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SERVICE & INSTALLATION MANUAL

1. e GENERAL INFORMATION Wiring connections must be made as shown in the wiring diagram found inside the heater cabinet and as shown in Figure 19 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 AS NZ 3000 and local electric codes 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 Most codes require that all metallic components of a pool structure including reinforcing steel metal fittings and above ground equipment be bonded together with a solid copper conductor wire gauge 8 AWG or larger 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 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS E AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au ELECTRICAL CONNECTIONS The heater is equipped with a direct spark 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
2. Connections Temperature Sensor Membrane Switch MODE TEMP SET Display Circuit Board REMOTE CONTROL CONNECTION The heater is equipped for connection to an external 2 wire remote thermostat or a 3 wire remote switch A 2 wire thermostat has its own temperature sensor for regulating water temperature A 3 wire remote switch allows the POOL or SPA models to be remotely selected Connect remote wiring to the terminal block located in the lower compartment inside the junction box see Figures 16 and 17 The heater has 2 junction boxes one on each side of the heater Only one junction box should be used for remote wiring Do not remove the wires connected to the remote connection terminal block Remote wiring must be run in a separate conduit Use 22 AWG wire for runs less than 30 feet Use 20 AWG wire for runs over 30 feet The maximum allowable run is 200 feet 2 WIRE REMOTE CONTROL CONNECTION Before using the heater with a 2 wire remote thermostat the user must first configure the TCM To configure the the user first presses the MODE button to select STANDBY mode The user then presses and holds both the DOWN and MODE buttons for 3 seconds until the display shows bo indicating Bypass Operation mode At the remote control wiring terminal block located in the lower compartment inside one of the junction boxes on either side of the heater connect one of the two remote thermostat wires
3. HAYWARD POOL AND SPA HOT TUB HEATERS H150FDAU H250FDAU amp H400FDAU MODELS FOR USE IN AUSTRALIA 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 e 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 6 026 804 amp 6 321 833 amp 7 971 603 1301272601 Rev B 0813 CONTENTS Section General information 7 Gas valve replacement 36 LOGO icol p T T OR a 37 AE E E T
4. 33 Maintenance 33 Heat exchanger inspection and cleaning 34 Combustion chamber 34 Heat exchanger removal 34 Burner inspection and cleaning 35 Burner removal and replacement 30 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au SAFETY INFORMATION Basic safety precautions should always be followed including the following Failure to follow instructions can cause severe injury and or death A This 1s 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 A 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 A 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 thi
5. Reypad button stuck closed N b Bypass Operation mode dot Auto restarts disabled HAYWARD Poo Products A Hayward Industries Inc Company If the string of limit switches opens while there is a call for heat the heater will shutdown and go into lock out Automatic restart 2 minutes after the limit string error condition is corrected An excessive temperature difference between the two thermistors 3 C or more or an out of bounds condition on either sensor temperature less than 2 C or greater than 82 C The heater will shut down and go into lock out Automatic restart 2 minutes after the thermistor error condition is corrected If water temperature rises too rapidly in two consecutive 10 second periods the heater will shut down and go into lock out Automatic restart after 2 minutes After the third occurrence in the same call for heat the heater will go into lock out with automatic restarts disabled Manual restart is required Inlet water temperature sensor is reporting a temperature in excess of 40 C Normal operation resumes 2 minutes after inlet water temperature sensor reports temperatures of 40 C or less This error functions in both normal and remote thermostat modes If the string of limit switches opens while there is no call for heat the error code will be displayed but the control will continue to function The error code will be cleared when the condition 15 corrected If one of
6. AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au NOTES NOTES 9 HAYWARD Poo Products A Hayward Industries Inc Company Hayward Pool Products Inc Hayward Pool Products Inc Hayward Pool Products Inc Hayward S A 620 Division St 28 5 Pomona Boulevard 2880 Plymouth Drive Zoming de Jumet Elizabeth NJ 07207 Pomona CA 91768 Oakville Ontario L6H 5R4 B6040 Jumet Belgium 2013 Hayward Printed in U S A
7. AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au 48 WHAT TO DO IF YOU HAVE A WARRANTY CLAIM The faulty product is to be returned to the place of purchase or to an authorised warranty agent Unless prior authorisation is provided no returns will be received directly from end consumers by Hayward Pool Products You are responsible for arranging removal of the defective product and arranging installation of the repaired or replacement product all transportation and any applicable insurance costs of transporting the product to the supplier and transporting the replaced or repaired product from the supplier All returns are subject to Hayward Pool Products written approval and must be accompanied by either 1 A Field Inspection Report authorised by the Local Customer Service Manager or 2 A Return Goods Authorisation form obtained from Hayward Pool Products prior to shipment Unauthorised returns will not be accepted All Hayward Pool Products warranty parts taken as an across the counter warranty exchange must be held for inspection until authorisation has been given by the Local Branch Customer Service Manager to dispose of them Hayward Pool Products reserves the right to provide replacement or credit for any items authorised under this warranty program All serial numbers must place the product within the warranty period or a proof of purchase is
8. 14 Reverse the above steps to reassemble the heater USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au Figure 5 Top Flue Cover Louvered Exhaust Panel Rain Shield Assembly Heat Exchanger Assembly B Pressure Switch Port A Temperature AW E Limit Switches Upper Plastic Heater Side Panel Thermostat Control Upper Plastic Heater Circuit Board Side Panel Front Access Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD po ol Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au Gas Supply and Piping Refer to the charts below in Figure 6 for gas pipe sizing for low pressure natural gas low pressure propane gas two stage natural gas and two stage propane gas systems Figure 6 GAS PIPE SIZE Follow local gas codes for proper gas line material selection copper iron plastic etc LOW PRESSURE NATURAL GAS PIPE SIZING Based upon an inlet gas pressure of 3 45 kPa or less at a pressure drop of 125 Pa Distance from Gas H150FDAU H250FDAU H400FDAU 2 4 22 em LOW PRESSURE PROPANE GAS PIPE SIZING Based upon an inlet gas pressure of 2 75 kPa or less at a pressure drop of 125 Pa H150FDAU H250FDAU H400FDAU ee ee le ess DT ow
9. ONLY 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 ZI i 5 Va abr n en F acceptable to the authority having jurisdiction Ac Heat sinks heat tapes firemen switches and check Union nuts valves are not required on the heater However if there Flanged pipe nipples is any chance of back siphoning of hot water when the Pol pump stops running it is suggested that a check valve be used on the heater inlet pipe Note inlet outlet markings molded into header The built in bypass inside the header will maintain proper flow through the heat exchanger if the flow rate 1s within the range for the heater See Figure 10 on page 19 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au If the normal pump and filter system flow rate exceeds 475 L min then a manual bypass valve must be installed as shown in Figure 11 Damage caused by flow rates out side this range will void the manufacturer s warranty Figure 10 Allowable Water Flow Rate Range Model Minimum Flow Maximum Flow Rate L min Rate L m
10. 1300 POOLS1 www hayward pool com au 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 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 Effect of Low Levels Effect of High Levels Level 1 3 ppm 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 water scaling of heat exchanger 7 4 7 6 pin swimmer irritation reduced sanitizer effectiveness T 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 IC 2700 5000 ppm _ poor salt chlorinator performance corrosive to heat
11. Figure 24 Keypad OPERATION SET POINT ADJUSTMENT Set point temperature is displayed by momentarily pressing the UP or DOWN buttons while in POOL or SPA mode The set point for the selected mode will blink while it is displayed Further pressing of the UP or DOWN buttons will adjust the set point temperature up down as desired To accept the adjustment press the MODE button or the adjustment will be automatically accepted in 10 seconds The set point range 1s 18 C to 40 C FAHRENHEIT VERSUS CELSIUS The temperature can be displayed in Celsius or Fahrenheit 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 C F selection Press the DOWN button to toggle between selections To accept the selection press the MODE button or the selection will be automatically accepted in 10 seconds HEATING MODE The TCM provides a thermostatic temperature control action by continually comparing the temperature of the water returning from the pool or spa with set point and calling for heat or not Specifically when the water temperature is more than 0 55 C 1 F below set point a call for heat is generated and a heating cycle 1s initi ated 1 The DSICM checks the blower vacuum switch for open contacts 2 The blower is then energised and once the vacuum switch contac
12. Flame sensor eue 37 Maintaining proper water chemistry Burner orifices Of Gas conversion 37 Section Il Installation 9 Electrical wiring 38 Equipment inspection 9 Ignition control system 38 Important notice NN TO 9 Blower vacuum switch 38 Conformance with codes 9 LOIS MCE 39 Altitude of installation 9 Thermistor 40 Uncrating the heater 11 Water pressure switch 40 Locating the heater 11 Translormer th 41 moo diee 12 SION EAA 41 Tie Down Brackets 12 By pass service cartridge 41 Reversible water connections 13 Gas supply and piping 15 Section V Troubleshooting 42 Water DIDIRON er UE QU E 18 42 Installation above pool surface 20 Automatic reset time 42 Chlorinator chemical feed
13. Pool Products Australia Pty Ltd A Hayward industries he Company Tel 1300 POOLS1 www hayward pool com au Figure 18 Control Panel Layouts H150FDAU Control Panel Assembly wiring not shown 1 Direct Spark Ignition Controller 2 Thermostat Control Board 3 Transformer 240V Primary 24V Secondary Blower Proving Switch 5 Manual Reset High Limit mounted to rear side of panel Figure 19 Wiring connection diagram 240 V Primary 24V Secondary 240VAC 50HZ WHT GRN lt GRN Transformer Blower Vacuum Switch Fenwal 35 61 Ignition Control Module Water Pressure Switch MRL TON Gas Valve TEM dm a ww Limit Switch Spark Igniter Flame Sensor H250FDAU and H400FDAU Control Panel Assembly wiring not shown NOTE 1 For field power connections use 14 AWG or larger wire rated for at least 75 C 167 F 2 For field remote thermostat connections use 22 AWG or larger wire 3 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 4 Unit comes from the factory pre wired with the power connections in the left junction box and the remote thermostat connections wired to the right junction box Both of these can be re wired to the other junction box for ease of use in the field Thermostat Control Board R Remote W Thermostat ORG
14. This is a normal display when the pump is off Turn pump on LO code switch fault running should clear If LO code does not clear proceed to step 2 2 Verify that water flow is Verify that water flow rate to heater is above minimum required 76 adequate LPM for H150FD and H200FD 95 LPM for H250FD and H300FD 114 LPM for H350FD and H400FD If OK proceed to step 3 3 Check for faulty wiring or Inspect water pressure switch wiring Ensure wire harness terminals are connection securely fastened to spade terminals on water pressure switch If OK proceed to step 4 4 Verify state of water Remove wire leads from water pressure switch and jumper leads LO pressure switch contacts Operate heater Measure continuity 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 5 Ensure that low pump Clean filter or clear blockages Check position of valves in plumbing pressure does not exist system If OK proceed to step 6 6 Check for correct water Adjust water pressure switch as shown in Section III If LO does not pressure switch setting clear proceed to step 7 7 Water pressure switch 15 Replace water pressure switch defective Temperature 1 Check for faulty wiring or Inspect temperature limit switch wiring Ensure wire harness terminals limit switch fault connection are securely
15. allume automatiquement les br leurs Ne pas tenter d allumer manuellement les br leurs 9 Tourner le bouton de commande du gaz en sens a horaire OFF ferm BOUTON DE COMMANDE EN POSITION FERM OFF 6 Attendre cing 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 Passer l tape suivante en l absence d odeur de gaz Tourner le bouton de commande du gaz en sens anti horaire ON OUVERT 4 Ss Replacer le panneau d acc s avant de l appareil de chauffage R gler le MODE du tableau de commande a SPA ou a 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 acces 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 REV A SECTION Ill INSTALLER CHECK OUT AND START UP Some of the following procedures will require the heat
16. au Model Number H150FDAU H250FDAU H400FDAU Heater Capacity Gas Type Heater Width Packaged Weight 158 MJ h Natural Propane 04 6 cm 64 kg 264 MJ h Natural Propane 71 1 cm 5 kg 422 MJ h Natural Propane 92 7 cm 89 kg A 5 61 0 35 2cm WIDTH FRONT 14 5cm LEFT RIGHT USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Industries Inc Company H CJ HAYWARD Products Hayward Pool Products Australia Pty Ltd Tel 1300 POOLS1 www hayward pool com au UNCRATING THE HEATER To remove the shipping carton from the heater 1 Remove the corrugated carton from the p heater The carton top pad bottom pad and 4 The screw through the the four corner posts can be recycled f E rear shipping bracket 2 There are three 3 screws total used to se is located in this area cure the heater to the wood pallet All three Remove the screw must be removed to separate the heater from f the pallet One 1 1s located in the lower M ae It is not necessary to rear of the heater as shown in Figure 1 remove the bracket or 3 To access the other two 2 screws open the N the rear louvered panel front access panel by removing the black phillips head screw Then remove the two 2 screws which hold the heater base pan to
17. days of the receipt of the defective product barring unforeseen delays This warranty is personal to the original purchaser and does not pass to any subsequent purchaser s 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 accident weather 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 rating plate 3 A heater on which the serial numbers have been altered defaced or removed 4 Leaks arising from defective installation 5 Production of noise odours or discoloured rusty ect water 6 Leakage substantially contributed to by sediment lime precipitate and or higher than normal dissolved 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 Leakag
18. fastened to spade terminals on the temperature switches If OK proceed to step 2 2 Verify state of temperature For each temperature limit switch in turn remove wires from the limit limit switch contacts switch and jumper leads Operate heater Measure continuity across limit LO switch If closed LO code is not caused by this limit switch Test the next limit switch If a limit switch 1s open proceed to step 3 Remove jumper from leads and reconnect leads to all temperature limit switches 3 Verify that water flow 1s Verify that water flow rate to heater is above minimum required 76 adequate LPM for H150FD 95 LPM for H250FD and 114 LPM for H400FD If OK proceed to step 4 4 Temperature limit switch Replace temperature limit switch is defective USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au TROUBLESHOOTING continued Ignition failure 1 Ensure gas supply shutoff Ensure that the main gas shutoff installed adjacent to the heater is valves are open open Ensure 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 En
19. have been sold and installed by technicians approved by Hayward Pool Products where installation has not been carried out in accordance with this requirement warranty labour and support will be the sole responsibility of the reseller supplying the product Claims will only be accepted where evidence is provided that installation has been completed by an organization business or individual who has been authorised or approved by Hayward Pool Products Australia Pty Ltd to undertake such installation HEATING PRODUCTS Please note that warranty claims for gas Heaters are handled directly by Hayward Pool Products and are not authorised for over the counter exchanges These items are site specific and involve local conditions such as placement installation water chemistry fuel supply and electricity Each unit needs to be evaluated on the site utilising Hayward Pool Products authorised service network Hayward Pool Products will not be responsible for additional costs incurred where a heater has been installed at a location situated further than 20km from an authorised service outlet Advice must be sought in writing from Hayward Pool Products to determine appropriate service procedure on a case by case basis Under no circumstances should a complete Heater or Heat Pump be returned without prior written approval from either Hayward Pool Product warranty department or your local Branch Customer Service Centre USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
20. hole in the heater chassis Unscrew the thermistor from the bushing in the header Replace the thermistor Use new sealant on the thermistor threads before re installing Reverse steps 1 6 to complete the procedure WATER PRESSURE SWITCH The water pressure switch Figure 34 see Figure 31 for its location is factory pre set for deck level installations When the heater 1s located below the level of Lem the spa or pool the water pressure switch may require an adjustment to compen sate for the no flow static head If adjustment is needed the procedure is detailed in Section III under Water Pressure Switch Test Adjustment Procedure page s No 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 pressure switch Use new sealant on the pressure switch threads before re installing Reverse steps 1 5 to complete the procedure EP oe USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com a
21. 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 hazardous 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 a
22. ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au GAS SUPPLY INSTALLATION The heater is shipped from the factory with the gas connection 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 8 A union should be installed outside the heater cabinet for easy remov al of the gas manifold assembly during service An AGA approved main gas shutoff valve must be installed out side the cabinet and within 1 8 m 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 7 If BSP threads are to be used the included BSP to NPT adapter will be required to attach the piping to the gas valve NPT threads are located on the side of the adapter with the chamfer on the inside diameter 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 q DL Use joint compounds resistant to the action of lique 8 inlet fied petroleum gas Do not overtighten the gas inlet oe pipe or damage may result Bonding A ATTENTION Do not use flexible appliance con lug nectors on any gas connections unless the connector is CSA approved for outdoor installation is marked with BTUH capacity which must be equal to or great
23. the pallet as shown in Figure 2 4 Lift the heater clear of the corrugat ed bottom pad and off of the pallet ATTENTION Do not drop the A heater from a pickup truck tailgate to the ground This may damage the Remove the 2 heater shipping screws and discard bottom corrugated tray LOCATING THE HEATER This heater is intended for outdoor installation at an altitude below 610 M 2 000 ft only 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 restrict airflow This heater must be installed at least 1 5 meters from the inside wall of a pool 1n ground or above ground 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 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS i AYWARD ool Products Hayward Pool Products Australia Pty Ltd AlHayward Industries Ine Company Tel 1300 POOLSI www hayward pool com au Table 1 Outdoor Installation Clear
24. union joint in the gas supply piping outside the heater cabinet Remove the front access panel It is secured with 1 screw 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 YOANN PB D ATTENTION Do not enlarge orifice holes 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 instructions are included with each kit USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au SECTION V CONTROL LOCATIONS The following sections give a brief overview of the various heater controls and service replacement proce dures The text describes the function of the controls See Figure 21 ELECTRICAL WIRING A ATTENTION If it is necessary to replace any of the original wiring it must be replaced with Hayward supplied replacement parts IGNITION CONTROL SYSTEM The ignition control s
25. wwe tr osm ue wr MetertoHeaterGas 158 24 _ 1 1 1 HIGH PRESSURE 2 STAGE SYSTEMS HIGH PRESSURE NATURAL GAS PIPE SIZING FIRST STAGE Based upon an inlet gas pressure of 13 8 kPa or less at a pressure drop of 6 8 kPa LOW PRESSURE NATURAL GAS PIPE SIZING SECOND STAGE Based upon an inlet gas pressure of 2 5 kPa or less at a pressure drop of 125 Distance from Outlet H150FDAU H250FDAU H400FDAU art eater Mmm Regulator to Heater MJ hr input 198 264 422 Gas Valve Inlet Line Material lron or Plastic Pipe lron or Plastic Pipe lron or Plastic Pipe USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au It is VERY IMPORTANT when installing a propane heater on a 2 stage regulation system to follow the gas line sizing chart below without exception HIGH PRESSURE PROPANE GAS PIPE SIZING FIRST STAGE Based upon an inlet gas pressure of 68 kPa or less at a pressure drop of 6 9 kPa rm H150FDAU H250FDAU H400FDAU LOW PRESSURE PROPANE GAS PIPE SIZING SECOND STAGE Based upon an inlet gas pressure of 2 75 kPa or less at a pressure drop of 125 Pa Distance from Tank H150FDAU H250FDAU H400FDAU P MJ hr input 158 264 422 USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARDp
26. 50 HEAT BARRIER PANEL H250FD FDXLHBP1400 HEAT BARRIER PANEL H400FD 15 FDXLBBN1150AU BLOWER INLET BAFFLE H150FDAU FDXLBBN1250AU BLOWER INLET BAFFLE H250FDAU FDXLBBN1400AU BLOWER INLET BAFFLE H400FDAU 16 FDXLIAC1930AU IGNITER ACCESS COVER AUS 17 FDXLGSV0001 GAS VALVE NATURAL FD FDXLGSV0002 GAS VALVE PROPANE FD FDXLBRN1930 BURNER NOT SHOWN 18 FDXLBON1930 BURNER ORIFICE NATURAL FD FDXLBOP1930 BURNER ORIFICE PROPANE FD 19 FDXLMAN1150 GAS MANIFOLD H150FD FDXLMAN1250 GAS MANIFOLD H250FD HAYWARD Poo Products A Hayward Industries Inc Company USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products Australia Pty Ltd Tel 1300 POOLSI www hayward pool com au ITEM 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 3 38 39 ITEMS NOT SHOW ON PAGE 49 PART NO FDXLMAN1400 FDXLBWR1930AU FDXLBWR1400AU FDXLBVS1150AU FDXLBVS1250AU FDXLBVS1400AU FDXLTCB1930AU FDXLDSCB1930AU FDXLDSI1930AU IDXLFLS1930 FDXLXFR1930AU FDXLWPS1930 FDXLDSB1930AU FDXLBKP1930 FDXLHLI1930 FDXLTER1930 FDXLMRL1930AU FDXLMRL1931AU FDXLHXA1150AU FDXLHXA1250AU FDXLHXA1400AU FDXLFHD1930 FDXLHDVV1930 FDXLHMB1930 FDXLBPR1930 FDXLFOR1930 FDXLCRN1930 FDXLFHA1930AU SPX4000F G FDXLGCK1150NP FDXLGCK1250NP FDXLGCK1400NP FDXLWHA1150AU FDXLWHA1400AU FDXLESC1930AU IDXLTMB1931 FDXLFSK1930AU FDXLGSK1930AU HAYWARD Products A Hayward Industries Inc Company DESCRIPTION GAS MANIFOL
27. AGE 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 un commutateur lectrique Ne pas utiliser le t l phone dans la maison e Appeler imm diatement fournisseur de gaz chez un voisin Suivreles instructions du fournisseur de gaz e Si le fournisseur ne peut pas tre atteint appeler le service des incendies Utiliser uniquement les mains pour actionner les boutons de commande du gaz Ne jamais utiliser d outils Si le bouton ne s enfonce pas ou ne se tourne pas la 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 Sile systeme 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 1 STOP Read the safety information on this label 2 Change the MODE on the control panel to STANDBY 3 Remove the heater s front acces
28. Check status of Remove front panel and inspect the DSICM fault indicator DSICM LED If the LED is illuminated steady or flashing there is a DSICM fault condition and the module is in lock out Refer to the DSICM FAULT CONDITIONS section of this manual A DSICM lock out can be reset by pressing the MODE button to cycle through STANDBY and back to the original mode SPA or POOL USE ONLY HAYWARD GENUINE REPLACEMENT PARTS K3JHAYWARDiooProduts ___ Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au TROUBLESHOOTING continued Diagnosis Step Keypad Failure 1 Keypad is defective Replace Display Interface Assembly Temperature 1 Check for faulty wiring or Inspect sensor wiring Ensure sensor is plugged into back of control SF sensor input connection module If OK proceed to step 2 2 Sensor is defective Replace temperature sensor Bypass 1 Check to see if heater is in This is normal display when heater is being controlled by a remote Operation Bypass Operation 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 in STANDBY Press and hold the DOWN key and then press and hold the MODE key Hold down both keys for 3 seconds until the indication bO is removed from the display Water pressure 1 Verify that the pump is
29. D H400FD COMBUSTION BLOWER H150 250FDAU COMBUSTION BLOWER H400FDAU BLOWER VACUUM SWITCH H150FDAU BLOWER VACUUM SWITCH H250FDAU BLOWER VACUUM SWITCH H400FDAU THERMOSTAT CONTROL BOARD 50 HZ FD DIRECT SPARK IGNITION CONTROLLER DIRECT SPARK IGNITER 50 HZ FD FLAME SENSOR 90 HZ FD TRANSFORMER WATER PRESSURE SWITCH DISPLAY BOARD ONLY 50 HZ FD NOT SHOWN BEZEL amp KEYPAD ASSEMBLY HIGH LIMIT 135 F THERMISTOR MANUAL RESET LIMIT H150 400FDAU MANUAL RESET LIMIT H250FDAU HEAT EXCHANGER ASM H150FDAU HEAT EXCHANGER ASM H250FDAU HEAT EXCHANGER ASM H400FDAU HEADER ONLY HEADER HARDWARE KIT HEADER MOUNTING BASE KIT BYPASS CARTRIDGE KIT HEADER O RING KIT HEADER CARTRIDGE RETAINING NUT HEADER ASSEMBLY FDAU INCLUDES ITEMS 27 29 30 33 38 DRAIN PLUG WITH GASKET CONVERSION KIT NA TO LP QUICK CHANGE H150FD NOT SHOWN CONVERSION KIT NA TO LP QUICK CHANGE H250FD NOT SHOWN CONVERSION KIT NA TO LP QUICK CHANGE H400FD NOT SHOWN WIRING HARNESS 50HZ H150FDAU NOT SHOWN WIRING HARNESS 50HZ H250 400FDAU NOT SHOWN 240V ELECTRICAL SUPPLY CORD WITH STRAIN RELIEF NOT SHOWN TERMINAL BLOCK 5 POLE NOT SHOWN FUSE SERVICE KIT FDAU NOT SHOWN GASKET KIT AIR SIDE FDAU NOT SHOWN USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products Australia Pty Ltd Tel 1300 POOLSI www hayward pool com au ITEM PART NO DESCRIPTION FDXLFSK1930 INCLUDES GASKET KIT AIR SIDE FD AL
30. INSPECTION On receipt of the heater inspect the heater carton s for damage If any carton s 1s damaged note it when signing for it Remove the heater from the carton s inspect 1 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 1s the case 1n the state or province where heater 1s located the contractor must be 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 This appliance shall be installed only by authorised persons and in accordance with the manufacturer s installation instructions local gas fitting regulations municipal building codes electrical wiring regulations local water supply regulations AS 5601 1 2010 Gas Installations and any other statutory regulations USE ONLY HAYWARD GENUINE REPLACEMENT PARTS E AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com
31. L NOT SHOWN GASKET BLOWER MOUNTING GASKET COVER AIR BOX FRNT H400FD GASKET COVER AIR BOX FRNT H250FD GASKET COVER AIR BOX FRNT H150FD GASKET MANIFOLD AIR BOX FRNT H400FD GASKET MANIFOLD AIR BOX FRNT H250FD GASKET MANIFOLD AIR BOX FRNT H150FD FDXLGSK1931 INCLUDES GASKET EXHAUST SIDE FD ALL NOT SHOWN GASKET FLUE COLLECTOR SIDE GASKET RAIN GUARD SIDE GASKET RAIN GUARD BOTTOM SIDE GASKET FLUE COLLECTOR TOP H400FD GASKET FLUE COLLECTOR TOP H250FD GASKET FLUE COLLECTOR TOP H150FD GASKET RAIN GUARD FRNT amp REAR H400FD GASKET RAIN GUARD FRNT amp REAR H250FD GASKET RAIN GUARD FRNT amp REAR H150FD GASKET RAIN GUARD BOTTOM FRNT amp REAR H400FD GASKET RAIN GUARD BOTTOM FRNT amp REAR H250FD GASKET RAIN GUARD BOTTOM FRNT amp REAR H150FD USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd A Hayward industries he Company Tel 1300 POOLS1 www hayward pool com au SPECIFICATIONS Total Nominal Gas Consumption Model Natural Gas Propane Gas H150FDAU 158 MJ h 158 MJ h H250FDAU 264 MJ h 264 MJ h H400FDAU 422 MJ h 422 MJ h Gas Pressure Fuel Natural Propane Manifold 0 45 0 50 1 70 1 75 Inlet Minimum 1 12 2 24 Inlet Maximum 2 61 3 24 Burner Configuration Natural Gas Main Injector Main Burner 25 Propane Gas Main Injector mm Main Burner 2 26mm USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
32. NER INSPECTION AND CLEANING With the heater ON remove the front access panel and make a visual inspection of the main burners through the sight glass see Figure 21 The main burner flames should be about 1 2 to 2 in height and should not lift off the burner ports see Figure 27 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 mixture due to restricted air supply Spider nests in the burner and or gas orifices may also cause yellow tips Figure 27 Burner Flame characteristics BURNER REMOVAL AND REPLACEMENT Refer to Figures 21 and 27 as needed Turn pump gas supply and heater power OFF Turn gas valve knob OFF Remove the front access panel It is secured with 1 screw 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 9 Remove the air box cover Do not remove the blower from the air box cover 10 Remove the 2 screws securing each burner to the combustion chamber front 11 Pull the burners straight out of the heater 12 Reverse the above procedure to install the burners 13 Turn the g
33. NG 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 e Do not try to light any appliances e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department C 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 technician Force or attempted repair may result in a fire or explosion D 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 E Should over heating occur or the gas supply fails to shut off turn off manual gas valve to the appliance POUR VOTRE SECURITE LIRE AVANT L ALLUMAGE MISE EN GARDE Si vous ne suivez pas exactement ces instructions un incendie ou une explosion AU riete a vie Survenir et causer des map ae a la ue e des blessures corporelles ou la perte Cet appareil n a pas de pilote Un m canisme d allumage automatique pour les br leurs N essayer pas d allumer les br leurs la main AVANT L ALLUM
34. NGER INSPECTION AND CLEANING Remove the heater top and inspect the external surfaces of the heat exchanger for soot accumulation If soot has accumulated it must be removed by following the recommended procedure 1 Turn pump main gas valve and heater power OFF 2 Remove the trim panels at each end of the heater Each is secured with 4 screws 3 Remove upper end caps on both ends of the heater Each cap 1s attached with 4 screws located inside the slots at the top and side of the part 4 Remove the louvered top panel There are 3 screws at each end of the top panel and 2 screws in back 5 Remove the rain shield There are 12 screws on the top surface of this panel 6 Remove the flue collector side panels on both ends of the heater Each panel is secured with 2 screws that are accessed from the outside of the heater 7 Remove the front access panel It is secured with 1 screw 8 Disconnect the water pressure switch leads at the switch which is located on the water header 9 Disconnect the limit leads at each limit which are located on the underside of the water header 10 Disconnect the thermistor lead from the ignition control board inside the control box Pull it out of the control box and free of the heater chassis 11 Remove manual reset sensing bulb from bulbwell and move so that the capillary tube will not be damaged 12 Lift and remove the heat exchanger Place it on a clean surface WARNING BURN HAZARD Do not use
35. T PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd AHayward Industries ne Company Tel 1300 POOLSI www hayward pool com au gt 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 Ist and 2nd stage regulators are large enough to handle the BTUH input listed for the heater s being used Hayward will not be responsible for heaters that soot up due to improper gas line or propane tank sizing resulting in improper gas volume 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 6000 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 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 the header Assemble these parts to the heater prior to plumbing Tighten union nuts securely before gluing fittings to the Turn clockwise ends of the pipe nipples to tighten _ HAND TIGHT The CPVC flanged pipe nipples must be installed on
36. TTENTION A heater damaged by freezing is not covered under the Hayward warranty REMOVING THE DRAIN PLUG This procedure applies to installations where the heater is located higher than the pool water level If it is necessary to drain a pool heater located below the pool water level you must either partially drain the pool or isolate the pool heater from the pool using valves CO IN WN SPR 1 2 3 4 gt 6 See Figure 25 for the location of the drain valve on the header Set the keypad to STANDBY Turn the electricity OFF at the circuit breaker Turn the heater gas valve OFF using the knob on the valve Turn the heater s gas supply OFF at the main shut off valve outside the heater cabinet Be sure the circulating pump is OFF Remove the drain plug from the heater and allow all water to drain from the heater Reinstall the drain plug ING START UP Inspect and clean the heater being sure the heater is free of leaves and debris prior to startup Be sure inlet and outlet piping are properly attached to the heater and the drain valve 15 closed Turn the filtration system pump ON and allow the system to run long enough to purge all the air from the lines Turn the gas supply to the heater ON Set the temperature control using the keypad to POOL or SPA and adjust the set point to the desired temperature setting If operating difficulties are enc
37. The following inspection procedures are recommended to be performed as part of annual heater mainte nance and to ensure safe operation 1 External heat exchanger 2 Internal heat exchanger 3 Main burner flame patterns 4 Main burner orifices 5 Operating controls Inspection procedures are covered below Some of the procedures will require disconnecting and remov ing wires in the control compartment See Control access CONTROL ACCESS To access the operating controls as shown in Figure 26 1 Remove the screw from the front access panel 2 Label all wires prior to disconnec tion when servicing controls Figure 26 Panel removal for various maintenance procedures 3 If there are questions when recon Note not all panels need to be removed for every procedure necting the wires refer to the wiring follow the written instructions in Section VI diagram in Figure 19 Pan hield Top panel 4 Verify proper operation after assembly Flue cover servicing a 5 After service is complete assembly Flue collector Heat exchanger is the reverse of Steps 1 2 above panel 2 Water header Blank side trim panel Header side trim panel cep End cap Front access panel Side jacket Control boards USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd AHayward Industries ne Company Tel 1300 POOLSI www hayward pool com au EXTERNAL HEAT EXCHA
38. a wire brush to remove soot from the A heat exchanger This could cause a spark and ignite the gases trapped within the soot 14 Using a soft tipped brush such as a paint brush apply a degreaser to the entire heat amm exchanger 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 Follow the steps above in reverse order to reinstall the heat exchanger Although the heat exchanger should be cleaned of soot and reinstalled the fact that sooting oc curred should be investigated as it may indicate other problems such as e 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 e Incorrect gas supply pipe size Excessive water flow through heat exchanger e LP tank below 30 full COMBUSTION CHAMBER The combustion chamber 15 a single piece casting If damaged the entire chamber must be replaced HEAT EXCHANGER REMOVAL Follow steps 1 12 under External heat exchanger inspection and cleaning in this section USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au BUR
39. ances Heater Panel Required Clearance Top Unobstructed Water Connection Side 12 inches 300mm Side Opposite Water Connection 6 inches 150mm Outdoor installation and service clearances The heater must be installed outdoors such that the installation and service clearances from combustible materials shown in Table 1 are maintained This heater may be installed on combustible floors 1 The heater is self venting 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 1 meter 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 6 Do not install within 0 6 m of any outdoor HVAC equipment 7 Do not install where water may run off a 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 30 cm of the bottom of the enclosure The vent opening shall have a minimum free area of 645 mm per 4 000 btu hr input rating of all gas appliances in the enclosure See Table 1 FLOORING This heater may be installed on either non combustible or com
40. as supply ON Use a soapy water solution to check for leaks 14 Bubbles forming indicate a leak 15 To start the heater follow the instructions on the label inside the front access panel see Figure 20 CONN NA BWN USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au 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 Figure 21 22 amp 28 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 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 1 screw 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 Remove the BSP to NPT adapter if used for use on replacement valve Reassemble the gas manifold assembly using the new gas valve See Figure 41 for the correct orientation of the manifold pipe pipe elbows and gas valve Only use liquid pipe dope on the male threads of the elbows and the gas manifold pipe Do not p
41. at remains the DSICM will wait for proper air flow to return If proper air flow 1s not detected after 30 seconds an air flow fault signal will be declared If proper air flow is detected at any time a normal sequence will being with the pre purge period FLAME FAULT If at any time the gas valve fails to close completely and maintains a flame the flame sense circuit will detect it and energise the blower Should the gas valve later close completely removing the flame signal the blower will be turned off following the post purge period DSICM FAULT CONDITIONS LED Indication Internal control failure St Flame with no call for heat 2 Flashes Ignition lockout 3 Flashes USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au AUTOMATIC RESET TIME The heater will automatically reset when an error condition is corrected and resumes operation as detailed in Figure 52 ERROR CODES Alternatively the heater can be manually reset using the keypad by pressing the MODE button to cycle through STANDBY and back to the original mode SPA or POOL If the DSICM is in lock out and if the thermostat is still calling for heat after one hour the DSICM will automatically reset and attempt to ignite the burner again PERIODIC INSPECTION The heater is designed and built for long performance life when
42. ately and the blower will be turned off following the post purge period FLAME FAILURE RE IGNITION If the established flame signal is lost the DSICM will respond with 0 8 seconds The HV spark will be energised for a trial ignition period in an attempt to relight the burner If the burner does not light the DSICM will de energise the gas valve The DSICM will make two 2 more attempts to relight the burner If the burner does not relight the DSICM will go into lock out as above in Failure to Light If the flame 15 re established normal operation resumes BLOWER AIRFLOW PROBLEMS Blower air flow is continually monitored during an ignition sequence by the vacuum switch If during the initial call for heat the switch contacts are in the closed position for 30 seconds without the blower be ing energised an air flow fault will be declared and the control will remain in this mode with the combustion blower off If the pressure switch remains open for more than 30 seconds after the blower output is energised an air flow fault will be declared and the DSICM will stay in this mode with the blower on waiting for the pressure switch to close When proper air flow is detected from the vacuum switch the DSICM begins the pre purge period with a normal ignition sequence following If the air flow signal 1s lost while the burner 1s firing the DSICM will immediately de energise the gas valve and the blower will remain on If the call for he
43. blower outlet gasket 1s in place before proceeding BYPASS SERVICE CARTRIDGE Turn pump main gas valve and heater power off Remove drain plug and drain water out of heat exchanger Remove 6 screws and remove the upper plastic heater side panel to allow access to the header Remove cartridge retaining nut from end of header see Figure 31 Slide out the bypass cartridge from the end of the header see Figure 31 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 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 QV Un B ND USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd AHayward Industries ne Company Tel 1300 POOLSI www hayward pool com au SECTION VI TROUBLESHOOTING GENERAL A 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 ins
44. board If not OK replace harness If OK proceed to step 5 5 Verify that F101 fuse Remove F101 fuse from fuse holder Measure continuity on IOPS is not open across fuse If OK replace IOPS board If fuse is open proceed to section titled Open F101 Fuse 1 Check for faulty Gas Inspect Gas Valve wiring Ensure insulation on wiring 1s not Valve wiring worn If OK proceed to step 2 2 Verify that Gas Valve is Measure for resistance across Gas Valve terminals and Open F101 Fuse not defective between each terminal and ground If short exists replace Gas Valve If OK proceed to step 3 None 3 Check for faulty IOPS Inspect board amp DSICM wiring Ensure insulation on board or DSICM wiring wiring is not worn If OK proceed to step 4 4 Either IOPS board or Disconnect wire at R terminal on DSICM replace fuse F101 DSICM 1s defective and try again If fuse remains OK replace DSICM Otherwise replace IOPS board and fuse F101 If fuse blows again replace DSICM also Burner is not operating when the Heating LED is illuminated 1 Ensure gas supply Ensure that the main gas shutoff installed adjacent to the shutoff valves are open heater is open Ensure that knob on Gas Valve inside unit is in on position If OK proceed to step 2 2 Check for low gas Ensure inlet gas supply pressure 1s between the minimum and supply pressure maximum values indicated on rating plate If OK proceed to step 3 3
45. bustible flooring Ultralite or equivalent concrete over foam HVAC pads are acceptable USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au REVERSIBLE WATER CONNECTIONS Figure 4 This heater is designed so that it can be installed with the water connections located on either the right Screw Locations or left side Heaters are factory shipped with right side water connections To move the connections to the left side follow the instructions below and see Figure 4 A trained service technician should perform these steps before the heater is installed 1 Before beginning be aware that it 15 not necessary to remove the water header from the heat exchang er When this procedure 1s complete the water inlet will be located at the BACK of the heater The water outlet will be located at the FRONT 2 Remove screws and remove both of the upper plastic heater side panels see Figures 5 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 3 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
46. e Orange wire POOL White wire 24V and the Red wire SPA To operate the heater with the 3 wire remote switch the user must select STANDBY mode by pressing the MODE button When in STANDBY and when the remote switch is set to Pool Low the POOL LED will be illuminated and the water temperature will be displayed Similarly when the remote switch is set to Spa High the SPA LED will be illuminated and the water temperature will be displayed Note that the STANDBY LED will also be illuminated to indicate that the heater is now in 3 wire remote switch control mode The TCM will regulate the water temperature to the set point of the mode selected To deactivate the heating cycle the user presses the MODE button to return to STANDBY mode USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au Figure 20 Lighting amp Operating Instructions label C e rri FOR YOUR SAFETY READ BEFORE LIGHTING VVARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A 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 B BEFORE LIGHTI
47. e caused by 1 Clogged filter or strainer 2 Excessive flow through the external bypass if one 1s used 3 Lime scale accumulation in the heat exchanger Figure 31 Component locations on header Cartridge Retaining Nut Water Pressure Bypass Service Switch Cartridge Inlet Outlet N WU Temperature Limits Bulbwell Drain Plug Brass Bushing Thermistor Figure 32 Automatic Reset High Limit Switch 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 Reassembly is a reverse of steps 1 4 re USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au THERMISTOR Figure 33 Thermistor The thermistor monitors the return water temperature See Figure 31 for its location To replace the thermistor Turn pump gas supply and heater power OFF Drain the heat exchanger of all water Remove the front access panel It is secured with 1 screw Unplug the thermistor connector from the thermostat control board From outside the heater pull the thermistor leads out of the control box and through the
48. e of water from this device can be expected at some time due to malfunctions or limitations 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 To the extent permitted by law except as set out in this Warranty Hayward Pool Products excludes all statutory or implied conditions and warranties and any other liability it may have to the Customer including liability for indirect or consequential loss that may arise under statute or at law including without limitation for breach of contract in tort including negligence or under any other cause of action To the extent permitted by law except as set out in this Warranty Hayward Pool Products limits its liability under any condition or warranty which cannot be legally excluded in relation to the supply of Goods and Services to 1 Replacing the Goods or supplying equivalent Goods or Services again 2 Repairing the Goods 3 Paying the cost of replacing the Goods or of supplying equivalent Goods or Services again or 4 Paying the costs of repairing the Goods THIS PRODUCT REQUIRES QUALIFIED INSTALLATION All Hayward heaters due to their technical nature are only intended for sale by retail shops where local sales and technical support can be provided or as a part of a new Pool Installation Warranty claims for such products will only be recognised when the products
49. eater 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 future 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 1s out of service to prevent damage to the heater and piping Drain ing the heat exchanger 15 recommended as part of the season s shutdown procedures USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd A Hayward Industries Inc Company Tel 1300 POOLSI www hayward pool com au A A
50. ectrical 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 addition the licensed electrician must also conform to local electrical codes for bonding requirements USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au NOTES TO THE ELECTRICIAN Use a solid copper conductor 8 AWG 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 applicable local and national electric codes for all wiring standards including but not limited to ground ing bonding and ot
51. er 20 Supply wiring emet 42 Electrical specifications 21 Internal NITIAQ pec iont trees en 42 Electrical connections 22 Fuse specifications 42 Remote control connection 24 Ol COGS M ae er 43 Troubleshooting 44 Section 11 Check out amp Start up 26 47 General 26 Service Parts 50 Gas line testing 26 Gas pressure testing 27 Water pressure switch 28 Two speed pump 20 Temperature adjustment 29 Temperature lock out 29 Fahrenheit v Celsius 29 Heating mode 29 Retry Failure of light 30 Recycle Loss of flame 30 Keypad inputs reasons 30 Automatic reset time 31 Periodic inspection ixesxexchiuedimidmena ute 31 Winterization 31 Draining the heat exchanger 32 Spring start up 32 Section IV Technician Service 33 1
52. er 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 gas 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 AS NZS 5601 1 2010 Gas Installations 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 REPLACEMEN
53. er 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 21 Location of components Blower a Vacuum 39 T 4 Switch Keypad Direct Spark ALT F LE Transformer Ignition Control MI V ss at Gas Valve i i Mi lar 1 Thermostat E M co Control Board sight Glass Blower i Flame Sensor Igniter X k m Access Panel P Air Box Gas Manifold Keypad Thermostat Control Board Direct Spark Ignition Control Sight Glass Blower Flame Sensor ignitor Access Panel Gas Manifold H250FD 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 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 ga
54. 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 chemistry 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au SECTION Il INSTALLATION 9 EQUIPMENT
55. ger 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 15 state of the art in pool heater design and manufacture Yet 1 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 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 1s filled with water and purged of all air prior to starting the heater The minimum 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel
56. 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 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 Figure 10 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 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 press
57. her 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 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 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 1 lt floor wall must be installed a minimum of three feet 3 1 meter apart as mea su
58. in The installation is as follows 1 Install a flow meter on the outlet line of the heater Bag 75 2 Adjust the manual bypass valve until the flow rate is within the flow rate range specified for the H250FDAU 95 15 heater 3 Once the valve is set note the position and remove H400FDAU 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 Figure 10 under all operating conditions The heat ex changer will fail and this damage will not be covered under the Hayward warranty Figure 12 illustrates a typical pool piping diagram and layout for the pool equipment Figure 13 illustrates a multiple heater installation for very large pools with and without a manual bypass valve USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au TOPOOL em Figure 12 Typical plumbin Fig Multiple he ure 13 TH RMOMETER m INSTALLATION ABOVE POOL SPA SURFACE If the heater is installed less than one 1 meter 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
59. 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 clearances 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 heater 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 If the heater is operating on propane gas the tank must not fall below 30 full or damage to the heater may occur Hayward will not be responsible for heaters that soot up due to improper gas level in the tank resulting in inadequate gas volume 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 h
60. ir or air and water is discharged x em 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 spa circulation system manual air relief valve must be in open position Do not oper 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 1s in locked position in filter upper body y 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au A WARNING The following Safety Rules for Hot Tubs recommended by the U S Consumer Product Safety Co
61. is running If the heater is installed more than one 1 meter above the sur face of the pool spa water install a loop as shown in Figure 19 to pre vent drainage of water in the heater during a filter change For installation below the pool spa surface refer to Section III 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 15 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 1s created USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au 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 ELECTRICAL SPECIFICATIONS
62. lace pipe dope on the first two threads of any Joint 9 Complete assembly by reversing step 1 5 i o sia P de Figure 28 Correct orientation of components of gas manifold assembly USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au IGNITER Refer to Figures 21 and 26 To remove the igniter Turn pump gas supply and heater power OFF Remove the front access panel It is secured with 1 screw Disconnect the high voltage wire from the DSICM Remove the 1 screw from the igniter access panel Withdraw the access panel by sliding along the high voltage wire Disconnect high voltage wire from igniter Remove the 2 screws that secure the igniter Pull the igniter straight back until it 1s free of the combustion chamber then out of the air box Installation is the reverse of steps 1 7 BR WN Re CON ON tA FLAME SENSOR Refer to Figures 21 and 26 To remove the flame sensor 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel 1 screw 3 Disconnect the wire from the flame sensor 4 Remove the screw that secures the flame sensor to remove the sensor 5 Reverse the flame sensor by reversing steps 1 4 BURNER ORIFICES Refer to Figures 21 and 28 as needed To remove the igniter Turn pump gas supply and heater power OFF Disconnect the
63. minute delay if the pump primes quickly enough to activate the heater s water pressure switch If the pump 1s 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 FUSE SPECIFICATIONS The fuse designations are printed on the control board See Figure 18 for board locations Fuses are avail able as common hardware items or may be purchased from Hayward in a service parts kit The fuse specifica tions are e F101 fuse low voltage 3 15 A 250V slow blo 5x20 mm USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au Figure 36 ERROR CODES TCM ERROR CODES Note If two or more faults are present at the same time the error code highest on the following table will be displayed Code Limit string open ES while call for heat ery Thermistor fault Rapid water temperature rise es Excessive Water Temperature Limit string open while no call for heat
64. mmission should be observed when using the spa 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 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 Pregnant women beware Soaking in water above 100 F 38 C can cause fetal damage during the first three months of 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 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 22 Persons taking medications which induce drowsiness such as tranquilizers antihistamines or anti coagulants should not use spas or hot tubs If the 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 Persons with a medical histor
65. moved Removal of the screw with the gas valve ON could cause an explosion resulting in severe injury and or death USE ONLY HAYWARD GENUINE REPLACEMENT PARTS HAYWARD Products A Hayward Industries Inc Company Hayward Pool Products Australia Pty Ltd Tel 1300 POOLSI www hayward pool com au 9 Remove the manometer and replace the Figure 23 Correct gas pressures kPa f proper Da Manifold 0 45 0 50 170 175 staller must contact the gas supplier and re Inlet Minimum quest that the inlet pressure to the heater be Inlet Maximum set to within the gas pressure range shown in Figure 23 Fig 23 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 15 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 1s at least the rated minimum see Figure 10 3 Turn ON the
66. ountered 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 with the pool owner Figure 25 Drain plug location Exchanger Drain Plug Header Thermistor Location do not use to drain heater USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLSI www hayward pool com au 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 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
67. 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 installation for all users for the original purchaser repair or at our option replace without charge any defective part Hayward further warrant that 1f 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 1s 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 1s damaged or destroyed by improper maintenance exces sive water hardness incorrect water chemistry or freezing it is not covered under the manufacturer s watranty MAINTAINING PROPER WATER CHEMISTRY Failure to Maintain Proper Water Chemistry May Cause Premature Heat Exchan
68. ping sufficient airflow for combustion See Figure 30 When the blower achieves sufficient airflow the negative pressure created in the blower housing closes the contacts on the blower vacuum switch This indicates to the ignition control board that it 1s safe to continue the ignition sequence The tubing on the blower vacuum switch should be at tached to the blower housing pressure tap that faces the right side of the heater USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au To remove the blower vacuum switch Turn pump gas supply and heater power OFF Remove the front access panel It is secured with 1 screw 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 Replace the switch Reverse steps 1 6 to complete the procedure PI ass D cs HIGH LIMIT SWITCHES The high limit is an automatically resetting safety device wired in series with the thermostat and gas valve See Figure 31 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 b
69. red from near point to near point Dual suction outlets shall be placed in such locations and distances to avoid dual blockage by a user Dual suction fittings shall not be located on seating areas or on the backrest for such seating areas The maximum system flow rate shall not exceed the flow rating of any listed AS 1926 3 2010 A1 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 Replace damaged broken cracked missing or not securely attached suction outlet components im mediately 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au 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
70. required No claims in respect of the product can be made after the expiration of the warranty period STATUTORY RIGHTS 1 The benefits to the consumer under this warranty are in addition to other rights and remedies of the consumer under the laws in relation to the goods and services to which the warranty relates and 2 Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You may be entitled to a replacement or refund for a major failure and for compensation for any other loss or damage You are also entitled to have the goods repaired if the goods fail to be of acceptable quality and the failure does not amount to a major failure To register your product for warranty please go to www hayward pool com au warrantyregistration Warranty service requests can be faxed to Hayward Pool Products Australia Pty Ltd ACN 083 413 414 Fax 1300 POOLS2 1300 766572 or call 1300 POOLS1 A standard form is available to request warranty service We will require e Installation contact information including address daytime telephone numbers home phone number email etc Complete model and serial number e Proof of purchase if the serial number was manufactured gt 1 year ago Evidence that purchase and Installation was completed in one transaction by the one business or organization Nature of problem including specific faults and error codes USE ONLY HAYWARD GENUINE REPLACEMENT PARTS E AYWARD ool Produc
71. ressure b Small flat screwdriver 2 Using the screwdriver remove the screw in the manifold pressure tap 3 Attach the manometer to the pressure tap 4 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 1s more than one pool spa heater connected to the gas supply line turn each of those appliances ON while testing the heater 5 Take a pressure reading with the heater run Regulator adjustment screw under this screw cap i INCREASE cil PRESSURE Electrical terminals Figure 22 Gas Valve pr Inlet pressure ON OFF knob DECREASE PRESSURE Manifold pressure tap ning the value should agree with those in Figure 23 If the pressure 15 within the range shown then no further adjustment is needed 6 Ifthe gas pressure does not meet the above requirements the regulator must be adjusted 7 Gas pressure regulator adjustment procedure a Remove the screw cap over the regulator adjustment screw see Figure 22 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 A WARNING EXPLOSION HAZARD Do not remove the screw from the tap with the valve in the ON position The valve must be in the OFF position when the screw is re
72. s 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 9 Turn gas control knob clockwise to OFF GAS CONTROL RQJ KNOB SHOWN IN OFF POSITION 6 Wait five b minutes to clear out any gas If you then smell gas STOP Follow B in the TO TURN OFF GAS TO APPLIANCE OPERATING INSTRUCTIONS 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 9 Set the MODE on the control panel 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 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 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
73. s 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 constructed 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 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 el
74. s supply piping system at test pressure equal to or less than 1 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd A Hayward industries he Company Tel 1300 POOLS1 www hayward pool com au 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 Shut off gas and fix even the smallest leak right 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 p
75. stance across leads should be in the range 13 to 14 ohms If measured value varies substantially from this blower motor is defective Replace If OK proceed to step 5 5 Check for defective Disconnect blower motor from DSICM Place heater in Pool or Spa blower relay Mode Raise set point temperature to generate a call for heat During pre purge period measure for 240 VAC between the DSICM IND terminal and neutral If 240 VAC is not present the blower relay in the DSICM 1s defective Replace DSICM If OK proceed to step 6 6 Vacuum switch is Replace blower vacuum switch defective USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au HAYWARD POOL HEATER CERTIFICATE OF LIMITED WARRANTY i Hayward Pool Products Australia Pty Ltd ACN 083 413 414 Hayward Pool Products distributes Hayward Pool Products in Australia and provides the following warranty LIMITED HEATER WARRANTY Hayward Pool Products warrants that its products are free from defects in materials and manufacture for 12 months from the date of purchase unless otherwise specified Hayward Pool Products will at its discretion except in the circumstances described below either replace or repair any product proven to be defective during the warranty period for either materials or manufacture or alternatively pay the cost or repair or replacement within 90
76. sure wire harness terminals are securely sense wiring or connection fastened to flame sense and to the DSICM If OK proceed to step 4 4 Check for faulty gas valve Inspect gas valve wiring Ensure wire harness terminals are securely wiring or connection fastened 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 ignition If 24 VAC is failure or Gas Valve relay present and Gas Valve does not open Gas Valve is defective Replace failure Gas Valve 2 If 24 VAC 1s not present Gas Valve relay in DSICM is defective Replace DSICM 6 Check for blockages in Inspect gas orifices for blockages which could prevent gas flow gas orifices and burners Remove and inspect burners for blockages Blower vacuum 1 Vacuum switch is Replace blower vacuum switch switch closed 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 lower wiring If OK proceed to step 4 wiring or connection 4 Check for defective Disconnect blower motor from DSICM Measure resistance across blower motor blower motor windings Winding resi
77. tallation 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 for 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 mA A 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 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 POOL or SPA ERROR CODES See Figure 52 for an error code chart TROUBLESHOOTING See Figure 53 for troubleshooting guide SUPPLY WIRING If the heater 1s 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
78. 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 4 Remove countersunk screws on the heater top and remove louvered exhaust panel on heater top see Figure 15 5 Remove the heater top flue cover by removing 3 screws on each side of the heater see Figure 5 6 Remove screws and remove rain shield assembly see Figure 5 Note that there are screws which hold the rain shield assembly to the heat exchanger tube sheets which also must be removed 7 Remove the front access panel see Figure 5 8 Disconnect water temperature sensor plug from the thermostat control board located inside the heater see Figure 5 9 Pull the water temperature sensor wires out of the heater cabinet through the hole in the right hand metal side panel 10 Remove the manual reset high limit sensing bulb from the bulbwell in the header see Figure 5 and pull the bulb and capillary tube into the heater cabinet and re route them through the left hand metal side panel 11 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 12 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 13 Re connect the heater wire harness to the water pressure switch and temperature limit
79. the keypad buttons is closed pressed for more than 30 seconds the error code will be displayed but the control will continue to function The error code will be cleared when the condition 1s corrected This is NOT an error code If the user sees bo in the display the TCM is in Bypass Operation mode To exit Bypass Operation mode select STANDBY mode then press and hold both the DOWN and MODE buttons for 3 sec onds until the bo code is no longer displayed When a dot decimal point is displayed after the error code this is an indication that auto restarts are disabled The TCM must be manually restarted USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products Australia Pty Ltd Tel 1300 POOLS1 www hayward pool com au Figure 37 TROUBLESHOOTING Diagnosis Step None None Heater will not 1 Ensure field power Measure for field supply voltage across terminals of terminal power up supply to heater is turned block If OK proceed to step 2 on 2 Check for defective Measure for 24 VAC between low voltage pins of transformer transformer If 24 VAC is not present replace transformer Otherwise proceed to step 3 3 Check for faulty IOPS Inspect IOPS board wiring Ensure all plugs are securely board wiring fastened to IOPS board If OK proceed to step 4 4 Verify low voltage Verify 24 VAC across R E112 and C E113 terminals on input to IOPS board IOPS
80. to the terminal adjacent to the White wire 24V and the other wire to the terminal adjacent to the Orange wire POOL To operate the heater with the 2 wire remote thermostat the user must select either SPA mode or POOL mode by pressing the MODE button In Bypass Op eration mode the status of the remote thermostat directly controls calls for heat Specifically a closed thermostat con tact results in a call for heat an open contact no call for heat TCM set points are ignored However the TCM continues to monitor water temperature and will intervene to ensure the normal maximum limit 1s not exceeded Also the heater s string of limit switches water pressure switch and two temperature switches is still active To deactivate the heating cycle the user presses the MODE button to return to STANDBY mode To exit Bypass Operation mode the user selects STANDBY mode then presses and holds both the DOWN and MODE buttons for 3 seconds until the display no longer shows bo Note that Bypass Operation mode is maintained through a power down up cycle 3 WIRE REMOTE CONTROL CONNECTION A remote SPA POOL selection switch can be connected to the TCM via the remote control wiring terminal block located in the lower compartment inside one of the junction boxes on either side of the heater Connect the appropriate wires from the remote switch to the terminals adjacent to th
81. ts Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLSI www hayward pool com au Plastic Header Models Non ASME ITEM PART NO DESCRIPTION 1 FDXLJKT1150 JACKET TOP amp FLUE COVER H150FD FDXLJKT1250 JACKET TOP amp FLUE COVER H250FD FDXLJKT1400 JACKET TOP amp FLUE COVER H400FD 2 FDXLTFC1150 TOP FLUE COVER H150FD FDXLTFC1250 TOP FLUE COVER H250FD FDXLTFC1400 TOP FLUE COVER H400FD 3 FDXLFAD1151 ASSY ONE SCREW FRONT ACCESS DOOR H150FD FDXLFAD1251 ASSY ONE SCREW FRONT ACCESS DOOR H250FD FDXLFAD1401 ASSY ONE SCREW FRONT ACCESS DOOR H400FD 4 FDXLRAD 1150 REAR ACCESS DOOR ASM H150FD FDXLRAD1250 REAR ACCESS DOOR ASM H250FD FDXLRAD 1400 REAR ACCESS DOOR ASM H400FD 5 FDXLTFP1150 TOP amp FRONT PANEL H150FD FDXLTFP1250 TOP amp FRONT PANEL H250FD FDXLTFP1400 TOP amp FRONT PANEL H400FD 6 FDXLUEC1930 UPPER END CAP FD T FDXLLEC1930 LOWER END CAP FD 8 FDXLLTP1930 LEFT TRIM PANEL FD 9 FDXLRTP1930 RIGHT TRIM PANEL FD 10 FDXLLJB1930 LEFT JUNCTION BOX FD FDXLRJB1930 RIGHT JUNCTION BOX FD 11 FDXLPBL1930 BASE LEG FD 12 FDXLFCS1930 FLUE COLLECTOR SIDE PANEL 13 FDXLRGK1150 RAIN GUARD ASM H150FD FDXLRGK1250 RAIN GUARD ASM H250FD FDXLRGK1400 RAIN GUARD ASM H400FD 14 FDXLHBP1150 HEAT BARRIER PANEL H150FD FDXLHBP12
82. ts close a pre purge delay begins 3 Following the pre purge period 15 seconds the gas valve is energised and sparks commence for the trial for ignition period 4 seconds 4 When the flame is detected during the trial for ignition sparks are shutoff immediately and the gas valve remains energised 5 The thermostat vacuum switch and the burner flame are all constantly monitored to assure the system continues to operate properly 6 When the thermostat is satisfied and the call for heat ends the gas valve is de energised immediately 7 The DSICM senses the loss of flame and initiates a post purge period 15 seconds before de energising the blower USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd industrias ine Company Tel 1300 POOLS1 www hayward pool com au KEYPAD INPUTS In normal use the user activates the heating cycle by moving from STANDBY mode to SPA or POOL mode by pressing the MODE button The TCM amp DSICM will regulate the water temperature to the set point of the mode selected To deactivate the heating cycle the user presses the MODE button again once or twice to return to STANDBY mode FAILURE TO LIGHT RETRY If the first ignition attempt fails during a normal heating cycle the DSICM will make two 2 additional ignition trials before going into lock out The gas valve will be de energised immedi
83. u TRANSFORMER The transformer converts the 240 VAC 50 Hz field supply voltage to 24 VAC for powering the control circuits See Figure 21 for its location To replace the transformer 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel It is secured with 1 screw 3 Disconnect all wires from the transformer leads 4 Remove the 2 screws that secure the transformer to the control box 5 Replace the transformer Reassembly 15 the reversal of steps 1 4 BLOWER The blower provides the air that mixes with the gas at the main Figure burners for the combustion process The blower operates during the prepurge time approximately 15 seconds at the beginning of each ig Blower nition cycle during the entire time the gas valve 1s open and the burn ES A ers are firing and for 15 seconds after the gas valve closes See Figure jay y p Blower 21 for the location of the blower de air inlet em Hi plate To replace the blower 1 Turn pump gas supply and heater power OFF Blower 2 Remove the front access panel 1 screw d outlet 3 Disconnect the blower wires from the wire harness gasket 4 Pull the tubing from the hose barb on the blower housing 5 Remove the air inlet screen from the blower 5 screws i 6 Remove the blower from the air box cover 4 screws Attach tubing here only 7 Reverse steps 1 6 to install the new blower Be sure the
84. ure from a two speed pump 1s below the 1 pound minimum required to operate the wa ter pressure switch on the heater This 1s 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 HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au TEMPERATURE CONTROL OPERATION This model of Hayward gas fired pool spa heater 15 equipped with a temperature control module TCM and a direct spark ignition control module DSICM for automatically controlling pool and spa water tem peratures The TCM has three components the Display Control Board with its attached Keypad and the IO Power Supply Board The TCM keypad amp display are located on the top edge of the front panel and are used to enter Pool and Spa set points This display also indicates water temperature and if needed diagnostic information error codes The IO Power Supply Board is located inside the heater behind the removable front panel The DSICM manages the ignition of the burner and ensures safe operation by constantly monitoring the flame and the blower fan This module is also located behind the removable front panel
85. wired for use with 240 VAC 50 Hz field power supply All wiring connections to the heater must be made in accordance with the latest edition of AS NZ 3000 unless local code requirements specify otherwise The heater must be electrically grounded and bonded in accordance with local code or in the absence of local codes with AS NZ 3000 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 using the supplied 240V power cord or to the terminal block located in the upper compartment inside the junction box see Figures 16 and 17 The heater has 2 junction boxes one on each side of the heater Only one junction box should be used for field power wiring Figure 16 Location of field power wiring termi nal block and remote control terminal block Figure 17 Junction Box Wiring Make field power wiring Ground connections here if power cord is not used Make remote control L1 240v L2 240v connections here Field Power Wiring Terminal Block Remote Connection Terminal Block junction box cover not shown left side shown right side is similar Spa RED Common Pool WHITE ORANGE USE ONLY HAYWARD GENUINE REPLACEMENT PARTS AYWARD ool Products Hayward
86. y of heart disease circulatory problems diabetes or blood pressure problems should obtain a physicians advice before using spas or hot tubs 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 mu Unawareness of impending danger Failure to perceive heat Failure to recognize the need to leave the spa Physical inability to exit the spa Fetal damage in pregnant women Unconsciousness resulting in danger of drowning 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 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 AYWARD ool Products Hayward Pool Products Australia Pty Ltd ine Company Tel 1300 POOLS1 www hayward pool com au SECTION I GENERAL INFORMATION INTRODUCTION This manual contains instructions for installation operation maintenance troubleshooting and
87. ystem consists of two controls the thermostat control is a printed circuit board and the ignition control has its own casing The locations of these components are shown in Figure 31 The ignition control system functions as the heater s thermostat safety control and controller for the gas combustion system To remove the ignition control board or thermostat control 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel It is secured with 1 screw 3 Disconnect all wires from the ignition control board 4 Detach the board from the sheet metal panel 5 Replace the ignition control board Reassembly is the reversal of steps 1 5 DISPLAY BOARD AND KEYPAD The display board and keypad provide the user interface with the heater See Figure 29 The replacement part is only available as an assembly To remove the display board and keypad assembly 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel It is secured with 1 screw 3 Unplug the display connector from the thermostat control board 4 Remove the 4 screws along the edges of the bezel that retains the assembly 5 Pull the assembly forward and then lift it out 6 Replace the assembly Reverse steps 1 6 to complete the procedure Figure 29 Keypad FAN PROVING SWITCH The blower vacuum switch 15 a safety device that pre vents the ignition sequence from continuing unless the blower is develo

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SERVICE & INSTALLATION MANUAL