Hayward H150FDN Troubleshooting Manual
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Hayward H150FDN Troubleshooting Manual

Universal h series heaters
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Universal H Series Heaters
Troubleshoot ing Guide
HxxxFD(N/P)
HxxxFD(N/P)ASME
TSG-UHS16b
Copyright 2017 Hayward Industries Inc.

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Summary of Contents for Hayward H150FDN

  • Page 1 Universal H Series Heaters Troubleshoot ing Guide HxxxFD(N/P) HxxxFD(N/P)ASME TSG-UHS16b Copyright 2017 Hayward Industries Inc.

  • Page 2: Safety Precautions

    Safety Precautions Warning High Voltage Electrocution Hazard Hazardous voltage can shock, burn, cause serious injury and or death. To reduce the risk of electrocution and or electric shock hazards: • Only qualified technicians should remove the panel • Replace damaged wiring immediately •...

  • Page 3: Table Of Contents

    Table of Contents ICB and Fuse Board Layout Troubleshooting (cont.): Pg. 18-64 UHS Sequence of Operation: 7. “IO” or “SB” Code 38-39 Normal/Failure to Light 8. “SF” or “HS” Code 40-41 UHS Gas and Electrical Connections 9-11 9. “PF” Code 42-43 How To: Pg.

  • Page 4: Icb And Fuse Board Layout

    Integrated Control Board Layout (ICB) Remote Control: 24VAC (E1) Flame Sensor (E4) Temperature Sensor (E2) Display Output: 24VAC (E7) 3A Fuse (F1) Low Voltage R & C: 24VAC (E12, E13) Gas Valve & Safety Switches: 24VAC (E11) High Voltage: 120VAC (E10) Blower/Inducer (E6) Ignitor (E3)
  • Page 5 Fuse Circuit Board Layout Fuse board configuration Prior to November 2010 (Older Style) Power connection for junction boxes: 120/240VAC (P1) After Aug 08 Terminal block for field wiring connections: 120/240VAC (TB1) Before Aug 08 Input Voltage Selector 240 OR 120VAC determined by plug (P2): NOTE: 240VAC plug factory installed...
  • Page 6 Fuse: (FC3) has been removed, since the F1 fuse was added to the ICB Fuse: (FC4) is now a 3A fuse, matching the FC1 & FC2 NOTE: Fuses located on THIS board are all 250v SLO-BLO 5 x 20 mm. Hayward Part # FDXLFSK19F30 (Qty. 10)

  • Page 7: Uhs Sequence Of Operation: Normal/Failure To Light

    UHS Sequence of Operation: Normal The control continually compares the set temp to the actual water temp. When the water temp is 1º below the set point the following sequence starts: The control checks for open blower vacuum switch Blower starts pre-purge cycle as the ignitor heats up (20 Sec). The control checks for a closed blower vacuum switch.
  • Page 8 UHS Sequence of Operation: Failure to Light If trial fails: Gas valve de-energizes (for 30 second, blower post purge). Starts over at #2 of heating mode sequence. Retries 3 times until lockout (IF code). Waits 60 minutes then retries 3 more times. Will continue to retry every 60 minutes, until demand for heat is stopped.

  • Page 9: Uhs Gas And Electrical Connections

    UHS Electrical & Gas Connection Electrical & Gas connections as of September of 2008 (Newer Style) Connections located on both the left & right side of heater cabinet Bonding Lug High Voltage Gas Supply Low Voltage...
  • Page 10 Electrical & Control Connections (cont.) Electrical connections as of September of 2008 (Newer Style) 120VAC or 240VAC Connection Ground connection Three Wire Remote Two Wire Remote Connection: Connection: Orange (Pool), Orange (Pool) and White (24V), & Red White (Common) (Spa). Fig.
  • Page 11 Electrical & Control Connections (cont.) Electrical connections prior to September of 2008 (Older Style) Two wire hook-up Three wire hook-up Orange (Pool) & White (24VAC, Orange (Pool), White (24VAC, Common) Common), & Red (Spa) NOTE: Control hookup located outside control box.

  • Page 12: How To

    Universal H Series Heaters® How To:...
  • Page 13 How To: Program Heater Bypass Operation Follow the included steps to place the heater in bypass mode for external control. Step 1 Step 2 Press the ‘MENU ICON’ button to place the Press and hold the minus button and ‘MENU heater in ‘STANDBY’.
  • Page 14 How To: Program Temperature Lock-Out Follow the included steps to place the heater in bypass mode for external control. Step 1 Step 2 Press the ‘MENU ICON’ button to place the Press and hold the minus & plus buttons for 3 heater in ‘STANDBY’...
  • Page 15 How To: Program Temperature Lock-Out (cont.) This feature is available on heaters manufactured after February 25 2011. Step 5 Step 6 Press the ‘MENU ICON’ button to toggle to the Raise or lower the temperature displayed ‘POOL’ now that the ‘SPA’ is set. using the minus or plus button.

  • Page 16: Test/Adjust Gas Pressure

    How To: Test/Adjust Gas Pressure Measure the inlet static pressure Measure the outlet manifold (valve off) & load pressure (valve pressure (valve on / energized), as on / energized). shown below. Step 1 Step 2 The static & load values should be Manifold reading should be within the levels listed on the data between 1.8”- 2.0”...
  • Page 17 How To: Test/Adjust Gas Pressure (cont.) NOTE: IF incoming gas pressure is within range, then your manifold pressure should be correct per factory settings. Verify heater specifications off the heater *Adjust the manifold pressure plate (bottom front inside heater) (at the gas valve) Step 3 Step 4 IF inlet pressures are correct AND the...

  • Page 18: Troubleshooting

    Universal H Series Heaters® Troubleshooting:...

  • Page 19: Diagnostic Codes And Part Numbers

    Diagnostic Codes Below is a list of all Diagnostic Codes for the UHS Heater. Troubleshooting Steps for each Code are covered on the following pages. Diagnostic Description Code Blower Vacuum Switch closed Blower Vacuum Switch open Bad board or secondary high voltage fault Communication Error Between Control Module and Display Interface Assembly Bad board Flame present with Gas Valve not energized.

  • Page 20: Troubleshooting Guide

    Troubleshooting Part Numbers The following outlines the various replacement parts required for this troubleshooting guide. Heaters made prior to 07/16 that want the new display/bezel/keypad, will need to replace the old display with the Kit-Bezel Control Panel specific to their model heater. Part Number: Part Number: Part Number:...

  • Page 21: Heater Not Powering Up

    1. Heater Not Powering Up Inspect wires & Heater not Test FC1 & Is either Correct voltage connections, powering up FC2 fuses fuse blown? selector plug? are they OK? Replace harness Test transformer input Go to: Install correct Is incoming and/or reseat for 110-125VAC Section 2...
  • Page 22 1. Heater Not Powering Up (cont.) Disconnect and Section B Inspect wires & Is voltage test the red & (continued from connections, correct? grey wires on ICB previous page) are they OK? for 22-28VAC. Replace wire Secure harness: wiring/plugs FDXLWHA1930 and retest Replace fuse: On ICB, test 3A...
  • Page 23 1. Heater Not Powering Up Verify heater manufacture date Verify input power Step 1A Step 1B For models manufactured prior to August of 2008, Verify 110-125 or 220-245VAC off fuse board (TB1). proceed to step 1B. IF model is later, go to 1C. IF correct, go to 1D.
  • Page 24 1. Heater Not Powering Up (cont.) Inspect connections Test Fuses Step 1E Step 1F Verify that FC1 & FC2 fuses aren’t open. Replace all Inspect Fuse Board wiring, ensuring all plugs are open fuses & go to section 2. IF correct, go to 1G. securely fastened.
  • Page 25 1. Heater Not Powering Up (cont.) Test P5 (low voltage) Step 1I NOTE: Step 1I – Heaters older than 11/2010 – If no voltage across R & C, remove FC3 fuse and test for continuity. IF open go to page 24.
  • Page 26 1. Heater Not Powering Up (cont.) Test F1 (3AMP) fuse Test ICB’s display output Step 1L Step 1M On the ICB, locate and test the 3A fuse for On the ICB, verify 22–28VAC between AC & COM continuity. IF fuse is blown, replace it and go to terminals (pins 1 &...

  • Page 27: Open Fc1&/Fc2 Fuse

    2. Open FC1 &/or F2 Fuse Is transformer Correct/repair Open FC1 Correct voltage wiring damaged, transformer selector plug? &/or F2 Fuse pinched, or worn? wiring Install correct Test plug and transformer replace fuse resistance Did this Contact Problem Is resistance correct the Support solved...
  • Page 28 2. Open FC1 &/or F2 Fuse Verify voltage selector plug Inspect transformer wiring Step 2A Step 2B IF voltage selector plug matches voltage, go to step Inspect transformer wiring, ensuring the insulation 2B. IF not, power down, replace FC1 & FC2 fuses, & on the wiring is not damaged.

  • Page 29: Open Fc3&/F1 Fuse

    3. Open FC3 &/or F1 Fuse Replace wire harness: Check the remote Is low voltage Open FC3 FDXLWHA1930 connection/high wiring damaged, &/or F1 Fuse OR high limit if damaged: limits pinched, or worn? FDXLHLI1930 Replace wire harness: Test gas valve Is water pressure FDXLWHA1930 wires for...
  • Page 30 3. Open FC3 &/or F1 Fuse Inspect connections/high limits Inspect water pressure switch Step 3A Step 3B Power down and inspect all remote connections With power off, inspect the water pressure switch and high limit wiring for damage. IF damaged, wiring for damage.
  • Page 31 3. Open FC3 &/or F1 Fuse (cont.) When testing the gas valve, if continuity appears between any wires and ground, then this implies a short has occurred and the gas valve will need to be replaced (refer to pg. 20 for part number). Verify gas valve is not shorted ICB wiring Step 3F...

  • Page 32: Open Fc4 Fuse

    4. Open FC4 Fuse Inspect ignitor Is ignitor wiring Open FC4 Replace ignitor: wiring for damaged, pinched, Fuse FDXLIGN1930 damage or worn? Ohm out blower for 8- Is blower wiring 9ohms (before Sept. Replace blower: damaged, pinched, 2010) OR for 4-5ohms Please refer to (pg.
  • Page 33 4. Open FC4 Fuse Ignitor and blower wiring Verify ignitor resistance Step 4B Step 4A Inspect the Ignitor & Blower wiring. Verify Disconnect ignitor from ICB & measure resistance insulation is not damaged. IF wires are damaged, of ignitor. Verify 8-25 ohms between 20°-140°F. IF replace the damaged part (pg.

  • Page 34: Bd" Code

    5. Service LED ON: ‘BD’ Code Power down and Proceed to: ‘BD’ Code check the FC4 Is fuse blown? Section 4 fuse Disconnect P6 and test for 110 - 125VAC between pins 3-5. On P4, verify 110- Verify E10 for 110- Is voltage 125VAC between 125VAC between...
  • Page 35 5. Service LED ON: ‘BD’ Code Test the FC4 fuse (continuity) Verify ICB output Step 5A Step 5B With power off, verify the FC4 fuse has continuity. Disconnect the P6 connector and test voltage for IF fuse is good, go to 5B. IF fuse is blown, go to 110-125VAC between pins 3-5.

  • Page 36: Ee" Or "Ce" Code

    6. Service LED ON: “EE” OR “CE” Code “EE” OR Is “EE” code Check display for Replace ICB: “CE” Code present? “EE” code FDXLICB1930 The “CE” code may Problem clear with a reset of Replace ICB: Section B solved power, power cycle FDXLICB1930 the heater Did “CE”...
  • Page 37 6. Service LED ON: “EE” OR “CE” Code Check display for “EE” Check display for “CE” Step 6A Step 6B “EE” error indicates the you have a defective ICB “CE” (communication error) indicates a problem board. IF this error appears, replace ICB (pg.

  • Page 38: Io" Or "Sb" Code

    7. Service LED ON: “IO” OR “SB” Code Verify ignitor wiring is “IO” OR Is “IO” code Check display for not damaged and “SB” Code present? “IO” code plugged in securely The “SB” code may clear with a reset of Is ignitor wire power, power cycle damaged?
  • Page 39 7. Service LED ON: “IO” OR “SB” Code Check display for “IO” Inspect ignitor wires Step 7A Step 7B “IO” error stand for ignitor Open. IF this error Power down and inspect ignitor wiring, ensuring appears, go to step 7B. IF “IO” does not appear, go ignitor plug is securely attached to the ICB.

  • Page 40: Sf" Or "Hs" Code

    8. Service LED ON: “SF” OR “HS” Code Ohm thermistor, “SF” OR Is “SF” code Check display for checking each red to “HS” Code present? “SF” code black, do the readings differ by more than 1°? The “HS” code stands for High Replace ICB: Sense (water FDXLICB1930...
  • Page 41 8. Service LED ON: “SF” OR “HS” Code The “HS” (High Sense (water temperature)) will appear if the water sensor is reading above 105° OR if the sensor detects an increase of more than 6° with-in 60 seconds. Check display for “SF” “HS”, are inlet/outlet reversed? Step 8A Step 8B...

  • Page 42: Pf" Code

    9. Service LED ON: “PF” Code Inspect ground Verify incoming and neutral power is within 10% “PF” Code connections, are + or – of required they clean and voltage. secured? Replace ICB: Is the incoming FDXLICB1930 power within 10% of required voltage? Clear dirt/debris and Correct source secure ground and...
  • Page 43 9. Service LED ON: “PF” Code “Polarity Failure” This code will display if low voltage is detected, if the ground path is not sufficient, or the ICB is defective. Reset is immediate after error is corrected. Verify incoming power Inspect ground & neutral Step 9A Step 9B Ensure voltage is within 10% + or –...

  • Page 44: Hf" Code

    10. Service LED ON: “HF” Code Reduce the Power cycle the Did the “HF” temperature set “HF” Code heater at the code reappear? point until heater breaker stop firing Problem Does heater solved fire? Toggle the mode button and call for heat Did the “HF”...
  • Page 45 10. Service LED ON: “HF” Code (cont.) “HF” (heat or flame sensed) will occur if flame is sensed when the gas valve is off, the control will go into lockout. The blower will continuously run until corrected. When corrected, control will run blower for 5 seconds then restart heater after 2 minutes. Power cycle heater Call for heat and test gas valve Step 10A...

  • Page 46: Lo" Code

    11. Service LED ON: “LO” Code Check continuity of Is water pressure Verify adequate water pressure “LO” Code switch wiring free of water flow, is switch, is continuity damage? flow sufficient? present? Replace wire Replace water Increase flow harness: pressure switch: rate/clean filter FDXLWHA1930 FDXLWPS1930...
  • Page 47 11. Service LED ON: “LO” Code Section B Inspect vent Repair or replace Is tube (continued from pressure switch tube kit: damaged? previous page) tube & connections IDXL2SNT1930 Heater made Test vent Inspect flue and after Feb. pressure switch vent sizing 2016? continuity Contact...
  • Page 48 11. Service LED ON: “LO” Code “LO” Code (Limit Open) may relate to water flow. Verify the pump is running & adequate water is flowing through heater. “LO” is NORMAL when the pump is turned off. Inspect water pressure switch Continuity test Step 11A Step 11B...

  • Page 49: Pressure Switch Adjustment

    11. Service LED ON: “LO” Code (cont.) Pressure switch adjustment Inspect and test high limits Step 11C Step 11D Some sites may require a pressure switch Inspect & test high limits. Verify continuity across adjustment. IF adjustment does not correct or was the temperature limit switches.
  • Page 50 11. Service LED ON: “LO” Code (cont.) Note: Please ensure that the vent size is sufficient for the heater model installed. Failure to properly size venting may result in damage to heater OR COULD PUT INHABITANTS AT SERIOUS RISK. Inspect flue and vent sizing Vent pressure switch continuity Step 11G Step 11H...
  • Page 51 11. Service LED ON: “LO” Code (cont.) Note: This switch is a one time safety. Once the switch has tripped then it NEEDS to be replaced and the heat exchanger should be inspected for soot or damage. Indoor/Outdoor: Feb. 2016 and newer Step 11I Test continuity across the exhaust gas limit switch.

  • Page 52: If" Code

    12. Service LED ON: “IF” Code On ICB, verify flame Is heater’s gas sensor & gas valve Inspect gas “IF” Code valve ON? connections are valve in heater secure Turn ON gas connections Is main gas valve and retest secure? supply ON? Is inlet and manifold gas...
  • Page 53 12. Service LED ON: “IF” Code Section B Is correct flame Check for damaged (continued from sensor installed OR wrong blower previous page) OR damaged? air inlet plate Contact tech Replace flame Is plate sensor: damaged/ support: IDXLFLS1930 wrong? (908) 355-7995 Inspect and/or clean burner tubes &...
  • Page 54 12. Service LED ON: “IF” Code Inspect main gas supply Verify gas valve is ON Step 12A Step 12B IF “Ignition Failure”, Ensure main gas supply is in Verify that the gas valve, inside the heater, is in the the ON position. IF ON, go to step 12B. IF NOT, “ON”...
  • Page 55 12. Service LED ON: “IF” Code (cont.) Voltage/pressure off gas valve Verify correct flame sensor Step 12E Step 12F Verify 22-28VAC off gas valve during ignition trial. Verify that the installed flame sensor is 5”. IF 3” is IF present & no pressure (manometer attached), installed OR IF sensor is damaged, replace it with replace valve.
  • Page 56 13. Service LED ON: “AC” Code Test for continuity Replace blower Does the switch “AC” Code vacuum switch: on the blower have continuity? FDXLBVS1930 vacuum switch Put the heater in “Stand by” Replace ICB: Is the blower FDXLICB1930 running? Replace blower vacuum switch: FDXLBVS1930...

  • Page 57: Ac" Code

    13. Service LED ON: “AC” Code “AC” Code stands for “Air Switch Closed”. The blower vacuum switch closed, when it was expected to be open. Test blower vacuum switch Verify blower operation Step 13A Step 13B Isolate the blower vacuum switch. Measure With the heater off (in “Stand By”), IF the blower continuity between switch terminals.

  • Page 58: Ao" Code

    14. Service LED ON: “AO” Code Replace blower: Replace Is blower “AO” Code Please refer to vacuum tubing: damaged? (pg. 20) IDXL2SNT1930 Replace blower Are blower Is vacuum tube vacuum switch: vacuum switch damaged? FDXLBVS1930 wires damaged? Ohm out blower for 8- 9ohms (before Sept.
  • Page 59 14. Service LED ON: “AO” Code Blower & vacuum switch wiring Vacuum tube Step 14A Step 14B Check for bad blower and/or damaged blower Check for damaged vacuum tubing as well as its vacuum switch wiring. IF OK, go to step 14B. IF connection to the blower.
  • Page 60 14. Service LED ON: “AO” Code (cont.) Measure blower resistance Step 14D Before Sept. 2010 With power off, disconnect blower plug from ICB. Models manufactured before Sept. 2010: measure across pins 1-2 (black & red), then 3-4 (white & blue) for 8-9 ohms. Models after Sept. 2010: measure for 4-5 ohms across the two terminal with wires.

  • Page 61: Heat Exchanger: Flow Requirements

    Heat Exchanger: Flow Requirements Flow requirements should be checked to insure proper operation. Never allow heater to operate below minimum flow requirements or damage may occur. • Flow less than minimum could cause issues such as the heater dry firing or water to boil causing high limits to trip and possible damage to heat exchanger.

  • Page 62: Heat Exchanger: Inspection

    Heat Exchanger: Inspection 1. Remove black metal Trim Plate (around water manifold, 5 Black screws) 2. Remove water connection side Upper End Cap (Black Polymer- 4 screws in rectangle holes marked with an arrow) 3. Disconnect Unions from plumbing (water connections, 1 inlet, 1 outlet.) 4.

  • Page 63: Heat Exchanger: Potential Failure Causes

    Heat Exchanger: Potential Failure Causes New, Clean Exchanger Low pH or High Water Flow High Sanitizer Levels Annealed Fins – Low Water Flow Low pH High Sanitizer Levels Sooted – Improper Fuel High pH, Alkalinity or Calcium Freeze Damage and Air Mixture. Hardness...

  • Page 65: Uhs Wiring Diagram

    Wiring Connection Diagram...

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