Hayward ABG135 Service & Installation Manual Download

Page: 46 / 49

Pomona, CA Clemmons, NC Nashville, TN

Tel: 908-355-7995 www.hayward-pool.com

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS

ITEM

PART NO.

DESCRIPTION

IDXLJKT1135

JACKET TOP - H135ID/ABG135

IDXLFAD1135P

FRONT ACCESS DOOR ASSY - H135ID, PLATINUM -NO CONTROLS

IDXLFAD1135B

FRONT ACCESS DOOR ASSY - ABG135, BLACK - NO CONTROLS

FDXLFCS1931

FLUE COLLECTOR SIDE PANEL W/O TEMPERATURE LIMIT

IDXLBBN1135

BLOWER INLET BAFFLE - 135K BTU HEATER

FDXLIAC1930

IGNITER

ACCESS

COVER

FDXLGSV0001

GAS VALVE, NATURAL

FDXLGSV0002

GAS VALVE, PROPANE

IDXLBON1135

BURNER ORIFICE KIT, NATURAL - 135K BTU HEATER

IDXLBOP1135

BURNER ORIFICE KIT, PROPANE - 135K BTU HEATER

FDXLMAN1150

GAS MANIFOLD - 135K / 150K BTU HEATER

FDXLGCK1135NP

CONVERSION KIT, NA TO LP, QUICK-CHANGE - 135K BTU HEATER

FDXLGCK1135PN

CONVERSION KIT, LP TO NA, QUICK-CHANGE - 135K BTU HEATER

FDXLBWR1930

COMBUSTION

BLOWER

FDXLBVS1930

BLOWER VACUUM SWITCH

FDXLICB1930

INTEGRATED CONTROL BOARD

FDXLIGN1930

IGNITOR

IDXLFLS1930

FLAME

SENSOR

IDXLTRF1135

TRANSFORMER - 135K BTU HEATER

FDXLWPS1930

WATER PRESSURE SWITCH

IDXLBKP1135

BEZEL & KEYPAD ASSEMBLY

FDXLHLI1930

HIGH LIMIT KIT

FDXLTER1930

THERMISTOR

FDXLGSK1934

GASKET, CC FRONT/AIR BOX - ALL MODELS

FDXLHXA1150

HEAT EXCHANGER ASSY - 135K BTU HEATER

FDXLFHD1930

INLET/OUTLET HEADER ONLY

FDXLFHA1930

INLET/OUTLET

HEADER

ASSY

FDXLHDW1930

HEADER HARDWARE KIT

FDXLHMB1930

HEADER MOUNTING BASE KIT

FDXLBKP1930

BYPASS CARTRIDGE KIT

FDXLCRN1930

HEADER CARTRIDGE RETAINING NUT

SPX4000FG

DRAIN PLUG WITH GASKET

FDXLPRM1930

RETURN MANIFOLD REPLACEMENT KIT

CHXPLG1930

3/4” BRASS PLUG

NOT SHOWN:

CHXRLV1930

PRESSURE RELIEF VALVE

IDXLGSK1135

GASKET KIT - 135K BTU HEATER

INCLUDES:

GASKET, FLUE COLLECTOR SIDE

GASKET, BLOWER MOUNTING

GASKET, IGNITER COVER

GASKET, COVER/AIR BOX FRONT

GASKET, MANIFOLD/AIR BOX

FDXLGSK1933

INSULATION, RETURN SIDE TUBE SHEET

FDXLBRN1931

BURNER (QTY 1)

FDXLFOR1930

HEADER O-RING KIT

SERVICE PARTS

Summary of Contents for ABG135

Page 1: ...r 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 POOL AND SPA HOT TUB HEATERS H135ID ABG135 MODELS SERVICE INSTALLATION MANUAL FOR YOUR SAFETY This product must be installed and serviced by authorized personnel qualified in pool spa heater installation Improper inst...

Page 2: ...rature adjustment 24 Temperature lock out 25 Fahrenheit v Celsius 25 Heating mode 25 Retry Failure of light 26 Recycle Loss of flame 26 Keypad inputs 26 Automatic reset time 27 Periodic inspection 27 Winterization 27 Draining the heat exchanger 28 Spring start up 28 Section IV Technician Service 29 General 29 Maintenance 29 Heat exchanger inspection and cleaning 29 Combustion chamber 30 Burner ins...

Page 3: ...ter 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 origi nal integrity...

Page 4: ...isembowelment 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 resulti...

Page 5: ...perty damage severe personal injury or death Before servicing pool and spa water circulation system all system 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 r...

Page 6: ... 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 7 Persons with a medical history of heart dise...

Page 7: ...royed by improper maintenance exces sive water hardness incorrect water chemistry or freezing it is not covered under the manufacturer s warranty MAINTAINING PROPER WATER CHEMISTRY WARNING Failure to maintain proper water chemistry may cause premature heat exchanger damage or failure The heat exchanger in your Hayward pool heater is made from the highest quality of copper and nickel Cupronickel ma...

Page 8: ...revent high chemical concentrations from back flowing into the heater Make sure your piping arrangement meets the chlorinator installation requirements shown on page 16 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...

Page 9: ...an Electrical Code Part I SECTION II INSTALLATION LOCATING THE HEATER Locate the pool spa hot tub heater in an area where leakage of the heat exchanger or connections will not result in damage to the area adjacent to the heater or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan with drain outlet be installed under the heater The pan must not restr...

Page 10: ...ets see Figure 01 In Canada the heater must be installed with the top of the vent at least 10 feet 3m below or to either side of any opening into a building Table 2 Outdoor Installation Clearances Heater Panel Required Clearance Top Unobstructed Front 18 inches Back 6 inches Water Connection Side 12 inches Side Opposite Water Connec tion 6 inches 4 ft Minimum 4 ft Minimum 3 ft Minimum 10 ft Minimu...

Page 11: ... HAYWARD GENUINE REPLACEMENT PARTS 11 Figure 02 Sub Assemblies Top Jacket Flue Transition Top Cap Flue Collector Side Panels Heat Exchanger Assembly Pressure Switch Port Temperature Limit Switches Left Side Jacket Right Side Jacket Front Access Panel Heat Exchanger Cover Rear Jacket ...

Page 12: ...ithout exception Based upon an inlet pressure of 0 5 psig or less at a pressure drop of 0 5 in wc Based upon an inlet pressure of 11 in wc at a pressure drop of 0 5 in wc Table 3 Gas Pipe Sizing Low Pressure Single Stage Regulaion Distance from Gas Meter or Tank Regulator Outlet to Heater Gas Valve Inlet Gas Type Natural Gas Propane btu hr input 135 000 135 000 135 000 Line Material Iron or Plasti...

Page 13: ...e 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 applia...

Page 14: ...1 5 flexible hose fittings Assemble all water connection components as shown in Figure 05 Assemble these parts to the heater prior to plumbing Tighten all nuts securely ensuring a seal with the rubber gaskets before connecting flexible hose The CPVC flanged pipe nipples and reducers must be installed on the heater inlet and outlet without modi fication Pipe fittings valves and any other element of...

Page 15: ...o prevent drainage of water in the heater during a filter change For installation below the pool spa surface refer to Section III Figure 09 Heater installation above pool spa is within the range for the heater See Table 5 The minimum flow rate is to be calculated or measured with the in floor cleaning system in use if the pool is so equipped as well as any other jets or other demands on the water ...

Page 16: ...of pipe thread sealant or Teflon tape on the threads Install the pres sure relief valve with the discharge connection facing the ground If necessary connect a pipe of the same size as the valve outlet to the outlet and run it to a safe place of discharge Do not install any shut off or restriction in this drain line ELECTRICAL SPECIFICATIONS WARNING It is required that licensed electricians do all ...

Page 17: ...shown in Figure 12 Replace the plastic plug on the right side of the heater with the supplied star bushing and run remote wiring through the bushing to the external thermostat or switch Use 3 16 male quick connects to attach field supplied wiring to remote harness 2 WIRE REMOTE CONTROL CONNECTION To configure the heater for 2 wire remote thermostat control use the MODE key on the heater keypad to ...

Page 18: ...NE REPLACEMENT PARTS 18 1301300301 Rev A Wiring Connection Diagram Schéma de Connexion de Câblage Forced Draft Gas Heaters Chaudière Gas à Air pulsé Flue Gas Temperature Limit Switch Commutateur limiteur de température des gaz de combustion 120VAC 3 Prong Plug Figure 13 Wiring connection diagram ...

Page 19: ...Figure 14 Lighting Operating Instructions label 1919 ...

Page 20: ... 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 SECTION III INSTALLER CHECK OUT AND START UP Transfo...

Page 21: ...me 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 Refer to Figure 1616 for the location components used ...

Page 22: ...T ADJUSTMENT PROCEDURE The pressure switch is preset at the factory for most typical deck level installations When the heater is located above or below the level of the pool or spa the pressure switch may require adjustment to compensate for the change in static head pressure The following procedure is recommended when the switch needs adjustment and or is replaced For Installations with Heater Ab...

Page 23: ...Turning the adjustment knob clockwise increases the pressure needed to close the switch 5 Check the function of the pressure switch by turning the filter pump on and off several times The pool heater should turn off immediately when the pump is turned off Never allow the heater to operate with less than the minimum rated water flow rate TWO SPEED PUMP In a few cases the pressure from a two speed p...

Page 24: ...e use the UP and DOWN buttons The numeric display will flash to indicate the temperature setting is being displayed adjusted When the numeric display is not flashing the actual water temperature is being displayed The temperature settings for both SPA and POOL modes are initially set at the factory to 65 F The minimum allowed settings for SPA and POOL modes are both 65 F The maximum allowed settin...

Page 25: ... will return to STANDBY mode FAHRENHEIT VERSUS CELSIUS The temperature can be displayed in Fahrenheit or Celsius To change the display use the MODE button to place the heater in STANDBY Then press and hold the UP and MODE buttons until the display shows the F C selection Press the DOWN button to toggle between selections To accept the selection press the MODE button If the user does not act the se...

Page 26: ...d within 0 8 seconds 1 The control de energizes the gas valve and the blower 2 The control monitors for open contacts at the blower vacuum switch 3 The control performs a gas valve relay check 4 A normal ignition sequence resumes with Item 2 in Heating Mode page 25 5 If the tenth ignition trial fails the control enters a safety lockout or hard lockout after the post purge period of the tenth faile...

Page 27: ...or heaters that soot up due to improper gas level in the tank resulting in inadequate gas volume 5 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 6 Do not use the heater if any part has been under water Contact a qualified service technician to insp...

Page 28: ... on the valve see Figure 1616 4 Turn the heater s gas supply OFF at the main shut off valve outside the heater cabinet 5 Be sure the circulating pump is OFF 6 Remove the plastic drain plug see Figure 1818 7 Allow all water to drain from the heater 8 Re install the plastic drain plug SPRING START UP 1 Inspect and clean the heater being sure the heater is free of leaves and debris prior to startup 2...

Page 29: ...changer 2 Main burner flame patterns 3 Main burner orifices 4 Operating controls HEAT EXCHANGER INSPECTION AND CLEANING Remove the Top Jacket and Flue Transition Top Cap see Figure 2 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 Before beginning be aware that it is not necessary to r...

Page 30: ...HAMBER The combustion chamber is a single piece casting If damaged the entire chamber must be replaced 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 1515 The main burner flames should be about to 2 in height and should not lift off the burner ports see Figure 1919 A normal flame is...

Page 31: ...eplace 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 4 Disconnect the wires from the two terminals on the gas valve 5 Remove the gas manifold assembly It is attached to the air box using 4 screws 6 Unscrew the gas valve from th...

Page 32: ...as valve 5 Remove the gas manifold assembly It is attached to the air box using 4 screws 6 Remove the orifices using a 7 16 wrench 7 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 ATTENTION Do not enlarge orifice holes GAS CONVERSION The factory installed gas train may be changed from natural gas to ...

Page 33: ...sufficient airflow for combustion Figure 15 shows the location of the blower vacu um switch in the heater cabinet When the blower achieves sufficient airflow the negative pressure created in the blower housing closes the contacts on the blower vacuum switch indicating to the ignition control board that it is safe to continue the ignition sequence A silicone tube connects the blower vacuum switch w...

Page 34: ... transition top cap and heat exchanger cover see Figure 02 3 Unplug the two wires from the exhaust gas temperature limit located in the flue collector panel above the middle of the header 4 Unscrew the 2 screws securing the limit to the panel and remove the limit and gasket 5 Place the new limit and gasket in place and reverse the above steps to complete the procedure THERMISTOR The thermistor mon...

Page 35: ...closes See Figure 15 and Figure 20 To replace the blower 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel 3 Disconnect the blower from the ignition control board 4 Disconnect the tubing from the hose barb on the blower housing 5 Remove the blower from the air box cover 4 screws 6 Remove the blower air inlet plate from the blower 5 screws 7 Reverse the above steps to reas...

Page 36: ...ode of LO If there is a call for heat and the pump then restarts there will be a 2 minute delay for the heater to fire After the pump has been running for at least 2 minutes there is no delay for heater operation Wiring the heater to the load side of the timer or controller will not result in a 2 minute delay if the pump primes quickly enough to activate the heater s water pressure switch If the p...

Page 37: ...tch open error If the blower proving switch does not close after the blower starts the control will stop the ignition trial and go into lockout The blower will continue to run Automatic reset is immediate after the switch closes AO Blower vacuum switch open when expected closed error If the blower proving switch opens unexpectedly during operation the control will shut down and attempt to re light...

Page 38: ...d error If one of the keypad buttons is closed or pressed for more than 30 s the error code will be displayed but the control will continue to function The error code will be cleared when the condition is corrected IF Ignition failure error If the control exceeds the maximum number of ignition retries or recycles the heater will shut down and go into lockout Automatic reset is 60 minutes CE Commun...

Page 39: ...lve terminals and between each terminal and ground If short exists replace Gas Valve If OK proceed to step 3 3 Check for faulty Control Module wiring Inspect Control Module wiring Ensure insulation on wiring is not worn If OK proceed to step 4 4 Control Module is defective Replace Control Module bD Bad Board or Secondary High Voltage Fault 1 Check for defective Harness Disconnect plug from E10 con...

Page 40: ... Verify set point setting of remote thermostat is at or below 104 F If set point of remote thermostat is OK or if heater is not configured for remote thermostat proceed to step 2 2 Verify that the water flow is adequate Verify that water flow to heater is above minimum required 20 GPM Note that intermittent periods of low water flow will cause this error If OK proceed to step 3 3 Check inlet water...

Page 41: ...ring or connection Inspect temperature limit switch wiring Ensure wire harness teminals are securely fastened to spade terminals on temperature limit switches If OK proceed to step 2 2 Verify state of temperature limits contacts Remove wire leads from limit switch and jumper leads Operate heater Measure continity across limit switches If closed LO code is not caused by temperature limit switch fau...

Page 42: ...relay is defective Replace control module If OK proceed to step 2 2 Vacuum switch is defective Replace blower vacuum switch AO Blower vacuum switch open 1 Check for faulty vacuum switch tubing Check tubing and replace if necessary If OK proceed to step 2 2 Check for faulty vacuum switch wiring or connection Inspect vacuum switch wiring Ensure wire harness terminals are securely fastened to spade t...

Page 43: ...rviced by a licensed and qualified pool equipment professional with sufficient experience in pool equipment installation and maintenance and adhering to the requirements of the jurisdic tion where the product is installed There are no warranties which extend beyond the description on the face hereof We shall not in any event be held liable for any special indirect or consequential damages EXPENSE ...

Page 44: ...nspections repairs or to furnish replacements This warranty is intended as a legally binding obligation of Hayward Industries Inc enforceable in the courts This warranty may give you specific legal rights which may vary from state to state LIMITATION ON LIABILITY All intended representations have been expressly set forth in this document This warranty may not be extended by oral or any other addit...

Page 45: ...ona CA Clemmons NC Nashville TN Tel 908 355 7995 www hayward pool com USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 45 1 3 2 16 14 11 10 19 6 7 8 5 9 4 13 27 25 24 23 26 17 20 28 22 21 15 18 12 SERVICE PARTS ...

Page 46: ... BLOWER VACUUM SWITCH 11 FDXLICB1930 INTEGRATED CONTROL BOARD 12 FDXLIGN1930 IGNITOR 13 IDXLFLS1930 FLAME SENSOR 14 IDXLTRF1135 TRANSFORMER 135K BTU HEATER 15 FDXLWPS1930 WATER PRESSURE SWITCH 16 IDXLBKP1135 BEZEL KEYPAD ASSEMBLY 17 FDXLHLI1930 HIGH LIMIT KIT 18 FDXLTER1930 THERMISTOR 19 FDXLGSK1934 GASKET CC FRONT AIR BOX ALL MODELS 20 FDXLHXA1150 HEAT EXCHANGER ASSY 135K BTU HEATER 21 FDXLFHD193...

Page 47: ...PLACEMENT PARTS 47 ITEM PART NO DESCRIPTION SERVICE PARTS FDXLEGL1930 EXHAUST GAS TEMPERATURE LIMIT ONE USE IDXLWHA1135 WIRING HARNESS KIT COMPLETE FDXLFSKC30 FUSE KIT 3 0A FOR INTEGRATED CONTROL BOARD QTY 10 IDXLUKT1135 UNION KIT INCLUDES FITTINGS UNION NUTS GASKETS SP1493 COUPLING FOR FLEXIBLE HOSE ...

Page 48: ...nifold 1 8 2 0 w c 6 8 7 0 w c Inlet Minimum 4 5 w c 10 0 w c Inlet Maximum 10 5 w c 13 0 w c ORIFICE SIZES Models Natural Gas Propane Gas H135ID ABG135 0 143 2 10mm WATER FLOW REQUIREMENTS Model Minimum Maximum H135ID ABG135 20 125 Hayward Pool Products Inc 620 Division St Elizabeth NJ 07207 Hayward Pool Products Inc 2875 Pomona Boulevard Pomona CA 91768 Hayward Pool Products Inc 2880 Plymouth Dr...

Page 49: ...Pomona CA Clemmons NC Nashville TN Tel 908 355 7995 www hayward pool com USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 49 NOTES ...

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