Hayward H200FD Service & Installation Manual
Pool and spa/hot tub heaters
Hide thumbs
Also See for H200FD:
- Service & installation manual (66 pages) ,
- Manuel d'entretien et d'installation (64 pages) ,
- Owner's manual (32 pages)
Table of Contents
Advertisement
SERVICE & INSTALLATION 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 flam-
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
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.
U.S. PATENT NOS. 6,321,833 & 7,971,603
POOL AND SPA/HOT TUB HEATERS
H150FD, H200FD, H250FD, H300FD,
H350FD & H400FD MODELS
FOR YOUR SAFETY
PRINTED 10/24/2011 AT 1:13 PM
1301623301 Rev H 1211
Advertisement
Table of Contents
Troubleshooting
Related Manuals for Hayward H200FD
Summary of Contents for Hayward H200FD
- Page 1 POOL AND SPA/HOT TUB HEATERS H150FD, H200FD, H250FD, H300FD, H350FD & H400FD MODELS SERVICE & INSTALLATION MANUAL FOR YOUR SAFETY WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, PRINTED 10/24/2011 AT 1:13 PM injury, or death.
-
Page 2: Table Of Contents
Keypad inputs ..........38 Automatic reset time ........39 Periodic inspection ........39 Winterization ..........39 Draining the heat exchanger ....... 40 Spring start-up ..........40 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... - Page 3 To reduce the risk of electric shock, the electrician must comply with installation in- structions and must bond the heater accordingly. In addition, the licensed electrician must also conform to local electrical codes for bonding requirements. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
- Page 4 Install two or more suction outlets per pump in accordance with latest APSP (formally NSPI) Stan- dards and CPSC guidelines. Follow all applicable National, State, and Local codes. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
- Page 5 It is also necessary to allow the motor to cool for at least 20 minutes prior to maintenance to minimize the risk of burns. WARNING – Failure to install according to defined instructions may result in severe personal injury or death. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
- Page 6 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: 908-351-5400 www.haywardpool.com...
-
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 page 26 for further information. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
-
Page 9: Section Ii Installation
Table 1 lists the maximum installation altitudes using the included conversion plate(s). If installing above 7,700 ft, the high-altitude kit USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... - Page 10 * All indoor installations at altitudes above 2,000 ft also require a special vent pressure switch to be installed in addition to the blower air inlet plate. The special vent pressure switch is included with the appropriate indoor vent kit (UHXNEGVT1xxx or UHXPOSHZ1xxx), or the high-altitude vent pressure switch kit FDXLVPS1931. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
-
Page 11: Uncrating The Heater
4. Do not install the heater where water spray from ground sprinkler can contact the heater. The wa- ter could splash on the controls causing electrical damage. 5. Do not install under a deck. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... -
Page 12: Flooring
Install concrete tapping screws (field-supplied) secured to the heater and the pad. Install the ac- at these locations (front and rear) cess panels when complete. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 13: Indoor Installation And Venting
When air blowers are used in spa/hot tub installations and are located in proximity to the heater, caution must be observed to ensure sufficient combustion air is available to the heater for proper combustion. A separate blower air duct is recommended. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... - Page 14 Fuel Gas Code (ANSI Z223.1/NFPA 54). 400,000 150,000 1 sq. in. per 250 btu/hr 200,000 (paragraph B-4) 250,000 1000 1000 300,000 1200 1200 350,000 1400 1400 400,000 1600 1600 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
-
Page 15: Vertical Venting
Over 16/12 to 18/12 7.0 ft Minimum height from roof to lowest discharge opening Over 18/12 to 20/12 7.5 ft Over 20/12 to 21/12 8.0 ft USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 16: Horizontal Or Vertical Venting
The available parts are listed in the service parts section in the back of this manual. Also, Hayward publishes an instruction sheet which can be used as a guide in speci- fying installation. It can be obtained on Hayward’s website at www.haywardnet.com. If you need more spe- cialized fittings, you may order them directly from Heatfab, or from an authorized Heatfab dealer. - Page 17 * For vent pipe section length, “x” should be: 1, 2, 4, 5, or 7, where: 1=6 inches, 2=12 inches, 4=18 inches, 5=24 inches, and 7=36 inches. ** For vent pipe section length, “xx” should be: 06, 09, 12, 18, 24, or 36 indicating the length of the vent pipe section in inches. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
-
Page 18: Vent Kit Installation
15. Connect vent piping system to heater vent adapter. 16. If connected, turn pump, main gas valve, and heater power back on. 17. Activate heater and check for proper function. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... - Page 19 FIGURE 7 FIGURE 6 Flue Cover FIGURE 8 FIGURE 9 Vent Pressure Switch Blower Air Inlet Plate Blower Pressure Vent Pressure FIGURE 10 Switch Tubing USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
-
Page 20: Reversible Water Connections
12. Re-connect the heater wire harness to the water pressure switch and temperature limit. 13. Reverse the above steps to reassemble the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... - Page 21 Upper Plastic Heater Side Panel Ignition Control Upper Plastic Heater Circuit Board Side Panel Front Access Panel Figure 2 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 1303264301 rev B Page 2 of 2 Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
-
Page 22: Gas Supply And Piping
* Based upon an inlet gas pressure of 2 psig at a pressure drop of 1 psi ** Based upon an inlet gas pressure of 10 in-wc at a pressure drop of 0.5 in-wc USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... - Page 23 * 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: 908-351-5400 www.haywardpool.com...
- Page 24 (Example: 225 meter = 225,000 BTUH). 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 25: 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 sizing resulting in improper gas volume. - Page 26 ATTENTION: Improperly adjusted manual bypass valves will result in damage to the heater if the flow rates are not maintained as specified in Table 14 under all operating conditions. The heat exchang- er will fail and this damage will not be covered under the Hayward warranty. Figure 16: Manual Bypass valve...
-
Page 27: 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 Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 28: Drain Valve Installation (Asme Models)
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 teflon tape on the threads. Install the pressure relief valve with the discharge connection facing the ground. -
Page 29: 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 fittings and above ground equipment, be bonded together with a solid copper conductor wire gauge 8 AWG or larger. -
Page 30: Remote Control Connection
High” the “SPA” LED will be illuminated and the water temperature will be displayed. The heater will use its internal thermostat to regulate the water temperature to the set point of the mode selected. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... - Page 31 Figure 23: Wiring connection diagram.
- Page 32 Figure 24: Lighting & Operating Instructions label...
-
Page 33: 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 Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 34: Gas Pressure Testing
If there is more than one pool/spa heater USE ONLY HAYWARD GENUINE REPLACEMENT PARTS connected to the gas supply line, turn each of those appliances “ON” while testing the heater. -
Page 35: Water Pressure Switch
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: 908-351-5400 www.haywardpool.com... -
Page 36: Temperature Adjustment
This feature is useful for preventing unauthorized users from manually adjusting the temperature settings higher than desired. On a new heater, the maximum allowed USE ONLY HAYWARD GENUINE REPLACEMENT PARTS temperature lock settings are initially set at the factory to 90°F for POOL mode, and 104°F for SPA mode. -
Page 37: Temperature Lock-Out
6. When the thermostat is satisfied 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: 908-351-5400... -
Page 38: 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: 908-351-5400... -
Page 39: 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 40: Draining The Heat Exchanger
Figure 28: 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: 908-351-5400 www.haywardpool.com... -
Page 41: Section Iv Technician Service
1. External heat exchanger 2. Internal heat exchanger 3. Main burner flame patterns 4. Main burner orifices 5. Operating controls USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 42: Heat Exchanger Inspection And Cleaning
Spider nests in the burner and/or gas orifices may also cause yellow tips. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 43: Burner Removal And Replacement
Do not place pipe dope on the first two threads of any joint. 8. Reverse the above procedure to re-install the gas manifold. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... -
Page 44: Igniter
7. After cleaning or replacing orifices re-install into the gas manifold pipe being careful not to cross- thread or over tighten as a leak may result. ATTENTION: Do not enlarge orifice holes. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... -
Page 45: Gas Conversion
ATTENTION: Conversion kits are not available in Canada. Conversions must be performed by the conversion station at Hayward Pool Products Canada, Inc. ELECTRICAL WIRING: ATTENTION: If it is necessary to replace any of the original wiring, it must be replaced with Hayward supplied replacement parts. -
Page 46: Ignition Control System
4. Pull the tubing from the hose barb on the switch. 5. Remove the (2) screws that secure the pressure switch to the control panel. 6. Reverse the above procedure to install the blower vacuum switch. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... -
Page 47: High Limit Switch
5. Replace the high limit switch. Use new sealant on the high limit switch threads before reinstalling. Reverse the above procedure to install the high limit switch. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... -
Page 48: Thermistor
5. Using two ½” open-end wrenches 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 above to complete the procedure. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400... -
Page 49: Transformer
6. Check the function of the bypass valve to ensure the valve flaps 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 50: Section V Troubleshooting
When a heater is wired to the line side of the power circuit (continuous power) the blower will not oper- ate when the pump is cycled via a time clock or other switch method. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com... -
Page 51: Internal Wiring
The fuse designations are printed on the ignition board and the control board. See Figure 25 for board lo- cations. Fuses are available as common hardware items or may be purchased from Hayward in a service parts kit. The fuse specifications are: •... -
Page 52: 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: 908-351-5400... - Page 53 See below for more detail. EEPROM ERROR An error was detected in the ignition control circuit board. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Pomona, CA Clemmons, NC Nashville, TN...
-
Page 54: Troubleshooting
Figure 32: TROubLESHOOTING Code Fault Diagnosis Step Remedy Heater will not 1. Check for Low & High Disconnect plug from P5 connector from Fuse Board. Measure power up. Voltage Output from Fuse for 24VAC between pins of receptacle on Fuse Board. Reconnect Board plug. - Page 55 Igniter Failure 1. Check for faulty wiring or Inspect Igniter wiring. Ensure Igniter Plug is securely attached to connection. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Control Module. If OK, proceed to step 2. 2. Igniter is defective Replace Ignitier. Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
- Page 56 Verify that water flow to heater is above minimum required (20 GPM for is adequate H150FD and H200FD, 25 GPM for H250FD and H300FD, 30 GPM for H350FD and H400FD). Note that intermittent periods of low water flow will cause this error. If OK, proceed to step 3.
- Page 57 Verify that water flow rate to heater is above the minimum required adequate (20 GPM for H150FD and H200FD, 25 GPM for H250FD and H300FD, 30 GPM for H350FD and H400FD). If OK, proceed to step 4. 4. Temperature limit switch Replace temperature limit switch.
-
Page 58: 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 materi- als under normal use and service. Pursuant to this warranty and subject to the Conditions and Exceptions indicated below: 1. - Page 59 ALS, SUCH AS GASOLINE OR PAINT THINNERS, BE USED OR STORED IN THE VICINITy OF THE HEATER OR IN ANy LOCATION FROM WHICH FUMES COULD REACH THE HEATER. For your comfort, enjoyment and safety, please read the enclosed operating instructions carefully. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
-
Page 60: Service Parts
SERVICE PARTS Bronze Header Models (ASME) Plastic Header Models (Non-ASME) - Page 61 TOP FLUE COVER, GRAy, ASME - H250FD FDXLTFC1400A TOP FLUE COVER, GRAy, ASME - H400FD FDXLFAD1150 FRONT ACCESS DOOR ASSy - H150FD FDXLFAD1200 FRONT ACCESS DOOR ASSy - H200FD FDXLFAD1250 FRONT ACCESS DOOR ASSy - H250FD FDXLFAD1300 FRONT ACCESS DOOR ASSy - H300FD FDXLFAD1350...
- Page 62 CONVERSION KIT, NA TO LP, QUICK-CHANGE - H150FD FDXLGCK1150PN CONVERSION KIT, LP TO NA, QUICK-CHANGE - H150FD FDXLGCK1200NP CONVERSION KIT, NA TO LP, QUICK-CHANGE - H200FD FDXLGCK1200PN CONVERSION KIT, LP TO NA, QUICK-CHANGE - H200FD FDXLGCK1250NP CONVERSION KIT, NA TO LP, QUICK-CHANGE - H250FD...
- Page 63 FDXLTER1930 THERMISTOR FDXLGSK1934 GASKET, CC FRONT/AIR BOX - ALL MODELS FDXLHXA1150 HEAT EXCHANGER ASSy - H150FD FDXLHXA1200 HEAT EXCHANGER ASSy - H200FD FDXLHXA1250 HEAT EXCHANGER ASSy - H250FD FDXLHXA1300 HEAT EXCHANGER ASSy - H300FD FDXLHXA1350 HEAT EXCHANGER ASSy - H350FD...
- Page 64 FDXLDRV1930A DRAIN VALVE, ASME UHXNEGVT11501 INDOOR VENT ADAPTER KIT, NEG-PRESS (VERTICAL) - H150FD UHXNEGVT12001 INDOOR VENT ADAPTER KIT, NEG-PRESS (VERTICAL) - H200FD UHXNEGVT12501 INDOOR VENT ADAPTER KIT, NEG-PRESS (VERTICAL) - H250FD UHXNEGVT13001 INDOOR VENT ADAPTER KIT, NEG-PRESS (VERTICAL) - H300FD...