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SERVICE & INSTALLATION MANUAL

Contents

1. 41 Maintaining proper water chemistry 7 Heat exchanger inspection and cleaning 42 Combustion chamber 55 555 9 9 42 Section Il Installation 5 0 9 Heat exchanger removal 42 Equipment inspection 5 9 Burner inspection and cleaning 42 Important notice 9 Burner removal and replacement 43 Conformance with codes 9 Gas valve replacement 43 Altitude of installation 9 NITET ot fat ae via it koki ke eter tee ers 44 Uncrating the heater 505555 11 Flame SENSOM ek sesa saa n 44 Locating the 5 55555555 11 Burner orifices 44 FIOO re 12 Gas conversion 45 Tie Down Brackets us 12 Electrical wiring sciiciwstsrciccrertasniussacterradseanisde 45 Indoor Installation and Venting 13 Ignition control system 46 Clearances eneee 13 Blower vacuum SWItch 46 Air Su
2. 52 Troubleshooting 55e 54 Section III Check out amp Start up 33 WAI A on 58 General zeste 33 Service Parts asire 60 Gas line testing ana eee 33 Gas pressure testing 55555555555 55555 555 34 Water pressure SWItCh 5555555 55 35 Two speed PUMP eeeeecesceceeceeeeeeeeeaeeeaeeees 35 Temperature adjustment 36 Temperature lock out 0 05555559559 5 5 555 37 Fahrenheit v Celsius 37 Heating mode 000 05000095 995599555 37 Retry Failure of light 38 Recycle Loss of flame 38 Keypad inputs ccccceecceeceeeeeeeeeeeeeeeeeeees 38 Automatic reset time 39 Periodic inspection 39 Winterization 55555555555555555 5 55 555555 39 Draining the heat exchanger 40 Spring Start Up ccccccccscccsececeeeeeeeeeeeaeeees 40 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com SAFETY INFORMATION Basic safety precautions should always be followed including the following Failure to foll
3. HORIZONTAL OR VERTICAL VENTING POSITIVE PRESSURE VENT SIZING Vent pipe diameter must match the vent pipe diameter on the heater see Table 9 The vent pipe must be Heatfab single or double wall stainless steel sealed vent as listed in Table 9 Double wall vent must be used in non conditioned spaces The maximum total length of vent pipe and number of 90 degree elbows cannot exceed the limits specified in Table 8 The venting system must be installed in accordance with the vent manufacturer s Heatfab installation in structions and guidelines The installer is urged to visit Heatfab s website www heatfab com and review the installation information for Saf T Vent EZ Seal single wall and or Saf T Vent CI Plus double wall prod ucts VENT TERMINATION The vent system must terminate with a vent terminal approved for this pool heater Termination may be either horizontal or vertical See Table 9 for the Heatfab vent terminals which are approved OBTAINING VENT PIPE AND TERMINALS Hayward offers a variety of double wall vent components including terminals elbows and straight lengths which will satisfy the needs of most applications 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 fying installation It can be obtained on Hayward s website at www haywardnet com If you need more spe cialized fittings you
4. The CPVC flanged pipe nipples must be installed on the heater inlet and outlet without modification Pipe fittings valves and any other element of the filter system may be made of plastic materials if accept able to the authority having jurisdiction Heat sinks heat tapes firemen switches and check valves are not required on the heater However if there is any chance of back siphoning of hot water when the pump stops running it is suggested that a check valve be used on the heater inlet pipe The built in bypass inside the header will maintain proper flow through the heat exchanger if the flow rate is within the range for the heater See Table 14 The minimum flow rate is to be calculated or measured with the infloor cleaning system in use if the pool is so equipped as well as any other jets or other demands on the water flow USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD Pp ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com If the normal pump and filter system flow rate exceeds Table 14 125 gpm then a manual bypass valve must be installed as Allowable Water Flow Rate Range shown in Figure 16 Damage caused by flow rates outside TE Fi 7 FI inimum Flow aximum Flow Rate GPM Rate GPM this range will void the manufacturer s warranty The installation is as follows 1 Install a flow meter on the outlet line of the heater H200FD 2 Ad
5. d iring connection VV Figure 23 white blanc yellow jaune d Connexions d alimentation Remote Thermostat Connections Connexions de thermostat t l command POOL PISCINE lt 4 141 N L24 GND 4 SPA 4 COM lt Left Junction Box Boite de jonction de gauche NOTE 1 Heater is factory wired for 240VAC To convert to 120VAC install 120VAC plug into mating connector on fuse circuit board 2 For field power connections use 14 AWG or larger wire rated for at least 75 C 167 F 3 For field remote thermostat connections use 22 AWG or larger wire 4 If any of the original wire supplied with the heater must be replaced it must be replaced with 18 AWG UL or CSA approved wire rated for 600V and 105 C REMARQUE 1 Le r chauffeur est c bl l usine pour 240 V c a Pour le convertir 120 V c a installer la prise de 120 V c a dans le connecteur correspondant sur la carte de circuit a fusible 2 Pour les connexions d alimentation de terrain utiliser un fil de calibre 14 AWG ou plus gros homologu pour 75 C 167 F au moins 3 Pour les connexions de thermostat de terrain a distance utiliser un fil de calibre 22 AWG ou plus gros 4 Si tout fil fourni initialement avec le r chauffeur doit tre remplac il faut le remplacer par un fil de calibre 18 AWG appr
6. plier and request that the inlet pressure to Manifold 1 8 2 0 w c 6 8 7 0 w c the heater be set to within the gas pressure lk kai ds tor the installer must contact the gas sup Fig 33 could cause a gas leak or diaphragm rupture Gas leakage could cause an explosion resulting in severe injury or death 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 The following procedure is recommended when the switch needs adjustment and or is replaced For Installations with Heater Above Water Level 1 Be sure the filter is clean before making the adjustment 2 Turn ON the filter pump and ensure all air is out of the water lines and ensure water flow rate is at least the rated minimum see Table 14 3 Turn ON the heater and adjust the thermostat to create a call for heat 4 Ifthe heater does not light adjust the pressure switch by turning the adjustment knob on the pressure switch counter clockwise until the heater lights Turning the adjustment knob counterclockwise decreases the pressure needed to close the switch 5 Check the function of the pressure switch by turning the filter pump on and off several times The pool heater should turn off
7. 8 Insert bypass cartridge into header with the arrow on the end of the cartridge pointing up 9 Re install cartridge retaining nut Nut should be tightened hand tight only DO NOT OVER TIGHTEN 10 Re install the upper plastic heater side panel Se USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 8 OH AYWARDP ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com SECTION V TROUBLESHOOTING GENERAL ATTENTION These instructions are intended for the use of qualified 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 qualified should not attempt to repair this equipment according to these instructions These instructions and procedures are not or the use of do it yourself consumers WARNING BURN HAZARD The operation of the heater with the pump shut off could cause heater overheating and fire Never operate heater with the pump shut off ATTENTION As a preliminary check make sure that all wire connections are clean and tight and that all wiring conforms to the wiring diagram AUTOMATIC RESET TIME The heater will automatically reset when an error condition is corrected and resume operation The heater can be manually reset using the keypad by cycling the MODE
8. HAYWARD POOL AND SPA HOT TUB HEATERS H150FD H200FD H250FD H300FD H350FD amp H400FD MODELS SERVICE amp INSTALLATION MANUAL FOR YOUR SAFETY A 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 FOR YOUR SAFETY 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 6 321 833 amp 7 971 603 1301623301 Rev H 1211 CONTENTS Section General information 7 Section IV Technician Service 41 Introduction 7 General ins 41 Warranty MP sok ks pk 7 Maintenance
9. FDXLTFP1300 FDXLTFP1350 FDXLTFP1400 FDXLTFP1250A FDXLTFP1400A FDXLUEC1930 FDXLLEC1930 FDXLLTP1930 FDXLRTP1930 FDXLLJC1930 FDXLRJC1930 FDXLPBL1930 HAYWARD pool Products A Hayward Industries Inc Company DESCRIPTION JACKET TOP H150FD JACKET TOP H200FD JACKET TOP H250FD JACKET TOP H300FD JACKET TOP H350FD JACKET TOP H400FD JACKET TOP GRAY ASME H250FD JACKET TOP GRAY ASME H400FD TOP FLUE COVER H150FD TOP FLUE COVER H200FD TOP FLUE COVER H250FD TOP FLUE COVER H300FD TOP FLUE COVER H350FD TOP FLUE COVER H400FD TOP FLUE COVER GRAY ASME H250FD TOP FLUE COVER GRAY ASME H400FD FRONT ACCESS DOOR ASSY H150FD FRONT ACCESS DOOR ASSY H200FD FRONT ACCESS DOOR ASSY H250FD FRONT ACCESS DOOR ASSY H300FD FRONT ACCESS DOOR ASSY H350FD FRONT ACCESS DOOR ASSY H400FD FRONT ACCESS DOOR ASSY GRAY ASME H250FD FRONT ACCESS DOOR ASSY GRAY ASME H400FD REAR ACCESS DOOR ASSY H150FD REAR ACCESS DOOR ASSY H200FD REAR ACCESS DOOR ASSY H250FD REAR ACCESS DOOR ASSY H300FD REAR ACCESS DOOR ASSY H350FD REAR ACCESS DOOR ASSY H400FD REAR ACCESS DOOR ASSY GRAY ASME H250FD REAR ACCESS DOOR ASSY GRAY ASME H400FD TOP FRONT PANEL H150FD TOP FRONT PANEL H200FD TOP FRONT PANEL H250FD TOP FRONT PANEL H300FD TOP FRONT PANEL H350FD TOP FRONT PANEL H400FD TOP FRONT PANEL GRAY ASME H250FD TOP FRONT PANEL GRAY ASME H400FD UPPER END CAP LOWER END
10. Turn pump gas supply and heater power OFF Drain the heat exchanger of all water Remove the front access panel It is secured with 4 screws Unplug the thermistor connector from the ignition control board From outside the heater pull the thermistor leads out of the control box and through the hole in the heater chassis Unscrew the thermistor from the inlet side of the header Replace the thermistor Use new sealant on the thermistor threads before re installing Reverse steps above to complete the procedure TA No WATER PRESSURE SWITCH The water pressure switch Figure 28 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 If adjustment is needed the procedure is detailed in Section III under Water Pressure Switch Test Adjustment Procedure A ATTENTION Do not operate the pool heater without the function of a properly adjusted pressure switch or flow switch To replace the pressure switch Turn pump gas supply and heater power OFF Unplug the high limit terminals from the main wire harness Remove the 4 screws securing metal trim panel around the header Remove the wires from the pressure switch Using two 4 open end wrenches disconnect the pressure switch from the pressure switch tubing Replace the pres
11. and CCLOGWPNS wall penetration Heatfab P N 5690CI Heatfab P N CCEOGWP Heatfab P N 5890CI Heatfab P N CCE08VVP Heatfab P N 5600CI Heatfab P N CCA06RC Heatfab P N 5600CI Heatfab P N CCA06RC Heatfab P N 5800CI Heatfab P N CCA08RC For vent pipe section length x should be 1 2 4 5 or 7 where 1 6 inches 212 inches 4 18 inches 5724 inches and 7536 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 HAYWARD pool Products A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com VENT KIT INSTALLATION PROCEDURE positive and negative pressure venting 1 If connected turn pump main gas valve and heater power off 2 Locate the heater as close as practical to the gas vent exit 3 Remove the countersunk phillips head screws and remove the flue cover panel on top of the heater and discard Save the countersunk screws as they will be re used later 4 Remove the screws that fasten the heat barrier to the heater Remove the heat barrier and discard See Figure 6 5 Remove the screws that fasten the rain guard to the heater Remove the rain guard and discard See Figure 6 6 Install the vent pipe adapter plate included in the kit into the heater using the 10 screws included with the kit En
12. 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 H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com A 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 A 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 A WARNING Suction outlet components have a finite life the cover grate should be inspected fre quently and replaced at least every ten years or if found to be damaged broken cracked missing or not securely attached A WARNING All suction and discharge valves MUST be OPEN when starting the circulation system Failure to do so could result in severe personal injury and or property damage All drains and suction outlets MUST have properly installed covers securely attached using the screws supplied with the cov ers If screws are lost order replacement parts from your supplier A WARNING Hazardous Pressure Pool and spa water circulation systems operate under haz
13. gaz Ne jamais utiliser d outils Si le bouton ne s enfonce pas ou ne se tourne pasala main ne pas essayer de le r parer Appeler un technicien qualifi L utilisation de la force ou une tentative de r paration pourrait causer un incendie ou une explosion Ne pas utiliser cet appareil si une des composantes a t immerg e dans l eau Appeler imm diatement un technicien qualifi pour v rifier l appareil et remplacer toute composante du syst me de commande ou de gaz qui aurait t immerg e dans l eau Si le syst me surchauffait ou si le gaz refusait de se fermer placer le robinet d arr t manuel de gaz de l appareil en position FERM OFF OPERATING INSTRUCTIONS 1 STOP Read the safety information onthis label 2 Change the MODE on the control panel to STANDBY 3 Remove the heater s front access panel 4 This appliance is equipped with an ignition device which auto matically lights the burner Do not try to light the burners by hand 5 Turn gas control knob clockwise to OFF GAS CONTROL OJ KNOB SHOWN IN OFF POSITION a 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information on this label If you don t smell gas go to the next step 7 Turn gas control knob 4 counterclockwise to ON 8 Replace the heater s front access panel Set the MODE on the control pane
14. instructions are included with each kit A 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 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com IGNITION CONTROL SYSTEM The ignition control system in this heater consists of 3 printed circuit boards the ignition control board the display board and the fuse board and a keypad The locations of these components are shown in Figure 31 The ignition control system functions as the heater s thermostat safety control system and controller for the gas combustion system To remove replace the ignition control board or the fuse board Turn pump gas supply and heater power OFF Remove the front access panel Disconnect all wires from the printed circuit board Detach the board from the sheet metal panel by compressing the plastic stand offs Replace the board and reverse the above steps to reassemble So a bo To remove replace the display board or keypad Turn pump gas supply and heater power OFF Remove the front access panel Unplug the display board ribbon cable from the ignition control board Rem
15. may order them directly from Heatfab or from an authorized Heatfab dealer To locate a dealer for Heatfab venting parts contact Heatfab at Selkirk Corporation Heatfab Division 130 Industrial Blvd Turners Falls MA 01376 800 772 0739 www heatfab com Table 8 Maximum Vent Pipe Length and Number of Elbows for Positive Pressure Vent Systems Number of 90 Maximum Vent Pipe degree Elbows Length 9 horizontal amp vertical 50 ft USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Table 9 Vent Pipe amp Terminal Specifications for Positive Pressure Indoor Vent Kits 4 Heater Nominal Vent P Horizontal Vent Vertical Vent Pipe Diameter Vent Type a UHXPOSHZ11501 UHXPOSHZ12001 UHXPOSHZ12501 UHXPOSHZ13001 UHXPOSHZ13501 UHXPOSHZ14001 H150FD H200FD H250FD H300FD H350FD H400FD Single Wall Double Wall Single Wall Double Wall Single Wall Double Wall Heatfab Saf T Vent EZ Seal P N 960x Heatfab Saf T Vent Cl Plus P N CCA06LXX Heatfab Saf T Vent EZ Seal P N 960x Heatfab Saf T Vent Cl Plus P N CCA06Lxx Heatfab Saf T Vent EZ Seal P N 980x Heatfab Saf T Vent CI Plus P N CCA08Lxx Heatfab P N 9614TERM elbow terminal and 5691CI wall penetration Heatfab P N 9614TERM elbow terminal CCKO6FC collar CCAOGADSV connector ring
16. of sanitizers into the water is NOT covered under the terms of your warranty The following factors are critical to heat exchanger protection Follow these guidelines to help prevent pre mature damage or failure to your heater and heat exchanger 1 WATER FLOW THROUGH HEATER Water must be flowing through the heater at the minimum rated flow rate during operation Check that the pump is operating and the system is filled with water and purged of all air prior to starting the heater The minimun rated flow rates are listed on page 26 Some installations may require an adjustment to the water pressure switch for proper low flow protection Test your system and if necessary adjust the water pressure switch as described on page 35 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 2 POOL SPA WATER CHEMISTRY The chemistry balance and mineral content of swimming pool water changes daily due to the addition of pool and sanitizing chemicals bather loads rain runoff and the amount of sun to name a few Improper chem istry balance and mineral content can cause scaling and deposits to form on pool walls in the filtration system in the heat exchanger tubes and additionally can promote corrosive action to all metals in the water path Chang ing spa water regularly and maintaining the correct chemical balance in your pool
17. of water pressure switch contacts 5 Ensure that low pump pressure does not exist 6 Check for correct water pressure switch setting 7 Water pressure switch is defective 1 Check for faulty wiring or connection 2 Verify state of vent pressure contacts 3 Check for restricted or blocked flue 4 Vent pressure switch is Replace vent pressure switch defective 1 Check for faulty wiring or Inspect sensor wiring Ensure sensor is pluggd into back of control connection module If OK proceed to step 2 2 Sensor is defective Replace temperature sensor Verify set point setting of remote thermostat is at or below 104 F If set point of remote thermostat is OK or if heater is not configured for remote thermostat proceed to step 2 Verify that water flow to heater is above minimum required 20 GPM for H150FD and H200FD 25 GPM for H250FD and H300FD 30 GPM for H350FD and H400FD Note that intermittent periods of low water flow will cause this error If OK proceed to step 3 Compare the heater s temperature reading to the pool water temperature with an accurate thermometer If significantly different replace inlet water temperature sensor Replace Gas Valve This is normal display when heater is being controlled by a remote thermostat No service is required If heater is not being controlled by remote thermostat change setting by using the MODE key to put the heater into STANDBY Press and hold the DOWN ke
18. properly licensed WARNING Failure to comply with the appliance and vent package installation instructions and service instructions in this manual may result in equipment damage fire asphyxiation or carbon monoxide poi soning Exposure to products of incomplete combustion carbon monoxide can cause cancer and birth defects or other reproductive harm CONFORMANCE WITH CODES The heater shall be installed in accordance with all local and state codes The heater installation must con form to the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and with the requirements of the authority having jurisdiction Design certification of the heater is in compliance with ANSI Z21 56 CSA 4 7 For Canadian installations the heater is to be installed in accordance with the standards CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances and Equipment and or local codes and if appli cable CSA C22 1 Canadian Electrical Code Part I ALTITUDE OF INSTALLATION The heater may be installed at any altitude up to 10 100 ft above sea level provided the appropriate modification s are performed The altitudes which require modification vary depending on the model Parts necessary to convert the heater for outdoor installation at altitudes up to 7 700 ft minimum are included with the heater Conversion is accomplished by replacement of the blower air inlet plate and for indoor ap plications installation of a special
19. vent pressure switch The blower air inlet plates are clearly marked with the compatible heater model s vent configuration s and altitude range s Care should be taken to verify the correct plate and vent pressure switch when applicable is being used to ensure proper heater perfor mance The vent pressure switch should be provided with the indoor adapter kit or if you have an older indoor adapter kit order p n FDXLVPS1931 for the high altitude indoor vent pressure switch High Altitude Conversion Procedure 1 Identify the altitude of the installation site This may be done using a GPS device or by looking up the altitude for the geographic location Altitudes for all locations in the United States and Canada may be found using the zip postal code database at www zip codes com If the altitude for the installation site is greater than 10 100 ft the heater may not be installed Note that if installing outdoors some Universal H Series heaters may be compatible with your altitude without modification Table 1 lists the altitude ranges for heaters without modification All indoor heaters installed above 2 000 ft require a special vent pressure switch 2 Select the appropriate blower air inlet plate to use based on the heater model vent configuration outdoor or indoor and altitude needed Extra plate s are included with the heater packaged in the plastic bag with this manual Each plate has a label which identifies which model s vent con
20. www haywardpool com 6 Do not install within 24 of any outdoor Table 2 HVAC equipment Outdoor Installation Clearances 7 Do not install where water may run off a Heater Panel Required Clearance roof into the heater A gutter may be needed to protect the heater 8 Any enclosure around the heater must provide a combustion air vent commencing within 12 inches of the bottom of the enclo Water Connection Side sure The vent opening shall have a mini Side Opposite Water Connection mum free area of 1 square inch per 4 000 btu hr input rating of all gas appliances in the enclosure See Table 5 FLOORING This heater may be installed on either non combustible or combustible flooring Ultralite or equivalent 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 installation 1 Tie down brackets FACTORY SUPPLIED quantity 4 2 Sheet metal screws FACTORY SUPPLIED quantity 4 3 Concrete tapping screws tapcons field supplied quantity 4 size to be 4 diameter with a minimum length of 2 INSTALLING TIE DOWN BRACKETS 1 Locate the tie down brackets and the sheet metal screws 2 Obtain the tap cons Be sure the overall length of the concrete tapping screw is at least 2 3 Remove the front access panel 4 screw
21. 1 5400 www haywardpool com INTERNAL VVIRING If the heater display is blank after the electrical has been installed see Figures 43 and 44 to determine the cause The ribbon cable between the display board and the ignition control board is polarized and cannot be inserted upside down if it was removed when electrical was done FUSE SPECIFICATIONS 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 kit The fuse specifications are e FI fuse low voltage 3A blade style fast acting automotive fuse type 257 e FCI amp FC2 transformer primary and FC4 transformer secondary 3A slo blo fuse 5 x 20 mm USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Pomona CA Clemmons NC Nashville TN HAYWARD Poo Products Tel 908 351 5400 A Hayward Industries Inc Company www haywardpool com 52 ki Figure 31 ERROR CODES ao on on 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 error lockout Blower will operate until error condition is corrected Automatic restart 2 minutes after error is corrected Gas valve sensed If valve is closed but flame is sensed the blower will run for 5
22. 4 a Figure 32 TROUBLESHOOTING Diagnosis Step Heater will not power up Low voltage circuit fault Open FCI and or FC2 Fuses 1 Check for Low amp High Disconnect plug from P5 connector from Fuse Board Measure Voltage Output from Fuse for 24VAC between pins ofreceptacle on Fuse Board Reconnect Board plug Disconnect plug from P6 of Fuse Board Measure for 120VAC between pin 3 and 5 ofreceptacle on Fuse Board Reconnect plug If OK proceed to section titled Low voltage circuit fault Otherwise proceed to step 2 2 Ensure field power supply Measure for field supply voltage across terminals of TB1 terminal block to heater is turned on on Fuse Board If OR proceed to step 3 3 Check for faulty Fuse Insoect Fuse Board wiring Ensure all plugs are securely fastened to Board wiring Fuse Board If OK proceed to step 4 4 Verify that FC1 and FC2 Remove FCI and FC2 fuses from fuseholder Measure continuity Fuses on Fuse Board are not across fuse If fuses are open proceed to section titled Open FC1 and open or FC2 Fuses If fuses are OK reinstall them and proceed to step 5 5 Verify that 240vac Voltage Check that proper Volatage Selector Plug is installed in Fuse Board If Selector Plug is not installed OK proceed to step 6 with a 120vac field power supply 6 Check for defective Disconnect plug from P4 connector from Fuse Board Mesure for Transformer 24VAC between pins 1 amp 2 of plug of Transf
23. ANSFORMER K PRIMARY SECONDARY Water Temperature Sensor FUSES FUSE 1 FC2 FC4 Capteur de temp rature de l eau a R o TO JUNCTION BOX Water Temperature Limit Switch Gas Valve A S upap de daz Commutateur limiteur upap 9 de temp rature d eau ON L RJ 3A 3A 3A SLO BLO SLO BLO SLO BLO Flame Sensor Capteur de flammes 0000 DISPLAY Mi E7 1 gel VOLTAGE TRANSFORMER SELECTOR SECONDARY T2 T1 f T4 T3 24V c NI P2 0000 9000000 240 VAC Plug Prise de 240 V c a Re RR GY GY 120 VAC Plug Prise de 120 V 6 8 PETA BK w Transformer Transformateur o Water Pressure Switch Pressostat d eau Control Module Module de commande PSILIMITS 000000 SLOWSY Blower Vacuum Switch Commutateur a vide de soufflante ioucer E6 QQO IGNITOR QQ n 0000 120 VAC blue bleu kw Switch D d vent pad ee Ignitor Combustion Blower Indoor mod les d int rieur 9 Rallumeur Soufflante de combustion Models Only seulement gray gris o orange orange 120 NO 120 VAC iagram
24. CAP LEFT TRIM PANEL RIGHT TRIM PANEL JUNCTION BOX COVER LEFT JUNCTION BOX COVER RIGHT BASE LEG Pomona CA Clemmons NC Nashville TN Tel 908 351 5400 www haywardpool com 62 ITEM 12 13 14 15 16 17 18 19 20 21 22 23 24 PART NO FDXLFCS1930 FDXLRGR1151 FDXLRGR1201 FDXLRGR1251 FDXLRGR1301 FDXLRGR1351 FDXLRGR1401 FDXLHBP 1150 FDXLHBP 1200 FDXLHBP 1250 FDXLHBP 1300 FDXLHBP 1350 FDXLHBP 1400 FDXLBBN1150 FDXLBBN1200 FDXLBBN1250 FDXLBBN1300 FDXLBBN1350 FDXLBBN1400 FDXLIAC1930 FDXLGSV0001 FDXLGSV0002 FDXLBON1930 FDXLBOP 1930 FDXLMAN1150 FDXLMAN1200 FDXLMAN1250 FDXLMAN1300 FDXLMAN1350 FDXLMAN1400 FDXLGCK1150NP FDXLGCK1150PN FDXLGCK1200NP FDXLGCK1200PN FDXLGCK1250NP FDXLGCK1250PN FDXLGCK1300NP FDXLGCK1300PN FDXLGCK1350NP FDXLGCK1350PN FDXLGCK1400NP FDXLGCK1400PN FDXLBWR1930 FDXLBVS1930 FDXLICB1930 FDXLFWP1930 FDXLIGN1930 HAYWARD pool Products A Hayward Industries Inc Company DESCRIPTION FLUE COLLECTOR SIDE PANEL RAIN GUARD ASSEMBLY H150FD RAIN GUARD ASSEMBLY H200FD RAIN GUARD ASSEMBLY H250FD RAIN GUARD ASSEMBLY H300FD RAIN GUARD ASSEMBLY H350FD RAIN GUARD ASSEMBLY H400FD HEAT BARRIER PANEL H150FD HEAT BARRIER PANEL H200FD HEAT BARRIER PANEL H250FD HEAT BARRIER PANEL H300FD HEAT BARRIER PANEL H350FD HEAT BARRIER PANEL H400FD BLOWER INLET BAFFLE H150FD BLOWER INLET BAFFLE H200FD BLOWER INLET BAFFLE H250FD BLO
25. CRATING THE HEATER To remove the shipping carton from the heater Pigu 1 Remove the corrugated carton from the i heater The carton top pad bottom pad and The screw through the the four corner posts can be recycled rear shipping bracket 2 There are three 3 screws total used to se i 1 is located in this area cure the heater to the wood pallet All three kE r Remove the screw must be removed to separate the heater from Ms i the pallet One 1 is located in the lower i It is not necessary to rear of the heater as shown in Figure 1 La remove the bracket or 3 To access the other two 2 screws open the the rear louvered panel front access panel by removing the four 4 black phillips head screws Then remove the two 2 screws which hold the heater base pan to the pallet as shown in Figure 2 4 Lift the heater clear of the corrugat ed bottom pad and off of the pallet A ATTENTION Do not drop the Remove the 2 heater from a pickup truck tailgate to the ground This may damage the heater shipping screws and discard bottom corrugated tray LOCATING THE HEATER Locate the pool spa hot tub heater in an area where leakage of the heat exchanger or connections will not result in damage to the area adjacent to the heater or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan with drain outlet be installed under the heater The pan must not r
26. DOOR VENT ADAPTER KIT POS PRESS HORIZONTAL H200FD INDOOR VENT ADAPTER KIT POS PRESS HORIZONTAL H250FD INDOOR VENT ADAPTER KIT POS PRESS HORIZONTAL H300FD INDOOR VENT ADAPTER KIT POS PRESS HORIZONTAL H350FD INDOOR VENT ADAPTER KIT POS PRESS HORIZONTAL H400FD HEATFAB STAINLESS VENT KIT 6 HORIZONTAL ELBOW TERMINAL HEATFAB STAINLESS VENT KIT 6 HORIZONTAL STRAIGHT TERMINAL HEATFAB STAINLESS VENT KIT 6 90 DEGREE ELBOW HEATFAB STAINLESS VENT KIT 6 VENT PIPE 18 LONG HEATFAB STAINLESS VENT KIT 6 VENT PIPE 24 LONG HEATFAB STAINLESS VENT KIT 6 VENT PIPE 36 LONG HEATFAB STAINLESS VENT KIT 8 HORIZONTAL STRAIGHT TERMINAL HEATFAB STAINLESS VENT KIT 8 90 DEGREE ELBOW HEATFAB STAINLESS VENT KIT 8 VENT PIPE 18 LONG HEATFAB STAINLESS VENT KIT 8 VENT PIPE 24 LONG HEATFAB STAINLESS VENT KIT 8 VENT PIPE 36 LONG GAS CONVERSION KIT NA TO LP GAS CONVERSION KIT LP TO NA CONVERSION KIT HIGH ALTITUDE 2 000 10 100 FT VENT PRESSURE SWITCH INDOOR 0 2 000 FT VENT PRESSURE SWITCH INDOOR 2 000 10 100 FT Hayward Pool Products Inc Hayward Pool Products Inc Hayward Pool Products Inc Hayward S A 620 Division St Elizabeth NJ 07207 2004 Hayward Printed in U S A 2875 Pomona Boulevard Pomona CA 91768 2880 Plymouth Drive Oakville Ontario L6H 5R4 Zoming de Jumet B6040 Jumet Belgium
27. ENUINE REPLACEMENT PARTS H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com HIGH LIMIT SVVITCHES The high limit is an automatically resetting safety device wired in series with the thermostat and gas valve See Figure 28 The heater is equipped with two automatic high limits located on the water header If the water temperature exceeds the limit set point the gas valve will be closed shutting off gas supply to the burners Erratic high limit operation is often an indication of a problem with water flow Reduced flow may be caused by 1 Clogged filter or strainer 2 Excessive flow through the external bypass if one is used 3 Lime scale accumulation in the heat exchanger TO REPLACE A HIGH LIMIT SWITCH Turn pump gas supply and heater power OFF Drain the heat exchanger of all water Unplug the high limit wires from the wiring harness Unscrew the high limit switch from the header 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 FAN LE USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com THERMISTOR The thermistor monitors the return water temperature See Figure 28 To replace the thermistor
28. F knob DECREASE PRESSURE Manifold pressure tap plug connected to the gas supply line turn each of those appliances ON while testing the heater 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 7 Ifthe gas pressure does not meet the above requirements the regulator must be adjusted 8 Gas pressure regulator adjustment procedure a Remove the screw cap over the regulator adjustment screw see Figure 26 b Turn the regulator adjustment screw clockwise to increase pressure and counterclockwise to de crease pressure c Replace the screw cap over the regulator adjustment screw 22 A WARNING EXPLOSION HAZARD Do not remove the 1 8 pipe nipple with the valve in the ON position The valve must be in the OFF position when the nipple is removed Removal of the nipple with the gas valve on could cause an explosion resulting in severe injury and or death USE ONLY HAYWARD GENUINE REPLACEMENT PARTS HAYWARD pool Products A Hayward Industries Inc Company Pomona CA Clemmons NC Nashville TN Tel 908 351 5400 www haywardpool com 9 Remove the 1 8 pipe nipple and replace the Table 15 Correct gas pressures es achieved by adjusting the gas valve regula
29. HAYWARD GENUINE REPLACEMENT PARTS Fi AVYVWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 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 SPA in this mode the heater will automatically function to maintain the water temperature setting for SPA mode 3 POOL in this mode the heater will automatically function to maintain the water temperature setting for POOL mode Use the MODE button to change modes The indicator lights will illuminate to show which mode the heater is currently in Each mode has its own temperature setting allowing the user to have 2 individual pre set temperature settings To adjust the temperature while in SPA or POOL mode use the UP and DOWN buttons The numeric display will flash to indicate the temperature setting is being displayed adjusted When the numeric display is not flashing the actual water temperature is being displayed The temperature settings for both SPA and POOL modes are initially set at the factory to 65 F The minimum allowed settings for SPA and POOL modes are both 65 F The maximum allowed settings for SPA and POOL modes are adj
30. LHDVV1930 FDXLHMB1930 FDXLBRP 1930 CHXPLG1930 FDXLCRN1930 SPX4000FG FDXLDRV1930A CHXRLV1930 FDXLGSK1930 FDXLGSK1931 FDXLGSK1933 HAYWARD pool Products A Hayward Industries Inc Company A DESCRIPTION FLAME SENSOR TRANSFORMER VVATER PRESSURE SVVITCH DISPLAY BOARD ONLY BEZEL 8 REYPAD ASSEMBLY BEZEL amp KEYPAD ASSEMBLY BLUE ASME GASKET BEZEL TOP HIGH LIMIT KIT THERMISTOR GASKET CC FRONT AIR BOX ALL MODELS HEAT EXCHANGER ASSY H150FD HEAT EXCHANGER ASSY H200FD HEAT EXCHANGER ASSY H250FD HEAT EXCHANGER ASSY H300FD HEAT EXCHANGER ASSY H350FD HEAT EXCHANGER ASSY H400FD HEAT EXCHANGER ASSY ASME H250FD HEAT EXCHANGER ASSY ASME H400FD INLET OUTLET HEADER ONLY INLET OUTLET HEADER ASSY HEADER HARDWARE KIT HEADER MOUNTING BASE KIT BYPASS CARTRIDGE KIT 3 4 BRASS PLUG HEADER CARTRIDGE RETAINING NUT DRAIN PLUG WITH GASKET DRAIN VALVE ASME PRESSURE RELIEF VALVE GASKET KIT AIR SIDE ALL MODELS INCLUDES GASKET BLOWER MOUNTING GASKET IGNITER COVER GASKET COVER AIR BOX FRONT ALL MODELS GASKET MANIFOLD AIR BOX ALL MODELS GASKET KIT EXHAUST SIDE ALL MODELS INCLUDES GASKET FLUE COLLECTOR SIDE GASKET RAIN GUARD SIDE GASKET RAIN GUARD BOTTOM SIDE GASKET FLUE COLLECTOR TOP ALL MODELS GASKET RAIN GUARD FRONT amp REAR ALL MODELS GASKET RAIN GUARD BOTTOM FRONT amp REAR ALL MODELS INSULATION RETURN SIDE TUBE SHEET Pomona CA Clemmon
31. STANDBY mode using the keypad Turn the electricity to the heater OFF at the circuit breaker panel Turn the heater gas valve OFF using the knob on the valve see Figure 26 Turn the heater s gas supply OFF at the main shut off valve outside the heater cabinet Be sure the circulating pump is OFF On models with plastic headers remove the plastic drain plug see Figure 28 On models with bronze headers ASME models open the brass drain valve located on the header see Figure 21 Allow all water to drain from the heater On models with plastic headers re install the plastic drain plug On models with bronze headers ASME models close the brass drain valve located on the header SPRING START UP 1 Inspect and clean the heater being sure the heater is free of leaves and debris prior to startup 2 Be sure inlet and outlet piping are properly attached to the heater and the drain valve is closed 3 Turn the filtration system pump ON and allow the system to run long enough to purge all the air from the lines 4 Turn the gas supply to the heater ON 5 Set the temperature control using the keypad to POOL or SPA and adjust the set point to the desired temperature setting 6 If operating difficulties are encountered contact a qualified service company for assistance A ATTENTION Heater installation checkout and start up should now be completed BE SURE to leave the Owner s Manual w
32. This error functions in both normal and remote thermostat modes or B Inlet water temperature sensor is reporting a temperature change at a rate faster than 6 F in 60 seconds indicating a potentially damaging low water flow conditon Normal operation resumes when temperatures stabilize If this condi tion is detected 3 times the heater will lock out until the electrical power is cycled off and back on If one of the keypad buttons is closed or pressed for more than 30 s the error code will be displayed but the control will continue to function The error code will be cleared when the condition is corrected If the control exceeds the maximum number of ignition retries or recycles the heater will shut down and go into lockout Automatic reset is 60 minutes If communication between the ignition board and the display board is not estab lished within 3 s of power up an error will be displayed After communication is established if it is lost for 30 s the error will be displayed The error code will be cleared upon a valid data exchange between boards If the limit string opens the heater shuts down and goes into lockout Automatic restart is 2 minutes after the error condition is corrected and the limit string closes See below for more detail An error was detected in the ignition control circuit board USE ONLY HAYWARD GENUINE REPLACEMENT PARTS A Hayward Industries linc Company Tel 908 351 5400 www haywardpool com 5
33. WER INLET BAFFLE H300FD BLOWER INLET BAFFLE H350FD BLOWER INLET BAFFLE H400FD IGNITER ACCESS COVER GAS VALVE NATURAL GAS VALVE PROPANE BURNER ORIFICE KIT NATURAL BURNER ORIFICE KIT PROPANE GAS MANIFOLD H150FD GAS MANIFOLD H200FD GAS MANIFOLD H250FD GAS MANIFOLD H300FD GAS MANIFOLD H350FD GAS MANIFOLD H400FD CONVERSION KIT NA TO LP QUICK CHANGE H150FD CONVERSION KIT LP TO NA QUICK CHANGE H150FD CONVERSION KIT NA TO LP QUICK CHANGE H200FD CONVERSION KIT LP TO NA QUICK CHANGE H200FD CONVERSION KIT NA TO LP QUICK CHANGE H250FD CONVERSION KIT LP TO NA QUICK CHANGE H250FD CONVERSION KIT NA TO LP QUICK CHANGE H300FD CONVERSION KIT LP TO NA QUICK CHANGE H300FD CONVERSION KIT NA TO LP QUICK CHANGE H350FD CONVERSION KIT LP TO NA QUICK CHANGE H350FD CONVERSION KIT NA TO LP QUICK CHANGE H400FD CONVERSION KIT LP TO NA QUICK CHANGE H400FD COMBUSTION BLOWER BLOWER VACUUM SWITCH INTEGRATED CONTROL BOARD FIELD WIRING PANEL IGNITOR Pomona CA Clemmons NC Nashville TN Tel 908 351 5400 www haywardpool com ITEM 25 26 21 28 29 30 31 32 33 34 35 36 37 38 39 40 41 PART NO IDXLFLS 1930 IDXL2TRF 1930 FDXLWPS1930 IDXL2DB1930 FDXLBKP1930 FDXLBKP1931 FDXLGSK1932 FDXLHLI1930 FDXLTER1930 FDXLGSR1934 FDXLHXA1150 FDXLHXA 1200 FDXLHXA1250 FDXLHXA 1300 FDXLHXA1350 FDXLHXA 1400 FDXLHXA1250A FDXLHXA1400A FDXLFHD1930 FDXLFHA1930 FDX
34. arances must be observed to prevent restric tion of combustion and ventilation air Remember that shrubs grow and in time may obstruct a heater s venting areas 2 Check the venting of indoor heaters for looseness and possible leaks Keep all openings for combustion and ventilation air clear and unobstructed 3 Keep the entire pool heater area clean and free of all debris combustible materials gasoline and other flammable vapors and liquids Remove any leaves or paper from around the heater 4 Do not store chlorine other pool chemicals or other corrosives in the vicinity of the heater 5 Ifthe 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 6 If another appliance is added to the gas line at a later date consult the local gas company to be sure the gas line will have the capacity to supply both units at full input rating at the same time 7 Do not use the heater if any part has been under water Contact a qualified service technician to inspect the entire heater and replace any part of the control system or gas valve that was under water If heater has been totally submerged in water it must be removed and the entire heater must be replaced 8 An inspection program is a good preventative maintenance measure Keep this manual in a safe place for futur
35. ardous pressure during start up normal operation and after pump shut off Stand clear of circulation system equipment during start up Failure to follow safety and operation instructions could result in violent separation of the pump housing and cover due to pressure in the system which could cause property damage severe per sonal injury or death Before servicing pool and spa water circulation system all sys tem and pump controls must be in off position and filter manual air relief valve must be in open position Before starting system pump all system valves must be set in a position to allow system water to return back to the pool Do not change filter control valve position while system pump is running Before starting system pump fully open filter manual air relief valve Do not close filter manual air relief valve until a steady stream of water not air or air and water is discharged SN WARNING Separation Hazard Failure to follow safety and operation instructions could result in violent separation of pump components Strainer cover must be prop erly secured to pump housing with strainer cover lock ring Before servicing pool and y spa circulation system manual air relief valve must be in open position Do not oper VA ate pool and spa circulation system if a system component is not assembled properly damaged or missing Do not operate pool and spa circulation system unless filter air relief valve body is in l
36. art of annual heater mainte nance and to ensure safe operation External heat exchanger Internal heat exchanger Main burner flame patterns Main burner orifices Operating controls SO USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Fi AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com EXTERNAL HEAT EXCHANGER INSPECTION AND CLEANING Remove the louvered exhaust cover panel see Figure 12 and inspect the external surfaces of the heat exchang er for soot accumulation If soot has accumulated it must be removed by follovving the recommended procedure 1 Turn pump main gas valve and heater power OFF 2 Remove heat exchanger according to the procedure in Section II under Reversible Water Connections A WARNING BURN HAZARD Do not use a wire brush to remove soot from the heat exchanger This could cause a spark and ignite the gases trapped within the soot AT 3 Using a soft tipped brush such as a paint brush apply a degreaser to the entire heat ex t changer surface top and bottom Allow the heat exchanger to sit for a period of time to allow the degreaser to loosen the soot Wash the heat exchanger using a garden hose ensuring both the top and bottom surfaces are cleaned Re assemble the heater by reversing the disassembly steps Although the heat exchanger should be cleaned of soot and reinstalled the fact that sooting occurred should be inv
37. as meter must have the capacity to supply enough gas to the pool heater and any other gas appli ances if they are on the same pipeline 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 PROPANE GAS All propane gas tanks must be located outdoors and away from pool spa structure and in accordance with the standard for storage and handling of propane gas ANSI NFPA 58 latest edition and applicable local codes If the propane gas tank is installed underground the discharge of the regulator vent must be above the highest probable water level Propane tanks must have sufficient capacity to provide adequate vaporization for the full capacity of the equipment at the lowest expected temperatures Consult a propane company expert for correct sizing USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com A 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 151 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 u
38. astened to spade terminals on gas valve If OK proceed to step 5 5 Check for gas valve 1 Measure voltage across gas valve during trial for igintion If 24VAC failure or gas valve relay is present and gas valve does not open gas valve is defective Replace failure gas valve 2 If 24VAC is not present gas valve relay on control module is defective Replace control module 6 Check for blockages in Inspect gas orifices for blockages which could prevent gas flow Remove gas orifices and burners and inspect burners for blockages Blower vacuum 1 Check for defective Disconnect Blower plug fron Control Module With heater off measure switch closed blower on relay or control continuity across pins 1 and 2 of receptacle on Control Module If module closed control module relay is defective Replace control module If OK proceed to step 2 2 Vacuum switch is Replace blower vacuum switch defective Blower vacuum 1 Check for faulty vacuum Check tubing and replace if necessary If OK proceed to step 2 switch open switch tubing 2 Check for faulty vacuum Inspect vacuum switch wiring Ensure wire harness terminals are switch wiring or connection securely fastened to spade terminals on vacuum switch If OK proceed to step 3 3 Check for faulty blower Inspect blower wiring Ensure plug on blower is securely fastened to wiring or connection control module If OK proceed to step 4 4 Check for defective Disconnect Blower plu
39. attempts The control de energizes the gas valve after the 4 second ignition trial ends The control operates the blower during a 30 second post purge period The control monitors for open contacts at the blower vacuum switch The control performs a gas valve relay check A normal ignition sequence resumes with Item 2 in Heating Mode above If the third ignition trial fails the control enters a safety lockout or hard lockout after the postpurge period of the third failed trial 6 The error code IF is displayed and the SERVICE indicator is illuminated a The control automatically resets and clears the IF error code without any user intervention after 60 minutes If there is a call for heat after reset the control will make three 3 trials for ignition If ignition is not established the control will again enter safety lockout for 60 minutes This cycle will continue until ignition is established or the call for heat is removed b The user can reset the control and clear the IF error code by pressing the MODE button to move through STANDBY and return to the previous mode SPA or POOL ES SS LOSS OF FLAME RECYCLE If flame is established and then lost the control will make ten 10 attempts at ignition If flame is lost within ten 10 seconds of ignition the control will respond within 2 seconds If flame is lost more than ten 10 seconds after ignition the control will respond w
40. button through STANDBY and back to the original operating mode POOL or SPA ERROR CODES See Figure 31 for an error code chart TROUBLESHOOTING See Figure 32 for troubleshooting guide SUPPLY WIRING If the heater is connected to the line side of the circuit it will be powered at all times In this situation when the pump shuts down the heater will display a fault code of LO If there is a call for heat and the pump then restarts there will be a 2 minute delay for the heater to fire After the pump has been running for at least 2 minutes there is no delay for heater operation Wiring the heater to the load side of the timer or controller will not result in a 2 minute delay if the pump primes quickly enough to activate the heater s water pressure switch If the pump is slow to prime the heater may display an LO fault code and will take 2 minutes to automatically restart If the pump has primed this wait can be avoided by manually clearing the error code via the keypad by changing the mode through the STANDBY setting and returning to the initial setting SPA or POOL 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 H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 35
41. ctive Replace Fuse Board Fuse Board EE Bad Board 1 Control Module n Control Module Communication 1 Disconnect and then re Error between connect power to heater Control Module 12 Check for faulty wiring or Inspect Display Interface Wiring Ensure Display Interface Plug is ey connection securely attached to Control Module If OK proceed to step 2 nterface Assembly 3 Control Module and or Replace Control Module and or Display Interface Assembly Display Interface Assembly are defective Igniter Failure 1 Check for faulty wiring or Inspect Igniter wiring Ensure Igniter Plug is securely attached to connection Control Module If OK proceed to step 2 ok Igniter is defective Replace Ignitier Failure 1 Reypad is defective Replace Display Interface Assembly Nn A Code Figure 32 TROUBLESHOOTING Temperature sensor input failure Water Temperature Sensing Error Flame Present with Gas Valve not Energized Bypass Operation Water pressure switch fault Vent pressure switch fault applies only if indoor installation 1 Check remote thermostat setting 2 Verify that the water flow is adequate 3 Check inlet water temperature sensor 1 Gas Valve is defective 1 Check to see if Control Module is in Bypass Operation 1 Verify that the pump is running 2 Verify that water flow is adequate 3 Check for faulty wiring or connection 4 Verify state
42. dition the licensed electrician must also conform to local electrical codes for bonding requirements USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 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 1 5 m of inside walls of swimming pool or spa IMPORTANT Refer ence NEC codes for all wiring standards including but not limited to grounding bonding and other general wiring procedures A WARNING Suction Entrapment Hazard Suction in suction outlets and or suction outlet covers which are damaged broken cracked missing or unsecured can cause severe injury and or death due to the following entrapment hazards Hair Entrapment Hair can become entangled in suction outlets Limb Entrapment A limb inserted into an opening of a suction outlet or suction outlet cover that is damaged broken cracked missing or not securely attached can result in a mechanical bind or swelling of the limb Body Suction Entrapment A differential pressure applied to a large portion of the body
43. e ing the control will display the error code The post purge cycle will be com error pleted once the blower prover switch closes Blower vacuum switch If the blower prover switch is closed before blower start up the control will not AC _ closed when expected start the blower Automatic reset is immediate when the switch opens open error Igniter open error If the control is not in lockout and senses that the igniter circuit is open when the IO blower is running the control will turn off the blower and go into lockout Auto matic restart 2 min after error is corrected Thermistor error An excessive temperature difference between the two thermistors 5 F or more or an 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 SF USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 53 Figure 31 ERROR CODES continued ss Water Temperature Sensing Error Ignition failure error Communication error Limit string open error EEPROM ERROR Keypad button stuck Sb closed error A Inlet water temperature sensor is reporting a temperature in excess of 104 F Normal operation resumes 2 minutes after inlet water temperature sensor reports temperatures of 104 F or less
44. e 12 Natural Gas Pipe Sizing High Pressure 2 Stage Regulation H150FDN H200FDN H250FDN H300FDN H350FDN H400FDN Distance from Outlet of 1st Stage Regulator _ btu hr input 150 000 200 000 250 000 300 000 350 000 400 000 to Inlet of 2nd Stage Iron or Plastic or Plastic or Plastic Iron or Plastic Iron or Plastic Iron or Plastic Regulator Line Material I I Pipe Pipe Pipe Pipe Pipe Pipe Stage 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 a OH AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Table 13 Propane Gas Pipe Sizing High Pressure 2 Stage Regulation Distance from H150FDP H200FDP H250FDP H300FDP H350FDP H400FDP Tank Regulator btu hr input 150 000 200 000 250000 300000 390000 40000 Out Heater Gas Line Iron A ai 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 8 OH AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com GAS SUPPLY INSTALLATION The heater is shipped from the factory vvith the gas c
45. e maintained This heater may be installed on combustible floors Do not install heater in a closet AIR SUPPLY Indoor installations and outdoor shelters confined spaces must be provided with adequate combustion and ventilation air Connection vents to assure proper heater operation These vents must be sized according to the requirements stated in paragraph A or B below whichever applies to the installation These vents must never be obstructed when heater is in operation 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 H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com A ALL AIR SUPPLY FROM INSIDE THE BUILDING The confined space shall be provided with 2 permanent openings communicating directly with an addi tional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an uncon fined space a space whose volume is not less than 50 cubic feet per 1 000 btu hr The total input of all gas utilization equipment installed in the combined space shall be considered in making the determination Each opening shall have a minimum free area of 1 square inch per 1 000 btu hr of th
46. e reference for yourself as well as for a service technician to consult when inspecting or servic ing the heater Additional inspection procedures to be performed by a qualified service technician are covered in Section VI of this manual WINTERIZATION In moderate climates the heater can continue to operate during short term cold spells Do not use the heater to maintain the water temperature just above freezing or for freeze protection Care must be taken to avoid freeze up in the heater When it is used during freezing weather the pump must run continuously The heater is not warranted against freeze ups In regions where freezing temperatures are encountered all water must be drained from the heater when it is out of service to prevent damage to the heater and piping Drain ing the heat exchanger is recommended as part of the season s shutdown procedures A ATTENTION A heater damaged by freezing is not covered under the Hayward warranty USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 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 Set the heater to
47. e total input rating of all gas utilization equipment in the confined space but not less than 100 square inches See Table 5 One opening shall be within 12 inches of the top and and one within 12 inches of the bottom of the enclosure B ALL AIR SUPPLY FROM OUTDOORS Figure 4 The confined space shall be provided with 2 permanent Below Ground Pit Installation openings once commencing within 12 inches of the bottom of the enclosure The opening shall communicate directly or by ducts with the outdoors or spaces crawl or attic that ee bi freely communicate with the outdoors Ground Level Air 1 When communicating with the outdoors either di rectly or through vertical ducts each opening shall Rise of 1 inch have a minimum free area of 1 square inch per 4 000 btu hr of total input rating of all equipment in the enclosure See Table 5 2 When communicating with the outdoors through hori zontal ducts each opening shall have a minimum free area of square inch per 2 000 btu hr of total input rating of all equipment in the enclosure See Table 5 3 When ducts are used they shall be of the same cross sectional area as the free area of the openings to es ee which they connect The minimum dimension of rect or Slab angular air ducts shall not be less than 3 inches Table 5 Combustion and Ventilation Air Requirements 4 When installing a heater below Free Area per Btu Total Input Combustion Air Free Ventilation Air Free ground i
48. ed in or on the ground or in a building such that it cannot be readily disassembled for storage A storable pool is constructed so that it is capable of being readily disassembled for storage and reassembled to its original integrity Though this product is designed for outdoor use it is strongly recommended to protect the electrical components from the weather Select a well drained area one that will not flood when it rains It requires free circulation of air for cooling Do not install in a damp or non ventilated location e A WARNING It is required that licensed electricians do all electrical wiring Risk of Electric Shock Hazardous voltage can shock burn cause death or serious property damage To reduce the risk of electric shock do NOT use an extension cord to connect unit to electric supply Provide a properly located outlet All electrical wiring MUST be in conformance with applicable local and national codes and regulations Before work ing on this unit turn off power supply to the heater A WARNING To reduce the risk of electric shock replace damaged wiring immediately Locate conduit to prevent abuse from lawn mowers hedge trimmers and other equipment A WARNING Failure to bond to pool structure will increase risk for electrocution and could result in injury or death To reduce the risk of electric shock the electrician must comply with installation in structions and must bond the heater accordingly In ad
49. efore energizing the blower 2 Itis normal for the heater to display a 1 to 2 second delay in responding to any keypad input 3 Itis normal for the heater to display up to a 5 second delay when the keypad is used to reset the control to clear an error code 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 H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com AUTOMATIC RESET TIME The heater vvill automatically reset vvhen 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 Regular inspection by qualified service personnel is recommended to keep the heater working properly The following inspection points are suggested to help maximize heater life 1 Periodically check the venting on outdoor heaters The heater s venting areas the louvered top panel must never be obstructed in any way and minimum cle
50. er Resistance should be 10 9 19 7 ohms at at 77 F If out of this range replace igniter If OK proceed to step 4 one 4 Check for defective Disconnect Blower plug from Control Module Measure resistance Blower across Blower windings Winding resistance across lead should be in the following range Red to White 8 to 9 ohms If measured values vary substantially from these values blower is defective Replace Otherwise proceed to step 5 5 Control Module is Replace Control Module defective Bad Board or 1 Verify that FC4 Fuse on Remove FC from fuseholder Mesure continuity across fuse If OK Secondary Hig Fuse Board is not open reinstall fuse and proceed to step 2 If Fuse is open proceed to section Voltage Fault titled Open FC4 Fuse 2 Verify high voltage output Disconnect plug from P6 connector of Fuse Board Measure for from Fuse Board 120VAC across pins 3 and 5 of P6 receptacle on Fuse Board If OK reconnect plug and proceed to step 3 If not OK go to step 4 3 Check for defective Disconnect plug from E10 connector of Contol Module Measure for Harness 120VAC across pins and 3 of Plug on Harness If OK replace Control Module If not OK replace Harness 4 Check for defective Disconnect plug from P4 connector of Fuse Board Measure for Transformer 120VAC between pins 4 and 6 of plug from Transformer If OK proceed to step 5 If not OK replace Transformer 5 Fuse 5 Fuse Board is defective is defe
51. er We shall not pay nor be responsible for shipping or delivery charges to the place of instal lation nor for labor charges or other costs of removal or installation Every defective heater or part replaced under this warranty shall become our property and as such must be returned to our distribution center with transportation charges paid by the user Any replacement pool heater furnished under this warranty shall re main in warranty only for the unexpired portion of this warranty CONDITIONS AND EXCEPTIONS This warranty applies only to the pool spa at its original place of installation and only for the original owner It does not apply if the pool heater is installed in violation of any applicable code or ordinance or is not installed operated and maintained in accordance with our instructions or is misused damaged by ac cident weather act of God freezing water void and or excess pressure altered or disconnected It does not apply with respect to 1 A heater not equipped with Certified C S A limit controls or equivalent pressure relief valve 2 A heater operated with settings in excess of and or with fuel not conforming to those shown on rat ing plate A heater on which the serial numbers have been altered defaced or removed Leaks arising from defective installation Production of noise odors or discolored rusty etc water Leakage substantially contributed to by sediment lime precipitate and or higher than norma
52. er change For installation below the pool spa surface refer to Section II AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS If used a chlorinator must be installed downstream from the heater in the pool return line and at a lower elevation than the heater as shown in Figure 20 Install a separate positive seal corrosion resistant check valve between the heater outlet and the chlorinator to prevent highly concentrated sanitizers from backsiphoning into the heater Backsiphoning usually occurs when the pump is shut off and a pressure differential is created USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 8 OH AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com DRAIN VALVE INSTALLATION ASME MODELS ONLY If installing an ASME model heater a 3 4 brass drain valve must be installed A suitable drain valve is included separately with all ASME heaters Apply a suitable amount of pipe thread sealant or teflon tape to the threads and install as shown in Figure 21 Figure 21 Drain valve and PRESSURE RELIEF VALVE ASME MODELS ONLY relief valve locations e If installing an ASME model heater a 3 4 pressure relief valve having a discharge capacity greater than or equal to the Btu hr input of the heater and a ai pressure rating equal to or less than the working pressure must be installed See Si the rating plate located inside the front access panel
53. estigated as it may indicate other problems such as Insufficient air supply Inadequate venting High or low gas pressure Blockage of burner tubes or orifices Blockage of blower inlet Low voltage supply causing blower to spin slower Improper heater location installation Incorrect gas supply pipe size Excessive water flow through heat exchanger LP tank below 30 full COMBUSTION CHAMBER The combustion chamber is a single piece casting If damaged the entire chamber must be replaced HEAT EXCHANGER REMOVAL Follow steps in Section I under Reversible Water Connections for heat exchanger removal procedure BURNER INSPECTION AND CLEANING With the heater ON remove the front access panel and make a visual inspection of Figure 29 Burner Flame characteristics the main burners through the sight glass see Figure 25 The main burner flames should be about 4 to 2 in height and should not lift off the burner ports see Figure 29 A normal flame is blue without yellow tips Yellow tips or a totally yellow or lazy flame may be an indication of a fuel rich mix ture due to restricted air supply Spider nests in the burner and or gas orifices may also cause yellow tips USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com BURNER REMOVAL AND REPLACEMENT Refer
54. estrict airflow This heater must be installed at least 5 feet from the inside wall of a pool in ground or aboveground spa hot tub unless separated from the pool spa hot tub by a solid barrier The heater must be installed such that the location of the exhaust gas vent assembly outlet relative to adjacent public walkways adjacent buildings openable windows and building openings complies with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CGA B149 installation codes Outdoor instal lation and service clearances The heater must be installed outdoors such that the installation and service clearances from combustible materials shown in Table 2 are maintained This heater may be installed on combustible floors 1 The heater is self venting when installed outdoors and does not require additional vent piping 2 Do not install in a location where growing shrubs may in time obstruct a heater s combustion air and venting areas 3 Do not install this appliance under an overhang less than 3 feet from the top of the appliance The area under the overhang must be open on 3 sides 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 Fi AYVWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400
55. f pregnancy resulting in the birth of a brain damaged or deformed child Preg nant women should adhere to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate ther mometer spa or hot tub thermostats may err in regulating water temperatures by as much as 4 F 220 5 Persons taking medications which induce drowsiness such as tranquilizers antihistamines or anti coagulants should not use spas or hot tubs 6 Ifthe pool spa is used for therapy it should be done with the advice of a physician Always stir pool spa water before entering the pool spa to mix in any hot surface layer of water that might exceed healthful temperature limits and cause injury Do not tamper with controls because scalding can result if safety controls are not in proper working order 7 Persons with a medical history of heart disease circulatory problems diabetes or blood pressure problems should obtain a physicians advice before using spas or hot tubs 8 Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above normal body temperature of 98 6 F 37 C The symptoms of Hyperthermia include drowsi ness lethargy dizziness fainting and an increase in the internal temperature of the body The effects of Hyperthermia include Unawareness of impending danger Failure to perceive heat Failure to recognize the need to leave the spa Physica
56. figuration s and altitude range s it is designed for Table 1 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 H AVYVWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 9 FDXLHAR 1930 sold separately may be necessary 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 identifies which model s and altitude range s it is designed for If connected turn pump main gas valve and heater power off Remove heater front access door Remove the 4 10 hex head screws that fasten the blower air inlet plate to the blower and remove the blower air plate and discard Save the 4 screws as they will be needed to install the new plate See Figure 49 page 47 Install the appropriate blower plate from the kit using the 4 screws It may be helpful to drive the screws in and out of the plate outside of the heater first to thread the holes before installing it in the heater If the installation is configured for indoor venting a special high altitude vent pressure switch must be installed Follow the instructions for vent kit installation page 17 but use the appropriate blower air inlet plate and vent pressure switc
57. ft 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 A SD D 10 11 12 13 Before beginning be aware that it is not necessary to remove the water header from the heat exchang er When this procedure is complete the water inlet will be located at the BACK of the heater The water outlet will be located at the FRONT Remove screws and remove both of the upper plastic heater side panels see Figures 11 and 12 Note the wires that pass through a hole in the heater side panel go through a split bushing which will allow separation of the wires from the panel without disconnecting them Disconnect the 2 wires connecting the heater wire harness to the heat exchanger header One is lo cated on the water pressure switch and one is located on the temperature limit switch both on the top of the header Pull these wires into the heater cabinet from the hole in the right hand metal side panel in the heater and re route them out through the left hand metal side panel in the heater Remove countersunk screws on the heater top and remove louvered exhaust panel on heater top see Figure 12 Remove the heater top flue cover by removing 3 screws on each side of the heater see Figure 12 Remove screws and remove rain shield assembly see Figure 12 Note that there a
58. g from Control Module Measure resistance vacuum switch across Blower windings Winding resistance across lead should be in the following range Red to White 8 to 9 ohms If measured values vary substantially from these values Blower is defective Replace If OK proceed to step 5 5 Check for defective Disconnect Blower plug from Control Module Place heater in Pool blower relay or Spa Mode Lower set point temperature to generate call for heat During pre purge period measure for 120VAC across pins 1 and 2 If 120VAC is not present control module relay is defective Replace control module If OK proceed to step 6 6 Vacuum switch is Replace blower vacuum switch defective Ignition Failure 1 Ensure gas supply shutoff Ensure that main gas shutoff installed ea to heater is open Ensure valves are open that knob on gas valve inside unit is in on position If OK proceed to step 2 2 Check for low gas supply Ensure inlet gas supply pressure is between the minimum and maximum pressure values indicated on rating plate If OK proceed to step 3 3 Check for faulty flame Inspect flame sense wiring Ensure wire harness terminals are securely sense wiring or connection fastened to flame sense and to control module If OK proceed to step 4 HAYVVARD POOL HEATER CERTIFICATE OF LIMITED VVARRANTY Limited heater vvarranty TERMS AND COVERAGE We warrant our pool heater to be free from defects in workmanship and materi als under
59. h for your altitude Re install heater front door 10 If connected turn pump main gas valve and heater power back on 11 Activate heater and check for proper function Table 1 lists the maximum altitudes each model is designed for with a no modifications b the included conversion plate installed and c the accessory conversion kit FDXLHAR 1930 installed sold separately TABLE 1 Maximum Installation Altitude Outdoor Installation Indoor Installation Heater Modell Gas Included Conversion kit Included Conversion kit No Modifications Conversion Plate FDXLHAK1930 No Modifications Conversion Plate FDXLHAK1930 to Heater Installed on Installed on to Heater Installed on Installed on Heater Heater Heater Heater H250FDP KE 2 000 ft 7 700 ft 10 100 ft 2 000 ft 7 700 ft 10 100 ft H350FDP KE 2 000 ft 7 700 ft 10 100 ft 2 000 ft 7 700 ft 10 100 ft H400FDP EA 2 000 ft 7 700 ft 10 100 ft 2 000 ft 7 700 ft 10 100 ft 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 a OH AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com UN
60. he heater in STANDBY mode 2 Press and hold both the UP and DOWN buttons at the same time 3 After 3 seconds the thermostat enters maximum temperature lock adjustment mode 4 The SPA indicator light illuminates and the numeric display shows the current SPA mode maximum temperature lock setting Both the SPA indicator light and the numeric display flashes rapidly when in adjustment mode 5 Use the UP and DOWN buttons to set the desired maximum temperature lock setting When finished press the MODE button 6 The POOL indicator light illuminates and the numeric display shows the current POOL mode maximum temperature lock setting Both the POOL indicator light and the numeric display flashes rapidly when in adjustment mode 7 Use the UP and DOWN buttons to set the desired maximum temperature lock When finished press the MODE button 8 The heater will return to STANDBY mode FAHRENHEIT VERSUS CELSIUS The temperature can be displayed in Fahrenheit or Celsius TO change the display use the MODE button to place the heater in STANDBY Then press and hold the UP and MODE buttons until the display shows the F C selection Press the DOWN button to toggle between selections To accept the selection press the MODE button If the user does not act the selection will be automatically accepted after 60 seconds HEATING MODE The control continually compares the water temperature with the set point and the h
61. hnician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Should over heating occur or the gas supply fails to shut off turn off manual gas valve to the appliance POUR VOTRE S CURIT LIRE AVANT L ALLUMAGE MISE EN GARDE Si vous ne suivez pas exactement ces instructions un incendie ou une explosion pourrait survenir et causer des dommages a la ro ri t e des blessures corporelles ou la perte a vie Cet appareil n a pas de pilote Un m canisme d allumage automatique pour les brileurs N essayer pas d allumer les br leurs la main AVANT L ALLUMAGE sentir tout autour de l appareil pour d celer d ventuelles odeurs de gaz S assurer de sentir pr s du plancher parce que les gaz plus lourds que l air se concentrent au niveau du plancher QUE FAIRE EN PRESENCE D ODEURS DE GAZ e Ne pas essayer d allumer l appereil eNe pas toucher a un commutateur lectrique Ne pas utiliser le t l phone dans la maison e Appeler imm diatement fournisseur de gaz chez un voisin Suivre les instructions du fournisseur de gaz e Si le fournisseur ne peut pas tre atteint appeler le service des incendies Utiliseruniquement les mains pour actionner les boutons de commande du
62. ication we shall decide whether to repair such parts or replace any pool heater reserving at all times the right to inspect in order to verify any claimed defect We also reserve the right to have our representatives make any inspections repairs or to furnish replacements This warranty is intended as a legally binding obligation of the Company enforceable in the courts This warranty may give you spe cific legal rights which may vary from state to state LIMITATION ON LIABILITY All intended representations have been expressly set forth in this document This warranty may not be extended by oral or any other additional representations written sales information drawings or other mal function is strictly limited to repair or replacement of the defective heater or part as provided herein and the Company is not responsible hereunder for incidental or consequential or incidental costs or damages The company neither assumes nor authorizes any person or firm to assume for us any further liability or obligation in connection with the sale installation use maintenance or existence of the heater SAFETY WARNING Pool heaters are heat producing appliances and to avoid damage or injury in the event of pos sible overheating of the outer jacket 1 no materials should be stored against the jacket and 2 care should be taken to avoid unnecessary contact especially by children with the jacket When lighting a gas heater the lighting instructions mus
63. igh limit temperature When the water temperature is more than 1 below the set point a call for heat is generated and a heating cycle is initiated 1 The control checks for open contacts at the blower vacuum switch 2 The control energizes the blower and the igniter The igniter heat up time is approximately 20 seconds The blower is running a pre purge cycle during this time 3 The control checks for closed contacts at the blower vacuum switch 4 When the igniter reaches the proper temperature a 4 second trial for ignition begins The control opens the gas valve and monitors flame current The igniter is turned off when flame is sensed or after 4 sec onds 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 6 When the thermostat is satisfied and the call for heat ends the control immediately de energizes the gas valve Flame is extinguished 7 The control operates the blower during a 30 second post purge period USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com FAILURE TO LIGHT RETRY If the first ignition attempt fails during a normal heating cycle the control will make two 2 additional ignition
64. immediately when the pump is turned off Never allow the heater to operate with less than the minimum rated water flow rate For Installations with Heater Below Water Level 1 Be sure the filter is clean before making the adjustment 2 Turn ON the filter pump and ensure all air is out of the water lines and ensure water flow rate is at least the rated minimum see Table 14 3 Turn ON the heater and adjust the thermostat to create a call for heat 4 Turn the adjustment knob on the pressure switch clockwise until the heater turns off then turn the knob Va turn counter clockwise so that the heater turns back on Turning the adjustment knob clockwise increases the pressure needed to close the switch 5 Check the function of the pressure switch by turning the filter pump on and off several times The pool heater should turn off immediately when the pump is turned off Never allow the heater to operate with less than the minimum rated water flow rate TWO SPEED PUMP In a few cases the pressure from a two speed pump is below the 1 pound minimum required to operate the wa ter pressure switch on the heater 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 quired 1 pound minimum pressure cannot be obtained do not attempt to operate the heater Correct the installation USE ONLY
65. ith the pool owner Figure 28 Heat exchanger header components Inlet Outlet Bypass Service Cartridge Header Cartridge Retaining Nut Water Pressure Temperature Limits Thermistor Drain PI Pressure Relief ee Valve Port USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com SECTION IV QUALIFIED TECHNICIAN MAINTENANCE amp SERVICING GENERAL A ATTENTION Only qualified 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 Before proceeding with heater related troubleshooting tips covered in Section VII be certain that the pump is operating correctly the filters and strainers are not blocked the valves in the piping are properly positioned and the time clocks are properly set A WARNING EXPLOSION HAZARD Do not attempt to repair any components of this heater Do not modify the heater in any manner To do so may result in a mal function that could result in death personal injury or property damage Check with the consumer to see if any part of the heater has been under water Replace any part of the control system and any gas control that has been under water MAINTENANCE The following inspection procedures are recommended to be performed as p
66. ithin 0 8 seconds 1 The control de energizes the gas valve and the blower 2 The control monitors for open contacts at the blower vacuum switch 3 The control performs a gas valve relay check 4 A normal ignition sequence resumes with Item 2 in Heating Mode above 5 Ifthe tenth ignition trial fails the control enters a safety lockout or hard lockout after the post purge period of the tenth failed trial 6 The error code IF is displayed and the SERVICE indicator is illuminated a The control automatically resets after 60 minutes If there is a call for heat after reset the control will make three 3 trials for ignition If ignition is not established the control will again enter safety lockout for 60 minutes If flame is established but is lost the control will make ten 10 attempts at ignition This cycle will continue until ignition is established or the call for heat is removed b The user can reset the control and clear the IF error code by pressing the MODE button to move through STANDBY and return to the previous mode SPA or POOL KEYPAD INPUTS The control accepts user inputs via the keypad on the front panel 1 When changing the mode from STANDBY to either SPA or POOL there may be up to a 10 second delay for the blower fan to begin running The control performs an internal self test and then verifies that the blower vacuum switch contacts are open b
67. just the manual bypass valve until the flow H250FD rate is within the flow rate range specified for the heater 3 Once the valve is set note the position and remove ae the valve handle to prevent further adjustment A ATTENTION Improperly adjusted manual bypass valves will result in damage to the heater if the flow rates are not maintained as specified in Table 14 under all operating conditions The heat exchang er will fail and this damage will not be covered under the Hayward warranty Figure 16 Manual Bypass valve USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 11 AYWARD Poo Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Figure 17 illustrates a typical pool piping diagram and layout for the pool equipment Figure 18 illustrates a multiple heater installation for very large pools vvith and vvithout a manual bypass valve INSTALLATION ABOVE POOL SPA SURFACE If the heater is installed less than three 3 feet above the sur face of the pool spa water install eyeball fittings or directional flow fittings on the end of the return water line to the pool spa to create adequate back pressure at the heater to operate the pressure safety switch when the filter pump is running If the heater is installed more than three 3 feet above the surface of the pool spa water install a loop as shown in Figure 19 to prevent drainage of water in the heater during a filt
68. l dis solved solids pH above 7 8 in the tank copper tubes or water ways 7 Leakage caused substantially contributed to by corrosive elements in the atmosphere such as the storage of chlorine or other chemicals 8 Leakage caused substantially or contributed to by corrosive pool water in an acid condition pH below 7 2 9 Damage caused substantially or contributed to by an external source of energy 10 A pool spa heater is a water containing device Leakage of water from this device can be expected at some time due to malfunction or the limitations Nn BW USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com of the service life of various components Do not install this product where such leakage can cause damage MANUFACTURER IS NOT RESPONSIBLE OR LIABLE FOR ANY COSTS INCURRED BY SUCH DAMAGE IN NO CASE ARE WE TO BE HELD LIABLE FOR DAMAGE TO SURROUNDING AREA OR PROPERTY CAUSED BY LEAKAGE OR MALFUNCTION HOW TO CLAIM UNDER THIS WARRANTY The original owner upon discovering the defect must present the attached completed warranty claim card with proof of purchase either to the dealer or notify the Company in writing at either address HAYWARD POOL PRODUCTS INC 620 DIVISION ST ELIZABETH NJ 07207 OR HAYWARD POOL PRODUCTS INC 2875 POMONA BOULEVARD POMONA CA 91768 Upon receipt of such notif
69. l inability to exit the spa Fetal damage in pregnant women Unconsciousness resulting in danger of drowning Se DEFINITIONS Suction Outlet The term Suction Outlet is a fitting fitting assembly cover grate and related compo nents that provide a means for water to exit the pool and into the pump circulating system Inches of Mercury in Hg 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 H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com SECTION l GENERAL INFORMATION INTRODUCTION This manual contains instructions for installation operation maintenance troubleshooting and parts lists for the safe use of the swimming pool spa hot tub heaters Hayward strongly recommends that the installer read the manual before installing the swimming pool spa hot tub heater If after reviewing the manual any questions remain unanswered contact the factory or local representative Following heater installation the installer should leave all manuals with the consumer for future reference LIMITED WARRANTY SUMMARY Hayward warrants the pool spa hot tub heater to be free from defects in materials and workmanship and will within one year from date of installatio
70. l to SPA or POOL Set the set point temper ature on the control panel to the desired setting If the appliance does not operate repeat steps 2 thru 10 If the appliance still does not operate follow instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Change the MODE on the control panel to STANDBY 2 Remove the heater s front access panel 3 Turn the gas control knob clockwise to OFF 4 Replace the heater s front access panel INSTRUCTIONS D ALLUMAGE 1 STOP Lire les consignes de s curit sur cette tiquette 2 Changer le MODE du tableau de commande a STANDBY 3 Retirer le panneau d acc s avant de l appareil de chauffage 4 Cet appareil est pourvu d un dispositif d allumage qui allume automatiquement les br leurs Ne pas tenter d allumer manuellement les br leurs 5 Tourner le bouton de commande du gaz en sens horaire OFF ferm BOUTON DE COMMANDE RO DE GAZ MONTRE EN POSITION FERME OFF ON 6 Attendre cinq 5 minutes que tout gaz se dissipe Arr ter si l on sent alors une odeur de gaz Suivre B dans les consignes de s curit de cette tiquette 7 Passer l tape suivante en l absence d odeur de gaz Tourner le bouton de commande du gaz en sens anti horaire ON OUVERT AN Replacer le pannea
71. lector Plug is installed If OK proceed to Voltage Selector Plug is not step 2 installed with a 240VAC field power supply If 120VAC plug is installed and field supply voltage is 240VAC FCI and FC2 fuses will have to be opened Install the correct Voltage Selector Plug and new FC1 and FC2 fuses 2 Check for faulty Inspect Transformer wiring Ensure insulation on wiring is not worn If Transformer wiring OK proceed to step 3 3 Defective Transformer Replace Transformer 55 Figure 32 TROUBLESHOOTING ss ss Si Open FC3 and or 1 Check for faulty Gas Inspect Gas Valve wiring Ensure insulation on wiring is not worn If F1 Fuses Valve wiring OK proceed to step 2 2 Verify that Gas Valve is Mesure for resistance across Gas Valve terminals and between each not defective terminal and ground If short exists replace Gas Valve If OK proceed to step 3 3 Check for faulty Control Inspect Control Module wiring Ensure insulation on wiring is not worn Module wiring If OK proceed to step 4 4 Control Module is Replace Control Module defective Open FC4 Fuse 1 Check for faulty Igniter Inspect Igniter wiring Ensure insulation on wiring is not worn If OK wiring proceed to step 2 2 Check for faulty Blower Inspect Blower wiring Ensure insulation on wiring is not worn If OK wiring proceed to step 3 3 Check for defective Disconnect Igniter plug from Control Module Measure resistance Igniter across Ignit
72. n a pit combustion and Requirement btu hr Area Required sq in Area Required sq in Drip Tee Air Duct from Ground to Base Gas Cock rovided as shown in Figure 4 paragraph A DT 250 p j 300 300 i ini IM en 300 Each opening shall have a mini mum free area of 1 square inch per 250 btu hr or total input rating of 1 sq in per 2 000 btu hr all equipment in the pit See Table paragraph B 2 5 Below ground pit installations must be natural gas only IE 200 1 Sq in per 4 000 btu hr For more detailed methods of provid k er a ipatagtaph B 1 ing air for combustion and ventilation refer to the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 1 sq in per 250 btu hr paragraph B 4 400 000 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com VERTICAL VENTING NEGATIVE PRESSURE VENT SIZING Size the vent pipe according to the venting Table 6 tables in the National Fuel Gas Code ANSI a Z223 1 NFPA 54 for a Category I gas appliance Vent Pipe Diameters for using single wall or double wall Type B gas Negative Pressure Indoor Vent Kits vent Vent pipe diameter should not be less than Indoor Vent Kit Vent Pipe the size of the vent pipe adapter on the heater Part Number Heater Model Diameter see Table 6 The maximum ve
73. n accordance with the latest edition of the National Electrical Code ANSI NFPA 70 unless local code requirements specify otherwise In Canada follow CSA C22 1 Canadian Electrical Code Part 1 The heater must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with National Electrical Code ANSI NFPA 70 The heater may be installed with the electrical service and remote control entering the heater cabinet on either the left or right sides of the heater The heater is equipped with 4 openings for electrical entry Any unused openings must be plugged these are supplied Field power wiring connections are to be made to the terminal block located in the upper compartment inside the junction box see Figure 22 The heater has 2 junction boxes one on each side of the heater Only one junction box should be used for field power wiring USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com REMOTE CONTROL CONNECTION DR A nection to an external 2 wire remote thermostat or a 3 wire remote switch A 2 wire thermostat has its own tempera ture sensor for regulating water tempera ture A 3 wire remote switch allows the POOL or SPA models to be re motely selected Connect remote wiring to the terminal block located in the lower compartment inside the junction box
74. n for all users for the original purchaser repair or at our option replace without charge any defective part Hayward further warrant that if the heat exchanger or exchanger headers water containing section leak within one year from date of such installation for all users due to defects in materials and workmanship Hayward will provide a replacement part Cost of freight installation fuel and service labor after one year is at user s expense For full details of warranty agreement see war ranty certificate included in this manual A ATTENTION If the pool spa hot tub heater is damaged or destroyed by improper maintenance exces sive water hardness incorrect water chemistry or freezing it is not covered under the manufacturer s warranty MAINTAINING PROPER WATER CHEMISTRY Failure to Maintain Proper Water Chemistry May Cause SAS WNS 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 Yet it remains vital that the heat ex changer be protected from damaging or corrosive chemicals insufficient water flow or improperly balanced water chemistry Heat exchanger damage or failure resulting from improper flow improperly balanced pool water or the improper addition
75. nlet restrictor with the new one included in the kit a Remove the 4 10 hex head screws that fasten the plate to the blower and remove the blower air plate and discard Save the 4 screws as they will be needed to install the new plate b Install the new blower plate included in the kit using the 4 screws It may be helpful to drive the screws in and out of the plate outside of the heater first to thread the holes before install ing it in the heater See Figure 10 14 Re install heater front door 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 O USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Vent Adapter B cA Heat Barrier FIGURE 6 Flue Cover FIGURE9 Vent Pressure Switch Blower Air Inlet Plate Blower Pressure Tap SS i Vent Pressure FIGURE 10 Switch Tubing USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com REVERSIBLE WATER CONNECTIONS Fgure11 This heater is designed so that it can be installed with the water connections located on either the right Screw Locations or le
76. normal use and service Pursuant to this warranty and subject to the Conditions and Exceptions indicated below 1 We will replace cost of freight installation cost of fuel and service labor at user s expense with the prevailing comparable model or at our option repair any pool spa heater that leaks under nor mal use and service within one year from the date of original installation for all users 2 In addition we will replace cost of freight installation cost of fuel and service labor at user s expense or at our option repair any part or parts of the pool spa heater which malfunctions under normal use and service within one year from the date of original installation for all users LIMITATION ON IMPLIED WARRANTIES WE ARE NOT LIABLE FOR ANY CONSEQUENTIAL DAMAGES FOR BREACH OF ANY WRITTEN OR IMPLIED WARRANTY OF THIS PRODUCT Im plied warranties including the WARRANTY of MERCHANTABILITY and all other implied warranties that may arise from course of dealing or usage of trade imposed on the sale of this heater under laws of the state are limited in duration to the term of one 1 year for all users There are no warranties which extend beyond the description on the face hereof We shall not in any event be held liable for any special indirect or conse quential damages EXPENSE OF DELIVERY AND INSTALLATION Each pool heater or replacement part to be furnished under this warranty shall be furnished at our nearest distribution cent
77. nsor l 2 4 5 Turn pump gas supply and heater power OFF Remove the front access panel 4 screws Disconnect the wire from the flame sensor Remove the screws that secure the flame sensor to remove the sensor Reverse the above procedure to install the flame sensor BURNER ORIFICES Refer to Figures 12 and 25 as needed To remove the burner orifices BON m Turn pump gas supply and heater power OFF Disconnect the union joint in the gas supply piping outside the heater cabinet Remove the front access panel It is secured with 4 screws Disconnect the wiring terminals from the gas valve Remove the gas manifold assembly It is attached to the air box using 4 screws Remove the orifices using a 7 16 wrench 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 A ATTENTION Do not enlarge orifice holes USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com GAS CONVERSION The factory installed gas train where appropriate may be changed from natural gas to propane or from propane to natural gas using the appropriate conversion kits available from the factory Gas conversions are to be performed only by a qualified service agency Detailed
78. nt height can not exceed 50 ft The total lateral horizontal PHARES length cannot exceed 1 2 of the total vent height UHXNEGVT12001 The system may have up to 3 90 degree elbows maximum Single wall vent may be used in TRES conditioned spaces only Clearance to combus UHXNEGVT13001 tible materials for single wall vent is 9 inches Double wall Type B vent must be used in non ai conditioned spaces UHXNEGVT14001 VENT TERMINATION Vent extending through a roof or wall must be listed double wall Type B vent and pass through an approved roof jack or roof thimble A listed vent cap must be used Gas vents that are spaced less than 8 ft horizontally from a vertical wall or similar obstruction shall terminate not less than 2 ft above any portion of a building within 10 ft Gas vents that are spaced 8 ft or more horizontally from a vertical wall or similar obstruction shall terminate above the roof a distance H based on the roof pitch Using the roof pitch find the minimum value of H using Figure 5 and Table 7 Table 7 Height Requirements for Vent Caps see Figure 5 Figure 5 Min Height H from Roof to Minimum Height from Roof for Vent Cap Roof Slope Lowest Discharge Opening cap Listed gas H minimum om roof to lowest discharge opening USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com
79. nuity across vent pressure switch If closed LO code is not caused by vent pressure switch fault If open proceed to step 3 Remove jumper from wire leads and reconnect wire leads to vent pressure switch Ensure that flue is not blocked or restricted See indoor vent sizing requirements in installation manual If OK proceed to step 4 27 Figure 32 TROUBLESHOOTING 7 0 0 0 0 i M 32 TROUBLESHOOTING li 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 Verify state of temperature Remove wire leads from limit switch and jumper leads Operate heater limit switch fault limits contacts Measure continity across limit switches If closed LO code is not cont d caused by temperature limit switch fault If open proceed to step 3 Remove jumper from leads and reconnect leads to temperature limits 3 Verify that water flow is Verify that water flow rate to heater is above the minimum required adequate 20 GPM for H150FD and H200FD 25 GPM for H250FD and H300FD 30 GPM for H350FD and H400FD If OK proceed to step 4 4 Temperature limit switch Replace temperature limit switch is defective 4 Check for faulty gas valve Inspect gas valve wiring Ensure wire harness terminals are securely wiring or connection f
80. ocked position in filter upper body WARNING Never operate or test the circulation system at more than 40 PSI WARNING Fire and burn hazard Motors operate at high temperatures and if they are not properly isolated from any flammable structures or foreign debris they can cause fires which may cause severe personal injury or death It is also necessary to allow the motor to cool for at least 20 minutes prior to maintenance to minimize the risk of burns A WARNING Failure to install according to defined instructions may result in severe personal injury or death USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Fi AVYVWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com A WARNING The following Safety Rules for Hot Tubs recommended by the U S Consumer Product Safety Commission should be observed when using the spa 1 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 Special caution is suggested for young children Pro longed immersion in hot water can induce hyperthermia 2 Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant women beware Soaking in water above 100 F 38 C can cause fetal damage during the first three months o
81. on the heater for the input A aj rating and working pressure A suitable pressure relief valve is included sepa ott mae j rately with all ASME heaters Apply a suitable amount of pipe thread sealant or teflon tape to the threads and install as shown in Figure 21 Please note that the Vi drain valve must be installed before the pressure relief valve Install the pressure 0010 a relief valve with the discharge connection facing the ground If necessary con nect a pipe of the same size as the valve outlet to the outlet and run it to a safe Pressure place of discharge Do not install any shut off or restriction in this drain line valve PRESSURE RELIEF VALVE NON ASME MODELS ONLY Some local building codes require a pressure relief valve for non ASME pool spa heaters The plastic header has a 3 4 port vvhich can be used for this purpose see Figure 28 for location of port A 3 4 pressure relief valve having a discharge capacity greater than or equal to the Btu hr input of the heater and a pressure rating equal to or less than the working pressure is recommended See the rating plate located inside the front access panel on the heater for the input rating and working pressure 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
82. onnection 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 14 A union should be installed outside the heater cabinet for easy removal of the gas manifold assembly during service ACSA certified main gas shutoff valve must be installed outside the cabinet and within 6 feet of the heater This valve must have an I D large enough to supply the proper amount of gas volume to the heater See Figure 13 A ATTENTION Apply joint compound pipe dope sparingly and only to the male threads of pipe joints Do not apply joint compound to the first two threads Use joint compounds resistant to the action of lique fied petroleum gas Do not overtighten the gas inlet pipe or damage may result A ATTENTION Do not use flexible appliance con nectors on any gas connections unless the connector pon is CSA approved for outdoor installation is marked with BTUH capacity which must be equal to or greater than the heater rated input and the type of gas natural or LP Reduction of gas supply pipe or tubing to the inlet of the heater gas valve must be made at the valve only and must match the valve inlet size 3 4 NPT If more than one appliance is installed on the gas line consult the local gas company for the proper gas line size Questions on the installation of the proper gas line size can be directed to Hayward Technical Service NATURAL GAS The g
83. ons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com 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 It is VERY IMPORTANT when installing a propane heater on a 2 stage regulation system to follow the gas line sizing data in Table 13 without exception Table 10 Natural Gas Pipe Sizing Low Pressure Single Stage Regulation Model H150FDN H200FDN H250FDN H300FDN H350FDN H400FDN Distance from Gas Meter to Heater Gas input 150 000 200 000 250 000 300 000 350 000 400 000 Valve Inlet Line Material Iron or Plastic Pipe Iron or Plastic Iron or Plastic Iron or Plastic Pipe Iron or Plastic Pipe or Plastic Pipe CE CN Ve e lu Based upon an inlet gas pressure of 0 5 psig or less at a pressure drop of 0 5 in wc Table 11 Propane Gas Pipe Sizing Low Pressure Single Stage Regulation Distance from H150FDP H200FDP H250FDP H300FDP H350FDP H400FDP oh Co ET Ane btu hr input 150 000 20000 250000 300000 30 40000 Heater Gas Line A Un One ENTER 928 DU I A DS 1151 1 1 ET Lo Let Ter Tur Tue Ll Based upon an inlet gas pressure of 11 in wc at a pressure drop of 0 5 inch w c Tabl
84. or limbs can result in an entrapment Evisceration Disembowelment A vacuum applied directly to the intestines through an unprotected suction outlet sump or suction outlet cover which is damaged broken cracked missing or unsecured can result in evisceration disembowelment Mechanical Entrapment There is potential for jewelry swimsuit hair decorations finger toe or knuck le to be caught in an opening of a suction outlet or suction outlet cover resulting in mechanical entrap ment A WARNING To reduce the risk of entrapment hazards e When suction outlets are less than a 18 x 23 equivalent a minimum of two function ing suction outlets per pump must be installed Suction outlets in the same plane i e floor or wall must be installed a minimum of three feet 3 1 meter apart as mea sured from near point to near point e Dual suction outlets shall be placed in such locations and distances to avoid dual blockage by a user e Dual suction fittings shall not be located on seating areas or on the backrest for such seating areas e The maximum system flow rate shall not exceed the flow rating of any listed per current revision of ASME ANSI A112 19 8 suction outlet cover installed e Never use the Pool or Spa if any suction outlet component is damaged broken cracked missing or not securely attached e Replace damaged broken cracked missing or not securely attached suction outlet components im mediately e
85. ormer and 120VAC between pins 4 amp 6 If24VAC or 120VAC is not present replace Transformer Otherwise proceed to step 7 7 Fuse Board is defective Replace Fuse Board 1 Check for Low Voltage Diconnect plug from P5 connector from Fuse Board Measure for Output from Fuse Board 24VAC across pins Reconnect plug If OK proceed to step 2 Otherwise proceed to step 5 2 Check for faulty Control Inspect Control Module wiring Ensure all plugs are securly fastened to Module wiring Control Module If OK proceed to step 3 3 Verify low voltage input Verify 24VAC across R and C terminals on Control Module If not OK to Control Module replace harness If OK procced to step 4 4 Verify that F1 Fuse on Remove FI fuse from fuseholder Measure continuity across fuse If Control Board is not open OK replace Control Module If fuse is open proceed to section titled Open FC3 or FCI Fuses 5 Verify that FC3 on Fuse Remove FC3 fuse from fuseholder Measure continuity across fuse If Board is not open fuse is open proceed to section titled Open FC3 or FCI Fuses If OK reinstall fuse and proceed to step 6 6 Check for defective Disconnect plug from P4 connector from Fuse Board Mesure for Transformer 24VAC between pins amp 2 of plug from transformer If 24VAC is not present replace Transformer Otherwise proceed to step 7 7 Fuse Board is defective Replace Fuse Board 1 Verify that 120VAC Check that proper Voltage Se
86. ouv UL ou CSA homologu pour 600 V et 105 C BK N COM L SPA R LO Right Junction Box Boite de jonction de droite gt POOL PISCINE 4 GND Power Connections L2 af Connexions d alimentation L L Remote Thermostat Connections Connexions de thermostat t l command 1303103801 rev F Figure 24 Lighting amp Operating Instructions label FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliances Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service tec
87. ove the 4 screws and remove the plastic bezel amp keypad assembly from the sheet metal panel on the front of the heater The display board is attached to the back side of the bezel amp keypad assembly Unplug the keypad ribbon cable from the display board Detach the board from the plastic bezel by removing the 2 small screws Replace the display board or bezel amp keypad assembly and reverse the above steps to reassemble A No BLOVVER VACUUM SVVITCH The blower vacuum switch is a safety device that prevents the ignition sequence from continuing unless the blower is developing sufficient airflow for combustion Figure 31 shows the location of the blower vacu um switch in the heater cabinet When the blower achieves sufficient airflow the negative pressure created in the blower housing closes the contacts on the blower vacuum switch indicating to the ignition control board that it is safe to continue the ignition sequence A silicone tube connects the blower vacuum switch with the blower as shown in Figure 31 To remove the blower vacuum switch Turn pump gas supply and heater power OFF Remove the front access panel It is secured with 4 screws Remove the wires from the pressure switch Pull the tubing from the hose barb on the switch Remove the 2 screws that secure the pressure switch to the control panel Reverse the above procedure to install the blower vacuum switch DN USE ONLY HAYWARD G
88. ow instructions can cause severe injury and or death A 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 WARNING warns about hazards that could cause serious personal injury death or major property dam age and if ignored presents a potential hazard A CAUTION warns about hazards that will or can cause minor or moderate personal injury and or prop erty damage and if ignored presents a potential hazard It can also make consumers aware of actions that are unpredictable and unsafe ATTENTION indicates special instructions that are important but not related to hazards READ AND FOLLOW ALL INSTRUCTIONS IN THIS OWNER S MANUAL AND ON EQUIPMENT IMPORTANT SAFETY INSTRUCTIONS Before installing or servicing this electrical equipment turn power supply OFF KEEP SAFETY LABELS IN GOOD CONDITION AND REPLACE IF MISSING OR DAMAGED A WARNING To reduce risk of injury do not permit children to use or climb on the heater pumps or filters Closely supervise children at all times Components such as the filtration system pumps and heaters must be positioned to prevent children from using them as a means of access to the pool A CAUTION This heater is intended for use on permanently installed swimming pools and may also be used with spas Do NOT use with storable pools A permanently installed pool is construct
89. p due to improper gas line or propane tank sizing resulting in improper gas volume WATER PIPING The heater is designed for use with pool and spa hot tub water only as furnished by municipal water dis tribution systems The warranty does not cover heater use with mineral water seawater PPM gt 4000 or other non potable waters Do not install any restriction in the water pipe between the heater outlet and the pool spa with the exception of 1 three way switching valve Figure 15 Pipe nipples 2 in line chlorinator 3 chlorinator check valve WARNING EXPLOSION HAZARD Blockage of water flow from heater return to pool may result in fire or explosion causing property damage personal injury or loss of life Heater Header Gaskets Fittings Union Nuts Plastic Header The heater is equipped with CPVC flanged pipe nipples to accomodate water piping to and from the pool or spa These pipe nipples will accept piping by solvent welding PVC glue The fittings will accept either a 2 pipe or a 2 1 2 pipe fitting and seal to the heater header with rubber gaskets On plastic headers the fit tings are secured in place with plastic union nuts and on bronze headers ASME models the fittings are secured Header Gaskets Fittings in place with bolts Assemble these parts to the heater Bronze Header ASME prior to plumbing Tighten union nuts or bolts securely before gluing fittings to the ends of the pipe nipples See Figure 15
90. panel It is secured with 4 screws Disconnect the wiring terminals from the gas valve Remove the gas manifold assembly It is attached to the air box using 4 screws Unscrew the gas valve from the gas manifold pipe Reassemble the gas manifold assembly using the new gas valve Only use liquid pipe thread sealant on the male threads of the gas manifold pipe Do not place pipe dope on the first two threads of any joint Reverse the above procedure to re install the gas manifold USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com IGNITER Refer to Figures 12 and 25 as needed To remove the igniter AUN D I Un Turn pump gas supply and heater power OFF Remove the front access panel It is secured with 4 screws Disconnect the igniter wires from the ignition control board Remove the screws from the igniter access panel Working from the underside of the panel press the bushing out of the hole in the sheet metal panel Slide the igniter wires through the slot on the panel and pull the panel free Remove the 2 screws that secure the igniter Pull the igniter straight back until it is free of the combustion chamber then out of the air box Reverse the above procedure to install the igniter FLAME SENSOR Refer to Figures 12 and 25 as needed To remove the flame se
91. pply 9 9 13 811117 1 ken 47 Vertical Venting 15 Thermistor ii 48 Horizontal or Vertical Venting 16 Water pressure switch 48 Vent Kit Installation 18 Transformer 49 Reversible water connections o o o o o 20 BIOW T sis 855 49 Gas supply and piping 22 By pass service cartridge 49 Water Piping ccecssecssecseeecseeeteeeaeeeaeeees 25 Installation above pool surface 27 Section V Troubleshooting 50 Chlorinator chemical feeder 27 General sessions ent 50 Drain valve installation ASME Models 28 Automatic reset time sions 50 Pressure relief valve 28 Supply wiring llllilliiiiiirrrerrrertrtrtttrtttrttrtttsreonn 50 Electrical specifications 28 Internal wiring 51 Electrical connections 29 Fuse Specifications eeooeooeeononononnnsnnoon 51 Remote control connection eeeooee 30 Error codes
92. rds requiring Ground Fault Inter ruption protection via GFI Circuit Breaker or otherwise of Fixed or Stationary equipment under article 680 Swimming Pools Fountains amp Similar Installations BONDING A 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 Electrical Code NEC and most other 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 The heater along with pumps and other pool equipment must be connected to this bonding grid A bonding lug is provided on the side of the heater to ensure that this requirement is met 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 heater is shipped from the factory wired for use with 240VAC 60 Hz field power supply To convert the heater to 120VAC 60 Hz operation remove the 240VAC voltage selector jumper from the ignition con trol board and replace it with the 120VAC jumper These jumpers are tie wrapped together and are located on the fuse board See Figure 25 for location of the fuse board All wiring connections to the heater must be made i
93. re screws which hold the rain shield assembly to the heat exchanger tube sheets which also must be removed Remove the front access panel see Figure 12 Disconnect water temperature sensor plug from the ignition control board located inside the heater see Figure 12 Pull the water temperature sensor wires out of the heater cabinet through the hole in the right hand metal side panel Lift and rotate the heat exchanger Do not flip Use care when setting the heat exchanger in place not to damage the white sealing gaskets or combustion chamber Route the water temperature sensor wires into the heater cabinet through the hole in the left hand metal side panel and re connect to the ignition control board Re connect the heater wire harness to the water pressure switch and temperature limit Reverse the above steps to reassemble the heater USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Figure 12 Top Flue Cover Louvered Exhaust Panel Rain Shield Assembly Heat Exchanger Assembly de d Pressure 5 Switch Port Temperature Limit Switches P lt Drain Plug or Valve Upper Plastic Heater Side Panel Ignition Control Upper Plastic Heater Circuit Board Side Panel oN Front Access Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemm
94. rmination needs horizontal vertical and the cost of venting system Table 3 lists the indoor venting kits available and the limitations of each system Table 3 Indoor Vent Kits and Limitations of Venting Systems Indoor Vent Kit Part demes Ra Vent Pipe Labs Description Heater Vent Pipe Limitations Termination Number Material Models Requirement UHXNEGVT11501 UHXNEGVT12001 50 ft max vetical height Indoor Vent Adapter Kit 258 karis ki i th Single or Double Vertical Only max horizontal len UHXNEGVT12501 Negative Pressure 9 VVall Galvanized Termination Above horizontal length cannot UHXNEGVT13001 Vertical Venting a W a tical heigny Non Sealed Roof of House exceei or vertica eig i Applications Vent Pipe Buildin UHXNEGVT13501 PP 3 elbows max P i UHXNEGVT14001 UHXPOSHZ11501 Horizontal or UHXPOSHZ12001 Indoor Vent Adapter Kit 50 ft max with 1 elbow Single or Double Vertical Termi ertical Termina UHXPOSHZ12501 Positive Pressure 40 ft max with 2 elbows Wall Stainless Horizontal or Vertical 30 ft max with 3 elb 51 1 66 10 PME orizontal or Vertica or max with 3 elbows eel Seale UHXPOSHZ13001 VE arak tical ence Outside Wall of entin ications orizontal or vertica ent Pipe UHXPOSHZ13501 g APP House Building UHXPOSHZ14001 CLEARANCES Table 4 The heater must be installed such that the installation and Indoor Installation Clearances service clearances from combustible materials shown in Table 4 ar
95. s 4 Remove the rear access panel 4 screws Figure 3 5 Position the heater on the pad so that all tap cons can bite into the pad Observe local codes Install sheet metal screws supplied at regarding pad construction some jurisdictions these locations front and rear specify a minimum thickness for concrete pads 6 Slip the tie down brackets into the slots in the front of the heater base pan from underside of the heater so that they are positioned as shown in figure 3 Install the sheet metal screws through the holes in the bracket to secure the bracket to the heater base pan 7 Install the tap cons through the holes in the tie down brackets into the pad 8 Repeat Steps 6 amp 7 at the rear of the heater 9 Installation is completed when 4 brackets are secured to the heater and the pad Install the ac cess panels when complete Equipment pad Install concrete tapping screws field supplied at these locations front and rear USE ONLY HAYWARD GENUINE REPLACEMENT PARTS E OH AYWARD pool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com INDOOR INSTALLATION AND VENTING POSITIVE AND NEGATIVE PRESSURE VENTING SYSTEMS The heater is designed such that it may be vented using either a negative pressure or a positive pressure venting system The appropriate system of venting for a particular site will depend on many factors such as vent te
96. s NC Nashville TN Tel 908 351 5400 www haywardpool com ITEM PART NO FDXLBRN1930 FDXLFOR1930 FDXLWHA1930 FDXLVSJ1930 FDXLFSK1930 FDXLFSKF30 FDXLFSKC30 SPX3200UNRIT FDXLUNR1930A FDXLTDR1930 FDXLDRV1930A UHXNEGVT11501 UHXNEGVT 12001 UHXNEGVT 12501 UHXNEGVT 13001 UHXNEGVT 13501 UHXNEGVT 14001 UHXPOSHZ11501 UHXPOSHZ12001 UHXPOSHZ12501 UHXPOSHZ13001 UHXPOSHZ13501 W UHXPOSHZ14001 UHXHD6ETERM UHXHD6STERM UHXHD6ELBOW UHXHDGPIPE 18 UHXHD6PIPE24 UHXHD6PIPE36 UHXHD8STERM UHXHD8ELBOVV UHXHD8PIPE18 UHXHD8PIPE24 UHXHD8PIPE36 FDXLCNKOOO1 FDXLCNKOOO2 FDXLHAR1930 FDXLVPS 1930 FDXLVPS1931 DESCRIPTION BURNER HEADER O RING KIT WIRING HARNESS KIT COMPLETE VOLTAGE SELECTOR JUMPER FUSE SERVICE KIT FUSE KIT 3 0A FOR FIELD WIRING PANEL QTY 10 FUSE KIT 3 0A FOR INTEGRATED CONTROL BOARD QTY 10 UNION KIT INCLUDES FITTINGS UNION NUTS GASKETS ASME UNION FLANGE KIT INCL FITTINGS BOLTS GASKETS TIE DOWN KIT DRAIN VALVE ASME INDOOR VENT ADAPTER KIT NEG PRESS VERTICAL H150FD INDOOR VENT ADAPTER KIT NEG PRESS VERTICAL H200FD INDOOR VENT ADAPTER KIT NEG PRESS VERTICAL H250FD INDOOR VENT ADAPTER KIT NEG PRESS VERTICAL H300FD INDOOR VENT ADAPTER KIT NEG PRESS VERTICAL H350FD INDOOR VENT ADAPTER KIT NEG PRESS VERTICAL H400FD INDOOR VENT ADAPTER KIT POS PRESS HORIZONTAL H150FD IN
97. s from the ignition control board an 4 Disconnect the tubing from the hose barb on the blower W 1 housing 5 Remove the blower air inlet plate from the blower 4 screws 6 Remove the blower from the air box cover 4 screws 7 Reverse the above steps to reassemble the blower F Be sure the blower outlet gasket is in place before proceeding a 1 Sf Blower Outlet Gasket Air Box Cover S m Blower Air Inlet Plate BYPASS SERVICE CARTRIDGE The following procedure details how to remove and replace the internal pressure bypass valve in the header This procedure applies only to plastic non ASME headers On bronze ASME headers the bypass service cartridge is not field replacable Please contact Hayward technical support for more information Turn pump main gas valve and heater power off Drain heat exchanger according to instructions in Section IH of this manual Remove 6 screws and remove the upper plastic heater side panel to allow access to the header Remove the cartridge retaining nut from end of header see Figure 28 Slide out the bypass cartridge from the end of the header see Figure 28 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
98. s then start a new as OFF error ignition sequence If error occurs 10 times during a call for heat the control will go into lockout Automatic reset is 60 minutes Data retrieval error If control input data is corrupted the heater will shut down and go into lockout Flame present with gas If flame is sensed with the gas valve off the control will go into lockout The H valve OFF error blower will run until error condition is corrected When corrected control will run blower for 5 s then automatically restart after 2 minutes Electrical supply wiring This code will display if 120V polarity is reversed low voltage is detected or if error the ground path is not sufficient Reset is immediate after error is corrected Blower vacuum switch If the blower prover switch does not close after the blower starts the control will AO open error stop the ignition trial go into lockout The blower will continue to run Automatic reset is immediate after the switch closes Blower vacuum switch If the blower prover switch opens unexpectedly during operation the control will open when expected shut down and attempt to re light If the switch does not close after the blower closed error starts the control will go into lockout with the blower running Automatic reset is immediate after error is corrected AO Blower vacuum switch If the blower prover switch opens during the postpurge cycle heater is not fir AO open during post purg
99. se Board Gas Valve 3 Ignition Control Board Sight Glass Ignitor Access Panel Gas Manifold Flame Sensor Blower Vacuum Switch Keypad Transformer t dx m Ignition Control 4 Board Gas Valve Fuse Board Blower Flame Sensor Sight Glass Ignitor Access Panel Air Box a H250FD H300FD H350FD and H400FD 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 4 psig 3 45 kPa The heater must be isolated from the gas sup ply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 2 psig 3 45 kPa 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 H AYWARDP ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com GAS PRESSURE TESTING A WARNING EXPLOSIVE HAZARD The use of an open flame to check for gas leaks could cause an explosion resulting in severe injury and or death Sh
100. see Figure 22 The heater has 2 junction boxes one on each side of the heater 2 ae Capa Only one junction box should be used for 3 iid SSS A Block remote wiring Do not remove the wires NETO connected to the remote connection ter dg 2 minal block Remote wiring must be run Met 2 Remote in a separate conduit Use 22 AWG wire i Terminal Block for runs less than 30 feet Use 20 AWG r wire for runs over 30 feet The maximum allowable run is 200 feet Ground Spa RED Common Pool WHITE ORANGE 2 WIRE REMOTE CONTROL CONNECTION To configure the heater for 2 wire remote thermostat control use the MODE key on the heater keypad to put the control into STANDBY mode Then press and hold both the DOWN and MODE keys for 3 seconds until the display shows the code bo On the remote control wiring terminal block Figure 22 connect the appropriate wires from the remote control to the terminals adjacent to the ORANGE wire POOL and WHITE wire 24V To operate the heater by remote thermostat the heater s control must be in either POOL or SPA mode The display will show bo The POOL or SPA LED will be illuminated The remote thermostat will operate the heater The heater s thermostat will function to limit the water temperature to a maximum of 104 F 3 WIRE REMOTE CONTROL CONNECTION On the remote control wiring terminal block Figure 22 connect the appropria
101. 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 Recommended Effect of Low Levels Effect of High Levels E 1 3 1 3pm hazy water algea growth swimmer irritation bleaching of clothes hair 2 4 ppm bacteria causing infections corrosive to heat exchanger corrosive to heat exchanger cloudy vvater scaling of heat exchanger 7 4 7 6 p Rp e swimmer irritation reduced sanitizer effectiveness corrosive to heat exchanger Total Alkalinity 80 120 ppm large fluctuations in pH scaling of heat exchanger Calcium Hardness 200 400 ppm corrosive to heat exchanger scaling of heat exchanger Salt 2700 3400 ppm poor salt chlorinator performance corrosive to heat exchanger 3 SKIMMER CHLORINATION Placing chlorine or bromine tablets directly into the skimmer may result in high chemical concentrations flowing through the heater DO NOT place chlorine or bromine tablets in the skimmer 4 CHLORINATOR INSTALLATION Chlorinators must be installed downstream of the heater and a check valve must be installed between the heater and chlorinator to prevent high chemical concentrations from back flowing into the heater Make sure your piping arrangement meets the chlorinator installation requirements shown on page 27 5 BYPASS Until water chemi
102. stry is properly balanced and if your piping has a bypass valve installed for the heater open the bypass so that corrosive and potentially damaging water will not flow through the heater and there fore the heat exchanger Close the bypass valve once the water is properly balanced Failure to close the bypass valve when attempting to operate the heater will result in extensive damage to the heat exchanger Ensure water flow through the heater is restored before operating the heater A bypass feature is also advanta geous for service needs and for the ability to remove the heater from the water path when not heating Refer to page 26 for further information USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD gt p ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com SECTION Il INSTALLATION g EQUIPMENT INSPECTION On receipt of the heater inspect the heater carton s for damage If any carton s is damaged note it when signing for it Remove the heater from the carton s inspect it and advise the carrier of any damages at once IMPORTANT NOTICE The installation instructions are intended for the use of a qualified technician specifically trained and experienced in the installation of this type of heating equipment Some states or provinces require that instal lation be licensed If this is the case in the state or province where heater is located the contractor must be
103. sure switch Use new sealant on the pressure switch threads before re installing Reverse steps above to complete the procedure SENA al USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com TRANSFORMER The transformer converts the field supply voltage either 240 VAC or 120 VAC to a 120 VAC output for blower and igniter power and a 24 VAC output for powering the ignition control board control circuits and gas valve See Figure 25 for its location To replace the transformer Turn pump gas supply and heater power OFF Remove the front access panel It is secured with 4 screws Disconnect all wires from the transformer leads Remove the 2 screws that secure the transformer to the control box Replace the transformer Reassembly is the reversal of steps above AP BLOWER The blower provides the air that mixes with the gas at the main burners for the combustion process The blower operates during the pre purge time approximately 30 seconds at the beginning of each ignition cycle during the entire time the gas valve is open and the burners are firing and for 30 seconds after the valve gas closes See Figures 25 and 30 To replace the blower Figure 30 Blower 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel 4 screws 3 Disconnect the blower wire harnes
104. sure the white gaskets are in place under the vent pipe adapter plate before install ing See Figure 7 7 Install the new flue cover included with the kit over the vent pipe adapter and secure with the coun tersunk screws from step 3 above See Figure 8 Remove heater front access door The vent pressure switches included with the indoor kit are labeled based on heater model and altitude compatibility Depending on your model and altitude select the appropriate vent pressure switch and install inside the heater using 2 10 screws as shown in Figure 9 If your heater is above 2 000 ft elevation other high altitude conversion steps may be necessary for proper heater perfor mance Refer to the information on page 8 and or the instructions with the FDXLHAR 1930 high altitude kit 10 Remove the rubber cap from the blower outlet pressure tap and discard See Figure 10 for blower tap location 11 Attach the pressure switch tubing to the vent pressure switch and to the pressure tap on the blower outlet See Figure 10 for blower tap location 12 Connect the jumper wire included with the indoor kit onto one of the terminals on the vent pressure switch Unplug the in line quick connect on the red wire in the heater wire harness and connect the vent pressure switch in series with the red wire See heater wiring schematic on page 28 13 If installing the kit on models H250FDN H250FDP or H400FDP you must also replace the existing blower air i
105. t be followed exactly to prevent flashback of excess gas in the heater Electronic ignition heaters and electric heaters must have the power shut off when making adjustments to servicing or coming into contact with the heater UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERI 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 Fi AVYVWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com ko SERVICE PARTS 91 22 rego IH Plastic Header Models Non ASME Bronze Header Models ASME ITEM CO N O o 11 PART NO FDXLJKT 1150 FDXLJRT 1200 FDXLJKT1250 FDXLJRT 1300 FDXLJKT1350 FDXLJKT1400 FDXLJKT1250A FDXLJKT1400A FDXLTFC1150 FDXLTFC1200 FDXLTFC1250 FDXLTFC1300 FDXLTFC1350 FDXLTFC1400 FDXLTFC1250A FDXLTFC1400A FDXLFAD1150 FDXLFAD1200 FDXLFAD1250 FDXLFAD1300 FDXLFAD1350 FDXLFAD1400 FDXLFAD1250A FDXLFAD1400A FDXLRAD1150 FDXLRAD1200 FDXLRAD1250 FDXLRAD1300 FDXLRAD1350 FDXLRAD1400 FDXLRAD1250A FDXLRAD1400A FDXLTFP1150 FDXLTFP1200 FDXLTFP1250
106. te wires from the remote control to the terminals adjacent to the ORANGE wire POOL WHITE wire 24V and RED wire SPA To operate the heater with a remote 3 wire switch the heater s control must be in STANDBY mode The STANDBY LED will be illuminated When the remote switch is set to Pool Low the POOL LED will be illuminated and the water temperature will be displayed When the remote switch is set to Spa 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 H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Wiring Connection Diagram Sch ma de Connexion de Cablage H150FD H200FD H250FD H300FD H350FD H400FD Water Temperature Limit Switch Commutateur de temp rature d eau Fuse Circuit Board Carte de circuit RBK Y O RGY G fusible FT F4 Keypad Pav num rique v TAT SE 1 AG O POOL MODE TEMP SET 00000 Display Circuit Board Carte de circuit d affichage OOOO 00 211117 15 Esp SISINT TA TRANSFORMER Low HIGH VOLTAGE PRIMARY VOLTAGE P6 P3 P5 TRANSFORMER TR
107. threads Install the pressure relief valve with the discharge connection facing the ground If necessary connect a pipe of the same size as the valve out let to the outlet and run it to a safe place of discharge Do not install any shut off or restriction in this drain line ELECTRICAL SPECIFICATIONS e A WARNING It is required that licensed electricians do all electrical wiring Risk of Electric Shock Hazardous voltage can shock burn and cause death or serious property damage To reduce the risk of electric shock do NOT use an extension cord to connect unit to electric supply Provide a properly located electrical receptacle All electrical wiring MUST be in conformance with applicable local and national codes and regulations Before working on heater turn off power supply GENERAL INFORMATION Wiring connections must be made as shown in the wiring diagram found inside the heater cabinet and as shown in Figure 23 The heater must include a definite means of grounding and bonding There is a ground lug inside the control box and a bonding lug on the side of the heater MAIN POWER A WARNING Power connections supplied to the heater must be in accordance with National Electric USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARD P ool Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com Code NEC and local electric codes The NEC contains no standa
108. to Figures 12 25 and 26 as needed Turn pump gas supply and heater power OFF Turn gas valve knob OFF Remove the front access panel It is secured with 4 screws Disconnect the union joint in the gas supply piping outside the heater cabinet Disconnect the wiring terminals from the gas valve Disconnect the wiring terminals from the blower Remove the gas manifold assembly It is attached to the air box using 4 screws Remove the screws from the igniter access panel and pull it out of the way Do not disconnect the wires Remove the air box cover Do not remove the blower from the air box cover Remove the 2 screws securing each burner to the combustion chamber front 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 A WARNING EXPLOSION HAZARD The use of an open flame to check for gas leaks could cause an explosion resulting in severe injury and or death GAS VALVE REPLACEMENT Refer to Figures 12 and 25 as needed A ATTENTION Do not attempt to repair the gas valve If found defective replace the entire valve Attempts to repair it will void the warranty MAES SS Turn pump gas supply and heater power OFF Disconnect the union joint in the gas supply piping outside the heater cabinet Remove the front access
109. u d acc s avant de l appareil de chauffage R gler le MODE du tableau de commande SPA ou POOL tablir la valeur de r glage sur le tableau de commande la temp rature d sir e Si l appareil ne fonctionne pas r p terles tapes 2 10 Si l appareil refuse toujours de FERM fonctionner dissipe Suivre les instructions Pour tourner le gaz l appareil et appeler votre technicien de service ou votre fournisseur de gaz POUR FERMER LE GAZ SUR L APPAREIL Changer le MODE du tableau de commande STANDBY Retirer le panneau d acc s avant de l appareil de chauffage Tourner le bouton de commande du gaz en sens horaire OFF ferm Replacer le panneau d acc s avant de l appareil de chauffage 1301623001 REVA SECTION III INSTALLER CHECK OUT AND START UP GENERAL Some of the following procedures will require the heater to be operating Full lighting and shutdown instruc tions are included on the lighting and operating label affixed to the inside of the front access panel The heater automatically lights in response to a call for heat and automatically shuts down when that call for heat is satisfied Water must be flowing through the heater during operation Check that the pump is operating and the system is filled with water and purged of all air prior to starting the heater Figure 25 Location of components Blower Vacuum Switch Transformer Fu
110. ustable up to 104 F using the temperature lockout feature see below After selecting SPA or POOL mode or adjusting the temperature setting it is normal for the heater to delay up to 10 seconds before the heater starts operating This delay is an internal self test of the heater On occasion the numeric display may show a diagnostic error code refer to list of diagnostic error codes in Fig ure 31 Pressing the MODE button to cycle to STANDBY and back to SPA or POOL will clear a diagnostic error code When clearing a diagnostic error code this way it is normal for the heater to delay up to 5 seconds before resuming normal operation assuming the diagnostic error code does not re appear Figure 27 User interface keypad Numeric Display HAYWARD Indicator Lights Buttons USE ONLY HAYWARD GENUINE REPLACEMENT PARTS H AYWARDP 001 Products Pomona CA Clemmons NC Nashville TN A Hayward Industries Inc Company Tel 908 351 5400 www haywardpool com TEMPERATURE LOCR 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 To adjust these settings use the following procedure 1 Use the MODE button to put t
111. ut off gas and fix even the smallest leak r ight away Be sure to leak test the heater gas manifold fittings using the above procedure once the heater is in operation The following gas pressure requirements are important to the proper operation of the burners in gas heaters Improper gas pressure or gas volume will create the following conditions 1 Flame burns totally yellow 2 Flame lifts off burner 3 Heat exchanger soots up The gas pressure regulator on all heaters is preset at the factory but the setting should be verified by the installer to ensure proper operation If gas pressure is inadequate check for undersize piping between the gas meter and the heater or for a low capacity gas meter Gas pressure test procedure 1 Obtain the necessary equipment a Manometer to read pressure in inches of water column b 1 8 pipe nipple 1 8 thread x 1 long c 3 16 hex wrench d Flat screwdriver Remove the 1 8 plug from the gas valve Install the 1 8 pipe nipple into the gas valve Attach the manometer to the pipe nipple Turn on the water system and start the heater following the lighting amp operating instruc tions on the label affixed inside the front access panel If there is more than one pool spa heater aa Figure 26 Gas valve Regulator adjustment screw under this screw cap INCREASE PRESSURE Electrical terminals Inlet pressure tap plug ON OF
112. y and then press and hold the MODE key Hold down both keys for 3 seconds until the indication bO is removed from the display This is a normal display when the pump is off Turn pump on LO code should clear If LO does not clear proceed to step 2 Verify that water flow rate to heater is above minimum required 20 GPM for H150FD and H200FD 25 GPM for H250FD and H300FD 30 GPM for H350FD and H400FD If OK proceed to step 3 Inspect water pressure switch wiring Ensure wire harness terminals are securely fastened to spade terminals on water pressure switch If OK procced to step 4 Remove wire leads from water pressure switch and jumper leads Operate heater Measure continunity across water pressure switch If open proceed to step 5 If closed LO code is not caused by water pressure switch fault Remove jumper from wire leads and reconnect wire leads to water pressure switch Clean filter or clear blockages Check position of valves in plumbing system If OK proceed to step 6 Adjust water pressure switch setting as shown on page 33 of Installation Manual only if heater is above or below water level If LO does not clear proceed to step 7 Replace water pressure switch Inspect vent pressure switch wiring Ensure wire harness terminals are securely fastened to spade terminals on vent pressure switch If OK proceed to step 2 Remove wire leads from vent pressure switch and jumper leads Operate heater Measure conti

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