Hayward H150FD Service & Installation Manual
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Hayward H150FD Service & Installation Manual

Pool and spa/hot tub heaters
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See also: Owner's Manual , Service & Installation Manual
SERVICE & INSTALLATION MANUAL
FOR YOUR SAFETY
WARNING: If the information in these
explosion may result causing property damage,
injury, or death.
mable vapors or liquids in the vicinity of this
or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
any phone in your building.
neighbor's phone. Follow the gas supplier's
instructions.
- Installation and service must be performed by
gas supplier.
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

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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 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: 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 Suction outlets in the same plane (i.e. sured from near point to near point. seating areas. not securely attached. mediately. 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 death. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
  • Page 6 Inches of 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

    Premature Heat Exchanger Damage or Failure The heat exchanger in your Hayward pool heater is made from the highest quality of copper and nickel heat exchanger is state of the art in pool heater design and manufacture. Yet, it remains vital that the heat ex- water or the improper addition of sanitizers into the water is NOT covered under the terms of your warranty.
  • 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

    (outdoor or indoor), and altitude needed. Extra plate(s) are included with the heater, packaged in the 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

    8. Repeat Steps 6 & 7 at the rear of the heater. 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

    A or B below (whichever applies to the installation). These vents must never be obstructed when heater is in operation. blower air duct is recommended. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...
  • Page 14 87.5 87.5 400,000 150,000 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- cialized fittings, you may order them directly from Heatfab, or from an authorized Heatfab dealer. To locate a...
  • 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

    14. Re-install heater front door. 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 Page 2 of 2 1303264301 rev B 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 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)

    MAIN POWER : WARNING - Power connections supplied to the heater must be in accordance with National Electric USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...

  • Page 29: Electrical Connections

    (see Figure 22). The heater has 2 junction boxes (one on each side of the heater). Only one junction box USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...

  • Page 30: Remote Control Connection

    On the remote control wiring terminal block (Figure 22), connect the appropriate wires from the remote LED will be illuminated and the water 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...
  • Page 31 Figure 23: Wiring connection diagram.
  • Page 32 Figure 24: Lighting & Operating Instructions label...

  • Page 33: Section Iii Check-Out & Start-Up

    ½ psig (3.45 kPa). USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...

  • Page 34: Gas Pressure Testing

    & operating instruc- tap plug terminals USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN 6. Take a pressure reading with the heater running, the value should agree with those in Table 15. If the Tel: 908-351-5400 www.haywardpool.com...

  • Page 35: Water Pressure Switch

    This is apparent when the pressure switch cannot be further adjusted. In these cases the pump must be run at high speed to operate the heater. If the pump and piping arrangement are such that the re- 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

    5. The blower vacuum switch, the temperature limit switches, the vent pressure switch, the water pressure heat to assure the heater is operating properly. 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 www.haywardpool.com...

  • 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

    The following inspection procedures are recommended to be performed as part of annual heater mainte- nance and to ensure safe operation. 1. External heat exchanger 2. Internal heat exchanger 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

    Figure 29: Burner Flame characteristics the main burners through the sight glass (see ture due to restricted air supply. Spider nests in 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

    7. Reassemble the gas manifold assembly using the new gas valve. Only use liquid pipe thread sealant 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

    5. Remove the gas manifold assembly. It is attached to the air box using (4) screws. thread or over tighten as a leak may result. ATTENTION: USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...

  • Page 45: Gas Conversion

    The factory-installed gas train, where appropriate, may be changed from natural gas to propane or from 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

    4. Remove the wires from the pressure switch. 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

    8. Insert bypass cartridge into header with the arrow on the end of the cartridge pointing up. 10. Re-install the upper plastic heater side panel. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400...

  • 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 3A slo-blo fuse, 5 x 20 mm...

  • Page 52: Error Codes

    An excessive temperature difference between the two thermistors (5 °F or more) 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 Fault Diagnosis Step Remedy Heater will not Disconnect plug from P5 connector from Fuse Board. Measure power up. for 24 between pins of receptacle on Fuse Board. Reconnect Board plug. Disconnect plug from P6 of Fuse Board. Measure for 120 between pin 3 and 5 of receptacle on Fuse Board.
  • Page 55 Assembly Display Interface Assembly are defective. Igniter Failure Inspect Igniter wiring. Ensure Igniter Plug is securely attached to connection. USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 2. Igniter is defective Replace Ignitier. Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...
  • Page 56 Figure 32: TROUBLESHOOTING Fault Diagnosis Step Remedy Temperature Inspect sensor wiring. Ensure sensor is pluggd into back of control sensor input connection. failure 2. Sensor is defective Replace temperature sensor. Water Temperature setting Sensing Error remote thermostat, proceed to step 2. is adequate temperature sensor water temperature sensor.
  • Page 57 Figure 32: TROUBLESHOOTING Fault Diagnosis Step Remedy Temperature Inspect temperature limit switch wiring. Ensure wire harness teminals limit switch fault connection. are securely fastened to spade terminals on temperature limit switches. Temperature Remove wire leads from limit switch and jumper leads. Operate heater. limit switch fault limits’...

  • Page 58: Warranty

    HAyWARD POOL HEATER CERTIFICATE OF LIMITED WARRANTy Limited heater warranty: Exceptions indicated below: 1. We will replace (cost of freight, installation, cost of fuel, and service labor at user’s expense) with mal use and service within one year from the date of original installation for all users.
  • Page 59 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona, CA Clemmons, NC Nashville, TN Tel: 908-351-5400 www.haywardpool.com...

  • Page 60: Service Parts

    SERVICE PARTS Bronze Header Models (ASME) Plastic Header Models (Non-ASME)
  • Page 61 TOP FLUE COVER - H400FD FDXLTFC1250A 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...
  • Page 62 GAS MANIFOLD - H300FD FDXLMAN1350 GAS MANIFOLD - H350FD FDXLMAN1400 GAS MANIFOLD - H400FD FDXLGCK1150NP 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...
  • Page 63 GASKET, BEZEL/TOP FDXLHLI1930 HIGH LIMIT KIT 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...
  • Page 64 ASME UNION FLANGE KIT (INCL. FITTINGS, BOLTS, GASKETS) FDXLTDK1930 TIE-DOWN KIT 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...

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H200fdH300fdH350fdH400fdH250fd

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