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Hayward H150FDN Troubleshooting Manual Download Page 62

1. Remove black metal Trim Plate (around water manifold, 5 Black screws) 
2. Remove water connection side Upper End Cap (Black Polymer- 4 screws in 

rectangle holes marked with an arrow) 

3. Disconnect Unions from plumbing (water connections, 1 inlet, 1 outlet.) 
4. Remove (8) ½” hex head bolts ( 4 on each side-inlet and outlet) 
5. Remove water manifold (also called the “Header”) and black polymer 

“Mounting Blocks” to expose the ends of the heat exchanger tubes. 

6. If there is any doubt as to whether or not there is damage from aggressive 

water chemistry: take 3 pictures, 1 of each pair of tubes (inlet side and outlet 
side), as well as the Model & Serial number decal, and send to your local 
technical representative, or call (908) 355-7995 for further instructions.

 

62 

Heat Exchanger: Inspection 

Heat Exchanger tubes should look like this picture 

Summary of Contents for H150FDN

Page 1: ...HxxxFD N P ASME Universal HSeriesHeaters Troubleshooting Guide HxxxFD N P TSG UHS16b Copyright 2017 Hayward Industries Inc ...

Page 2: ...burn cause serious injury and or death To reduce the risk of electrocution and or electric shock hazards Only qualified technicians should remove the panel Replace damaged wiring immediately Insure panel is properly grounded and bonded 2 Warning Safety Precautions ...

Page 3: ...art Numbers 19 20 1 Heater not powering up 21 26 2 Open FC1 FC2 Fuse 27 28 3 Open FC3 F1 Fuse 29 31 4 Open FC4 Fuse 32 33 5 BD Code 34 35 6 EE or CE Code 36 37 Troubleshooting cont Pg 18 64 7 IO or SB Code 38 39 8 SF or HS Code 40 41 9 PF Code 42 43 10 HF Code 44 45 11 LO Code 46 51 12 IF Code 52 55 13 AC Code 56 57 14 AO Code 58 60 Heat Exchanger Flow requirements 61 Heat Exchanger Inspection 62 ...

Page 4: ...C Temperature Sensor E2 D Display Output 24VAC E7 E 3A Fuse F1 F Low Voltage R C 24VAC E12 E13 G Gas Valve Safety Switches 24VAC E11 H High Voltage 120VAC E10 I Blower Inducer E6 J Ignitor E3 C H G F D E J I B A Integrated Control Board Layout ICB ...

Page 5: ...age improper wiring shorted transformer or fuse board FC1 FC2 E Transformer Primary 120 240VAC P3 F Transformer Secondary 24 left 120VAC right P4 G Fuse 1 5A protects transformer secondary will fail if short occurs between fuse ICB FC3 H Fuse 2 5A protects transformer high voltage secondary will fail with blower ignitor or ICB failure FC4 I Low Voltage Output 24VAC P5 J High Voltage Output 120VAC ...

Page 6: ...010 Newer Style Changes compared to older style fuse board G Fuse FC3 has been removed since the F1 fuse was added to the ICB H Fuse FC4 is now a 3A fuse matching the FC1 FC2 NOTE Fuses located on THIS board are all 250v SLO BLO 5 x 20 mm Hayward Part FDXLFSK19F30 Qty 10 G ...

Page 7: ... sense The blower will turn off for one second The ignitor is de energized at flame sense or at completion of 4 sec trial If the flame is sensed The blower vacuum switch control loop temp sensor flame sensor are constantly monitored during call for heat 5 When set temp is reached the control ends the call for heat The gas valve is de energized and the flame is extinguished 6 The blower will operat...

Page 8: ...equence 3 Retries 3 times until lockout IF code 4 Waits 60 minutes then retries 3 more times 5 Will continue to retry every 60 minutes until demand for heat is stopped NOTE When making keypad entries of any type there may be a 5 10 sec delay for certain situations 8 UHS Sequence of Operation Failure to Light ...

Page 9: ...HS Electrical Gas Connection Connections located on both the left right side of heater cabinet Low Voltage High Voltage Gas Supply Bonding Lug Electrical Gas connections as of September of 2008 Newer Style ...

Page 10: ...ns cont Fig 1 Ground connection Two Wire Remote Connection Orange Pool and White Common Three Wire Remote Connection Orange Pool White 24V Red Spa 120VAC or 240VAC Connection Electrical connections as of September of 2008 Newer Style ...

Page 11: ...d outside control box 11 Orange Pool White 24VAC Common Orange Pool White 24VAC Common Red Spa Three wire hook up Two wire hook up Electrical Control Connections cont Electrical connections prior to September of 2008 Older Style ...

Page 12: ...Universal H Series Heaters How To ...

Page 13: ...temperature set point is 104 F Press the MENU ICON button to place the heater in STANDBY Press and hold the minus button and MENU ICON button for 3 seconds bo should appear on the display when the heater has successfully entered bypass mode Once in bypass press the MENU ICON button until POOL or SPA is illuminated Step 2 Step 3 Step 4 Step 1 ...

Page 14: ...e the heater in STANDBY mode Press and hold the minus plus buttons for 3 seconds The SPA indicator should illuminate the display should show the Max Temp set point Raise or lower the temperature displayed using the minus or plus button Step 2 Step 1 Step 3 Step 4 Follow the included steps to place the heater in bypass mode for external control ...

Page 15: ...apidly Press the MENU ICON button to toggle to the POOL now that the SPA is set Raise or lower the temperature displayed using the minus or plus button To finalize press the MENU ICON button until the heater goes back into STANDBY Step 6 Step 5 Step 7 This feature is available on heaters manufactured after February 25th 2011 ...

Page 16: ...n energized as shown below The static load values should be within the levels listed on the data plate example on Page 17 Manifold reading should be between 1 8 2 0 w c for natural Gas or 6 8 7 0 w c for propane NOTE Please refer to Installation Manual for proper gas line sizing Step 1 Step 2 How To Test Adjust Gas Pressure ...

Page 17: ...fer to installation manual and or contact installer Verify heater specifications off the heater plate bottom front inside heater 17 How To Test Adjust Gas Pressure cont Step 3 Adjust the manifold pressure at the gas valve Remove plug Once removed increase pressure by rotating valve clockwise counter clockwise to reduce pressure Step 4 NOTE IF incoming gas pressure is within range then your manifol...

Page 18: ...Universal H Series Heaters Troubleshooting ...

Page 19: ...mmunication Error Between Control Module and Display Interface Assembly EE Bad board HF Flame present with Gas Valve not energized HS Maximum return water temperature exceeded and or rapid water temperature rise IF Ignition Failure IO Ignitor Circuit Open LO Water Pressure Switch Vent Pressure Switch or Temperature Limit Switch Fault PF Voltage polarity reversed low voltage detected SB Keypad fail...

Page 20: ...l Control Panel 400 FDXLBCP1500 Kit Bezel Control Panel 500 20 Troubleshooting Part Numbers Part Number H150 H400 Part Number H500 Description FDXLBWR1930 FDXLBWR1500 Blower FDXLIGN1930 FDXLIGN1930 Ignitor FDXLTER1930 FDXLTER1930 Thermistor temperature sensor IDXL2SNT1930 IDXL2SNT1930 Combustion Blower Tube Kit FDXLEGL1931 FDXLEGL1931 Exhaust Gas Limit Switch FDXLHLI1930 FDXLHLI1930 High Limit Kit...

Page 21: ... Section 2 Test 22 28VAC between R C on P5 fuse board Test transformer output for 22 28VAC Is voltage correct NO Replace fuse board FDXLFWP1930 NO Install correct plug and retest Replace harness and or reseat connection FDXLWHA1930 YES YES NO Test transformer input for 110 125VAC YES Is voltage correct Replace transformer IDXL2TRF1930 YES NO Is voltage correct YES Go to section B next page NO Repl...

Page 22: ...rness FDXLWHA1930 Section B continued from previous page Secure wiring plugs and retest Is voltage correct NO On ICB test 3A fuse for continuity Is fuse blown NO YES On the ICB verify 22 28VAC between AC COM pins 1 4 Replace fuse FDXLFSK1930 then go to section 3 Is voltage correct Replace the ICB FDXLICB1930 Replace display bezel keypad See Pg 20 NO YES ...

Page 23: ...IF correct go to 1D IF NOT correct source power Verify heater manufacture date Step 1A Step 1B IF voltage is present go to step 1D IF voltage is incorrect correct source power Models after August 2008 Step 1C 23 Verify selector plug matches incoming line power IF it does not power OFF correct IF OK go to 1E Voltage selector plug Step 1D 1 Heater Not Powering Up ...

Page 24: ...Step 1F Disconnect the P3 plug from the fuse board Test 110 125VAC between pins 1 2 and 3 4 on the board IF good go to 1H IF NOT replace the Fuse board pg 20 Test transformer input Step 1G 24 Disconnect P4 plug from fuse board Verify 22 28VAC between pins 1 2 red wires then 110 125VAC between pins 4 6 grey wires IF correct go to 1I IF incorrect replace transformer pg 20 Test transformer output Ste...

Page 25: ...ge replace Fuse Board pg 20 If correct go to step 1J Inspect wiring Inspect ICB wiring ensuring all plugs are securely fastened IF wiring is OK go to Step 1K IF NOT secure wiring plugs then retest Test P5 low voltage Step 1I 25 Step 1J 1 Heater Not Powering Up cont Disconnect and test the red and grey wires from the ICB IF 22 28VAC is present go to step 1L IF NOT replace wire harness pg 20 Test IC...

Page 26: ...e is blown replace it and go to section 3 IF Ok go to step 1M On the ICB verify 22 28VAC between AC COM terminals pins 1 4 IF voltage is present replace display bezel keypad IF no voltage replace ICB pg 20 Test ICB s display output 26 1 Heater Not Powering Up cont Step 1L Step 1M ...

Page 27: ...ll correct plug and replace fuse Did this correct the problem YES NO Is transformer wiring damaged pinched or worn Problem solved Test transformer resistance Correct repair transformer wiring YES NO Is resistance correct NO YES Replace transformer IDXL2TRF1930 Contact Support 908 355 7995 ...

Page 28: ...eplace transformer pg 20 IF OK go to 2C Verify voltage selector plug Step 2A With power off remove the P3 P4 plugs On the P3 plug measure resistance between the orange yellow wires for 1 9 2 9 Ohms then do the same between the black and brown wires IF resistance is out of range replace transformer pg 20 IF OK and problem still persists contact technical support 908 355 7995 Test transformer resist...

Page 29: ...vacuum switch wiring damaged pinched or worn YES Is gas valve wiring damaged pinched or worn NO NO YES Test gas valve wires for continuity against ground Replace gas valve pg 20 YES Inspect ICB wiring any wires compromised YES Replace wiring harness FDXLWHA1930 Replace ICB FDXLICB1930 NO Replace wire harness FDXLWHA1930 OR pressure switch if damaged FDXLWPS1930 Replace wire harness FDXLWHA1930 OR ...

Page 30: ... replace the wire harness pg 20 IF OK go to step 3C Inspect connections high limits Step 3A With power off inspect the blower vacuum switch wiring for damage IF damaged replace the wire harness pg 20 IF OK go to step 3D Inspect blower vacuum switch Step 3C 30 With power off inspect the gas valve wiring for damage IF damaged replace the wire harness pg 20 IF OK go to step 3E Inspect gas valve wirin...

Page 31: ... damaged replace the wire harness with a new wire harness kit pg 20 IF OK and the problem still exists replace the ICB pg 20 Verify gas valve is not shorted Step 3E 31 Step 3F 3 Open FC3 or F1 Fuse cont When testing the gas valve if continuity appears between any wires and ground then this implies a short has occurred and the gas valve will need to be replaced refer to pg 20 for part number ...

Page 32: ... Replace ignitor FDXLIGN1930 YES NO YES NO Is the resistance incorrect NO YES Ohm out blower for 8 9ohms before Sept 2010 OR for 4 5ohms after Sept 2010 is resistance correct YES NO Replace blower Please refer to pg 20 Replace ignitor FDXLIGN1930 Ohm out the ignitor verifying 8 25ohms Contact Support 908 355 7995 Replace blower Please refer to pg 20 ...

Page 33: ...o to 4C IF NOT replace ignitor pg 20 Ignitor and blower wiring Step 4A 33 Step 4B 4 Open FC4 Fuse With power off disconnect blower plug from ICB Models manufactured before Sept 2010 measure across pins 1 2 black red then 3 4 white blue for 8 9 ohms Models after Sept 2010 measure for 4 5 ohms across the two terminal with wires IF out of range replace blower pg 20 IF correct contact technical suppor...

Page 34: ...3 5 Proceed to Section 4 YES NO YES NO On P4 verify 110 125VAC between 4 6 grey wires YES Is voltage correct Is voltage correct Replace fuse board FDXLFWP1930 NO Replace transformer IDXL2TRF1930 Verify E10 for 110 125VAC between 1 3 white black Is voltage correct YES NO Replace transformer IDXL2TRF1930 Replace wire harness FDXLWHA1930 ...

Page 35: ...o step 5D IF correct go to 5C Test the FC4 fuse continuity Step 5A Disconnect the E10 connector from ICB Verify 110 125VAC between 1 3 white black IF present replace ICB IF NOT replace wire harness pg 20 Verify ICB input Step 5C 35 Disconnect P4 from fuse board Verify 110 125VAC between 4 6 grey wires IF OK replace fuse board IF NOT replace transformer pg 20 Verify transformer output Step 5D Step ...

Page 36: ...e Check display ribbon cable connection 6 Service LED ON EE OR CE Code Replace ICB FDXLICB1930 Did the CE code clear YES NO Secure connections retest NO YES Did CE code clear YES Problem solved NO Replace display bezel keypad See Pg 20 Replace ICB FDXLICB1930 Go to section B Section B Did the CE code clear Problem solved YES Contact Support 908 355 7995 NO ...

Page 37: ...F error persists go to 6C Check display for EE Step 6A Verify ribbon cable is secure IF cable is secure replace display bezel keypad assy pg 20 then go to 6D IF NOT secured reconnect Inspect display connections Step 6C 37 IF after replacing display bezel keypad CE error persists replace ICB pg 20 IF replacing ICB fails to solve problem contact support 908 355 7995 Verify CE has cleared Step 6D Ste...

Page 38: ...er cycle the heater YES NO Verify ignitor wiring is not damaged and plugged in securely 7 Service LED ON IO OR SB Code 38 Is ignitor wire damaged Replace ignitor FDXLIGN1930 YES NO Ohm ignitor verify 8 25 ohms 20 140 F reading out of range YES NO Replace ICB FDXLICB1930 Replace display bezel keypad See Pg 20 ...

Page 39: ...o step 7C IF not secure plug Check display for IO Step 7A With power off verify ignitor ohm resistance 8 25 ohms between 20 140 F IF correct replace ICB IF out of range replace ignitor pg 20 Ohm out ignitor Step 7C 39 Stuck Button indicates display board is acting as if the button is being pressed and held Replace display bezel key pad pg 20 Go to pg 66 to test Check display for SB Step 7D Step 7B...

Page 40: ... by more than 1 40 Replace thermistor FDXLTER1930 YES NO 8 Service LED ON SF OR HS Code Replace ICB FDXLICB1930 Make sure water inlet outlet are plumbed correctly are they reversed YES Plumb correctly in compliance with installation manual NO Ohm thermistor checking each red to black do the readings differ by more than 1 NO Replace ICB FDXLICB1930 Replace thermistor FDXLTER1930 YES ...

Page 41: ...ersed Check display for SF Step 8A 41 Step 8B The HS High Sense water temperature will appear if the water sensor is reading above 105 OR if the sensor detects an increase of more than 6 with in 60 seconds 8 Service LED ON SF OR HS Code Verify the water inlet outlet are not reversed reversing these will often cause frequent occurrences of the HS error code Follow the steps outlined in 8A IF the th...

Page 42: ...oming power is within 10 or of required voltage YES 42 NO Replace ICB FDXLICB1930 Correct source power issue 9 Service LED ON PF Code Inspect ground and neutral connections are they clean and secured YES NO Clear dirt debris and secure ground and neutral wires and retest ...

Page 43: ...ral Verify incoming power Step 9A 43 Step 9B Polarity Failure This code will display if low voltage is detected if the ground path is not sufficient or the ICB is defective Reset is immediate after error is corrected Verify both neutral and ground connections both internal and external are clean and secured IF ground and neutral connections check out then replace the ICB pg 20 9 Service LED ON PF ...

Page 44: ...erature set point until heater stop firing 10 Service LED ON HF Code Did the HF code reappear YES NO Did the HF code reappear YES NO Problem solved Toggle the mode button and call for heat Test for 24VAC off the gas valve Is 24VAC present Do you have manifold gas pressure YES NO Replace ICB FDXLICB1930 YES NO Replace gas valve Please refer to pg 20 ...

Page 45: ...will occur if flame is sensed when the gas valve is off the control will go into lockout The blower will continuously run until corrected When corrected control will run blower for 5 seconds then restart heater after 2 minutes Press the mode button to toggle the heater and call for heat IF 24VAC is still present at gas valve AND manifold pressure is not present gas valve is defective and needs to ...

Page 46: ...tinuity present NO Replace water pressure switch FDXLWPS1930 YES Adjust switch if necessary Did error clear Problem solved YES Verify high limit wires are free of damage NO Are wires free of damage Replace high limits kit FDXLHLI1930 NO YES Is this heater installed indoors YES Go to section B next page NO Heater made after Feb 2016 YES NO Contact Support 908 355 7995 YES Does exhaust gas limit hav...

Page 47: ...and vent sizing Is flue dirty YES Clean flue and retest NO YES NO Vent sized correctly Refer to installation indoor vent instructions Test vent pressure switch continuity Continuity present YES NO Replace vent pressure switch FDXLVPS1930 Heater made after Feb 2016 YES NO Contact Support 908 355 7995 Does exhaust gas limit have continuity Replace exhaust gas limit switch FDXLEGL1931 NO YES ...

Page 48: ...est Inspect water pressure switch 48 LO Code Limit Open may relate to water flow Verify the pump is running adequate water is flowing through heater LO is NORMAL when the pump is turned off Remove wires from water pressure switch measure continuity across terminals while pump is running IF open replace water pressure switch IF OK go to Step 11C 11 Service LED ON LO Code Step 11A Step 11B ...

Page 49: ...d replace pg 20 IF OK go to 11E Pressure switch adjustment Step 11C IF this heater is installed in an indoor application proceed to step 11F IF heater is installed in an outdoor environment go to step 11I Indoor application Step 11E 49 Applies To Indoor Installations ONLY Inspect the vent pressure switch tube connections IF OK go to 11G IF NOT repair replace tubing pg 20 Vent pressure switch tubin...

Page 50: ...y Inspect flue and vent sizing Step 11G 50 Step 11H Note Please ensure that the vent size is sufficient for the heater model installed Failure to properly size venting may result in damage to heater OR COULD PUT INHABITANTS AT SERIOUS RISK Disconnect wires from vent pressure switch and measure continuity between VPS terminals IF open replace the vent pressure switch pg 20 IF OK go to 11I 11 Servic...

Page 51: ...lace switch pg 20 IF switch does not exist AND problem still persists contact support 908 355 7995 Indoor Outdoor Feb 2016 and newer Step 11I Note This switch is a one time safety Once the switch has tripped then it NEEDS to be replaced and the heat exchanger should be inspected for soot or damage ...

Page 52: ...lame sensor gas valve connections are secure Secure connections retest YES YES NO Is inlet pressure correct Adjust manifold gas pressure YES Correct inlet gas pressure NO Test 22 28VAC to gas valve during call for heat manometer attached Is voltage correct NO Replace ICB FDXLICB1930 YES Is there manifold gas pressure Replace gas valve Please refer to pg 20 NO YES Is inlet and manifold gas pressure...

Page 53: ...ES Replace flame sensor IDXLFLS1930 Check for damaged OR wrong blower air inlet plate Is plate damaged wrong NO NO YES NO Contact tech support 908 355 7995 Inspect and or clean burner tubes orifices Are burner tubes orifices damaged YES NO Replace with new burner kit FDXLBRN1930 OR Gas Valve includes orifices pg 20 ...

Page 54: ...ct go to step 12C IF NOT rotate knob to ON position Inspect main gas supply Step 12A Ensure both flame sensor and gas valve are both securely fastened to the ICB IF correct proceed to step 12D Flame sensor gas valve 54 Ensure gas static load and manifold pressures are correct See Page 16 17 IF OK go to Step 12E IF NOT go to Step 12F Verify gas pressure Step 12D Step 12B 12 Service LED ON IF Code S...

Page 55: ...th the 5 version pg 20 IF correct go to step 12G Voltage pressure off gas valve Step 12E Check for damaged wrong blower air inlet plate IF wrong or damaged contact tech support 908 355 7995 IF OK go to step 12H Verify blower air inlet plate Step 12G 55 Inspect Gas Orifices Burners for blockage Clean as required IF damaged replace pg 20 IF NOT damaged contact tech support 908 355 7995 Inspect orifi...

Page 56: ...uity YES Is the blower running NO Replace blower vacuum switch FDXLBVS1930 YES 13 Service LED ON AC Code Test for continuity on the blower vacuum switch Put the heater in Stand by Replace blower vacuum switch FDXLBVS1930 Replace ICB FDXLICB1930 ...

Page 57: ...3B Verify blower operation Test blower vacuum switch Step 13A 57 Step 13B AC Code stands for Air Switch Closed The blower vacuum switch closed when it was expected to be open With the heater off in Stand By IF the blower continues to run operate replace the ICB IF not replace the blower vacuum switch pg 20 13 Service LED ON AC Code ...

Page 58: ...um tubing IDXL2SNT1930 YES NO YES Correct voltage selector plug NO Install correct plug and replace fuse Ohm out blower for 8 9ohms before Sept 2010 OR for 4 5ohms after Sept 2010 is resistance correct Replace blower Please refer to pg 20 NO Verify 110 125VAC on Inducer off ICB between pins 1 2 left to right is voltage present YES NO Replace blower vacuum switch FDXLBVS1930 Replace ICB FDXLICB1930...

Page 59: ...ged vacuum tubing as well as its connection to the blower IF OK go to 14C IF NOT replace vacuum tubing pg 20 Blower vacuum switch wiring Step 14A IF voltage selector plug matches voltage go to step 14D IF not power down replace FC1 FC2 fuses if open switch plug to proper voltage Verify voltage selector plug Step 14C 59 Step 14B 14 Service LED ON AO Code ...

Page 60: ...ms Models after Sept 2010 measure for 4 5 ohms across the two terminal with wires IF out of range replace blower pg 20 IF correct go to step 14E Measure blower resistance Before Sept 2010 Step 14D On the ICB while calling for heat Verify 110 125VAC across Pins 1 2 of Inducer on ICB IF OK replace blower vacuum switch pg 20 IF NOT present replace ICB pg 20 Blower plug on ICB Step 14E ...

Page 61: ...ay occur Flow less than minimum could cause issues such as the heater dry firing or water to boil causing high limits to trip and possible damage to heat exchanger Flow exceeding maximum flow could cause issues such as damage to the heat exchanger by thinning the tube walls Flow Requirements NOTE Internal by pass should be inspected periodically as it could be the cause of low or high water flow t...

Page 62: ...t 5 Remove water manifold also called the Header and black polymer Mounting Blocks to expose the ends of the heat exchanger tubes 6 If there is any doubt as to whether or not there is damage from aggressive water chemistry take 3 pictures 1 of each pair of tubes inlet side and outlet side as well as the Model Serial number decal and send to your local technical representative or call 908 355 7995 ...

Page 63: ...r High Water Flow High Sanitizer Levels Annealed Fins Low Water Flow Freeze Damage High pH Alkalinity or Calcium Hardness Sooted Improper Fuel and Air Mixture High Sanitizer Levels Low pH 63 Heat Exchanger Potential Failure Causes ...

Page 64: ...64 ...

Page 65: ...Wiring Connection Diagram 65 ...

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