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SERVICE & INSTALLATION MANUAL FOR TR250 & TR400
MODEL POOL AND SPA/HOT TUB HEATERS
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 ammable vapors or
liquids in the vicinity of this or any other appliance.
This product must be installed and serviced by authorized
personnel, qualifi ed in pool/spa heater installation. Im-
proper 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
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 per-
formed by a qualifi ed installer, service
agency, or the gas supplier.
1301150301 Rev B 1015
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Summary of Contents for Trane TR250
- Page 1 SERVICE & INSTALLATION MANUAL FOR TR250 & TR400 MODEL POOL AND SPA/HOT TUB HEATERS WHAT TO DO IF YOU SMELL FOR YOUR SAFETY GAS: • Do not try to light any appliance. WARNING: If the information in these instructions •...
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Page 2: Table Of Contents
CONTENTS Safety Information ..........3 Section IV Technician Service ......41 General ............41 Section I General information ......7 Maintenance ..........41 Introduction ............ 7 Heat exchanger inspection and cleaning ..41 Warranty ............7 Combustion chamber ........42 Maintaining proper water chemistry .... -
Page 3: Safety Information
SAFETY INFORMATION Basic safety precautions should always be followed, including the following: Failure to follow instructions can cause severe injury and/or death. 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 NOTES TO THE ELECTRICIAN: Use a solid copper conductor, size 8 or larger. Run a continuous wire from external bonding lug to rein- forcing rod or mesh. Connect a No. 8 AWG solid copper bonding wire to the grounding lug provided on the heater and to all metal parts of swimming pool or spa, and to all electrical equipment, metal piping (except gas piping), and conduit within 5 ft.
- Page 5 WARNING – Failure to remove pressure test plugs and/or plugs used in winterization of the pool/spa from the suction outlets can result in an increase potential for suction entrapment as described above. WARNING – Failure to keep suction outlet components clear of debris, such as leaves, dirt, hair, paper and other material can result in an increase potential for suction entrapment as described above.
- Page 6 WARNING – The following “Safety Rules for Hot Tubs” recommended by the U.S. Consumer Product Safety Commission should be observed when using the spa. 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.
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Page 7: Section I General Information
The heat exchanger in your Trane pool heater is made from the highest quality of copper and nickel (Cu- pronickel) 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 ing spa water regularly and maintaining the correct chemical balance in your pool/spa will keep the pool/spa safe and sanitary, and will help protect the heat exchanger. Use a 4-way pool/spa water test kit to check your water frequently (at least weekly). Use the following guidelines to help protect your heater’s heat exchanger: 3.
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Page 9: Section Ii Installation
10,100 ft, the heater may not be installed. Note that if installing outdoors, some Trane heaters may be compatible with your altitude without modifi cation. Table 1 lists the altitude ranges for heaters without modifi cation. All indoor heaters installed above 2,000 ft require a special vent pressure switch. - Page 10 FDXLHAK1930 (sold separately) may be necessary. 3. If installing indoors, select the appropriate high-altitude indoor vent pressure switch from the indoor adapter kit or from the FDXLVPS1931 kit. Each switch has a label which identifi es which model(s) and altitude range(s) it is designed for. 4.
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Page 11: Uncrating The Heater
UNCRATING THE HEATER: Figure 1: Pallet Mounting Bracket Location To remove the shipping carton from the heater: 1. Remove the corrugated carton from the The screw through heater. The carton, top pad, bottom pad, the rear shipping and the four corner posts can be recycled. bracket is located in 2. - Page 12 Do not install under a deck. Table 2 Do not install within 24” of any outdoor Outdoor Installation Clearances HVAC equipment. Heater Panel Required Clearance Do not install where water may run-off a Unobstructed roof into the heater. A gutter may be need- Front 24 inches ed to protect the heater.
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Page 13: Flooring
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. TIE-DOWN BRACKETS: The heater is equipped for installation of factory-supplied tie-down brackets if required by local codes. The brackets are shipped in the consumer kit. You will need the following to complete the installa- tion: 1. -
Page 14: Indoor Installation And Venting
Number Material Models Requirement 50 ft max vertical height, Indoor Vent Adapter Kit, Single or Double Vertical Only, UHXNEGVT12501 TR250 25 ft max horizontal length Negative Pressure, Wall Galvanized Termination Above (horizontal length cannot Vertical Venting Non-Sealed Roof of House/... - Page 15 (A) ALL AIR SUPPLY FROM INSIDE THE BUILDING: The confi ned space shall be provided with 2 permanent openings communicating directly with an addi- tional room(s) of suffi cient volume so that the combined volume of all spaces meets the criteria for an uncon- fi...
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Page 16: Vertical Venting
Part Number Heater Model Diameter (see Table 6). The maximum vent height can- UHXNEGVT12501 TR250 6 inch not exceed 50 ft. The total lateral (horizontal) length cannot exceed 1/2 of the total vent height. UHXNEGVT14001 TR400... -
Page 17: Horizontal Or Vertical Venting
A variety of double-wall vent components, including terminals, elbows, and straight lengths, which will satisfy the needs of most applications of your Trane pool heater are available. The parts are listed in the ser- vice parts section in the back of this manual. Also, the instruction sheet included with the kit can be used as a guide in specifying installations. - Page 18 Diameter Single- Heatfab Saf-T Vent EZ Seal Heatfab P/N Heatfab P/N 5600CI Wall P/N 960x * 5690CI ‡” NAT & TR250 UHXPOSHZ12501 10,100 ft 6 inch Included in UHX kit Double- Heatfab Saf-T Vent CI Plus Heatfab P/N Heatfab P/N...
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Page 19: Reversible Water Connections
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. A trained service technician should perform these steps before the heater is installed. - Page 20 Figure 8: Sub-Assemblies Louvered Exhaust Panel Top Flue Cover Rain Shield Assembly Heat Exchanger Temperature Assembly Limit Switches Drain Plug or Valve Pressure Switch Port Upper Plastic Heater Side Panel Ignition Control Circuit Board Upper Plastic Heater Side Panel Front Access Panel...
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Page 21: Gas Supply And Piping
GAS SUPPLY AND PIPING: To properly size the gas piping for the heater, refer to Tables 10, 11, 12, and 13, depending on natural or propane gas, and single-stage or 2-stage regulation. Follow local gas codes for proper gas line material selection (copper, iron, plastic, etc.). - Page 22 Table 13 Propane Gas Pipe Sizing, High-Pressure, 2-Stage Regulation Distance from Tank Model TR250LP TR400LP Regulator Outlet to Btu/hr Input 250,000 400,000 Heater Gas Valve Line Material Iron Pipe Tubing Iron Pipe Tubing Inlet 0 to 50 ft 1/2” 1/2” 1/2”...
- Page 23 GAS SUPPLY INSTALLATION: Figure 9: Gas Piping The heater is shipped from the factory with the gas connection located on the left-hand side of the heater cabinet. Insert the pipe to the gas valve through the grommet in the cabinet side (see Figure 10.) A union should be installed outside the heater cabinet for easy removal of the gas manifold assembly during service.
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Page 24: Water Piping
ATTENTION: Whenever a high-pressure double regulation system is utilized for propane gas, consult a propane expert for accurate pipe and pressure sizing. Make sure that 1st and 2nd stage regulators are large enough to handle the BTUH input listed for the heater(s) being used. The manufacturer will not be responsible for heaters that soot up due to improper gas line or propane tank sizing resulting in improper gas volume. - Page 25 Rate (GPM) Rate (GPM) rate is within the fl ow rate range specifi ed for the heater. TR250 Once the valve is set, note the position and remove the valve handle to prevent further adjustment. TR400 ATTENTION: Improperly adjusted manual bypass valves will result in damage to the heater if the fl...
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Page 26: Installation Above Pool Surface
Figure 13 illustrates a typical pool piping diagram and layout for the pool equipment. Figure 14 illustrates a multiple heater installation for very large pools with and without a manual bypass valve. Figure 14: Multiple heater system Figure 13: Typical plumbing to pool Figure 15: Heater installation INSTALLATION ABOVE POOL/SPA SURFACE: above pool/spa... -
Page 27: Pressure Relief Valve
CAUTION - This heater must be connected to a bonding grid with a solid copper conductor wire gauge 8 AWG or larger. All Trane pool/spa 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 28: Electrical Connections
ELECTRICAL CONNECTIONS: The heater is equipped with a hot surface ignition control system that automatically lights the burners. An external power supply is required to power the control system. The electrical specifi cations for this heater are 120/204 VAC, 60Hz, 1-phase, 5.5A maximum current. It is recommended that circuit protection for the heater circuit be rated at 15 Amperes. -
Page 29: Remote Control Connection
REMOTE CONTROL CONNECTION: The heater is equipped for con- Figure 18: Junction Box connections nection to an external 2-wire remote L (120V) N (120V) thermostat or a 3-wire remote switch. A 2-wire thermostat has its own tempera- Ground L1 (240V) L2 (240V) ture sensor for regulating water tempera- ture. - Page 30 Figure 19: Wiring connection diagram.
- Page 31 Figure 20: Lighting & Oper- ating Instructions label...
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Page 32: Section Iii Check-Out & Start-Up
Access Panel Sight Glass Gas Manifold (TR250 and TR400 Models) GAS LINE TESTING: The appliance and its gas connection must be leak tested before placing the appliance in operation. The heater and its individual shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pressure in excess of ½... -
Page 33: Gas Pressure Testing
GAS PRESSURE TESTING: The following gas pressure requirements are important to the proper operation of the burners in gas heat- ers. Improper gas pressure or gas volume will create the following conditions: 1. Flame burns totally yellow. 2. Flame lifts off burner. 3. - Page 34 6. Take a pressure reading with the heater running, the value should agree with those in Table 15. If the pressure is within the range of 1.8” - 2.0” w.c. (natural) or 6.8” - 7.0” w.c. (propane), then no further adjustment is needed. Table 15: Correct Gas Pressures Fuel Natural...
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Page 35: Water Pressure Switch
WATER PRESSURE SWITCH TEST / ADJUSTMENT PROCEDURE: The pressure switch is preset at the factory for most typical, deck level installations. When the heater is located above or below the level of the pool or spa, the pressure switch may require adjustment to compensate for the change in static head pressure. -
Page 36: Temperature Adjustment
TEMPERATURE ADJUSTMENT: This pool heater is equipped with a digital thermostat which allows the user to select the desired water temperature. The heater will then function automatically to maintain the desired temperature. The heater has 3 modes of operation: 1. STANDBY: in this mode, the heater will not function to heat the water. 2. -
Page 37: Temperature Lock-Out
TEMPERATURE LOCK-OUT: The digital thermostat in this pool heater allows the user to lock the maximum temperature setting allowed. This feature is useful for preventing unauthorized users from manually adjusting the temperature settings higher than desired. On a new heater, the maximum allowed temperature lock settings are initially set at the factory to 90°F for POOL mode, and 104°F for SPA mode. -
Page 38: Retry (Failure Of Light)
FAILURE TO LIGHT – RETRY: If the fi rst ignition attempt fails during a normal heating cycle the control will make two (2) additional ignition attempts: 1. The control de-energizes the gas valve after the 4 second ignition trial ends. 2. -
Page 39: Automatic Reset Time
AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resume operation as detailed in the table below. The heater can be manually reset using the keypad by cycling the mode button through “STANDBY” and back to the original operating mode (“SPA” or “POOL”). PERIODIC INSPECTION: The heater is designed and built for long performance life when installed and operated according to the manufacturer’s directions. -
Page 40: Draining The Heat Exchanger
DRAINING THE HEAT EXCHANGER: 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 41: Section Iv Technician Service
SECTION IV. QUALIFIED TECHNICIAN – MAINTENANCE & SERVICING GENERAL: ATTENTION: Only qualifi ed service technicians, with appropriate test equipment, should be allowed to service the heater. Bear in mind that all of the components that comprise the system have an effect on heater operation. -
Page 42: Combustion Chamber
• Blockage of burner tubes or orifi ces • Blockage of blower inlet • Low voltage supply causing blower to “spin” slower • Improper heater location installation • Incorrect gas supply pipe size • Excessive water fl ow through heat exchanger •... -
Page 43: Gas Valve Replacement
Pull the burners straight out of the heater. Reverse the above procedure to install the burners. Turn the gas supply “on”. Use a soapy water solution to check for leaks. Bubbles forming indicate a leak. WARNING: EXPLOSION HAZARD The use of an open fl ame to check for gas leaks could cause an explosion resulting in severe injury and/or death GAS VALVE REPLACEMENT: Refer to Figure 8, Figure 21, and Figure 22 as needed. -
Page 44: Flame Sensor
FLAME SENSOR: Refer to Figure 8 and Figure 21 as needed. To remove the fl ame sensor: 1. Turn pump, gas supply, and heater power “OFF”. 2. Remove the front access panel (4 screws). 3. Disconnect the wire from the fl ame sensor. 4. -
Page 45: Blower Vacuum Switch
Detach the board from the sheet metal panel by compressing the plastic stand-offs. Replace the board, and reverse the above steps to reassemble. To remove/replace the display board or keypad: 1. Turn pump, gas supply, and heater power OFF. 2. Remove the front access panel. Unplug the display board ribbon cable from the ignition control board. -
Page 46: Exhuast Gas Temperature Limit
4. Unscrew the high limit switch from the header. 5. Replace the high limit switch. Use new sealant on the high limit switch threads before reinstalling. 6. Reverse the above procedure to install the high limit switch. EXHAUST GAS TEMPERATURE LIMIT: The exhaust gas temperature limit monitors the fl... -
Page 47: Transformer
4. Remove the wires from the pressure switch. 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. TRANSFORMER: The transformer converts the fi... -
Page 48: Bypass Service Cartridge
BYPASS SERVICE CARTRIDGE: The following procedure details how to remove and replace the internal pressure bypass valve in the header. 1. Turn pump, main gas valve, and heater power off. Drain heat exchanger according to instructions in Section III of this manual. Remove 6 screws and remove the upper plastic heater side panel, to allow access to the header. -
Page 49: Section V Troubleshooting
SECTION V. TROUBLESHOOTING GENERAL: ATTENTION: These instructions are intended for the use of qualifi ed personnel trained and experi- enced in the installation and servicing of this type of heating equipment and its related system compo- nents. Some states may require installation and service personnel to be licensed. Persons not qualifi ed should not attempt to repair this equipment according to these instructions. -
Page 50: Fuse Specifications
FUSE SPECIFICATIONS: The fuse designations are printed on the ignition board and the control board. See Figure 21 for board locations. Fuses are available as common hardware items or may be purchased from the manufacturer in a service parts kit. The fuse specifi cations are: •... -
Page 51: Error Codes
Error codes Figure 27: Code Description Information Internal fault/power-up On initial trial for ignition. Automatic reset is immediate once the gas valve relay error check results are acceptable. Gas valve sensed If valve is open when it should be closed the heater will shut down and go into as “ON”... - Page 52 Figure 27: ERROR CODES (continued) Code Description Information Water Temperature A) Inlet water temperature sensor is reporting a temperature in excess of 104°F. Sensing Error Normal operation resumes 2 minutes after inlet water temperature sensor reports temperatures of 104°F or less. This error functions in both normal and remote thermostat modes.
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Page 53: Troubleshooting
TROUBLESHOOTING Figure 28: Code Fault Diagnosis Step Remedy Heater will not 1. Check for Low & High Disconnect plug from P5 connector from Fuse Board. power up. Voltage Output from Fuse Measure for 24VAC between pins of receptacle on Fuse Board. Board Reconnect plug. - Page 54 TROUBLESHOOTING Figure 28: Code Fault Diagnosis Step Remedy Open FC1 and/ 1. Verify that 120VAC Check that proper Voltage Selector Plug is installed. If OK, or FC2 Fuses. Voltage Selector Plug proceed to step 2. is not installed with a 240VAC fi...
- Page 55 TROUBLESHOOTING Figure 28: Code Fault Diagnosis Step Remedy Bad Board or 1. Verify that FC4 Fuse on Remove FC from fuseholder. Mesure continuity across fuse. Secondary Hig Fuse Board is not open. If OK, reinstall fuse and proceed to step 2. If Fuse is open, Voltage Fault proceed to section titled ‘‘Open FC4 Fuse’’.
- Page 56 2. Verify that water fl ow Verify that water fl ow rate to heater is above minimum is adequate required (25 GPM for TR250 and 30 GPM for TR400). If OK, proceed to step 3 3. Check for faulty wiring Inspect water pressure switch wiring.
- Page 57 3. Verify that water fl ow Verify that water fl ow rate to heater is above the minimum is adequate required (25 GPM for TR250 and 30 GPM for TR400). If OK, proceed to step 4. 4. Temperature limit Replace temperature limit switch.
- Page 58 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. For further assistance, please contact technical service at 908-282-4897 or visit www.trane.com/poolcomfort.
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Page 59: Warranty
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 60 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. ® MANUFACTURED FOR TRANE BY HAYWARD INDUSTRIES, INC. 2935 Sidco Dr. Nashville, TN 37204...
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Page 61: Service Parts
SERVICE PARTS... - Page 62 JACKET TOP - TR400 TRXLTFC1250 TOP FLUE COVER - TR250 TRXLTFC1400 TOP FLUE COVER - TR400 TRXLFAD1250 FRONT ACCESS DOOR ASSY - TR250 TRXLFAD1400 FRONT ACCESS DOOR ASSY - TR400 TRXLRAD1250 REAR ACCESS DOOR ASSY - TR250 TRXLRAD1400 REAR ACCESS DOOR ASSY - TR400...
- Page 63 SERVICE PARTS ITEM PART NO. DESCRIPTION FDXLHLI1930 HIGH LIMIT KIT FDXLTER1930 THERMISTOR FDXLGSK1934 GASKET, CC FRONT/AIR BOX - ALL MODELS FDXLHXA1250 HEAT EXCHANGER ASSY - 250K BTU HEATER FDXLHXA1400 HEAT EXCHANGER ASSY - 400K BTU HEATER FDXLFHD1930 INLET/OUTLET HEADER ONLY FDXLFHA1930 INLET/OUTLET HEADER ASSY FDXLHDW1930...
- Page 64 GAS CONVERSION KIT, LP TO NA FDXLHAK1930 CONVERSION KIT, HIGH ALTITUDE, 2,000-10,100 FT FDXLVPS1930 VENT PRESSURE SWITCH, INDOOR, 0-2,000 FT FDXLVPS1931 VENT PRESSURE SWITCH, INDOOR, 2,000-10,100 FT ® Trane and the Trane Logo are registered trademarks of Trane International Inc.
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Page 65: Specifi Cations
SPECIFICATIONS UNIT RATED CAPACITY Model Natural Gas Propane Gas TR250 250,000 Btu/hr 250,000 Btu/hr TR400 399,000 Btu/hr 399,000 Btu/hr GAS PRESSURE Fuel Natural Gas Propane Gas Manifold 1.8” - 2.0” w.c. 6.8” - 7.0” w.c. Inlet, Minimum 4.5” w.c. 9.0” w.c.
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