POOL AND SPA/HOT TUB HEATERS H150FDAU, H250FDAU, & H400FDAU MODELS FOR USE IN AUSTRALIA SERVICE & INSTALLATION MANUAL FOR YOUR SAFETY WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, injury, or death. - Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: • • Do not try to light any appliance.
CONTENTS Section I General information ........................... 7 Introduction .................................................... 7 Warranty ........................................................ 7 Maintaining proper water chemistry ............... 7 Section II Installation ......................................... 9 Equipment inspection .................................... 9 Important notice ............................................. 9 Conformance with codes ...............................
SAFETY INFORMATION Basic safety precautions should always be followed, including the following: Failure to follow instructions can cause severe injury and/or death. This is the safety-alert symbol. When you see this symbol on your equipment or in this manual, look for one of the following signal words and be alert to the potential for personal injury. WARNING warns about hazards that could cause serious personal injury, death or major property damage and if ignored presents a potential hazard.
NOTES TO THE ELECTRICIAN: Use a solid copper conductor, 8 AWG or larger. Run a continuous wire from external bonding lug to reinforcing 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 1.5 m of inside walls of swimming pool or spa.
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. 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.
WARNING – The following “Safety Rules for Hot Tubs” recommended by the U.S. Consumer Product Safety Commission should be observed when using the spa. 1. Spa or hot tub water temperatures should never exceed 40°C [104°F]. A temperature of 38°C [100°F] is considered safe for a healthy adult. Special caution is suggested for young children. Prolonged immersion in hot water can induce hyperthermia. 2.
SECTION I. GENERAL INFORMATION 7 INTRODUCTION: This manual contains instructions for installation, operation, maintenance, troubleshooting, and parts lists for the safe use of the swimming pool/spa/hot tub heaters. Hayward strongly recommends that the installer read the manual before installing the swimming pool/spa/hot tub heater. If after reviewing the manual any questions remain unanswered, contact the factory or local representative.
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 chemistry 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.
SECTION II. INSTALLATION EQUIPMENT INSPECTION: On receipt of the heater, inspect the heater carton(s) for damage. If any carton(s) is damaged, note it when signing for it. Remove the heater from the carton(s) inspect it and advise the carrier of any damages at once. IMPORTANT NOTICE: The installation instructions are intended for the use of a qualified technician, specifically trained and experienced in the installation of this type of heating equipment.
Model Number Heater Capacity Gas Type Heater Width Packaged Weight H150FDAU 158 MJ/h Natural/Propane 54.6 cm 64 kg H250FDAU 264 MJ/h Natural/Propane 71.1 cm 75 kg H400FDAU 422 MJ/h Natural/Propane 92.7 cm 89 kg 61.0cm 35.2cm WIDTH FRONT 74.8cm 34.6cm 37.3cm 38.3cm 9.5cm 19.1cm LEFT 24.8cm 37.7cm 31.9cm 7.8cm 14.5cm RIGHT USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.
UNCRATING THE HEATER: Figure 1 To remove the shipping carton from the heater: 1. Remove the corrugated carton from the heater. The carton, top pad, bottom pad, and the four corner posts can be recycled. 2. There are three (3) screws total used to secure the heater to the wood pallet. All three must be removed to separate the heater from the pallet. One (1) is located in the lower rear of the heater as shown in Figure 1. 3.
Table 1 Outdoor Installation Clearances Heater Panel Required Clearance Top Unobstructed Front 0.6 m Back 0.15 m Water Connection Side 0.3 m Side Opposite Water Connection 0.15 m 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.
REVERSIBLE WATER CONNECTIONS: This heater is designed so that it can be installed with the water connections located on either the right 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. Figure 4: Screw Locations Figure 14 1.
Figure 5 Top Flue Cover Louvered Exhaust Panel Rain Shield Assembly Heat Exchanger Assembly Pressure Switch Port Temperature Limit Switches Drain Plug or Valve Water temperature sensor Manual Reset Sensing Bulb Upper Plastic Heater Side Panel Thermostat Control Circuit Board Upper Plastic Heater Side Panel Front Access Panel USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.
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 twostage 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.
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.
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 removal of the gas manifold assembly during service. An AGA approved main gas shutoff valve must be installed outside the cabinet and within 1.8 m of the heater. This valve must have an I.D.
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 1st and 2nd stage regulators are large enough to handle the MJ/h 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.
If the normal pump and filter system flow rate exceed 475 L/min then a manual bypass valve must be installed as shown in Figure 11. Damage caused by flow rates outside this range will void the manufacturer’s warranty. The installation is as follows: 1. Install a flow meter on the outlet line of the heater. 2. Adjust the manual bypass valve until the flow rate is within the flow rate range specified for the heater. 3.
Figure 13: Multiple heater system Figure 12: Typical plumbing to pool INSTALLATION ABOVE POOL/SPA SURFACE: Figure 14: Heater installation above pool/spa If the heater is installed less than one (1) meter above the surface of the pool/spa water, install eyeball fittings or directional flow fittings on the end of the return water line to the pool/spa to create adequate back pressure at the heater to operate the pressure safety switch when the filter pump is running.
ELECTRICAL SPECIFICATIONS : 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.
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 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.
Figure 18: Control Panel Layouts H150FDAU Control Panel Assembly (wiring not shown) 3 4 1 2 5 H250FDAU and H400FDAU Control Panel Assembly (wiring not shown) 3 1 2 1. Direct Spark Ignition Controller 2. Thermostat Control Board 3. Transformer 240V Primary / 24V Secondary 4. Blower Air Pressure Switch 5.
GND S1 Spark YLW YLW TDR Blower Pressure Switch TDR V2 V1 Spark Igniter YLW Gas Valve YLW RED MRL BLU Limit Switch Limit Switch Water Pressure Switch BLU BLK BLK BLU GRN 24 V Secondary Transformer R BLU Combustion Fan WHT WHT 240 V Primary BLK BRWN YLW BLK WHT BLK TH Flame Sensor Fenwal 35-61 Ignition Control Module PSW IND LINE EMC Line Filter LOAD RED BLK PUR GRN 1 7 E12 E7 Display Circuit Board Thermostat Control Board R BLK R Temperature Sensor
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).
Figure 20: Lighting & Operating Instructions label USE ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.
SECTION III. INSTALLER CHECK-OUT AND START-UP: Some of the following procedures will require the heater to be operating. Full lighting and shutdown instructions are included on the lighting and operating label affixed on 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.
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. GAS PRESSURE TESTING: The following gas pressure requirements are important to the proper operation of the burners in gas heaters.
9. Remove the manometer and replace the screw. If proper pressure cannot be achieved by adjusting the gas valve regulator, the installer must contact the gas supplier and request that the inlet pressure to the heater be set to within the gas pressure range shown in Figure 23. Figure 23: Correct gas pressures (kPa) Fuel Natural Propane Manifold 0.45-0.50 1.70-1.75 Inlet, Minimum 1.12 2.24 Inlet, Maximum 2.61 3.24 WARNING EXPLOSION HAZARD: Gas pressures in excess of those listed in Fig.
TEMPERATURE CONTROL OPERATION: This model of Hayward gas fired pool/spa heater is equipped with a temperature control module (TCM) and a direct spark ignition control module (DSICM) for automatically controlling pool and spa water temperatures. The TCM has three components, the Display/Control Board with its attached Keypad and the IO/ Power Supply Board. The TCM keypad & display are located on the top edge of the front panel, and are used to enter Pool and Spa set points.
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 & 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.
AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resumes operation as detailed in Figure 36: TCM 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.
ATTENTION: A heater damaged by freezing is not covered under the Hayward warranty. REMOVING THE DRAIN PLUG: This procedure applies to installations where the heater is located higher than the pool water level. If it is necessary to drain a pool heater located below the pool water level, you must either partially drain the pool, or isolate the pool heater from the pool using valves. 1. See Figure 25 for the location of the drain valve on the header. 2. Set the keypad to “STANDBY”. 3.
SECTION IV. QUALIFIED TECHNICIAN – MAINTENANCE & SERVICING GENERAL: 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.
EXTERNAL HEAT EXCHANGER 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.
BURNER 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 13 mm to 50 mm 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.
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 & 28. ATTENTION: Do not attempt to repair the gas valve. If found defective, replace the entire valve. Attempts to repair it will void the warranty. 1. Turn pump, gas supply, and heater power “OFF”. 2. Disconnect the union joint in the gas supply piping outside the heater cabinet. 3. Remove the front access panel.
IGNITER: Refer to Figures 21 and 26. To remove the igniter: 1. Turn pump, gas supply, and heater power “OFF”. 2. Remove the front access panel. It is secured with (1) screw. 3. Disconnect the high voltage wire from the DSICM. 4. Remove the (1) screw from the igniter access panel. Withdraw the access panel by sliding along the high voltage wire. 5. Disconnect high voltage wire from igniter. 6. Remove the (2) screws that secure the igniter. 7.
SECTION V. CONTROL LOCATIONS The following sections give a brief overview of the various heater controls and service/replacement procedures. The text describes the function of the controls. See Figure 21. ELECTRICAL WIRING: ATTENTION: If it is necessary to replace any of the original wiring, it must be replaced with Hayward supplied replacement parts.
To remove the blower air pressure switch: 1. Turn pump, gas supply, and heater power “OFF”. 2. Remove the front access panel. It is secured with (1) screw. 3. Remove the wires from the pressure switch. 4. Pull the tubing from the hose barb on the switch. 5. Remove the (2) screws that secure the pressure switch to the control panel. 6. Replace the switch. Reverse steps 1-6 to complete the procedure.
THERMISTOR: Figure 33: Thermistor The thermistor monitors the return water temperature. See Figure 31 for its location. To replace the thermistor: 1. Turn pump, gas supply, and heater power “OFF”. 2. Drain the heat exchanger of all water. 3. Remove the front access panel. It is secured with (1) screw. 4. Unplug the thermistor connector from the thermostat control board. 5. From outside the heater, pull the thermistor leads out of the control box and through the hole in the heater chassis. 6.
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 is the reversal of steps 1-4.
SECTION VI. TROUBLESHOOTING 43 GENERAL: ATTENTION: These instructions are intended for the use of qualified personnel trained and experienced in the installation and servicing of this type of heating equipment and its related system components. Some states may require installation and service personnel to be licensed. Persons not qualified should not attempt to repair this equipment according to these instructions. These instructions and procedures are not for the use of “do-it-yourself” consumers.
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 Description Information Limit string open while call-for-heat 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.
DSICM ERROR CODES: If the display appears as if the unit is functioning normally, but unit will not light, remove front access panel and inspect the DSICM fault indicator LED. DSICM FAULT CONDITIONS ERROR MODE: LED INDICATION: Internal control failure Steady On Air flow fault 1 Flash Flame with no call for heat 2 Flashes Ignition lockout 3 Flashes Figure 37: TROUBLESHOOTING Display Fault Heater will not power up. None Open F101 Fuse None Diagnosis Step 1.
TROUBLESHOOTING continued Display Fault Diagnosis Step Remedy Sb Keypad Failure 1. Keypad is defective Replace Display Interface Assembly. SF Temperature sensor input failure 1. Check for faulty wiring or connection. Inspect sensor wiring. Ensure sensor is plugged into back of control module. If OK, proceed to step 2. 2. Sensor is defective Replace temperature sensor. Bypass Operation 1.
TROUBLESHOOTING continued Display Normal Heating Fault Burner is not operating when the “Heating” LED is illuminated Diagnosis Step Remedy 1. Ensure gas supply shutoff valves are open. Ensure that the main gas shutoff installed adjacent to the heater is open. Ensure that knob on Gas Valve inside unit is in “on” position. If OK, proceed to step 2. 2 Check to see if manual reset limit is tripped Press red button on control panel to reset limit, refer to page 23 for placement of manual reset limit.
TROUBLESHOOTING continued Display Normal Heating DSICM CODE 3 Flashes Fault Diagnosis Step Remedy 1. Ensure gas supply shutoff valves are open. Ensure that the main gas shutoff installed adjacent to the heater is open. Ensure that knob on Gas Valve inside unit is in the “ON” position. If OK, proceed to step 2. 2. Check to see if manual reset limit is tripped. Press red button on control panel to reset limit, refer to page 23 for placement of manual reset limit.
HAYWARD POOL HEATER CERTIFICATE OF LIMITED WARRANTY 49 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 speciĮed).
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 authorisaƟon is provided, no returns will be received directly from end consumers by Hayward Pool Products.
2 5 8 1 28 13 12 14 4 6 10 10 31 3 7 9 11 17 16 15 18 20 19 25 24 35 38 27 32 30 36 33 37 39 29 34 Plastic Header (Non-ASME) USEModels ONLY HAYWARD GENUINE REPLACEMENT PARTS Hayward Pool Products (Australia) Pty Ltd. Tel: 1300 POOLS1 www.hayward-pool.com.
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO.
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SPECIFICATIONS Total Nominal Gas Consumption Model H150FDAU H250FDAU H400FDAU Natural Gas 158 MJ/h 264 MJ/h 422 MJ/h Propane Gas 158 MJ/h 264 MJ/h 422 MJ/h Nominal Heat Output 36.05 kW 60.08 kW 96.13 kW Gas Pressure Fuel Manifold Inlet, Minimum Inlet, Maximum Natural (kPa) 0.45-0.50 1.12 2.61 Propane (kPa) 1.70-1.75 2.24 3.24 Burner Configuration Natural Gas Main Burner Main Injector #25 Propane Gas Main Burner Main Injector (mm) 2.
NOTES
Hayward Pool Products, Inc. 620 Division St. Elizabeth, NJ 07207 Hayward Pool Products, Inc. Hayward Pool Products, Inc. 2875 Pomona Boulevard 2880 Plymouth Drive Pomona, CA 91768 Oakville, Ontario L6H 5R4 © 2013 Hayward Printed in U.S.A. Hayward S.A.
