Hayward Universal H-Series Low NOx Service & Installation Manual

Pool and spa/hot tub heaters

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Owner's manual (16 pages)

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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, injury, or death.
Page 2: Table Of Contents
Keypad inputs ..........37 Automatic reset time ........38 Periodic inspection ........38 Winterization ..........38 Draining the heat exchanger ....... 39 Spring start-up ..........39 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 3: Safety Information
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 A 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
Maximum Vent Pipe Length and Number of Elbows for Positive-Pressure Vent Systems Maximum Vent Pipe Number of 90- Length degree Elbows (horizontal & vertical) 50 ft 50 ft 40 ft 30 ft USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
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 5 FIGURE 4 Flue Cover FIGURE 6 FIGURE 7 Vent Pressure Switch Blower Air Inlet Plate Blower Pressure Vent Pressure FIGURE 8 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 Limit Switch Water Pressure Switch Water Temperature Sensor Upper Plastic Heater Side Panel Ignition Upper Plastic Heater Control Side Panel Board Front Access Panel Figure 15 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 22: All Gas Installations
Iron or Plastic Pipe Iron or Plastic Pipe Iron or Plastic Pipe Iron or Plastic Pipe 0 to 10 ft 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 23 Iron Pipe Tubing Iron Pipe Tubing Gas Valve Inlet Material 0 to 10 ft 1/2" 5/8" 1/2" 5/8" 1/2" 3/4" 3/4" 3/4" 3/4" 7/8" 3/4" 7/8" 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 Figure 20 under all operating conditions. The heat ex- changer will fail and this damage will not be covered under the Hayward warranty. Figure 22 illustrates a typical pool piping diagram and layout for the pool equipment.
Page 27: Installation Above Pool Surface
Back- siphoning 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 Electri- cal Code (NEC), and most other codes require that all metallic components of a pool structure, including re- inforcing steel, metal fittings and above ground equipment, be bonded together with a solid copper conductor wire gauge 8 AWG or larger.
Page 30 Figure 28: Wiring connection diagram.
Page 31: 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 32 Figure 30: 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 Control Operation
5. The blower vacuum switch, the temperature limit switches, the vent pressure switch, the water pressure switch, the water temperature sensors, and the flame sensor are constantly monitored during a call for heat to assure the heater is operating properly. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
Page 37: Retry (Failure Of Light)
2. It is normal for the heater to display a 1- to 2-second delay in responding to any keypad input. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 38: 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 39: Draining The Heat Exchanger
Figure 36: 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 40: Section Iv Technician Service
Steps 1-2 panel (2) Water header above. Blank side Header side trim panel trim panel End cap End cap Front access Side jacket panel Control boards USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 41: Heat Exchanger Inspection And Cleaning
The combustion chamber is a single-piece casting. If damaged, the entire chamber must be replaced. HEAT EXCHANGER REMOVAL: Follow steps 1-12 under “External heat exchanger inspection and cleaning” in this section. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 42: Burner Inspection
9. Remove the air box cover. Do not remove the blower from the air box cover. 10. Remove the (2) screws securing each burner to the combustion chamber front. 11. Pull the burners straight out of the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
Page 43: Burner Installation
Do not place pipe dope on the first two threads of any joint. 9. Complete assembly by reversing steps 1 – 5. Figure 41: Correct orientation of components of gas manifold assembly USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
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. CONTROL LOCATIONS: The following sections give a brief overview of the various heater controls and service/replacement pro- cedures.
Page 46: Ignition Control Board
The tubing on the blower vacuum switch should be attached to the blower housing pressure tap that faces the front of the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
Page 47: High Limit Switch
5. Replace the high limit switch. Use new sealant on the high limit switch threads before reinstalling. Reassembly is a reverse of steps 1 – 4. Figure 46: High Limit Switch USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
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 1 – 5 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 26 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 53: 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 Figure 53: TROubLESHOOTING Code Fault Diagnosis Step Remedy Temperature 1. Check for faulty wiring or Inspect sensor wiring. Ensure sensor is pluggd into back of control sensor input connection. module. If OK, proceed to step 2. failure 2. Sensor is defective Replace temperature sensor.
Page 57 Figure 53: TROubLESHOOTING Code Fault Diagnosis Step Remedy Temperature 1. Check for faulty wiring or Inspect temperature limit switch wiring. Ensure wire harness teminals limit switch fault connection. are securely fastened to spade terminals on temperature limit switches. If OK, proceed to step 2. Temperature 2.
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 ITEM PART NO. DESCRIPTION FDXLJKT1150 JACKET TOP - H150FD FDXLJKT1200 JACKET TOP - H200FD FDXLJKT1250 JACKET TOP - H250FD FDXLJKT1300 JACKET TOP - H300FD FDXLJKT1350 JACKET TOP - H350FD FDXLJKT1400 JACKET TOP - H400FD FDXLJKT1250A JACKET TOP, GRAy, ASME - H250FD FDXLJKT1400A JACKET TOP, GRAy, ASME - H400FD FDXLTFC1150...
Page 62 ITEM PART NO. DESCRIPTION FDXLRJC1930 JUNCTION BOX COVER, RIGHT FDXLPBL1930 BASE LEG FDXLFCS1930 FLUE COLLECTOR SIDE PANEL FDXLRGK1151 RAIN GUARD ASSEMBLy - H150FD FDXLRGK1201 RAIN GUARD ASSEMBLy - H200FD FDXLRGK1251 RAIN GUARD ASSEMBLy - H250FD FDXLRGK1301 RAIN GUARD ASSEMBLy - H300FD FDXLRGK1351 RAIN GUARD ASSEMBLy - H350FD FDXLRGK1401...
Page 63 ITEM PART NO. DESCRIPTION FDXLFWP1930 FIELD WIRING PANEL FDXLIGN1930 IGNITOR IDXLFLS1930 FLAME SENSOR IDXL2TRF1930 TRANSFORMER FDXLWPS1930 WATER PRESSURE SWITCH IDXL2DB1930 DISPLAy BOARD ONLy FDXLBKP1930 BEZEL & KEyPAD ASSEMBLy FDXLBKP1931 BEZEL & KEyPAD ASSEMBLy, BLUE, ASME FDXLGSK1932 GASKET, BEZEL/TOP FDXLHLI1930 HIGH LIMIT KIT FDXLTER1930 THERMISTOR FDXLGSK1934...
Page 64 Hayward Pool Products, Inc. Hayward Pool Products, Inc. Hayward S.A. 620 Division St. 2875 Pomona Boulevard 2880 Plymouth Drive Zoming de Jumet Elizabeth, NJ 07207 Pomona, CA 91768 Oakville, Ontario L6H 5R4 B6040 Jumet, Belgium © 2004 Hayward Printed in U.S.A.

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H150fd H200fd H250fd H300fd H350fd H400fd