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SERVICE & INSTALLATION MANUAL
Unit must be installed outdoors only and below an
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.hayward-pool.com/patent for U.S. and
Canadian patent information
POOL AND SPA/HOT TUB HEATERS
H135ID & ABG135 MODELS
altitude of 2000 feet
FOR YOUR SAFETY
1301503701
Rev B 0917
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Troubleshooting
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Summary of Contents for Hayward H135ID
- Page 1 POOL AND SPA/HOT TUB HEATERS H135ID & ABG135 MODELS SERVICE & INSTALLATION MANUAL Unit must be installed outdoors only and below an altitude of 2000 feet 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.
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Page 2: Table Of Contents
Heat exchanger inspection and cleaning ..29 Combustion chamber ........30 Burner inspection and cleaning ....30 Burner removal and replacement ....30 Gas valve replacement ........ 31 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 3: Safety Information
To reduce the risk of electric shock, the electrician must comply with installation instructions and must bond the heater accordingly. In addition, the licensed electrician must also con- form to local electrical codes for bonding requirements. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... - Page 4 Install two or more suction outlets per pump in accordance with latest APSP (formally NSPI) Standards and CPSC guidelines. Follow all applicable National, State, and Local codes. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995...
- 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 Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
- Page 6 Inches of Mercury (in Hg) - A unit for measuring pressure below atmospheric (“suction” or “vacuum”) (1.0 inch Hg = .491 PSI) Main Drain – See Suction Outlet PSI – An abbreviation for pounds per square inch. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
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Page 7: Section I General Information
WARNING: Failure to maintain proper water chemistry may cause 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 page 15 for further information. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995...
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Page 9: Section Ii Installation
Do not install within 24” of any outdoor HVAC equipment. Do not install where water may run-off a roof into the heater. A gutter may be needed to protect the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 10: Flooring
Forced Air Inlet FLOORING: This heater may be installed on either non-combustible or combustible fl ooring. Ultralite™ or equiva- lent concrete-over-foam HVAC pads are acceptable. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... - Page 11 Side Panels Pressure Switch Heat Exchanger Port Assembly Temperature Limit Switches Rear Jacket Heat Exchanger Cover Left Side Jacket Right Side Jacket Front Access Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
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Page 12: Gas Supply And Piping
***Based upon an inlet gas pressure of 10 psig at a pressure drop of 1 psi. ****Based upon an inlet gas pressure of 11 in-wc at a pressure drop of 0.5 in-wc. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 13: Gas Supply Installation
If more than one appliance is installed on the gas line, consult the local gas company for the proper gas line size. Questions on the installation of the proper gas line size can be directed to Hayward Technical Service. NATURAL GAS:... -
Page 14: Water Piping
Make sure that 1st and 2nd stage regulators are large enough to handle the BTUH 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 15: Installation Above Pool Surface
ATTENTION: Improperly adjusted manual bypass valves will result in damage to the heater if the fl ow rates are not maintained as specifi ed in Table 5 under all operating conditions. The heat exchanger will fail and this damage will not be covered under the Hayward warranty. Figure 08:... -
Page 16: Chlorinator/Chemical Feeder
See the rating plate located inside the front access panel on the heater for the input rating and working pressure. If desired, you may order the pressure relief valve from Hayward; order p/n CHXRLV1930. Remove the factory-installed pipe plug, and install the pressure relief valve using a suitable amount of pipe thread sealant or Tefl... -
Page 17: Electrical Connections
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. The National Electrical Code (NEC), and most other codes require that all metallic components of a pool structure, including reinforcing steel, metal fi... - Page 18 Figure 13: Wiring connection diagram. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
- Page 19 19 19 Figure 14: Lighting & Operating Instructions label...
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Page 20: Section Iii Check-Out & Start-Up
Figure 15: Location of Components Ignition Control Transformer Board Blower Vacuum Switch Valve Blower Sight Air Box Glass Flame Sensor Igniter Access Gas Manifold Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 21: Gas Line Testing
PRESSURE PRESSURE adjustment screw as shown below. 7. If the gas pressure does not meet the above requirements the regulator must be adjusted. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 22: Water Pressure Switch
Never allow the heater to operate with less than the minimum rated water fl ow rate. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 23: Two-Speed Pump
If the pump and piping arrangement are such that the re- quired 1-pound minimum pressure cannot be obtained, do not attempt to operate the heater. Correct the installation. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 24: Temperature Adjustment
Figure 17: User Interface Keypad Indicator Lights UP and DOWN Buttons MODE Button Numeric Display USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 25: Temperature Lock-Out
6. When the thermostat is satisfi ed and the call for heat ends the control immediately de-energizes the gas valve. Flame is extinguished. 7. The control operates the blower during a 30-second post-purge period. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 26: Retry (Failure Of Light)
4. The control will accept a mode change during lockout after 5 seconds. The control will continue to display the error code and remain in lockout until it is reset. At reset the control will go to the last saved mode. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 27: Automatic Reset Time
4. 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 28: Draining The Heat Exchanger
Figure 18: Heat exchanger header components Bypass Service Cartridge Inlet/Outlet Water Pressure Cartridge Retaining Nut Header Switch Temperature Limits Thermistor Drain Plug Pressure Relief Valve Port USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 29: Section Iv Technician Service
(top and bottom). Allow the heat exchanger to sit for a period of time to allow the degreaser to loosen the soot. Wash the heat exchanger using a garden hose ensuring both the top and bottom USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 30: Combustion Chamber
Remove the front access panel. Disconnect the union joint in the gas supply piping outside the heater cabinet. Disconnect the wires from the two terminals on the gas valve. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 31: Gas Valve Replacement
5. Slide the igniter wires through the slot on the panel and pull the panel free. 6. Remove the (2) screws that secure the igniter. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 32: Flame Sensor
The locations of these components are shown in Figure 15. The igni- tion control system functions as the heater’s thermostat, safety control system, and controller for the gas combustion system. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... -
Page 33: Blower Vacuum Switch
1. Clogged fi lter or strainer. 2. Excessive fl ow through the external bypass if one is used. 3. Lime scale accumulation in the heat exchanger. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... -
Page 34: Exhaust Gas Temp Limit
Replace the limit as well as the heat exchanger before operating the unit again. Running the unit without replacing the heat exchanger after this limit trips could damage the entire unit and will not be covered by Hayward’s warranty. To replace the exhaust gas temperature limit: 1. -
Page 35: Transformer
5. 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. 6. 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 36: Section V Troubleshooting
FUSE SPECIFICATIONS: The fuse designations are printed on the ignition control board. See Figure 15 for board locations. Fuses are available as common hardware items or may be purchased from Hayward in a service parts kit. The fuse specifi cations are: •... -
Page 37: Error Codes
“out of bounds” condition on both sensors (less than 10°F or greater than 180°F) will result in the error code. Automatic restart is 2 minutes after the error is corrected. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995... - Page 38 2 minutes after the error condition is corrected and the limit string closes. See the troubleshooting section for more detail. EEPROM error An error was detected in the ignition control circuit board. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
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Page 39: Troubleshooting
If ground wire is not connected, have an electrician remedy this wire is connected in the issue. If ground wire is conected, proceed to step 3. electrical outlet powering the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... - Page 40 24 VAC is present at the gas valve connections. If so, replace ICB. If not, move to step 2. 2. Gas Valve is defective Replace Gas Valve USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
- Page 41 Continuing to run the heater after this limit has tripped will cause damage to the entire unit and will not be covered by the warranty. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995...
- Page 42 STANDBY. Press and hold the DOWN key and then press and hold the MODE key. Hold down both keys for 3 seconds until the indication ‘‘bO’’ is removed from the display. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995...
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Page 43: Warranty
HAYWARD POOL HEATER CERTIFICATE OF LIMITED WARRANTY LIMITED HEATER WARRANTY: TERMS AND COVERAGE: We warrant our pool heater to be free from defects in workmanship and materials under normal use and service. Pursuant to this warranty and subject to the Conditions and Exceptions indicated below: 1. - Page 44 The original owner, upon discovering the defect, must present the attached completed warranty claim card with proof of purchase either to the dealer or notify Hayward in writing as described on the warranty card. Upon receipt of such notifi cation we shall decide whether to repair such parts or replace any pool heater, reserving at all times the right to inspect in order to verify any claimed defect.
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Page 45: Service Parts
SERVICE PARTS USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... - Page 46 ITEM PART NO. DESCRIPTION IDXLJKT1135 JACKET TOP - H135ID/ABG135 IDXLFAD1135P FRONT ACCESS DOOR ASSY - H135ID, PLATINUM -NO CONTROLS IDXLFAD1135B FRONT ACCESS DOOR ASSY - ABG135, BLACK - NO CONTROLS FDXLFCS1931 FLUE COLLECTOR SIDE PANEL W/O TEMPERATURE LIMIT IDXLBBN1135 BLOWER INLET BAFFLE - 135K BTU HEATER...
- Page 47 WIRING HARNESS KIT, COMPLETE FDXLFSKC30 FUSE KIT, 3.0A, FOR INTEGRATED CONTROL BOARD (QTY 10) IDXLUKT1135 UNION KIT (INCLUDES FITTINGS, UNION NUTS, GASKETS) SP1493 COUPLING FOR FLEXIBLE HOSE USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
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Page 48: Specifications
620 Division St. 2875 Pomona Boulevard 2880 Plymouth Drive Elizabeth, NJ 07207 Pomona, CA 91768 Oakville, Ontario L6H 5R4 © 2017 Hayward Industries, Inc. Printed in U.S.A. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com... - Page 49 NOTES USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-355-7995 www.hayward-pool.com...
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