    Figure 19. 4. Verify proper operation after servicing. 5. After service is complete, assembly is the reverse of Steps 1-2 above. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 35: Heat Exchanger Inspection And Cleaning

    The combustion chamber is a single-piece casting. If damaged, the entire chamber must be replaced. HEAT EXCHANGER REMOVAL: Follow steps 1-12 under “External heat exchanger inspection and cleaning” in this section. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 36: Burner Inspection And Cleaning

    14. Bubbles forming indicate a leak. 15. To start the heater, follow the instructions on the label inside the front access panel (see Figure 20). USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 37: Gas Valve Replacement

    Do not place any joint compound on the fi rst two threads of any joint. 9. Complete assembly by reversing step 1-5. Figure 28: Correct orientation of components of gas manifold assembly USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 38: Igniter

    Gas conversions are to be performed only by a qualifi ed service agency. Detailed instructions are included with each kit. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 39: Electrical Wiring

    The tubing on the blower air pressure switch should be attached to the blower housing pressure tap that faces the right side of the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 40: High Limit Switch

    5. Replace the high limit switch. Use new sealant on the high limit switch threads before reinstalling. Reassembly is a reverse of steps 1-4. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 41: Thermistor

    5. Using two ½” open-end spanners, disconnect the pressure switch from the pressure switch tubing. 6. Replace the pressure switch. Use new sealant on the pressure switch threads before re-installing. 7. Reverse steps 1-5 to complete the procedure. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 42: Transformer

    6. Check the function of the bypass valve to ensure the valve fl aps rotate smoothly on the shaft, and the spring fully closes the valve. 7. Apply silicone o-ring grease (Hayward Jack’s 327 Multilube P/N SP032712, or equivalent) on o-ring seals on the bypass cartridge before inserting into the header.
  • Page 43: Section V Troubleshooting

    The fuse designations are printed on the control board. See Figure 18 on pg. 23 for component locations on the control panel. Fuses are available as common hardware items or may be purchased from Hayward in a service parts kit. The fuse specifi cations are: •...
  • Page 44 When a dot (decimal point) is displayed after the error code, this is an indication . (dot) Auto restarts disabled that auto restarts are disabled. The TCM must be manually restarted. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 45 If fuse remains OK, replace DSICM. Otherwise, board is defective. replace IOPS board and fuse F101. If fuse blows again, replace DSICM also. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 46 2. Verify that water fl ow is Verify that water fl ow rate to heater is above minimum required (75 LPM for adequate. H150FDAU, 95 LPM for H250FDAU, 115 LPM for H400FDAU). If OK, proceed to step 3. 3. Check for faulty wiring or Inspect water pressure switch wiring.
  • Page 47 If fl ame signal is not lost after gas is shut off, check fl ame sense circuit and DSICM for damage. Replace if needed. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 48 7. Check for blockages in gas Inspect gas orifi ces for blockages which could prevent gas fl ow. orifi ces and burners Remove and inspect burners for blockages. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 49: Warranty

    THIS PRODUCT REQUIRES QUALIFIED INSTALLATION All Hayward heaters due to their technical nature are only intended for sale by retail shops where local sales and technical support can be provided or as a part of a new Pool Installa on. Warranty claims for such products will only be recognised when the products have been sold and installed by technicians approved by Hayward Pool HEATING PRODUCTS Please note that warranty claims for gas Heaters are handled directly by Hayward Pool Products and are not authorised for over the counter exchanges.
  • Page 50 The faulty product is to be returned to the place of purchase or to an authorised warranty agent. Unless prior authorisa on is provided, no returns will be received directly from end consumers by Hayward Pool Products. You are responsible for arranging removal of the defec ve product and arranging installa on of the repaired or replacement product, all transporta on (and any applicable insurance costs) of transpor ng the product to the supplier and transpor ng the replaced or repaired product from the supplier.
  • Page 51 Plastic Header Models (Non-ASME) USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 52: Service Parts

    HEAT BARRIER PANEL - H150FD FDXLHBP1250 HEAT BARRIER PANEL - H250FD FDXLHBP1400 HEAT BARRIER PANEL - H400FD FDXLBBN1150AU BLOWER INLET BAFFLE - H150FDAU FDXLBBN1250AU BLOWER INLET BAFFLE - H250FDAU FDXLBBN1400AU BLOWER INLET BAFFLE - H400FDAU FDXLIAC1930AU IGNITER ACCESS COVER - AUS...
  • Page 53 CONVERSION KIT, NA TO LP, QUICK-CHANGE - H250FD (NOT SHOWN) FDXLGCK1400NP CONVERSION KIT, NA TO LP, QUICK-CHANGE - H400FD (NOT SHOWN) FDXLWHA1150AU WIRING HARNESS 50HZ H150FDAU (NOT SHOWN) FDXLWHA1400AU WIRING HARNESS 50HZ H250/400FDAU (NOT SHOWN) FDXLESC1930AU 240V ELECTRICAL SUPPLY CORD WITH STRAIN RELIEF (NOT SHOWN)
  • Page 54 GASKET, RAIN GUARD BOTTOM FRNT & REAR - H400FD GASKET, RAIN GUARD BOTTOM FRNT & REAR - H250FD GASKET, RAIN GUARD BOTTOM FRNT & REAR - H150FD USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 55: Gas Pressure

    Inlet, Minimum 1.12 2.24 Inlet, Maximum 2.61 3.24 Burner Confi guration Natural Gas Main Injector Main Burner Propane Gas Main Injector (mm) Main Burner 2.26mm USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 56 NOTES...
  • Page 57 Hayward Pool Products, Inc. Hayward Pool Products, Inc. Hayward S.A. 620 Division St. 2875 Pomona Boulevard 2880 Plymouth Drive Zoming de Jumet Elizabeth, NJ 07207 Pomona, CA 91768 Oakville, Ontario L6H 5R4 B6040 Jumet, Belgium © 2013 Hayward Printed in U.S.A.

This manual is also suitable for:

H400fdauH250fdau

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