Hayward 150 Installation & Operation Manual
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Hayward 150 Installation & Operation Manual

In ground pool/spa gas heaters
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IN GROUND POOL/SPA GAS HEATERS
INSTALLATION & OPERATIONS MANUAL
FOR YOUR SAFETY:
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, injury, or death.
• Do not store or use gasoline or other
flammable 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 fire department.
• Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
This product must be installed and serviced by
authorized personnel, qualified in pool/spa heater
installation. Improper installation and/or operation
can create carbon monoxide gas and flue gases
that can cause serious injury, property damage,
or death.
SAVE THESE
INSTRUCTIONS
CONTENTS
USE ONLY GENUINE REPLACEMENT PARTS
51300004201B
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  • Page 1: Table Of Contents

    51300004201B IN GROUND POOL/SPA GAS HEATERS INSTALLATION & OPERATIONS MANUAL FOR YOUR SAFETY: CONTENTS WARNING: If the information in these GETTING STARTED instructions is not followed exactly, a fire or explosion may result causing property INSTALLATION damage, injury, or death. LOCATING THE HEATER •...

  • Page 2: Getting Started

    51300004201B GETTING STARTED WHAT TO EXPECT WHEN OPERATING YOUR POOL HEATER This flow chart provides guidance to protect pool users and product by maintaining good water quality. INSTALLATION Verify that product installation was performed to local codes and according to this manual. INITIAL USE OR SPRING STARTUP Check all pool / spa water piping.
  • Page 3 51300004201B PLEASE READ BEFORE PROCEEDING Basic safety precautions should always be followed, including the following: Failure to follow instructions can cause death and/or severe injury. This is the safety-alert symbol. When you see this symbol on your equipment or in this manual, look for one of the following signal words and be alert to the potential for personal injury.
  • Page 4 51300004201B HEATER CONSTRUCTION Figure1: Sub-Assemblies Top Flue Cover Rain Shield Assembly Heat Exchanger Water Pressure Assembly Switch Water Upper Side Temperature Panels Switches Drain Plug or Relief Valve Control Lower Side Combustion Control Bezel Panels Blower and Control Boards Front Access Panel USE ONLY GENUINE REPLACEMENT PARTS...
  • Page 5 Integral low loss bypass, maximum water flow for all models is 125 GPM Model Gas Input Minimum Thermal Heater Heater Natural or Propane Water Flow Efficiency Width Weight *xxx* btu/hr lbs. 150,000 82.7 199,900 250,000 300,000 82.7 350,000 399,900 500,000 250ASME 250,000 400ASME 400,000 36.5 500ASME 500,000 40.5...
  • Page 6 51300004201B Wiring Connection Diagram WARNING - Risk of Electric Shock Before working on any electrical equipment, turn off power supply to the equipment. WARNING - Risk of Electric Shock. All electrical wiring MUST conform to applicable local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can cause death, shock, burn, and/or serious property damage.
  • Page 7 51300004201B Table2: CERTIFICATION AND COMPLIANCE CERTIFICATION CODES AND STANDARDS CANADA DESIGN CERTIFIED DESIGN COMPLIANT ANSI Z21.56 CSA 4.7 NFPA 54/ANSI Z223.1 INSTALLATION COMPLIANT GAS CAN/CSA-B149.1-2 NFPA 58 ANSI/NFPA 70 CSA C22.1 – Canadian INSTALLATION COMPLIANT ELECTRIC Electrical Code, Part I EMISSIONS SCAQMD 1146.2 SHIPPING COMPLIANT...
  • Page 8 51300004201B WARNING – Suction outlet components have a finite life, the cover/grate should be inspected frequently and replaced at least every seven years or if found to be damaged, broken, cracked, missing, or not securely attached. – CAUTION Components such as the filtration system, pumps and heater must be positioned so as to prevent their being used as means of access to the pool by young children.
  • Page 9 51300004201B WARNING – Risk of Hyperthermia. To avoid hyperthermia the following “Safety Rules for Hot Tubs” are recommended by the U.S. Consumer Product Safety Commission. Spa or hot tub water temperatures should never exceed 104°F [40°C]. A temperature of 100°F [38°C] is considered safe for a healthy adult.

  • Page 10: Installation

    51300004201B INSTALLATION: This manual contains instructions for installation, operation, maintenance, troubleshooting, and parts lists for the proper operation of the swimming pool/spa/hot tub heaters. It is strongly recommended that the installer read the manual before installing the swimming pool/spa/hot tub heater. If after reviewing the manual any questions remain unanswered, contact tech services or local representative.

  • Page 11: Locating The Heater

    51300004201B SPRINKLER HEADS: The heater is designed to handle the wettest weather conditions that are typical of rain and high humidity. Sprinkler heads force high-pressure water into the unit from the side at an odd angle. Make sure there are no sprinkler heads near the heater that will spray on or into the unit.
  • Page 12 51300004201B EQUIPMENT PAD : Place the heater on a level surface such as concrete or a fabricated slab (pad). This allows proper drainage of condensation and rainwater from the base of the unit. If possible, the pad should be placed at the same level or slightly higher than the filter system equipment pad.

  • Page 13: Altitude Of Installation

    51300004201B GAS CONVERSION: Where permitted by local codes, the factory-installed gas train may be changed from natural gas to propane or from propane to natural gas, using the appropriate conversion kits. Gas conversions are to be performed only by a qualified service agency. Detailed instructions are included with each kit.

  • Page 14: Air Supply

    (a space whose volume is not Requirement Required Required less than 50 cubic feet per 1,000 btu/hr of total input all gas 150,000 1 sq. in. per utilization equipment installed in the combined space shall). 200,000 1,000 Btu/hr...

  • Page 15: Flue Gas Venting

    51300004201B Figure8: Air from Inside Building Installation Figure10: Air Below-Ground 1 square inch per 1,000 btu/hr of the total input (Pit for Natural Gas only Installations) Table3 Indoor Clearance Apply 1 square inch per 4,000 btu/hr of total input Table3 Indoor Clearance Apply Vent Cap Vent Cap Ventilation...
  • Page 16 51300004201B Table6 Negative-Pressure (CATI) Indoor Vent Kits with Vent Pipe & Terminal Specifications Vent Indoor Vent Kit Vent Vent Pipe Vent Pipe Models Description Termination Part Number Dia(in) Application Material Requirement UHXNEGVT11506 Indoor Vent Vent pipe to be Single or UHXNEGVT12006 Adapter Kit, installed according to...
  • Page 17 51300004201B POSITIVE PRESSURE (HORIZONTAL OR VERTICAL, CATIII) VENTING: When installed according to the following instructions, heaters meet the criteria for category III venting. VENT SIZING: Vent pipe diameter must match the vent pipe diameter on the heater (see Table9). The vent pipe must be single or double-wall stainless steel sealed vent as listed in Table9.
  • Page 18 51300004201B Table9 Positive-Pressure (CATIII) Indoor Vent Kits with Vent Pipe & Terminal Specifications Heatfab Saf-T Vent EZ Seal (CI Plus) or Vent DuraVent FasNSeal (W2) Maximum Heater Indoor Vent Kit Pipe Appliance Vent Pipe Installation Vent Pipe Horizontal Vertical Vent Model Part Number Dia.
  • Page 19 51300004201B Table9b Positive-Pressure (CATIII) Vent Termination Clearances Clearance Description U.S. Installation (1) Canadian Installation (2) Clearance above grade, veranda, porch, deck, 12 in. (305 mm) 12 in. (305 mm). 18 in. (457 mm) above roof surface. balcony or anticipated snow level 12 in.

  • Page 20: Gas Supply

    51300004201B GAS SUPPLY: The heater is shipped from the factory with the gas connection located on the left side of the heater cabinet. The gas connection can also be configured from the right. Insert the pipe to the gas valve through the grommet in the cabinet side (see Figure13.) A union should be installed outside the heater cabinet for easy removal of the gas manifold assembly during service.
  • Page 21 Distance of First 1st Stage then 50 to 100 Stage * 2nd Stage to 100 to 150 Gas Valve Second 0 to 10 Inlet (ft.) Stage ** * Based upon an inlet gas pressure of 2 psig at a pressure drop of 1 psi ** Based upon an inlet gas pressure of 10 inwc at a pressure drop of 0.5 inwc...

  • Page 22: Water Piping

    51300004201B WATER PIPING: REVERSIBLE WATER CONNECTIONS: This heater is designed so that it can be installed with the water connections located on either the right or left side. Heaters are factory-shipped with right-side water connections. To move the connections to the left side follow the instructions below and reference Figures1 and 14 as needed.
  • Page 23 51300004201B Figure15: Water Connections Figure16: Bypass Valve(s) Polymer Header Header Outlet Flow Meter Header Union Fitting Gasket Bronze Header (ASME) Header Inlet Bypass From Valve Pool/SPA Header Bolts Gasket Fitting WARNING: EXPLOSION HAZARD Blockage of water flow from heater return to pool may result in fire or explosion causing property damage, personal injury, or loss of life.
  • Page 24 51300004201B Figure17 illustrates a typical pool piping diagram and layout for the pool equipment. Figure18 illustrates a multiple heater installation for very large pools with and without a manual bypass valve. Figure17: Typical Plumbing to Pool or Spa Figure18: Multiple Heater System INSTALLATION ABOVE POOL/SPA SURFACE: If the heater is installed less than three (3) feet above the surface AUTOMATIC CHLORINATORS AND CHEMICAL...

  • Page 25: Electrical Connections

    51300004201B DRAIN VALVE INSTALLATION (ASME MODELS ONLY): If Figure21: Drain and relief valve locations installing an ASME model heater, a 3/4” brass drain valve must be installed. A drain valve is included separately with all ASME heaters. Apply a suitable amount of pipe thread sealant or Teflon tape to the threads and install as shown in Figure21.

  • Page 26: Check-Out & Start-Up

    51300004201B supplied caps. The power connections are to be made to the Figure22a: Junction Box Connections supplied wires inside the junction box (see Figure22a) using field supplied wire nuts. All connections are to be stored within Fuse Board Connection junction box attached to side panel. REMOTE CONTROL CONNECTION: Remote control can be accomplished via a 2-wire or 3-wire connection (see Figure22b).

  • Page 27: Control Setup

    51300004201B Figure23: Location of Components User Panel Fuse Board Pressure Switches(2) Ignition Control Transformer Gas Valve Flame Sensor Combustion Blower Ignitor Access Sight Glass Air Box Gas Manifold CONTROL SETUP This pool heater is equipped with a digital thermostat which allows the user to select the desired water temperature (see figure24). The heater will then function automatically to maintain the desired temperature.
  • Page 28 51300004201B NORMAL OPERATION FOR POOL & SPA MODES: The control continually compares the water temperature with the set point and the high limit temperature. When the water temperature is more than 1°F below the set point a call for heat is generated and a heating cycle is initiated.

  • Page 29: Gas Testing

    51300004201B LOSS OF FLAME – RECYCLE: If flame is established and then lost, the control will make ten (10) attempts at ignition. If flame is lost within ten (10) seconds of ignition, the control will respond within 2 seconds. If flame is lost more than ten (10) seconds after ignition the control will respond within 0.8 seconds.
  • Page 30 51300004201B Figure25: Lighting & Operating Instructions Label USE ONLY GENUINE REPLACEMENT PARTS...
  • Page 31 51300004201B GAS PRESSURE TEST PROCEDURE: Follow the lighting instructions on the unit (or from Figure25). Refer to Figure23: Location of Components for the location of the gas valve. See figure26 for pressure regulation adjustment for use in this procedure. Note that even though the valves look different, the required pressure taps and regulation adjustment screws are present on every gas valve.

  • Page 32: Water Testing

    51300004201B 5. Check the function of the pressure switch by turning WATER TESTING: the filter pump on and off several times and confirming WATER PRESSURE SWITCH TEST / ADJUSTMENT PROCEDURE: that the heater turns off immediately when the pump is The pressure switch is preset at the factory for most typical deck level installations.

  • Page 33: Water Chemistry

    51300004201B WATER CHEMISTRY: WARNING: WATER CHEMISTRY Failure to maintain proper water chemistry may cause premature heat exchanger damage or failure The heat exchanger in your pool heater is made from the highest quality of copper and nickel (Cupronickel) materials. This premium material and the exacting processes used to manufacture the heat exchanger is state of the art in pool heater design and manufacture.

  • Page 34: Winterization

    51300004201B WINTERIZATION: In moderate climates, the heater can continue to operate during short-term cold spells. Do not use the heater to maintain the water temperature just above freezing or for freeze protection. Care must be taken to avoid freeze-up in the heater. When it is used during freezing weather, the pump must run continuously.
  • Page 35 51300004201B SERVICE OF HEATER: The following service procedures: HEAT EXCHANGER INSPECTION AND CLEANING and BURNER INSPECTION AND CLEANING are recommended to be performed as part of annual heater maintenance to ensure proper heater operation and long life. HEAT EXCHANGER INSPECTION AND CLEANING: Remove the louvered exhaust cover panel (see Figure1: Sub-Assemblies) and inspect the external surfaces of the heat exchanger for debris or soot accumulation.
  • Page 36 51300004201B 12. Turn pump, gas valve knob and heater power “ON”. Test fire heater by following the GAS PRESSURE TEST PROCEDURE. GAS VALVE REPLACEMENT: Refer to Figure1: Sub-Assemblies, Figure23: Location of Components and Figure26: Gas Valves as needed. 1. Turn pump, gas supply, and heater power “OFF”. 2.
  • Page 37 51300004201B BLOWER VACUUM SWITCH: The blower vacuum switch is a safety device that prevents the ignition sequence from continuing unless the blower is developing sufficient airflow for combustion. Figure23: Location of Components shows the location of the blower vacuum switch in the heater cabinet. When the blower achieves sufficient airflow, the negative pressure created in the blower housing closes the contacts on the blower vacuum switch, indicating to the ignition control board that it is safe to continue the ignition sequence.
  • Page 38 51300004201B THERMISTOR: The thermistor monitors the return water temperature to thermostatically control pool and spa water to the selected temperature and to shut the heater off as the return water reaches 104 F. See Figure28: Heat Exchanger Header. To replace the thermistor: 1.
  • Page 39 51300004201B COMBUSTION BLOWER: The blower provides the air that mixes with the gas in the burners for the combustion process. The blower operates during the pre-purge time (approximately 30 seconds) at the beginning of each ignition cycle, during the entire time the gas valve is open and the burners are firing, and for 30 seconds after the gas valve closes.

  • Page 40: Troubleshooting

    51300004201B TROUBLESHOOTING: Error and Display Codes: See Table16: Display Code Index. Troubleshooting the unit: See Table17: Troubleshooting Lookup Chart. AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resume operation. The heater can be manually reset using the keypad by cycling the MODE button through “STANDBY” and back to the original operating mode (“POOL”...
  • Page 41 51300004201B Table16: Display Code Index NOTE: Continuation of control sequence is immediate after error is corrected. Automatic reset may take up to 2min for control self-diagnostics to complete. Lockout recover may take up to 60 min. Code Description Information Air switch circuit Blower vacuum switch closed when expected open.
  • Page 42 51300004201B Table16: Display Code Index NOTE: Continuation of control sequence is immediate after error is corrected. Automatic reset may take up to 2min for control self-diagnostics to complete. Lockout recover may take up to 60 min. High temperature A) Inlet water temperature sensor is reporting a temperature in excess of sensing error 104°F.
  • Page 43 51300004201B Table17: Troubleshooting Lookup Chart Code/ Fault Diagnostic Step Suggested Troubleshooting Action No code 1. Check for Low & Disconnect plug from P5 connector from Fuse Board. Measure for 24VAC displayed High voltage output between pins of receptacle on Fuse Board. Reconnect plug. Disconnect from fuse board plug from P6 of Fuse Board.
  • Page 44 51300004201B Table17: Troubleshooting Lookup Chart Code/ Fault Diagnostic Step Suggested Troubleshooting Action No code 1. Verify that Check that proper Voltage Selector Plug is installed. If OK, proceed to step displayed 120VAC Voltage 2.If 120VAC plug is installed and field supply voltage is 240VAC, FC1 and Selector Plug is not FC2 fuses may be blown.
  • Page 45 51300004201B Table17: Troubleshooting Lookup Chart Code/ Fault Diagnostic Step Suggested Troubleshooting Action 1. Check for faulty Check tubing and replace if necessary. If OK, proceed to step 2. displayed vacuum switch tubing Air switch 2. Check for faulty Inspect vacuum switch wiring. Ensure wire harness terminals are securely circuit open vacuum switch fastened to spade terminals on vacuum switch.
  • Page 46 51300004201B Table17: Troubleshooting Lookup Chart Code/ Fault Diagnostic Step Suggested Troubleshooting Action 1. Disconnect and Reset communication between Display Interface and Ignition control board displayed then re- connect power to heater. Control to 2. Check for faulty Inspect Display Interface Wiring. Ensure Display Interface Plug is securely display wiring or attached to ignition control board.
  • Page 47 51300004201B Table17: Troubleshooting Lookup Chart Code/ Fault Diagnostic Step Suggested Troubleshooting Action 1. Verify that the This is a normal display when the pump is off. Turn pump on. LO code displayed pump is running. should clear. If LO does not clear, proceed to step 2. 2.
  • Page 48 51300004201B Table17: Troubleshooting Lookup Chart Code/ Fault Diagnostic Step Suggested Troubleshooting Action 1. Check for faulty Inspect temperature limit switch wiring. Ensure wire harness terminals are displayed wiring or connection securely fastened to spade terminals on temperature limit switch located in the flue collector panel above the center of the header.

  • Page 49: Parts

    51300004201B PARTS: Figure31: Service Parts Exploded View USE ONLY GENUINE REPLACEMENT PARTS...
  • Page 50 51300004201B Table18: Service Kits Item Description 250ASME 400ASME 500ASME TOP FLUE FDXLJKT FDXLJKT FDXLJKT FDXLJKT FDXLJKT FDXLJKT FDXLJKT COVER (PLASTIC 1150 1200 1250 1300 1350 1400 1500 HEADER) ASME (BRONZE FDXLJKT FDXLJKT FDXLJKT HEADER) * 1250A 1400A 1500A FRONT ACCESS DOOR ASSY FDXLFAD FDXLFAD...
  • Page 51 51300004201B Table18: Service Kits Item Description 250ASME 400ASME 500ASME BLOWER INLET FDXLBBN FDXLBBN FDXLBBN FDXLBBN FDXLBBN FDXLBBN FDXLBBN BAFFLE 1150 1200 1250 1300 1350 1400 1500 COMBUSTION FDXLBWR FDXLBWR1930 BLOWER 1500 IGNITOR FDXLIGN1930 FLAME SENSOR IDXLFLS1930 GASKET KIT, FDXLGSK1930 BLOWER/IGN BLOWER VACUUM FDXLBVS1930...
  • Page 52 51300004201B Table18: Service Kits Item Description 250ASME 400ASME 500ASME RETURN MANIFOLD FDXLPRM1930 REPLACEMENT INLET/OUTLET FDXLFHD1930 HEADER ONLY INLET/OUTET FDXLFHA1930 HEADER ASSY HEAT EXCHANGER FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA ASSY (PLASTIC 1150 1200 1250 1300 1350 1400 1500 HEADER) ASME WATER FDXLWPS FDXLWPS...
  • Page 53 51300004201B Table18: Service Kits (Items Not Shown in Diagram) Item Description 250ASME 400ASME 500ASME ASME UNION FLANGE KIT FDXLUNK FDXLUNK1930A INCL. FITTINGS, 1930A BOLTS, GASKETS UNION FLANGE KIT ( INCLUDES SPX3200UNKIT FITTINGS, UNION NUTS, GASKETS TIE-DOWN KIT FDXLTDK1930 BURNER FDXLBRN1930 (qty8) / FDXLBRN1931 (qty1) INSULATION, RETURN SIDE FDXLGSK1933...
  • Page 54 51300004201B Table18: Service Kits (Items Not Shown in Diagram) Item Description 250ASME 400ASME 500ASME INDOOR VENT ADPTR KIT, UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT NEG-PRESS 11506 12006 12506 13008 13508 14008 15008 6”dia 6”dia 6”dia 8”dia 8”dia 8”dia 8”dia CATI (VERTICAL) INDOOR VENT...
  • Page 55 51300004201B USE ONLY GENUINE REPLACEMENT PARTS...
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