Hayward H150FDAU Service & Installation Manual

Hayward H150FDAU Service & Installation Manual

Pool and spa/hot tub heaters for use in australia
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H150FDAU, H250FDAU, & H400FDAU 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.
- 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. 6,026,804 & 6,321,833 & 7,971,603
POOL AND SPA/HOT TUB HEATERS
FOR USE IN AUSTRALIA
FOR YOUR SAFETY
PRINTED 10/24/2011 AT 1:13 PM
1301272601 Rev B 0813

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Summary of Contents for Hayward H150FDAU

  • Page 1 POOL AND SPA/HOT TUB HEATERS H150FDAU, H250FDAU, & H400FDAU MODELS FOR USE IN AUSTRALIA 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

    Heat exchanger inspection and cleaning ..34 Combustion chamber ........34 Heat exchanger removal ......34 Burner inspection and cleaning ....35 Burner removal and replacement ....35 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • 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 Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • 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 Hayward Pool Products (Australia) Pty Ltd.
  • Page 5 WARNING – Failure to install according to defined instructions may result in severe personal injury or death. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • 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 Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • 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 Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 9: Section Ii Installation

    AS 5601.1-2010 - Gas Installations and any other statutory regulations. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 10 422 MJ/h Natural/Propane 92.7 cm 89 kg 61.0cm 35.2cm WIDTH FRONT 74.8cm 34.6cm 24.8cm 38.3cm 37.7cm 37.3cm 31.9cm 9.5cm 7.8cm 19.1cm 14.5cm LEFT RIGHT USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 11: Uncrating The Heater

    National Fuel Gas Code (ANSI Z223.1/NFPA 54) and/or CAN/CGA B149 installation codes. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 12: Flooring

    4,000 btu/hr input rating of all gas appliances in the enclosure. See Table 1. FLOORING: This heater may be installed on either non-combustible or combustible flooring. Ultralite™ or equivalent concrete-over-foam HVAC pads are acceptable. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 13: Reversible Water Connections

    13. Re-connect the heater wire harness to the water pressure switch and temperature limit. 14. Reverse the above steps to reassemble the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 14 Water temperature sensor Manual Reset Sensing Bulb Upper Plastic Heater Side Panel Thermostat Control Upper Plastic Heater Circuit Board Side Panel Front Access Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 15: Gas Supply And Piping

    Line Material Iron or Plastic Pipe Iron or Plastic Pipe Iron or Plastic Pipe Gas Valve Inlet 0 to 3 m 3/4” 3/4” 3/4” USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 16 Line Material Iron Pipe Tubing Iron Pipe Tubing Iron Pipe Tubing Gas Valve Inlet 0 to 15 m 1/2” 5/8” 1/2” 3/4” 3/4” 7/8” USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 17: Natural Gas

    (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 18: 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 19 Figure 10 under all operating conditions. The heat ex- changer will fail and this damage will not be covered under the Hayward warranty. Figure 12 illustrates a typical pool piping diagram and layout for the pool equipment.
  • Page 20: 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 Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 21: Electrical Specifications

    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. Most 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 22: Electrical Connections

    Wiring Terminal Block Remote Connection Terminal Block (junction box cover not shown) (left side shown, right side is similar) Common Pool Spa (RED) (WHITE) (ORANGE) USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 23 Figure 18: Control Panel Layouts Figure 18: Control Panel Layouts H150FDAU Control Panel Assembly H150FDAU Control Panel Assembly (wiring not shown) (wiring not shown) H250FDAU and H400FDAU Control Panel Assembly H250FDAU and H400FDAU Control Panel Assembly (wiring not shown) (wiring not shown)
  • Page 24: Remote Control Connection

    To deactivate the heating cycle, the user presses the “MODE” button to return to “STANDBY” mode. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 25 Figure 20: Lighting & Operating Instructions label...
  • Page 26: 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 Hayward Pool Products (Australia) Pty Ltd.
  • Page 27: Gas Pressure Testing

    “ON” while testing the heater. 5. Take a pressure reading with the heater run- USE ONLY HAYWARD GENUINE REPLACEMENT PARTS ning, the value should agree with those in Figure 23. Pomona, CA Clemmons, NC Nashville, TN If the pressure is within the range shown, then no further adjustment is needed.
  • Page 28: 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 Hayward Pool Products (Australia) Pty Ltd.
  • Page 29: Temperature Adjustment

    TEMPERATURE CONTROL OPERATION: This model of Hayward gas fired pool/spa heater is equipped with a temperature control module (TCM) and a direct spark ignition control module (DSICM) for automatically controlling pool and spa water tem- peratures. The TCM has three components, the Display/Control Board with its attached Keypad and the IO/ Power Supply Board.
  • Page 30: Retry (Failure Of Light)

    LED Indication: Internal control failure Steady On Air flow fault 1 Flash Flame with no call for heat 2 Flashes Ignition lockout 3 Flashes USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 31: 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 32: Draining The Heat Exchanger

    ATTENTION: A heater damaged by freezing is not covered under the Hayward warranty. REMOVING THE DRAIN PLUG: 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 33: Section Iv Technician Service

    Figure 19. 4. Verify proper operation after servicing. 5. After service is complete, assembly is the reverse of Steps 1-2 above. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 34: 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 Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 35: Burner Inspection And Cleaning

    14. Bubbles forming indicate a leak. 15. To start the heater, follow the instructions on the label inside the front access panel (see Figure 20). USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 36: Gas Valve Replacement

    Do not place pipe dope on the first two threads of any joint. 9. Complete assembly by reversing step 1-5. Figure 28: Correct orientation of components of gas manifold assembly USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 37: Igniter

    Gas conversions are to be performed only by a qualified service agency. Detailed instructions are included with each kit. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 38: Electrical Wiring

    The tubing on the blower vacuum switch should be at- tached to the blower housing pressure tap that faces the right side of the heater. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 39: 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. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 40: 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 Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 41: 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 42: Section V Troubleshooting

    FUSE SPECIFICATIONS: The fuse designations are printed on the control board. See Figure 18 for board locations. Fuses are avail- able as common hardware items or may be purchased from Hayward in a service parts kit. The fuse specifica- tions are: •...
  • Page 43 When a dot (decimal point) is displayed after the error code, this is an indication . (dot) Auto restarts disabled that auto restarts are disabled. The TCM must be manually restarted. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 44 A DSICM lock-out can be reset by pressing the “MODE” button to cycle through “STANDBY” and back to the original mode (“SPA” or “POOL”). USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 45 LPM for H150FD, 95 LPM for H250FD, and 114 LPM for H400FD. If OK, proceed to step 4. 4. Temperature limit switch Replace temperature limit switch. is defective. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 46 If 240 VAC is not present, the blower relay in the DSICM is defective. Replace DSICM. If OK, proceed to step 6. 6. Vacuum switch is Replace blower vacuum switch. defective. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 47: Warranty

    THIS PRODUCT REQUIRES QUALIFIED INSTALLATION All Hayward heaters due to their technical nature are only intended for sale by retail shops where local sales and technical support can be provided or as a part of a new Pool Installation. Warranty claims for such products will only be recognised when the products have been sold and installed by technicians approved by Hayward Pool Products where installation has not been carried out in accordance with this requirement, warranty, labour and support will be the sole responsibility of the reseller supplying the product.
  • Page 48 Unauthorised returns will not be accepted. All Hayward Pool Products warranty parts taken as an across the counter warranty exchange must be held for inspection until authorisation has been given by the Local Branch Customer Service Manager to dispose of them. Hayward Pool Products reserves the right to provide replacement or credit for any items authorised under this warranty program.
  • Page 49 Plastic Header Models (Non-ASME)
  • Page 50: Service Parts

    HEAT BARRIER PANEL - H150FD FDXLHBP1250 HEAT BARRIER PANEL - H250FD FDXLHBP1400 HEAT BARRIER PANEL - H400FD FDXLBBN1150AU BLOWER INLET BAFFLE - H150FDAU FDXLBBN1250AU BLOWER INLET BAFFLE - H250FDAU FDXLBBN1400AU BLOWER INLET BAFFLE - H400FDAU FDXLIAC1930AU IGNITER ACCESS COVER - AUS...
  • Page 51 CONVERSION KIT, NA TO LP, QUICK-CHANGE - H250FD (NOT SHOWN) FDXLGCK1400NP CONVERSION KIT, NA TO LP, QUICK-CHANGE - H400FD (NOT SHOWN) FDXLWHA1150AU WIRING HARNESS 50HZ H150FDAU (NOT SHOWN) FDXLWHA1400AU WIRING HARNESS 50HZ H250/400FDAU (NOT SHOWN) FDXLESC1930AU 240V ELECTRICAL SUPPLY CORD WITH STRAIN RELIEF (NOT SHOWN)
  • Page 52 GASKET, RAIN GUARD BOTTOM FRNT & REAR - H400FD GASKET, RAIN GUARD BOTTOM FRNT & REAR - H250FD GASKET, RAIN GUARD BOTTOM FRNT & REAR - H150FD USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1...
  • Page 53: Gas Pressure

    Inlet, Minimum 1.12 2.24 Inlet, Maximum 2.61 3.24 Burner Configuration Natural Gas Main Injector Main Burner Propane Gas Main Injector (mm) Main Burner 2.26mm USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.au...
  • Page 54 NOTES...
  • Page 55 NOTES...
  • Page 56 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 © 2013 Hayward Printed in U.S.A.

This manual is also suitable for:

H250fdauH400fdau

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