Hayward H250FDN Service & Installation Manual Download

Page: 7 / 64

Pomona, CA Clemmons, NC Nashville, TN

Tel: 908-351-5400 www.haywardpool.com

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS

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. 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 if 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) is at user’s expense. For full details of warranty agreement, see war-

ranty certificate included in this manual.

ATTENTION:

If the pool/spa/hot tub heater is damaged or destroyed by improper maintenance, exces

sive water hardness, incorrect water chemistry, or freezing it is not covered under the manufacturer’s

warranty.

SECTION I. GENERAL INFORMATION

Summary of Contents for H250FDN

Page 1: ...upplier 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 POOL AND SPA HOT TUB HEATERS H250FDN H250FDP H350FDN H350FDP H400FDN H400FDP MODELS SERVICE INSTALLATION MANUAL HAYWARD FOR YOUR SAFETY This product must be instal...

Page 2: ...ssure test procedure 29 Install below pool surface 31 Two speed pump 31 Temperature control operation 32 Set point adjustment 32 Fahrenheit v Celsius 32 Heating mode 32 Retry 33 Recycle 33 Learning routine 33 Keypad inputs 34 Automatic reset time 34 Periodic inspection 34 Winterization 35 Removing the drain plug 35 Spring start up 35 Section IV Technician Service 37 General 37 Maintenance 37 Contr...

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 original integrity ...

Page 4: ...embowelment 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...

Page 5: ...ty 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 ru...

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 disea...

Page 7: ...t 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 if the heat exchanger or exchanger headers water containing section leak within one year from date of such installation for all users due to defect...

Page 8: ...eproductive harm Conformance with codes The heater shall be installed in accordance with all local and state codes The heater installation must con form to the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and with the requirements of the authority having jurisdiction Design certification of the heater is in compliance with ANSI Z21 56 CSA 4 7 For Canadian installations the heat...

Page 9: ...e the 2 shipping screws that secure the heater to the pallet These screws are installed through the heater base pan See Figure 2 5 Lift the heater clear of the corrugated bottom pad and off of the pallet ATTENTION Do not drop the heater from a pickup truck tailgate to the ground This may damage the heater Remove the 2 shipping screws and discard bottom corrugated tray Figure 2 ...

Page 10: ...ter is self venting when installed outdoors 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 3 feet 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 ...

Page 11: ...ws 5 Position the heater on the pad so that all tap cons can bite into the pad Observe local codes regarding pad construction some jurisdictions specify a minimum thick ness for concrete pads 6 Slip the tie down brackets into the slots in the front of the heater base pan from underside of the heater so that they are positioned as shown in figure 5 Install the sheet metal screws through the holes i...

Page 12: ...h per 4 000 BTU per hour of total input rating of all equipment in the enclosure See Figure 8 2 When communicating with the outdoors through vertical ducts each opening shall have a mini mum free area of 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure See Figure 8 3 When communicating with the outdoors through horizontal ducts each opening shall have a ...

Page 13: ...proved vent brand and manufacturer Only a venting system comprised of components manufactured by the Heatfab division of Selkirk Corp may be connected to this heater No other venting system may be connected to this heater The vent system must terminate with an approved vent terminal as listed in Table DD The correct vent adapter kit as shown in Table BB must be installed on the heater before conne...

Page 14: ...them later Remove the flue cover 2 Remove the screws that fasten the heat barrier to the heater Remove the heat barrier Do not install the vent adapter with the heat barrier in place 3 Using the high temperature sealant supplied in the vent kit seal the rectangular drain slots at the back of the flue collector 4 Reuse the screws that secured the flue cover to attach the vent adapter to the heater ...

Page 15: ...specified by the vent manufacturer Do not drill holes or use screws to connect Vent to Vent Adapter 1 Apply a bead of adhesive about 1 8 in diameter completely around the male end of the vent sec tion between 1 4 to 3 8 from the end of the section 2 Fully insert the male section into the female fitting of the Vent Adapter 3 Secure vent section Vent Adapter by sliding the ring of the vent section o...

Page 16: ... through the grommet in the header side trim panel and disconnect from the wiring harness 3 Remove the side trim panels 4 screws each 4 Remove upper end caps on both ends of the heater 4 screws each inside the slots at the top and sides Look for the triangles to indicate screw locations 5 Remove the flue cover 10 screws 6 Remove rain shield 8 screws 7 Remove the flue collector side panels 3 screws...

Page 17: ...FD2 BTU 250 000 350 000 400 000 LINE MATERIAL IRON PIPE TUBING IRON PIPE TUBING IRON PIPE TUBING 0 to 50 feet 1 1 1 8 1 1 1 8 1 50 to 100 feet 1 1 1 8 1 1 4 1 1 4 100 to 150 feet 1 1 4 1 1 4 1 1 4 200 to 300 feet 1 1 4 1 1 4 1 1 2 LOW PRESSURE PROPANE GAS PIPE SIZING Based upon gas pressure of 11 in w c inlet pressure at a pressure drop of 0 5 inch w c DISTANCE FROM OUTLET OF 1st STAGE REGULATOR T...

Page 18: ...5 8 DISTANCE FROM OUTLET OF 2nd STAGE REGULATOR TO GAS VALVE INLET MODEL H250FDP H350FDP H400FDP BTU 250 000 350 000 400 000 LINE MATERIAL IRON PIPE TUBING IRON PIPE TUBING IRON PIPE TUBING 0 to 50 feet 1 2 3 4 3 4 7 8 3 4 7 8 It is VERY IMPORTANT when installing a propane heater on a two stage regulation system to follow the gas line sizing chart below without exception HIGH PRESSURE PROPANE GAS ...

Page 19: ... 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 m...

Page 20: ...loss of life The heater is equipped with CPVC flanged pipe nipples union nuts O rings for use with 2 or 2 1 2 pipe connections Figure 19 shows the method for installing these parts on the header Assemble these parts to heater prior to plumbing Tighten union nuts securely before gluing fittings to ends of pipe nipples The CPVC flanged pipe nipples must be installed on the heater inlet and outlet wi...

Page 21: ...ater 3 Once the valve is set note the position and remove the valve handle to prevent further adjustment ATTENTION Improperly adjusted manual bypass valves will result in damage to the heater if the flow rates are not maintained as specified in Figure 20 under all operating conditions The heat ex changer will fail and this damage will not be covered under the Hayward warranty Figure 22 illustrates...

Page 22: ...shown in Figure 24 to prevent drainage of water in the heater during a filter change For installation below the pool spa surface refer to Section III Figure 22 Typical plumbing to pool Figure 23 Multiple heater system Figure 25 Automatic chlorinator Figure 24 Heater installation above pool spa Automatic chlorinators and chemical feeders If used a chlorinator must be installed downstream from the h...

Page 23: ...operly 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 General Information Wiring connections must be made as shown in the wiring diagram found on the inside of the control box cover The heater must include a definite means of grounding and bonding There is a ground lu...

Page 24: ... with local codes or in the absence of local codes with National Electrical Code ANSI NFPA 70 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 wiring connections are to be made ...

Page 25: ...25 Figure 28 Wiring connection diagram The wiring diagram label is affixed to the control box cover ...

Page 26: ...e 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 on the exterior of the control box see Figure A below Do not remove the wire harness and attempt to connect remote controls directly to the ignition control board Remote wiring must be run in a separate conduit Use 22 AWG wire for runs l...

Page 27: ...ontrol must be in either POOL or SPA mode The display will show bo The POOL or SPA LED will be illuminated The remote thermostat will operate the heater The heater s thermostat will function to limit the water temperature to a maximum of 104 F 3 wire remote control connection On the remote control wiring terminal block Figure 29 connect the appropriate wires from the remote control to the terminal...

Page 28: ...28 Figure 30 Lighting Operating instructions label ...

Page 29: ...during any pressure testing of the gas supply piping system at test pressure equal to or less than 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 solu tion WARNING EXPLOSIVE HAZARD The use of an open flame to check for gas leaks cou...

Page 30: ...Take a pressure reading with the heater running the value should agree with those in Figure 33 If the pressure is within the range of 1 8 2 0 w c natural or 6 8 7 0 w c propane then no further adjustment is needed 7 If the gas pressure does not meet the above requirements the regulator must be adjusted 8 Gas pressure regulator adjustment procedure a Remove the screw cap over the regulator adjustme...

Page 31: ...rom a two speed pump is below the 1 pound minimum required to operate the water pressure switch on the heater This is 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 arrange ment are such that the required 1 pound minimum pressure cannot be obtained do not attempt to operate the heater Corre...

Page 32: ...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 selection will be automatically accepted after 60 sec onds Heating mode The control continually compares the water temperature with the set point and the high limit temperature When the water temperature is more than 1 below the set point...

Page 33: ... at ignition If flame is lost within ten 10 seconds of ignition the control will respond within 2 seconds If flame is lost more than ten 10 seconds after ignition the control will respond 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 s...

Page 34: ... The heater s venting areas the louvered top panel must never be obstructed in any way and minimum clearances must be observed to prevent restriction 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 heaters for looseness and possible leaks Keep all openings for combus tion and ventilation air clear and unobs...

Page 35: ...not covered under the Haywawrd warranty Removing the drain plug 1 This procedure is for above pool installations only 2 See Figure 36 for the location of the drain valve on the header 3 Set the keypad to STANDBY 4 Turn the electricity OFF at the circuit breaker 5 Turn the heater gas valve OFF using the knob on the valve 6 Turn the heater s gas supply OFF at the main shut off valve outside the heat...

Page 36: ...r ON 5 Set the temperature control using the keypad to POOL or SPA and adjust the set point to the desired temperature setting 6 If operating difficulties are encountered contact a qualified service company for assistance ATTENTION Heater installation checkout and start up should now be completed BE SURE to leave the Owner s Manual with the pool owner ...

Page 37: ...nance 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 compartme...

Page 38: ...header 11 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 12 Lift and remove the heat exchanger Place it on a clean surface WARNING BURN HAZARD Do not use a wire brush to remove soot from the heat exchanger This could cause a spark and ignite the gases trapped within the soot Using a soft tipped bru...

Page 39: ...r OFF 2 Turn gas valve knob OFF 3 Remove the front access panel It is se cured with 4 screws 4 Disconnect the union joint in the gas sup ply piping outside the heater cabinet 5 Disconnect the wiring terminals from the gas valve 6 Disconnect the wiring terminals from the blower 7 Remove the gas manifold assembly It is attached to the air box using 4 screws 8 Remove the screws from the igniter ac ce...

Page 40: ...alve 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 It is secured with 4 screws 4 Disconnect the wiring terminals from the gas valve 5 Remove the gas manifold assembly It is attached to the air box using 4 screws 6 Unscrew the gas valve with bot...

Page 41: ...chamber then out of the air box 10 Installation is the reverse of steps 1 9 Figure 41 Flame sensor FLAME SENSOR Refer to Figure 40 To remove the flame sensor 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel 4 screws 3 Disconnect the wire from the flame sensor 4 Remove the screw that secures the flame sensor to remove the sensor 5 Replace the flame sensor by reversing ste...

Page 42: ...da Conversions must be performed by the conversion station at Hayward Pool Products Canada Inc Control locations The following sections give a brief overview of the various heater controls and service replacement pro cedures The text describes the function of the controls See Figure 42 Electrical wiring ATTENTION If it is necessary to replace any of the original wiring it must be replaced with Hay...

Page 43: ... board and keypad assembly 1 Turn pump gas supply and heater power OFF 2 Remove the front access panel It is secured with 4 screws 3 Remove the control box cover It is secured with 2 screws 4 Unplug the display connector from the ignition control board 5 Remove the 2 screws along the lower edge of the bezel that retain the assembly 6 Pull the assembly forward and then lift it out 7 Replace the ass...

Page 44: ... the same temperature settings and are interchangeable 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 be caused by 1 Clogged filter or strainer 2 Excessive flow through the external bypass if one is used 3 Lime scale accumulatio...

Page 45: ... adjust ment to compensate for the no flow static head The following procedure is recommended when the switch needs adjustment and or replacement 1 Be sure the filter is clean before making any adjustment 2 With the pump ON in either POOL or SPA mode the heater is ON turn the adjustment dial on the pressure switch clockwise until a click is heard from the gas valve 3 Turn the adjustment dial count...

Page 46: ...access panel 4 screws 3 Remove the control box cover 2 screws 4 Disconnect the blower wire harness from the ignition control board 5 Pull the tubing from the hose barb on the blower housing 6 Remove the air inlet screen from the blower 4 screws 7 Remove the blower from the air box cover 3 screws 8 Slip the blower from beneath the securing flange 9 Reverse steps 1 8 to install the new blower Be sur...

Page 47: ...Pomona CA Clemmons NC Nashville TN Tel 908 351 5400 www haywardpool com USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 47 Figure 50 Components of water header and bypass valve ...

Page 48: ...d procedures are not or 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 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 automati...

Page 49: ...line side of the power circuit continuous power the blower will not operate when the pump is cycled via a time clock or other switch method Internal wiring If the heater display is blank after the electrical has been installed see Figures 43 and 44 to determine the cause The ribbon cable between the display board and the ignition control board is polarized and cannot be inserted upside down if it ...

Page 50: ... Prover switch open error If the blower prover switch does not close after the blower starts the control will stop the ignition trial go into lockout The blower will continue to run Automatic reset is immediate after the switch closes AO Prover switch open when expected closed error If the blower prover switch opens unexpectedly during operation the control will shut down and attempt to re light I...

Page 51: ...nue 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 Communication error If communication between the ignition board and the display board is not estab lished within 3 s of power up an error will...

Page 52: ...cuit fault 1 Check for Low Voltage Output from Fuse Board Diconnect plug from P5 connector from Fuse Board Measure for 24VAC across pins Reconnect plug If OK proceed to step 2 Otherwise proceed to step 5 2 Check for faulty Control Module wiring Inspect Control Module wiring Ensure all plugs are securly fastened to Control Module If OK proceed to step 3 3 Verify low voltage input to Control Module ...

Page 53: ...ule is defective Replace Control Module bD Bad Board or Secondary Hig Voltage Fault 1 Verify that FC4 Fuse on Fuse Board is not open Remove FC from fuseholder Mesure continuity across fuse If OK reinstall fuse and proceed to step 2 If Fuse is open proceed to section titled Open FC4 Fuse 2 Verify high voltage output from Fuse Board Disconnect plug from P6 connector of Fuse Board Measure for 120VAC ...

Page 54: ... to step 3 3 Check for faulty wiring or connection Inspect water pressure switch wiring Ensure wire harness terminals are securely fastened to spade terminals on water pressure switch If OK procced to step 4 LO Water pressure switch fault 4 Verify state of water pressure switch contacts Remove wire leads from water pressure switch and jumper leads Operate heater Measure continunity across water pr...

Page 55: ... valve during trial for igintion If 24VAC is present and gas valve does not open gas valve is defective Replace gas valve 2 If 24VAC is not present gas valve relay on control module is defective Replace control module AC Blower vacuum switch closed 1 Check for defective blower on relay or control module Disconnect Blower plug fron Control Module With heater off measure continuity across pins 1 and...

Page 56: ...r be responsible for shipping or delivery charges to the place of instal lation nor for labor charges or other costs of removal or installation Every defective heater or part replaced under this warranty shall become our property and as such must be returned to our distribution center with transportation charges paid by the user Any replacement pool heater furnished under this warranty shall re ma...

Page 57: ...Y All intended representations have been expressly set forth in this document This warranty may not be extended by oral or any other additional representations written sales information drawings or other mal function is strictly limited to repair or replacement of the defective heater or part as provided herein and the Company is not responsible hereunder for incidental or consequential or inciden...

Page 58: ...58 SERVICE PARTS 4 2 1 6 9 7 11 10 3 41 10 14 13 12 31 43 35 36 44 30 8 25 5 32 33 39 18 15 24 23 17 19 20 21 16 28 29 26 27 23 30 25 47 43 49 45 35 48 50 44 36 31 ...

Page 59: ...EL H400FD 6 FDXLUEC1930 UPPER END CAP FD 7 FDXLLEC1930 LOWER END CAP FD 8 FDXLLTP1930 LEFT TRIM PANEL FD 9 FDXLRTP1930 RIGHT TRIM PANEL FD 10 FDXLLCB1930 LEFT CONNECTION BOX FD FDXLRCB1930 RIGHT CONNECTION BOX FD 11 FDXLPBL1930 BASE LEG FD 12 FDXLFCS1930 FLUE COLLECTOR SIDE PANEL 13 FDXLRSA1250 RAIN SHIELD ASM H250FD FDXLRSA1350 RAIN SHIELD ASM H350FD FDXLRSA1400 RAIN SHIELD ASM H400FD 14 FDXLHBP1...

Page 60: ... CAL 34 FDXLFSK1930 FUSE SERVICE KIT FD NOT SHOWN 35 FDXLHLI1930 HIGH LIMIT 135 F 36 FDXLTER1930 THERMISTOR 37 FDXLGSK1930 GASKET KIT AIR SIDE FD ALL NOT SHOWN includes GASKET BLOWER MOUNTING GASKET IGNITER COVER GASKET COVER AIR BOX FRNT H400FD GASKET COVER AIR BOX FRNT H350FD GASKET COVER AIR BOX FRNT H250FD GASKET MANIFOLD AIR BOX H400FD GASKET MANIFOLD AIR BOX H350FD GASKET MANIFOLD AIR BOX H2...

Page 61: ...30 HEADER HARDWARE KIT 46 FDXLFOR1930 HEADER O RING KIT NOT SHOWN 47 FDXLHMB1930 HEADER MOUNTING BASE KIT 48 FDXLBPK1930 BYPASS CARTRIDGE KIT 49 FDXLPLG1930 1 8 NPT BRASS PLUG 50 CHXPLG1930 3 4 DRAIN PLUG 51 fdxlivt1400N VENT ADAPTER H400FD NATURAL GAS FDXLIVT1350N VENT ADAPTER H350FD NATURAL GAS FDXLIVT1250N VENT ADAPTER H250FD NATURAL GAS FDXLIVT1400P VENT ADAPTER H400FD PROPANE FDXLIVT1350P VEN...

Page 62: ...Pomona CA Clemmons NC Nashville TN Tel 908 351 5400 www haywardpool com USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 62 ...

Page 63: ...Pomona CA Clemmons NC Nashville TN Tel 908 351 5400 www haywardpool com USE ONLY HAYWARD GENUINE REPLACEMENT PARTS 63 ...

Page 64: ...on St Elizabeth NJ 07207 Hayward Pool Products Inc 2875 Pomona Boulevard Pomona CA 91768 Hayward Pool Products Inc 2880 Plymouth Drive Oakville Ontario L6H 5R4 Hayward S A Zoming de Jumet B6040 Jumet Belgium 2004 Hayward Printed in U S A ...

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