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In ground pool/spa gas heaters
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- Troubleshooting manual (57 pages)
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- Contents
- Table of Contents
- Troubleshooting
- Bookmarks
Table of Contents
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Table of Contents
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Getting Started
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Installation
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Locating the Heater
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Gas Conversion Procedure
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Altitude of Installation
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Air Supply
- Flue Gas Venting
- Gas Supply
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Water Piping
- Electrical Connections
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Control Setup
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Gas Testing
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Water Chemistry
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Winterization
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Spring Start-Up
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- Troubleshooting
- Service Parts
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Quick Links
- 1 Installation
- 2 Flue Gas Venting
- 3 Gas Supply
- 4 Electrical Connections
- 5 Control Setup
- 7 Troubleshooting
- 8 Service Parts
- Download this manual
IN GROUND POOL/SPA GAS HEATERS
INSTALLATION & OPERATIONS MANUAL
FOR YOUR SAFETY
WARNING:
If the information in these instructions is
not followed exactly, a fire or explosion may result caus-
ing 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.
Do not touch any electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instruc-
tions. 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 sup-
plier.
FOR YOUR SAFETY:
This product must be installed and serviced by au-
thorized personnel, qualified in pool/spa heater in-
stallation. Improper installation and/or operation
can create carbon monoxide gas and flue gases
that can cause serious injury, property damage, or
death.
SAVE THESE
INSTRUCTIONS
ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS
CONTENTS
GETTING STARTED
INSTALLATION
LOCATING THE HEATER
GAS CONVERSION PROCEDURE
ALTITUDE OF INSTALLATION
AIR SUPPLY
FLUE GAS VENTING
GAS SUPPLY
WATER PIPING
ELECTRICAL CONNECTIONS
CONTROL SETUP
GAS TESTING
WATER PRESSURE SWITCH SETUP
WATER CHEMISTRY
WINTERIZATION
SPRING START-UP
TROUBLESHOOTING
SERVICE PARTS
51300803801REVB
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Table of Contents
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Summary of Contents for Hayward HDF400
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Page 1: Table Of Contents
This product must be installed and serviced by au- thorized personnel, qualified in pool/spa heater in- stallation. Improper installation and/or operation can create carbon monoxide gas and flue gases that can cause serious injury, property damage, or death. SAVE THESE INSTRUCTIONS ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 1... -
Page 2: Getting Started
DISCONNECT ISPOOL/SPAIN WATERPIPINGTO NO CHEMICALBALANCE? PRODUCT PRODUCT OPEN CONNECTWATERPIPINGTOPRODUCT,BYPASSTOOPENPOSITION POOL/SPA SETBYPASSTO OPENPOSITION, ISHEATING/COOLING NO WATERDIVERTED NEEDEDWITHIN1WEEK? FROMPRODUCT PRODUCT CLOSED BYPASSTOCLOSEDPOSITION,WATERDIRECTEDTOPRODUCT POOL/SPA TURNONELECTRICPOWERAND GASASREQUIRED. STARTPRODUCT.PROGRAMREQUIREDWATER TEMPERATUREONPRODUCTCONTROLPANEL. ENJOYYOURPOOL/SPA TURNOFFELECTRIC ISHEATING/COOLING NO POWERANDGASAS NEEDEDFORRESTOFYEAR? REQUIRED 2 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS... - Page 3 It can also make consumers aware of actions that are unpredictable and unsafe. NOTICE indicates special instructions that are important but not related to hazards. See product rating plate for manufacturer’s information. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 3...
- Page 4 Figure 1: HEATER CONSTRUCTION AND SUB-ASSEMBLIES Control Access Panel Assembly Cabinet Top Control Assembly Exhaust Box Assembly Combustion Bower and Gas Manifold Assemblies Zero Clearance Panel (Both Sides) Burner Exhaust Side Panel Combustion Chamber Assembly Header Controls Cover Water Side Panels Cabinet Base 4 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 5 Integralwaterbypasstomaintaincorrectwaterflowthroughtheheatexchanger.Maximumwaterflowthrough theunitis125GPM. Model GasInput Minimum Thermal Heater Heater NaturalorPropane WaterFlow Efficiency Width Weight Btu/hr GPM % in. lbs. HDF400 400,000 30 84 21 135 GAS REQUIREMENTS OPERATINGPRESSURES NaturalGas PropaneGas GasManifoldPressure*[in.wc] ‐0.1to‐0.3 GasInletPressure,Minimum[in.wc] 4.0 4.0 GasInletPressure,Maximum[in.wc] 14.0 14.0...
- Page 6 The unit wiring diagram is shown in Figure 2. A separate diagram is included in the electrical accessory kit supplied with your unit. This kit is located in the low voltage junction box on the exhaust side of the unit. For more detailed troubleshooting and service instructions. Please refer to HDF Service Kit Instructions supplied with any service part and available on Hayward’s website. 6...
- Page 7 51300803801REVB Figure 2: Wiring Diagram ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 7...
- Page 8 Install two or more suction outlets per pump in accordance with latest ASME, APSP Standards and CPSC guidelines. Follow all applicable National, State, and Local codes. Installation of a vacuum release or vent system, which relieves entrapping suction, is recommended. 8 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 9 GFCI is defective. If the GFCI interrupts power to the electrical equipment without the test button being pushed, a ground current is flowing, indicating the possibility of an electrical shock. Do not use this electrical equipment. Disconnect the electrical equipment and have the problem corrected by a qualified service representative before using. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 9...
- Page 10 Inches of Mercury (inHg) is typically used with atmospheric pressure measurements. Pounds per square inch (PSI) is typically used with water “pressure”, “suction” or system measurements. Inches of Water (inwc) is typically used with gas or air pressure measurements (1.0 inHg = .49 PSI = 13.5inwc) 10 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
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Page 11: Installation
You may also consider protecting the unit by eachofthefour creating a physical barrier outside of the minimum clearances be- corners.(4)screws tween the unit and the prevailing beachfront wind. Damage caused total by sand or salt spray is not covered by the warranty. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 11... -
Page 12: Locating The Heater
(consult NFGC) Table 3: Installation Required Clearances (in.) HeaterPanel OutdoorClearance IndoorClearance Top Unobstructed 36 Front 18 18 (UserInterface) Back* 0** 0** WaterSideConnec on 12 12 ExhaustSideConnec on* 6 6 * Iftheheateristobeinstalledwithvinylsidingbehindorontheexhaustsideoftheheater,increasetheclearanceinTable3to12inches toavoidpoten aldiscolora onofsiding. **Whiletheheaterisdesignedfornoclearancetocombus blesurfaces,itisrecommendedtoleaveasmallgapfornon‐bindingremoval ofthetopaccesspanels. 12 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS... - Page 13 3. Install the Tapcons® through the provided holes in the flanges of the heater feet with the washers on the top of the mounting flanges into the equipment pad. 4. Anchoring is completed when all (4) feet are secured to the pad with washers and Tapcons®. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 13...
- Page 14 Because of this, observations of how much condensation is created by the unit will vary greatly. Consideration has gone into the design of Hayward’s HDF series pool heater to allow any moisture in the combustion chamber to drain out of the unit. Not allowing moisture to dwell in the unit will increase the life and reliability of your new pool heater.
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Page 15: Gas Conversion Procedure
GAS CONVERSION PROCEDURE: These instructions are intended to be used only with the HDF gas pool heaters from Hayward. All HDF heaters are shipped from the factory ready to be installed and used with Natural Gas. If your application requires the use of propane gas (LP), the fuel/air mixer installed in the com- bustion blower inlet must be replaced with the fuel/air mixer designed for use with propane. -
Page 16: Altitude Of Installation
51300803801REVB ALTITUDE OF INSTALLATION: Hayward’s HDF heaters are rated for installations up to, and including, 2,000 ft above sea level. WARNING: Failure to comply with the appliance installation and service instructions in this manual may result in equipment damage, fire, asphyxiation, or carbon monoxide poisoning. Exposure to products of incomplete combustion (carbon monoxide) can cause cancer and birth defects or other reproductive harm. - Page 17 A) 1 sq. in. per 4,000 Btu/hr of total input Figure 9: Air Below-Ground (Pit for Natural Gas Installations ONLY) 1 sq. in. per 4,000 Btu/hr of total input Table 3 Indoor Clearance Apply B) 1 sq. in. per 2,000 Btu/hr of total input ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 17...
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Page 18: Flue Gas Venting
Material Requirement Vent pipe to be installed ac- Single or Double Vertical Vent- cording to the venting tables in Wall, Galvanized, HDF400 ing Applica- the National Fuel Gas Code Vertical Only Non-Sealed Vent tions (ANSI Z223.1/NFPA 54) for a Pipe Category I gas appliance. - Page 19 They can be ordered directly from the manufacturer, or one of their authorized dealers. To locate an authorized 1 45 dealer for venting parts, contact the appropriate manu- facturer at: 2 35 SelkirkCorpora on Hea abDivision 3 25 130IndustrialBlvd TurnersFalls,MA01376 (800)772‐0739 www.hea ab.com Hea abSaf‐TVentEZSeal(CIPlus) ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 19...
- Page 20 Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat exchangers. Do not vent under a deck or large overhang. Recirculation could occur and cause performance or system problems. 3. 20 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 21 (2) In accordance with the current CAN/CSA B149.1, Natural Gas and Propane Installation Code For clearances not specified in ANSI Z223.1 / NFPA 54 or CAN/CSA B149.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 21...
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Page 22: Gas Supply
Total piping length Distance from tank or length of First 100 to 150 regulator to gas valve Stage* inlet (ft) or 2nd stage 100 to 200 1-1/2 1-1/4 regulator 200 to 300 1-1/2 Second Stage** 0 to 10 22 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS... -
Page 23: Water Piping
Figure 13: Water Connections Figure 14: Bypass Valve(s) WARNING: EXPLOSION HAZARD Blockage of water flow from heater return to pool may result in fire or explosion caus- ing property damage, personal injury, or loss of life. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 23... - Page 24 Figure 15 illustrates a typical pool piping diagram and layout for the pool equipment. Figure 16 illustrates a multiple heater installation for very large pools with and without a manual bypass valve. Figure 15: Typical Plumbing to Pool or Spa Figure 16: Multiple Heater System 24 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
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Page 25: Electrical Connections
Risk of Electric Shock Review all safety information provided in the GETTING STARTED section of this manual prior to servicing. Always disconnect power circuit before servicing. This heater contains wiring that carries high voltage. Contact with these wires could result in death or personal injury. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 25... - Page 26 “Spa” the “SPA” LED will be illuminated and the water temperature will be displayed. The heater will use its internal thermostat to regulate the water temperature to the set point of the mode selected. 26 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 27 51300803801REVB Figure 19: Location of Components (Top and Side Panels removed for Clarity) Control Panel Assembly (See Fig. 20) Gas Valve Gas Manifold Combustion Blower (see Fig. 22) Burner Igniter / Flame Sensor Header (See Fig. 21) ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 27...
- Page 28 Figure 20: Control Assembly Components (Wiring Hidden for Clarity) Differential Pressure Switch Fuse Board Ignition Control Transformer Figure 21: Header Assembly Components Temperature Limits Water Pressure Integrated Bypass Switch Thermistor Outlet Header Inlet Header V-Header Pressure Relief Valve Port Drain Plug 28 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 29 51300803801REVB Figure 22: Combustion Blower Assembly Components Combustion Blower Negative Pressure Tap Fuel/Air Mixer Reference Pressure Tap Blower Gasket Gas Manifold Assembly Burner 29 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
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4SEC.MAX properly. When the thermostat is satisfied and the call for heat ends, the control immediately de-energizes the gas valve and flame extinguishes. The control operates FLAMESENSED, the blower an additional 30 seconds as a post-purge. IGNITIONSUCCESSFUL ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 30...
- Page 31 AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resume operation as detailed in NORMAL OPERATION FOR POOL & SPA MODES. The heater can be manually reset using the keypad by cycling the mode button through “STANDBY” and back to the original operating mode (“SPA” or “POOL”). 31 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
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Page 32: Gas Testing
WARNING: EXPLOSION HAZARD Gas pressures in excess of those listed in Table 11 could cause a gas leak or dia- phragm rupture. Gas leakage could cause an explosion resulting in severe injury or death. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 32... - Page 33 -0.1 to -0.3 Pressure* Inlet Pressure, +4.0 +4.0 Minimum Inlet Pressure, +14.0 +14.0 Maximum Figure 26: Gas Valve Gas Inlet Pressure Tap ON / OFF Switch Vent Tap Pressure Tap Manifold pressure Electric adjustment under Terminals screw cap 33 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 34 51300803801REVB Figure 27: Lighting and Operating Instruction Label (This label is also located on the inside surface of the Water Side Top Panel) ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 34...
- Page 35 If the pump and piping arrangement are such that the required 1-pound minimum pres- sure cannot be obtained, do not attempt to operate the heater. Correct the installation. NOTICE: Heater installation, checkout, and start-up should now be completed. BE SURE to leave this manual with the pool owner. 35 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
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Use a 4- way pool/spa water test kit to check your water frequently (at least weekly). Use the guidelines in Table 15 to help maintain proper water chemistry: ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 36...
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Page 37: Winterization
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 (see Figure 26). Allow all water to drain from the heater. Re-install drain plug. 37 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS... -
Page 38: Spring Start-Up
Insufficient air supply; Inadequate venting; High or low gas pressure; Blockage of burner or orifices; Blockage of blower inlet; Low voltage supply causing blower to “spin” slower; Improper heater location / installation; Incorrect gas supply pipe size; Excessive water flow through heat exchanger; or an LP tank below 30% full level. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 38... - Page 39 Pull the flame sensor straight back until resistance is felt. Rotate the flame sensor 180° and lift up and out to remove it from the combus- tion chamber. Remove the old gasket from the front of the combustion chamber. 10. Replace the gasket, igniter, and flame sensor and reverse the above procedure to reassemble unit. 39 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 40 Verify manifold pressure after replacing the fuel/air mixer. Instructions for manifold pressure measurements can be found in the GAS TESTING section of this manual on page 31 and following. NOTICE: Do not enlarge orifice holes. NOTICE: All replacement wiring must be replaced with manufacturers supplied replacement parts. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 40...
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Page 41: Troubleshooting
WARNING: UNDER NO CIRc*msTANCES SHOULD FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNERS, BE USED OR STORED IN THE VICINITY OF THE HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE HEAT- ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 41... - Page 42 3 s of power-up or is lost for 30s during operation unit will shut down and error will be displayed. The error code will be cleared upon a valid data exchange between boards. EEPROM error An error was detected in the ignition control board. 42 ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS...
- Page 43 (5 °F or more) or a sensor “out of bounds” condition with either thermistor (less than 10°F or greater than180°F) will result in unit shut down and the error code displayed. Automatic restart is 2 minutes after the error is cor- rected. ONLYUSEGENUINEHAYWARDREPLACEMENTPARTS 43...
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Page 44: Service Parts
The following repair parts are available from Hayward and through your local distributor. When ordering parts, include the complete pool heater model number listed on the unit’s rating plate, located near the junction boxes on the exhaust side of the heater. (Example: HDF400) All ser- vice must be performed by a qualified technician.
