Hayward H150FDAU User manual

FOR YOUR SAFETY
WARNING: If the information in these
instructions is not followed exactly, a re or
explosion may result causing property damage,
injury, or death.
- Do not store or use gasoline or other am-
mable 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
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
re department.
- Installation and service must be performed by
a qualied installer, service agency, or the
gas supplier.
POOL AND SPA/HOT TUB HEATERS
H150FDAU, H250FDAU, & H400FDAU MODELS
FOR USE IN AUSTRALIA
SERVICE & INSTALLATION MANUAL
FOR YOUR SAFETY
This product must be installed and serviced by authorized personnel, qualied in pool/
spa heater installation. Improper installation and/or operation can create carbon monoxide gas
and ue gases that can cause serious injury, property damage, or death.
PRINTED 10/24/2011 AT 1:13 PM
1301272601 Rev B 0813
U.S. PATENT NOS. 6,026,804 & 6,321,833 & 7,971,603

Hayward Pool Products (Australia) Pty Ltd.
Tel: 1300 POOLS1 www.hayward-pool.com.au
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
2CONTENTS
Section I General information ........................... 7
Introduction .................................................... 7
Warranty ........................................................ 7
Maintaining proper water chemistry ............... 7
Section II Installation ......................................... 9
Equipment inspection .................................... 9
Important notice ............................................. 9
Conformance with codes ............................... 9
Altitude of installation ..................................... 9
Uncrating the heater .................................... 11
Locating the heater....................................... 11
Flooring ........................................................ 12
Tie-Down Brackets ....................................... 12
Reversible water connections ...................... 13
Gas supply and piping ................................. 15
Water piping ................................................. 18
Installation above pool surface .................... 20
Chlorinator/chemical feeder ......................... 20
 Electricalspecications ................................ 21
Electrical connections .................................. 22
Remote control connection .......................... 24
Section III Check-out & Start-up ..................... 26
General ........................................................ 26
Gas line testing ............................................ 26
Gas pressure testing ................................... 27
Water pressure switch ................................. 28
Two-speed pump ......................................... 28
Temperature adjustment .............................. 29
Temperature lock-out ................................... 29
Fahrenheit v. Celsius ................................... 29
Heating mode .............................................. 29
Retry (Failure of light) .................................. 30
 Recycle(Lossofame) ............................... 30
Keypad inputs .............................................. 30
Automatic reset time .................................... 31
Periodic inspection ...................................... 31
Winterization ................................................ 31
Draining the heat exchanger ....................... 32
Spring start-up ............................................. 32
Section IV Technician Service ........................ 33
General ........................................................ 33
Maintenance ................................................ 33
Heat exchanger inspection and cleaning ..... 34
Combustion chamber .................................. 34
Heat exchanger removal ............................. 34
Burner inspection and cleaning ................... 35
Burner removal and replacement ................ 35
Gas valve replacement ................................ 36
Igniter ........................................................... 37
Flame sensor ............................................... 37
 Burnerorices ............................................. 37
Gas conversion ............................................ 37
Electrical wiring ............................................ 38
Ignition control system ................................. 38
Blower vacuum switch .................................. 38
High limit switch ........................................... 39
Thermistor .................................................... 40
Water pressure switch ................................. 40
Transformer ................................................. 41
Blower .......................................................... 41
By-pass service cartridge ............................ 41
Section V Troubleshooting ............................. 42
General ........................................................ 42
Automatic reset time .................................... 42
Supply wiring ............................................... 42
Internal wiring .............................................. 42
 Fusespecications ...................................... 42
Error codes ................................................... 43
Troubleshooting ........................................... 44
Warranty ....................................................... 47
Service Parts ................................................ 50

Hayward Pool Products (Australia) Pty Ltd.
Tel: 1300 POOLS1 www.hayward-pool.com.au
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
3
SAFETY INFORMATION
Basic safety precautions should always be followed, including the following: Failure to follow instructions
can cause severe injury and/or death.
This is the safety-alert symbol. When you see this symbol on your equipment 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 serious personal injury, death or major property dam-
age and if ignored presents a potential hazard.
CAUTION warns about hazards that will or can cause minor or moderate personal injury and/or prop-
erty damage and if ignored presents a potential hazard. It can also make consumers aware of actions that
are unpredictable and unsafe.
ATTENTION indicates special instructions that are important but not related to hazards.
READ AND FOLLOW ALL INSTRUCTIONS IN THIS OWNER’S
MANUAL AND ON EQUIPMENT.
IMPORTANT SAFETY INSTRUCTIONS
Before installing or servicing this electrical equipment, turn power supply OFF.
KEEP SAFETY LABELS IN GOOD CONDITION AND REPLACE IF MISSING OR DAMAGED.
WARNING – To reduce risk of injury, do not permit children to use or climb on the heater, pumps or
lters. Closely supervise children at all times. Components such as the ltration system, pumps, and
heaters must be positioned to prevent children from using them as a means of access to the pool.
CAUTION – This heater 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.
Though this product is designed for outdoor use, it is strongly recommended to protect the electrical
components from the weather. Select a well drained area, one that will not ood when it rains. It requires free
circulation of air for cooling. Do not install in a damp or non-ventilated location.
WARNING – It is required that licensed electricians do all electrical wiring. Risk of
Electric Shock. Hazardous voltage can shock, burn, cause death or serious property
damage. To reduce the risk of electric shock, do NOT use an extension cord to connect
unit to electric supply. Provide a properly located outlet. All electrical wiring MUST be
in conformance with applicable local and national codes and regulations. Before work-
ing on this unit, turn off power supply to the heater.
WARNING – To reduce the risk of electric shock replace damaged wiring immediately. Locate conduit
to prevent abuse from lawn mowers, hedge trimmers and other equipment.
WARNING – Failure to bond to pool structure will increase risk for electrocution and could result in
injury or death. To reduce the risk of electric shock, the electrician must comply with installation in-
structions and must bond the heater accordingly. In addition, the licensed electrician must also conform
to local electrical codes for bonding requirements.

Hayward Pool Products (Australia) Pty Ltd.
Tel: 1300 POOLS1 www.hayward-pool.com.au
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
4
NOTES TO THE ELECTRICIAN:
Use a solid copper conductor, 8 AWG or larger. Run a continuous wire from external bonding lug to rein-
forcing rod or mesh. Connect a No. 8 AWG solid copper bonding wire to the grounding lug provided on the
heater and to all metal parts of swimming pool or spa, and to all electrical equipment, metal piping (except
gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming pool or spa. IMPORTANT -Refer-
ence applicable local and national electric codes for all wiring standards including, but not limited to, ground-
ing, bonding, and other general wiring procedures.
WARNING – Suction Entrapment Hazard.
Suction in suction outlets and/or suction outlet covers which are damaged, broken,
cracked, missing, or unsecured can cause severe injury and/or death due to the following
entrapment hazards:
Hair Entrapment- Hair can become entangled in suction outlets.
Limb Entrapment- A limb inserted into an opening of a suction outlet or suction outlet
cover that is damaged, broken, cracked, missing, or not securely attached can result in a
mechanical bind or swelling of the limb.
Body Suction Entrapment- A differential pressure applied to a large portion of the body or limbs can
result in an entrapment.
Evisceration/ Disembowelment - 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, nger, toe or knuck-
le to be caught in an opening of a suction outlet or suction outlet cover resulting in mechanical entrap-
ment.
WARNING - To reduce the risk of entrapment hazards:
• When suction outlets are less than a 18” x 23” equivalent, a minimum of two function-
ing suction outlets per pump must be installed. Suction outlets in the same plane (i.e.
oor or wall), must be installed a minimum of three feet (3’) [1 meter] apart, as mea-
sured from near point to near point.
• Dual suction outlets shall be placed in such locations and distances to avoid “dual
blockage” by a user.
• Dual suction ttings shall not be located on seating areas or on the backrest for such
seating areas.
• The maximum system ow rate shall not exceed the ow rating of any listed (AS 1926.3-2010(+A1))
suction outlet cover installed.
• Never use the Pool or Spa if any suction outlet component is damaged, broken, cracked, missing, or
not securely attached.
• Replace damaged, broken, cracked, missing, or not securely attached suction outlet components im-
mediately.
• Install two or more suction outlets per pump in accordance with latest APSP (formally NSPI) Stan-
dards and CPSC guidelines. Follow all applicable National, State, and Local codes.

Hayward Pool Products (Australia) Pty Ltd.
Tel: 1300 POOLS1 www.hayward-pool.com.au
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
5
WARNING – Failure to remove pressure test plugs and/or plugs used in winterization of the pool/spa
from the suction outlets can result in an increase potential for suction entrapment as described above.
WARNING – Failure to keep suction outlet components clear of debris, such as leaves, dirt, hair, paper
and other material can result in an increase potential for suction entrapment as described above.
WARNING – Suction outlet components have a nite life, the cover/grate should be inspected fre-
quently and replaced at least every ten years or if found to be damaged, broken, cracked, missing, or not
securely attached.
WARNING – All suction and discharge valves MUST be OPEN when starting the circulation system.
Failure to do so could result in severe personal injury and/or property damage. All drains and suction
outlets MUST have properly installed covers, securely attached using the screws supplied with the cov-
ers. If screws are lost, order replacement parts from your supplier.
WARNING – Hazardous Pressure. Pool and spa water circulation systems operate
under hazardous pressure during start up, normal operation, and after pump shut off.
Stand clear of circulation system equipment during start up. Failure to follow safety
and operation instructions could result in violent separation of the pump housing and
cover due to pressure in the system, which could cause property 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 lter 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 lter control
valve position while system pump is running. Before starting system pump, fully open
lter manual air relief valve. Do not close lter manual air relief valve until a steady
stream of water (not air or air and water) is discharged.
WARNING – Separation Hazard. Failure to follow safety and operation instructions
could result in violent separation of pump components. Strainer cover must be prop-
erly secured to pump housing with strainer cover lock ring. Before servicing pool and
spa circulation system, manual air relief valve must be in open position. Do not oper-
ate pool and spa circulation system if a system component is not assembled properly,
damaged, or missing. Do not operate pool and spa circulation system unless lter air
relief valve body is in locked position in lter upper body.
WARNING – Never operate or test the circulation system at more than 40 PSI.
WARNING – Fire and burn hazard. Motors operate at high temperatures and if they are not properly
isolated from any ammable structures or foreign debris they can cause res, which may cause severe
personal injury or death. It is also necessary to allow the motor to cool for at least 20 minutes prior to
maintenance to minimize the risk of burns.
WARNING – Failure to install according to dened instructions may result in severe personal injury or
death.