Universal H-Series Troubleshooting Guide
Contents
1. Page 4 Beginning Sept 08 120 VAC or 240 VAC Connection IN h 120V SEE MANUAL Three Wire Remote Connection Orange Pool White 24V and Red Spa 2 WIRE REMOTE 3 WIRE REMOTE 1303277301 Two Wire Remote Connection Orange Pool and White Common Page 5 Control Hookup Through August 08 Control hookup located outside control box n NI 25 Vort 2 common Two Wire Hook up Three Wire Hook up Orange Pool and White 24v Orange Pool White 24v and Red Spa HAYWARD Page 6 Step 1 Press the Mode button to place the heater in Standby Mode Hold the Mode and Down Arrow buttons simultaneously for 3 seconds for Bypass operation bo will be displayed on the screen _ Heater must then be in Spa or Pool Mode for operation The heater will Step 3 fire when instructed by the external control H SERIES Step 2 Note 104 maximum temperature Page 7 Gas Pressure Testing Measure the inlet Static Pressure valve off and Load Pressure Step 2 Measure the outlet Manifold valve on energized Pressure valve on energized 0 Ela E m The Static and Load values should Manifold reading should be be within the levels listed on the between 1 8 2 0 w c for Natural Data Plate example on Page 9 or 6 8 7 0 w c for Propane HAYWARD Page 8 Gas Pressure Testing Turn c2. HAYWARD Page 45 Service Light On AO Code A ECT N WIL Paves ECI FC2 Service Light On AO Code If resistance is out of range replace the Blower If OK proceed to Step 4 Step 4 Disconnect Blower Plug from ICB and generate a call for heat While in pre purge measure for 110 125 VAC across Pins 1 amp 2 of inducer on ICB ANIM r K M 1 La D c If 110 125 VAC is not present replace the ICB If 110 125 VAC is present and Blower is running replace the Blower Vacuum Switch HAYWARD Page 47 Temperature Lock Out Sequence AA EU The default Max temp lock out j H SERIES settings are 90 for the Pool and 1042 for the Spa Use the MODE button and place the heater in STANDBY mode Press and hold the UP and Down buttons at the same time Wait three seconds The SPA indicator light illuminates and the display shows the current Max Temp Lock out setting Use the up and down buttons to set the desired Max Temp Lock out setting Press the mode button and the POOL indicator light illuminates Follow the same sequence as with the SPA settings above E s d X on Press the mode button again to return to STANDBY When setting the max temp lock out setting the lights and display will flash rapidly Page 48 Heat Exchanger Flow requirements Flow requirements should be checked to insure proper operation v Flow less than minimum could cause h
3. c gt e UC un e i a 9 m F0059 476200 Ly AYW ARD POOL 1 HiAYWARTD EPI PANDI If wiring is OK and plugs are securely fastened proceed to Step 9 OHAYWARD Page 19 Troubleshooting Heater will not power up Step 9 Verify low voltage 22 28 VAC to ICB between R amp C terminals 401494v0 dW Lgs LI n es R2 gu p yj EI T n EINE M_a nei Ns xy 4 Get Nein IMS 13S YOSNIS 3 i R35 Ti fj a gt RAI Po WET ic R If voltage is incorrect replace the Wire Harness If voltage is correct proceed to Step 10 Page 20 Troubleshooting Heater will not power up Step 10 Verify that F1 Fuse 3 AMP on ICB is not open by measuring continuity across the Fuse If fuse OK proceed to Step 11 If fuse is blown proceed to page 24 Wer Nis NY Verify 22 28 VAC is present between COM and AC terminals on ICB board If Step 11 voltage is present and display is blank replace Display Board If voltage is not present replace ICB HAYWARD o C It i Page 21 Troubleshooting Open FC1 and or FC2 Fuses If correct plug is installed proceed to Step 2 If incorrect turn the power off and install the 240 VAC plug Then replace FC1 and FC2 Fuses OO HAYWARD Page 22 Troubleshooting Open FC1 and or FC2 Fuses Check for faulty Transformer Remove P4 and P3 plugs Measure wiring and ensure the insulation Transformer for resistance of on the
4. are significantly different from each other replace the temperature sensor Otherwise replace the ICB High Temperature Sense If water temperature exceeds 105 F the heater will HS Code shut down and go into lockout Automatic restart is 2 minutes after water temp drops le below 105 F Code could also mean rapid water temperature rise 6 rise in 60 seconds Continued on next page HAYWARD Page 35 Service Light On HE and PF Codes This code could be in conjunction with a SF code and replacing HS Code Cont d the Temperature sensor could cure the problem Make sure the water connections are not reversed Otherwise replace the ICB Polarity Failure This code will display if 120VAC polarity is reversed PF Code low voltage is detected or if the ground path is not sufficient Reset is immediate after error is corrected HAYWARD Page 36 Service Light On HF Code Heat or Flame Sensed Heat sensed when gas valve should be OFF HF Code If flame is sensed with the gas valve off the control will go into lockout The blower will continuously run until error condition is corrected When corrected control will run blower for 5 seconds then automatically restart heater after 2 minutes Heset heater cycle line power off and on If the code is still present the Gas Valve may be defective If 24 VAC is not present at gas valve valve is defective Otherwise replace
5. transformer 24VAC secondary output voltage Situations that will cause this fuse to blow include Short between FC3 to R C on the ICB e Any short to ground at the E1 connector external remote terminal on the ICB or 24 VAC circuit HAYWARD Page 12 Remaining 3 fuses are now all 3amp Different fuse kits will reflect the change ANSF ORMER PRIMARY A 4 94V HAYWARD POOL PRODUCTS P N adita al REV A JOVE JVE 82 LOM vot TAGE ip 035 sor qm 5137 1 A 5010 16775 ICB F1 fuse Beginning Nov 2010 the F3 fuse has been removed from the Fuse Circuit Board Since the F1 Fuse automotive style fuse on the ICB protects the same circuit it will be the only fuse going forward Troubleshooting Heater will not power up Verify incoming voltage to heater is present 110 125 or 220 245 VAC if Step 1 voltage is present proceed to Step 2 Otherwise correct incoming line power to heater O HAYWARD Pace d Troubleshooting Heater will not power up 2 sse Step 2 Verify Voltage Selector Plug matches incoming line power ET j ATT y 7 RN HAYWARD a Troubleshooting Verify that FC1 and FC2 Fuses are not open Check incoming voltage at bottom of both fuses Fig A and out going voltage at top of both fuses Fig B if no voltage present at top of both fuses remove fuses from the Fuse Holders and measure continuity across each Fus
6. wiring is not worn 1 9 2 9 ohms between Black to Brown wires and between Orange to Yellow wires of P3 If resistance Is out of range replace the Transformer Troubleshooting oa Step 1 Check low voltage wiring connections for worn insulation or pinched wiring O HAYWARD Pad dd Troubleshooting Open FC3 and or F1 Fuses Inspect Gas Valve wiring and ensure insulation is not worn Step 2 If wiring is OK proceed to Step 3 HAYWARD Page 25 Troubleshooting Open FC3 and or F1 Fuses Measure resistance across Gas Valve terminals greater than 5 ohms and between each terminal to Ground for short there should be no continuity between either terminal to ground Step 3 If a short exists less than 5 ohms replace the Gas Valve Otherwise proceed to Step 4 Page 26 Troubleshooting oo KUW VS 8 77H82 WARE WW sr lt 4 4 i az la an gt a Ss Us t mn lil nes a AE a TY 1 a 2513 ar XA 4014948 FeeS9 476206 a HAYWARD POOL 2 1101643301 T 06169 6042UER18 MADE IN MEXICO HAYWART Par PRODLCE If wiring is OK replace the ICB HAYWARD Page 27 Troubleshooting Open FC4 Fuse Step 1 Inspect the Igniter and Blower Wiring and ensure the insulation is not worn If wiring is OK proceed to Step 2 Otherwise replace the defective component s Page 28 Troubleshooting Open FC4 Fuse Step 2 Disconnect the I
7. Universal H Series OHA ies O 20111Hayward Industries Table of Contents Important Safety Instructions Sequence of Operation Electric and Gas Connections Control Hookup Gas Pressure Testing Control Board Connections Fuse Board Connections Fuses Heater will not power up Open FC1 and or FC2 Fuse Open FC3 and or F1 Fuse Open FC4 Fuse Diagnostic Codes BD Code HAYWARD Page 1 Pages 2 3 Pages 4 5 Pages 6 Pages 8 9 Page 10 Page 11 Page 12 13 Pages 14 21 Pages 22 23 Pages 24 27 Pages 28 29 Page 30 Pages 31 32 EE and CE Codes IO and SB Codes SF and HS Codes HS and PF Codes HF Code LO Code IF Code AC Code AO Code Temperature Lock Out Heat Exchanger Flow Charts Wiring Schematic Wiring Diagram Page 33 Page 34 Page 35 Page 36 Page 37 Pages 38 41 Pages 42 44 Page 45 Page 46 47 Page 48 Page 49 50 Pages 51 56 Page 57 Page 58 High Voltage Electrocution Hazard Read and follow all instructions in the service and installation manual and on the equipment Failure to follow instructions can cause severe injury and or death Hazardous voltage can shock burn cause serious injury and or death To reduce the risk of electrocution and or electric shock hazards e Only qualified technicians should attempt repairs Replace damaged wiring immediately e Insure Heater is properly grounded and bonded HAYWARD Page 1 UHS Sequence Of Operation The contro
8. WARD Page 41 Service Light On IF Code IF Ignition Failure Ensure main gas shutoff outside the heater is open and that the Gas Valve inside the heater is in the ON position Step 2 Inspect Flame Sensor and Gas Valve wiring and ensure wire harness is securely fastened to the terminals Step 3 Ensure Gas Static Load and Manifold pressures are correct See Page 8 If OK proceed to Step 5 Otherwise proceed to Step 4 HAYWARD Page 42 Service Light On IF Code Step 4 Measure for 22 28 VAC across Gas Valve during trial for ignition If 22 28 VAC is present and Gas Valve does not open with manometer connected to valve replace Gas Valve See Page 8 for reference If 22 28 VAC is not present replace the ICB For models manufactured prior to 4 14 2009 Step 5 Verify which flame sensor is installed If 3 flame sensor installed replace to 5 flame sensor Part 4 IDXLFLS1930 OHAYWARD Page 43 Service Light On IF Code Step 6 Remove and inspect Gas Orifices and Burners for blockage Spider webs NOTE Check for excessive moisture in combustion chamber Determine possible causes roof run off sprinklers etc HAYWARD Page 44 Service Light On AC Code AC Code Air Switch Closed Blower vacuum switch closed when expected open Disconnect wires and tubing from switch measure continuity between terminals on switch if continuity exist replace switch
9. age 38 Pressure Switch Is water flow Is the Water Are the High Limit Switches closed Page 39 closed Page 40 No No No No Adjust Water Pressure s ne Backwash or Switch if needed refer Is the flue blocked n Ce Raon clean the filter to the pressure switch or restricted i PUMA pump on adjustment section of Switches the installation service manual LO Code Cleared No Replace the Replace the Water Vent Pressure Pressure Switch Switch HAYWARD Page 54 Flow Chart IF Code I Gas supply Is inlet gas supply Is the Flame During 4 sec trial for shutoff valves pressure between Yes Sensor plugged ignition is 22 28 VAC and Gas Valve min and max in and 5 in present at Gas Valve turned on Page 8 length Page 43 and 110 125 VAC at Igniter Page 43 Turn on Gas Adjust the gas Plug in or replace Replace the ICB valves pressure the Flame Page 8 Sensor Inspect Orifices Is the Manifold and Burner Tubes gas pressure Page 44 correct Page 8 Inspect Combustion Chamber for moisture Adjust Manifold Page 44 gas pressure Page 9 O HAYWARD Page 55 Flow Chart AO amp AC Code Is the Blower Is the correct Is the Blower Is 110 125 Replace the Vacuum tubing Voltage Selector resistance VAC present Blower and wiring OK Plug installed within range at Blower Vacuum Page 46 Page 46 Page 47 relay Page 47 Switch Is
10. e Fig C If Fuses are open proceed to Page 22 Otherwise reinstall the Fuses and continue to Step 5 HAYWARD Page 16 Troubleshooting Heater will not power up Step 5 Disconnect plug from P4 connector from Fuse Board Measure for 22 28 VAC between pins 1 2 of plug from Transformer and 110 125 VAC between pins 4 amp 6 If either voltage is incorrect proceed to Page 22 Otherwise proceed to Step 6 HAYWARD Page 17 Troubleshooting Heater will not power up _ X For Fuse board Older than Nov 2010 Disconnect plug from P5 connector on Fuse Board and measure for low voltage 22 28 VAC between R amp C pins of P5 receptacle on Fuse Board If voltage is not present proceed to Step 7 For boards Nov 2010 forward replace the fuse board Otherwise proceed to Step 8 Step 6 For Fuse board Older than Nov 2010 Measure for low voltage 22 28 VAC between P5 C pin and bottom of FC3 fuse If voltage is not present replace Fuse Board Otherwise measure for low voltage between P5 C pin and top of FC3 fuse If voltage is not present check for blown fuse If fuse is blown proceed to Page 12 if voltage is present proceed to Step 8 Step 7 HAYWARD Page 18 Troubleshooting oo Step 8 Inspect ICB wiring and ensure all plugs are securely fastened E PNE ES OS wt r 9 X sl KUW VS 77H82 Or LIAE
11. eater to dry fire or water to boil causing high limits to trip and possible damage to heat exchanger v Flow exceeding maximum flow could cause damage to the heat exchanger by thinning the tube walls Internal By Pass Internal by pass should be inspected periodically as it could be the cause of low or high water flow through the exchanger Flow Requirements Model Min GPM H150FD H200FD H200FD H300FD H350FD H400FD Maximum water flow 125 GPM O HAYWARD Page 49 Heat Exchanger Failure Modes A ulli ii j f E eos cma a 77 A iW i ANN ni y ON NS NM NS AS Y y Hi pH Alkalinity or Calcium Sooted Improper Fuel Hardness and Air Mixture E Freeze Damage Flow Chart Heater will not power up Is 22 28 VAC Go to Open Is 22 28 VAC Yes Is all ICB Yes present on Yes sF1 Fuse Yes FC3 and or F1 present on P5 Wiring Secure terminals R amp C of Open fuse section and correct Control Board No Page 24 N N N E o o O Is 22 28 VAC ves Replace present on pins Di E isplay Harness No Go to Open gt and or F1 fuse Is all Fuse Board Yes Yes C2 fuse blown section wiring secure and Is FC1 or FC2 Fuses Open section No correct ageda No Is 22 28 Is field supply Ho E irai Yes VAC voltage present on Correct wiring ibi uic cda present on P1 No pins 1 amp 2 of P4 Install correct plug Is 110 125 VAC present at Replace Trans
12. former P4 O HAYWARD Page 51 Is field supply voltage present in junction box Replace Wire Harness Replace Transformer Replace Fuse Board Correct field wiring to heater Flow Chart Blown FC1 and or FC2 Fuse Is Transformer wiring Yes Correct repair damaged pinched or Is proper voltage selector installed No No Yes Install proper Is Transformer resistance Heplace voltage selector out of range Transformer No Flow Chart Blown FC3 and or F1 Fuse Transformer worn wiring Is Gas Valve wiring damaged pinched or worn Correct repair Yes Gas Valve wiring Is Control Board wiring damaged pinched or Correct repair board wiring ue worn J Is resistance on Gas Yes Replace Gas Valve less than 5 ohms Valve No Replace ICB O HAYWARD Page 52 Flow Chart BD Code ls the FC4 Yes D DER Fuse open FC4 Fuse Section No Page 28 Is 110 125 VAC Is 110 125 VAC present on pins 3 8 5 present on pins 1 4 3 Replace the ICB of P6 receptacle of E10 Plug Page 32 Page 31 Replace the Wire Harness Is 110 125 VAC Replace the present on pins 4 amp 6 Replace the Transformer of P4 Plug Page 32 Fuse Board OHAYWARD Page 53 Flow Chart LO Code pu A Indoor Installations Is the pump Yes above Yes Pressure Yes Only running minimum owitch closed Is the Vent required P
13. gniter Plug from the ICB and measure resistance across the Igniter Resistance should be 10 9 19 7 ohms 9 77 degrees Se m VT 7 ar sin A E a A If resistance is out of range replace the Igniter If OK proceed to Step 3 Step 3 Disconnect the Blower Plug from ICB and measure the Blower resistance Resistance should be 8 9 ohms from Black to Red wires and White to Blue wires If resistance is out of range replace the Blower Otherwise proceed to Page 31 HAYWARD Page 29 Diagnostic Codes Below is a list of all Diagnostic Codes for the UHS Heater Troubleshooting Steps for each Code are covered on the following pages Flame present with Gas Valve not energized Maximum return water temperature exceeded and or rapid water temperature rise Temperature Sensor thermistor input failure OHAYWARD Page 30 Service Light On BD Code ammm a Step 1 BD Code Bad Board or Secondary High Voltage Fault Remove FC4 de Fuse and measure continuity a If Fuse is blown go to Page 27 Open FC4 Fuse If OK proceed to Step 2 Step 2 Disconnect plug from P6 connector of Fuse Board and measure for 110 125 VAC across Pins 3 and 5 of P6 receptacle on Fuse Board If OK proceed to Step 3 Otherwise go to Step 4 HAYWARD Page 31 Service Light On BD Code Step 3 Disconnect plug from E10 connector of ICB and measure for 110 125 VAC across pins 1 and 3 of plug on Wire Har
14. l continually compares the Set Temp to the actual water temp When the water temp is 1 below the set point the sequence starts The control checks for open Blower Vacuum Switch Blower starts pre purge cycle as the igniter heats up 20 Sec The Control checks for a closed Blower Vacuum Switch At proper Igniter temp a 4 second trial begins Gas valve opens and monitors flame sense The blower will turn off for one second The Igniter is de energized at flame sense or at completion of 4 sec trial If the flame is sensed The Blower Vacuum Switch Control Loop Temp Sensor amp Flame Sensor are constantly monitored during call for heat When set temp is reached the control ends the call for heat The gas valve is de energized flame is extinguished The blower will operate for a 30 second post purge HAYWARD Page 2 UHS Sequence Of Operation Failure to Light Retry Sequence Gas Valve de energizes 30 second blower post purge Starts over at 2 of heating mode sequence Retries 3 times until lockout IF Code Waits 60 minutes then retries 3 more times Will continue to retry every 60 minutes until demand for heat is stopped Note When making keypad entries of any type there may be a 5 10 sec delay for certain situations OHAYWARD Page 3 UHS Electrical and Gas Connections Gas Supply Bonding Lug Beginning Sept 08 High Voltage Low Voltage
15. le Vent Pressure Switch Indoor iadaa Only i Power NOTE l Power A 2 Heater ls factory wired for 240VAC_ To conven io 120WAC Matall 1209 C plug Inte mairg connector on fuss VM cicug board 2 Far fall power connections use 14 AWG ar larger wire rated for ai leas 75 C 187 F A Forfleld remote thermastal connecfons use 22 AWG or larger wire l Remote 4 f ary of fhe orfginal wire supplied with the healer must be replaced t must be replaced with 18 AWG UL cr Remets Therrrestat CSA approved wire rated for BODV and 105 C Thermostat Connecions Connections HAYWARD Page 58
16. lockwise to Remove plug Increase pressure If inlet pressures are correct and the Manifold Step 3 Pressure is low or high adjust the Manifold Pressure at the Gas Heater Data Plate located on bottom front inside heater eae Page 9 Display AN A MA F1 dt i Mas O EEN E Ae el Temp Voltage R amp C E12 E13 D ww R2 Au Ne aer E4 Flame Sensor E4 7 JWE Jg El du Gas Valve and Safety Switches E11 MERR LOJES 21 C19 ro Remote Control E1 HILIMS R47 EEN Page 10 Power Connection for junction boxes after Aug 08 P1 Terminal block for field wiring connections TB1 through Aug 08 Configure heater for 240 VAC or 120 VAC by installing correct plug P2 240 VAC plug factory installed 3 Low Voltage High Voltage P6 PS PTS HAYWARD POOL PRODUCTS P N 11803743701 W LOW VOLTAF m Transformer Secondary P4 Fuse board configuration through Oct 2010 Page 11 HAYWARD POOL PRODUCTS P N 1183843701 FC1 and FC2 fuses mesroen mam LO VOLTAGE protect the primary input voltage These fuses blow due to a shorted Fuse Board shorted Transformer improper or excessive voltage The FC4 fuse protects the transformer 120VAC secondary output voltage from a failed Blower Igniter or ICB SiNi FUSE BOARD The FC3 fuse protects the
17. ness w g E A gt a HE ON SE MAI A If 110 125 VAC is present replace the Fuse Board Otherwise replace the Transformer HAYWARD Page 32 Service Light On EE and CE Codes Communication Error between ICB and display board Error may be CE Code cleared by cycling line power off and on Otherwise inspect Display Interface ribbon cable and ensure plug is securely attached to ICB Back ICB Display f Board If Display Interface ribbon cable and connector plug is OK replace the Display Interface Assembly and or Key Pad If code is still present HAYWARD replace the ICB Page 33 Service Light On lO and SB Codes lO Code Igniter Open Inspect Igniter wiring ensure Igniter plug is securely attached to the ICB Verify Igniter ohm resistance 10 9 19 7 Ohms If wiring damaged and or ohms resistance is out of range replace the Igniter SB Code Stuck Button requires the Bezel Keypad assembly to be replaced OHAYWARD Page 34 Service Light On SF and HS Codes Step 1 SF Code Sensor Failure Inspect Temperature Sensor thermistor wire make sure sensor is plugged into ICB 073 FP i fe cM TP r f l iB 5 e C z BN EL Xe a s a Measure resistance between black wire and each red wire the Temperature Step 2 Sensor resistance should be the same 10k ohms at 77 degrees If readings
18. the Blower relay open Page 45 Replace the Blower Vacuum Switch Replace the ICB OHAYWARD Page 56 L LI S h t m N L2 240v EE A plug 120v a J plug tw A P12 P1 1 E P2 T4 Y P2 T3 P2 T2 B M 7 FWP FWP LJ FC2 Fuse FC1 Fuse circuit 1 circuit 3 P3 T3 P3 TI P3 T4 120v P3 T2 120v Isolation a Transformer 7T P4 C 24v P4 24v PA 120v 0 120v P4 N Ej circuit 2 FC3 Fuse FC4 Fuse circuit 4 P5 C FWP P5 R P H FWP rl P6 N EIS CU A 2 n 3 El2 R El0 H E z e T E10 N A s E lt E3L Igniter E3R D 7 gt B z lt Y Fe E 7 E 2 gt z Fl 3 Amp Fuse C C O 7 O E e 1 E E6 R Blower E6 W Fag hE z D Note Integrated MR RREENRAXANEMMM NM MER A or ccc bague gxEa dax RUE RENNES l The Igniter Blower and Gas Valve Bezel Ribbon Cable Continuity lt ontrol Board amp 4 Mode Switch Temp Sensor ohms Q 25 between black and each red should read the same 77 F 10 000 Q 3 HAYWARD relays are an integral part of the ICB Integrated Control Board Wiring internal to the ICB and temp sensor are indicated by a dotted line E Serene ree Isolation transformer creates 4 circuits as shown for troubleshooting 1 amp 3 Temp Set Red up 1 amp 2 Temp Set Blue down Top PN WA Page 57 iring Connection Diagram CORE OSEE z MODE TRS EXT E Corral Modu
19. the ICB OHAYWARD Page 37 Service Light On LO Code LO Code Limit Open Verify pump is running and adequate water is flowing through heater LO Code is normal when the pump is turned off Remove wires from Water Pressure Switch and measure continuity across the Step 3 terminals while pump is running If open replace Pressure Switch Otherwise go to Step 4 OHAYWARD Page 38 Service Light On LO Code Certain applications will require the adjustment of the Pressure Switch refer to section of the installation service manual Water Pressure Switch Test Adjustment Procedures HAYWARD Page 39 Service Light On LO Code Applies Only To Indoor Installations Inspect the Vent Pressure Switch Wiring and Hose connections Ensure Wire Harness Is securely fastened and tubing is attached to Blower and Vent Pressure Switch Step 7 O HAYWARD If OK proceed to Step 8 Page 40 Service Light On LO Code Applies Only To Indoor Installations Step 7 Ensure that flue is not blocked or restricted See indoor vent sizing requirements in Installation Manual Hemove wires from Vent Pressure Switch and measure continuity between Step 8 terminals While heater is running measure continuity across the Vent Pressure Switch T a a O uw o cs a e x db N oo O oo o QQ x O e On N ao Ny 22 a If open replace Vent Pressure Switch HAY
Download Pdf Manuals
Related Search