Hayward HDF400 Installation & Operation Manual Download | Manualshive

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ONLY USE GENUINE HAYWARD REPLACEMENT PARTS

51300803801 REV B

Fuse Board

Ignition Control

Transformer

Differential Pressure

Switch

Figure 20: Control Assembly Components

(Wiring Hidden for Clarity)

Figure 21: Header Assembly Components

V-Header

Outlet Header

Temperature Limits

Drain Plug

Integrated Bypass

Water Pressure
Switch

Thermistor

Inlet Header

Pressure Relief

Valve Port

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Summary of Contents for HDF400

Page 1: ... 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 CONTENTS Pg GETTING S...

Page 2: ...ODUCT PERFORMANCE Verify Chlorine or Bromine level every 2 3 days Verify PH level every week Verify Alkalinity level every 3 4 weeks 2 weeks if using an Automa c Chlorine or Bromine Feeder Verify Water Hardness and Total Dissolved Solids TDS every month it is recommended that a pool professional perform this tes ng IS HEATING COOLING NEEDED WITHIN 1 WEEK CONNECT WATER PIPING TO PRODUCT BYPASS TO O...

Page 3: ...pment 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 death and or severe injury or major property damage and if ignored presents a potential hazard CAUTION warns about hazards that could cause minor or moderate personal injury and or property damage and if ignored presents a potential hazar...

Page 4: ...CTION AND SUB ASSEMBLIES Control Access Panel Assembly Cabinet Top Control Assembly Exhaust Box Assembly Combustion Bower and Gas Manifold Assemblies Burner Combustion Chamber Assembly Cabinet Base Header Controls Cover Water Side Panels Exhaust Side Panel Zero Clearance Panel Both Sides ...

Page 5: ... with silicon nitride hot surface igni on Cupronickel heat exchanger tubes standard Integral water bypass to maintain correct water ﬂow through the heat exchanger Maximum water ﬂow through the unit is 125 GPM GAS REQUIREMENTS OPERATING PRESSURES Natural Gas Propane Gas Gas Manifold Pressure in wc 0 1 to 0 3 Gas Inlet Pressure Minimum in wc 4 0 4 0 Gas Inlet Pressure Maximum in wc 14 0 14 0 Gas Air...

Page 6: ...tension cord to connect unit to electric supply Provide a properly located electrical receptacle To reduce the risk of electric shock replace damaged wiring immediately Locate conduit to prevent abuse from lawn mowers hedge trimmers and other equipment Do NOT ground to a gas supply line The unit wiring diagram is shown in Figure 2 A separate diagram is included in the electrical accessory kit supp...

Page 7: ...7 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 51300803801 REV B Figure 2 Wiring Diagram ...

Page 8: ...tive pressure applied to a large portion of the body or limbs can result in an entrapment Evisceration Disembowelment A negative pressure 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 hai...

Page 9: ... the cir culation system at more than 50 PSI Do not purge the system with compressed air Purging the system with com pressed air can cause components to explode with risk of severe injury or death to anyone nearby Use only a low pressure below 5 PSI high volume blower when air purging the pump filter or piping WARNING Risk of Electric Shock All electrical wiring MUST be in conformance with applica...

Page 10: ... 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 disease circulatory problems diabetes or blood pressure problems should obtain ...

Page 11: ...steps to remove the shipping carton from the heater 1 Open the top of the corrugated carton and remove the consumer kit 2 Remove the corrugated carton from the heater The carton top pad bottom pad and the four corner posts can be recycled 3 There are four 4 external screws see Figure 3 used to secure the heater to the wood pallet All four must be removed to sepa rate the heater from the pallet 4 D...

Page 12: ... the heater The water could reach the controls causing electrical damage 8 Do not install under a deck 9 Do not install within 24 inches of any outdoor HVAC equipment 10 Do not install where water may run off a roof into the heater A gutter may be needed to protect the heater CAUTION Make sure the heater is not located where large amounts of water may run off from the roof into the unit Sharp slop...

Page 13: ...l State and National requirements regarding wind load anchoring Anchor your heater to the pad through the same anchor point used to secure the heater to the pallet when it was delivered You will need the following to complete the installation Concrete tapping screws FIELD SUPPLIED Tapcons qty 4 stainless steel size to be diameter with a minimum length of 1 1 2 Fender washers FIELD SUPPLIED stainle...

Page 14: ...e from the unit needs to be routed off the equipment pad or into a drain the unit has been supplied with a 6 foot length of rubber hosing and a connection on the bottom of the exhaust side of the unit If a longer length is needed any 3 8 ID rubber hose can be connected to the drain of the unit An overflow indicator has also been molded into the base of the unit If a hose is connected to the drain ...

Page 15: ...y in accordance with the manufacturer s instructions and all applicable codes and requirements of the authority having jurisdiction The information in these instructions must be followed to minimize the risk of fire or explosion or to prevent property damage personal injury or death The qualified service agency is responsible for the proper installation of this kit The installation is not proper a...

Page 16: ...he heater for proper combustion A separate blower air duct is recommended Minimum installation clearances shown in Table 4 apply ALL AIR SUPPLY FROM INSIDE THE BUILDING The confined space shall be provided with 2 permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space a space whose...

Page 17: ...total input Table 3 Indoor Clearance Apply Figure 8 Air from Outside Building Installation Table 3 Indoor Clearance Apply A 1 sq in per 4 000 Btu hr of total input B 1 sq in per 2 000 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 ...

Page 18: ...ioned spaces Clearance to combustible materials for double wall vent is 6 inches Smaller clearances may be available consult the National Fuel Gas Code CAT I MECHANICAL DRAFT SYSTEMS Vent systems requiring power venting must use mechanical draft systems listed in accordance with UL378 Draft Equipment Selection of power venter and required clearances from combustible materials must follow draft equ...

Page 19: ...d orientations OBTAINING VENT PIPE AND TERMINATIONS A variety of vent components including terminals elbows and straight lengths are available for use with this appli ance Approved parts are listed in Table 8 and in the service part instructions supplied with any service kit They can be ordered directly from the manufacturer or one of their authorized dealers To locate an authorized dealer for ven...

Page 20: ...operty damage or Where condensate vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment 2 When locating vent terminations consideration must be given to prevailing winds location and other conditions which may cause recirculation of the combustion products of adjacent vents Recirculation can cause poor combustion inlet condensate problems ...

Page 21: ...ulator vent outlet See note 3 0 9m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 9 in 229mm for appliances 10 000 Btuh 3kW and 50 000 Btuh 15kW 12 in 305mm for appliances 50 000 Btuh 15 kW 12 in 305mm for appliances 10 000 Btuh 3kW and 100 000 Btuh 30 kW 36 in 914mm for appliances 100 000 Btuh 30kW K Clearance to a mechanical air supp...

Page 22: ...s utility for assistance Natural gas must be pipeline quality supplied from a natural gas utility company NOTICE Manufacturer is not responsible for heaters that are damaged if connected to a natural gas well PROPANE GAS All propane gas tanks must be located outdoors and away from pool spa structure and in accordance with the standard for storage and handling of propane gas ANSI NFPA 58 latest edi...

Page 23: ...anel elevated slide the panel toward the rear of the unit until the tabs holding the rear side down are disen gaged from the cabinet top 4 Carefully lift the top access panel free of the unit ensuring excess tension is not placed on the ribbon cable attached to the ignition con trol board inside the heater cabinet and rotate it 180 degrees so that the user interface is now on the opposite side of ...

Page 24: ...g er if the flow rate is within the range specified in the GETTING STARTED section 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 flow If the normal pump and filter system flow rate exceeds 125 gpm then a manual bypass valve must be installed as shown in Figure 14 Dama...

Page 25: ...nvert the heater to 120VAC 60 Hz operation remove the 240VAC voltage selector jumper from the fuse board and replace it with the 120VAC jumper These jumpers are tie wrapped together See Figure 20 for location of the fuse board All wiring connections to the heater must be made in accord ance with the latest edition of the National Electrical Code ANSI NFPA 70 unless local code requirements specify ...

Page 26: ...is 200 feet 2 WIRE REMOTE CONTROL CONNECTION Connect the appropriate wires from the remote control to the factory harness ORANGE wire POOL and WHITE wire COM To configure the heater for 2 wire remote thermostat control use the MODE key on the heater keypad to put the control into STANDBY mode Then simultaneously press and hold the and MODE keys for 3 seconds until bo bypass operation is displayed ...

Page 27: ...CEMENT PARTS 51300803801 REV B Figure 19 Location of Components Top and Side Panels removed for Clarity Gas Valve Gas Manifold Igniter Flame Sensor Burner Combustion Blower see Fig 22 Control Panel Assembly See Fig 20 Header See Fig 21 ...

Page 28: ...rol Transformer Differential Pressure Switch Figure 20 Control Assembly Components Wiring Hidden for Clarity Figure 21 Header Assembly Components V Header Outlet Header Temperature Limits Drain Plug Integrated Bypass Water Pressure Switch Thermistor Inlet Header Pressure Relief Valve Port ...

Page 29: ...UINE HAYWARD REPLACEMENT PARTS 51300803801 REV B Figure 22 Combustion Blower Assembly Components Burner Combustion Blower Negative Pressure Tap Fuel Air Mixer Reference Pressure Tap Blower Gasket Gas Manifold Assembly ...

Page 30: ...for the heater to encounter a 1 to 2 second delay in responding to any user panel input 3 It is normal for the heater to encounter up to a 5 second delay when the user panel is used to reset the control to clear an error code 4 The control will accept a mode change during lockout after 5 seconds The control will continue to display the error code and remain in lockout until it is reset At reset th...

Page 31: ...ignition attempts 1 The control de energizes the gas valve after the 4 second ignition trial ends 2 The control operates the blower during a 30 second post purge period 3 The control monitors for open contacts at the blower vacuum switch 4 The control performs a gas valve relay check 5 A normal ignition sequence resumes with Item 2 in NORMAL OPERATION FOR POOL SPA MODES see above If the third igni...

Page 32: ...openings 3 Remove the factory installed silicon hose from the fitting on the outlet side of the gas valve marked as vent see Fig 26 and place hoses a barbed tee and a manometer in line with the original hose as shown in Figure 25 4 Securely connect the hoses and manometers to the barb fittings Make sure the manometers have ample range and accuracy to proper ly read the gas inlet pressure and manif...

Page 33: ...Table 11 Required Gas Pressures in wc Measurement Natural Gas Propane Manifold Pressure Inlet Pressure Minimum 4 0 4 0 0 1 to 0 3 Inlet Pressure Maximum 14 0 14 0 Manifold pressure adjustment under screw cap Gas Inlet Pressure Tap ON OFF Switch Electric Terminals Pressure Tap Vent Tap Figure 26 Gas Valve ...

Page 34: ...34 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 51300803801 REV B Figure 27 Lighting and Operating Instruction Label This label is also located on the inside surface of the Water Side Top Panel ...

Page 35: ...o close the switch see Figure 27 5 For Installations with Heater below water level Turn the adjustment knob on the pressure switch clockwise until the heater turns off then turn the knob turn coun ter clockwise so that the heater turns back on Turning the adjustment knob clock wise increases the pressure needed to close the switch 6 Check the function of the pressure switch by turning the filter p...

Page 36: ...dures are to be per formed by a qualified service technician WATER CHEMISTRY The heat exchanger in your pool heater is made from the highest quality of copper and nickel Cupronickel materials This premium material and the exacting processes used to manufacture the heat exchanger is state of the art in pool heater design and manufacture However it remains vital that the heat exchanger be protected ...

Page 37: ...mpting to operate the heater will result in extensive damage to the heat exchanger Ensure water flow through the heater is restored before operating the heater A bypass feature is also advantageous for service needs and for the ability to remove the heater from the water path when not heating WINTERIZATION In moderate climates the heater can continue to operate during short term cold spells Do not...

Page 38: ...lace any electrically operated component that has been under water SERVICE OF HEATER The following service procedures HEAT EXCHANGER INSPECTION AND CLEANING and BURNER INSPECTION AND CLEANING are recommended to be performed as part of annual heater maintenance to ensure proper heater operation and long life HEAT EXCHANGER INSPECTION AND CLEANING Loosen the flare nut holding the gas manifold assemb...

Page 39: ...e the heater by reversing the above steps Tighten the four nuts securing the blower to a torque of 5 ft lbs Tighten the flare nut securing the gas manifold to the blower to a torque of 50 ft lbs 10 Turn the gas supply ON Use a soapy water solution to check for leaks Bubbles forming indicate a leak WARNING EXPLOSION HAZARD The use of an open flame to check for gas leaks could cause an explosion res...

Page 40: ...it The hose barb should point towards the ground when the mixer is in the unlocked position 6 Remove the fuel air mixer by pulling it straight out from the combustion blower inlet 7 Install new fuel air mixer by reversing the above steps 8 Verify that the mixer being inserted is marked with the correct fuel gas and the capacity rating matches that on the rating plate of the heat er 9 Verify manifo...

Page 41: ...A slo blo fuse 5 x 20 mm INTERNAL WIRING If the heater display is blank after the electrical has been installed refer to Troubleshooting Lookup Chart to determine the cause Note the ribbon cable between the display board and the ignition control board is keyed to ensure correct connection SUPPLY WIRING If the heater is connected to the line side of the circuit it will be powered at all times In th...

Page 42: ...l board does not satisfy self diagnostic on power up or initial trial for ignition the ignition control board will lockout until error con dition is corrected b2 Gas valve sensed as ON error If gas valve is powered when it should be off the heater will shut down and go into lockout The blower will operate until error condition is correct ed b3 Gas valve sensed as OFF error If gas valve is unpowere...

Page 43: ...n a one hour period the heater will lockout IF Ignition failure error If the maximum number of ignition retries is exceeded the heater will shut down and go into lockout Automatic reset is 60 minutes IO Igniter open error If the ignition control board is not in lockout and senses that the igniter circuit is open when the blower is running the ignition control board will turn off the blower and go ...

Page 44: ...ONIC CONTROLS Ignition Control Board Display Board and Ribbon Cable Field Wiring Panel Fuse Board Inlet Water Thermistor Water Pressure Switch High Temperature Limits Exhaust Temperature Limit Differential Pressure Switch Transformer Ignitor and Flame Sensor Voltage Selector Jumper Fuses Wiring Harnesses Electrical Accessory Kit HEATING COMPONENTS Blower Fuel Air Mixers Natural or LP Burner Gas Va...

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