Hayward Pools H200 Owner's Manual
POOL AND SPA/HOT TUB HEATERS
H150, H200, H210, H250, H300,
H350 & H400 MODELS
INSTALLATION, OPERATION, & SERVICE 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
ammable 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 qualied installer,
service agency, or the gas supplier.
FOR YOUR SAFETY
This product must be installed and serviced by authorized personnel, qualied 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.
U.S. PATENT NOS. 6,026,804 & 6,321,833
1301371801 Rev C 1114
CONTENTS
SECTION 1 GENERAL INFORMATION......................................................................... 2
SECTION 2 HEATER SIZING......................................................................................... 4
SECTION 3 INSTALLATION........................................................................................... 5
Introduction.................................................................................................. 2
Hayward Heaters........................................................................................ 3
Selecting the Correct Size Heater............................................................... 4
For A Swimming Pool................................................................................. 4
For A Spa Or Hot Tub................................................................................. 4
Equipment Inspection................................................................................. 5
Conformance With Codes........................................................................... 5
Sea Level/High Altitude Installation............................................................. 5
Location Of Heater...................................................................................... 5
Flooring........................................................................................................ 5
Outdoor/Indoor Vents.................................................................................. 6
Outdoor Heater - High Wind Conditions..................................................... 6
Reversible Water Connections.................................................................... 7
Outdoor Installation And Venting................................................................. 8
Indoor Installation And Venting.................................................................... 9
Air Supply.................................................................................................... 9
Equipment Located in Conned Spaces..................................................... 9
Venting......................................................................................................... 10
Gas Supply And Piping................................................................................ 11
Gas Pipe Size............................................................................................. 11
All Gas Installations..................................................................................... 12
Water Piping................................................................................................ 12
Installation Above Pool/Spa Surface........................................................... 14
Automatic Chlorinators And Chemical Feeders.......................................... 14
Pressure Relief Valve.................................................................................. 14
Millivolt System........................................................................................... 15
Electronic Ignition System........................................................................... 14
Remote Control Connection........................................................................ 17
SECTION 4 INSTALLER CHECK-OUT & START-UP.................................................... 19
General........................................................................................................ 19
Gas Line Testing.......................................................................................... 19
Gas Pressure Test Procedure..................................................................... 19
Installation Below Pool/Spa Surface........................................................... 20
Two Speed Pump....................................................................................... 20
SECTION 5 CONSUMER OPERATION & MAINTENANCE PROCEDURES ............... 21
General........................................................................................................ 21
Pool/Spa Water Chemistry.......................................................................... 21
Using Chlorinators And Chemical Feeders................................................. 21
Facts About Water Chemistry...................................................................... 21
SECTION 5 (CONT.) CONSUMER OPERATION & MAINTENANCE PROCEDURES.............. 21
Heater Operation......................................................................................... 21
Lighting Instructions - Millivolt..................................................................... 22
Operating Instructions - Electronic Ignition................................................. 23
Temperature Controls.................................................................................. 24
Periodic Inspection...................................................................................... 24
Winterization................................................................................................ 25
Spring Start-up............................................................................................ 25
SECTION 6 QUALIFIED TECHNICIAN - MAINTENANCE/SERVICING....................... 26
General........................................................................................................ 26
Maintenance................................................................................................ 26
Control Access............................................................................................ 26
External Heat Exchanger Inspection And Cleaning.................................... 26
Heat Exchanger Removal........................................................................... 27
Combustion Chamber.................................................................................. 27
Internal Heat Exchanger Inspection And Cleaning..................................... 27
Burner Inspection And Cleaning.................................................................. 28
Burner Assembly Removal.......................................................................... 28
Burner Assembly Installation....................................................................... 28
Gas Valve Replacement.............................................................................. 29
Pilot Assembly Removal.............................................................................. 29
Igniter Assembly Removal........................................................................... 30
Main Burner Orices.................................................................................... 30
Gas Conversion........................................................................................... 30
Control Locations........................................................................................ 31
Electrical Wiring........................................................................................... 31
System Switch............................................................................................. 31
Temperature Controls.................................................................................. 31
High Limits................................................................................................... 31
Temperature Limiter Switches..................................................................... 32
Pressure Switch.......................................................................................... 32
By-pass Valve.............................................................................................. 32
Thermal Control Valve................................................................................. 33
Transformer................................................................................................. 34
Thermistor.................................................................................................... 34
CONTENTS
SECTION 7 TROUBLESHOOTING................................................................................ 34
Troubleshooting Chart................................................................................. 35
Troubleshooting Chart - Millivolt.................................................................. 36
Troubleshooting Chart - Electronic.............................................................. 38
PARTS LIST - MILLIVOLT.................................................................................................................. 40
PARTS ILLUSTRATION - MILLIVOLT................................................................................................ 41
PARTS LIST - ELECTRONIC IGNITION............................................................................................ 43
PARTS ILLUSTRATION - ELECTRONIC IGNITION......................................................................... 44
SECTION I. GENERAL INFORMATION
Introduction:
This manual contains instructions for installation, oper-
ation, maintenance, troubleshooting and parts lists for the
safe use of the Model H150, H200, H210, H250, H300,
H350 and H400 swimming pool/ spa/hot tub heaters.
Hayward strongly recommends that the manual be read
by the installer before installing the swimming pool/spa/
hot tub heater. If after reviewing the manual, any ques-
tions still remain unanswered, contact the factory or local
representative. Following heater installation, the installer
should leave the manual with the consumer for future
reference.
The H-Series pool/spa heaters are so similar in design
that many operating controls and other components are
interchangeable. For this reason, the procedures in this
manual pertain to all 7 models unless otherwise noted.
Hayward heaters:
The H-Series gas-red pool/spa heater is the result of
nearly 50 years in the engineering and production of the
nest in water heating equipment. The direct red nnedtube design of the pool /spa heater is the most advanced
in the industry, offering highly efcient, economical pool/
spa heating and scale free operation. No effort has been
spared in making the pool /spa heater the most rugged,
highly dependable, easy-to-maintain pool/spa heater
available.
The H-Series heaters are suitable only for heating of
swimming pools, spas, or hot tubs. These heaters should
not be used as space heating boilers, general purpose
water heaters or for heating salt water pools and sh
ponds. When installed and operated in accordance with
the manual’s instructions, the H-Series heater will provide
many years of trouble-free service and increased pool/spa
enjoyment.
2
SECTION I. GENERAL INFORMATION
Failure to Maintain Proper Water Chemistry May Cause
This additional information is intended to provide the most current and up-to-date information to the customer.
Please refer the the below text, in add
ition to the manual for information and warnings about your product.
Models H150, H200, H250, H300, H350, H400
Addendum to H-Series Heater Manual
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) materials. The
premium materials and the exacting processes used in the manufacture of the heat exchanger is state of the art in pool heater design and
manufacture. Yet, it remains vital that the heat exchanger be protected from damaging or corrosive chemicals, insufficient water flow
or improperly balanced water chemistry. Heat exchanger damage or failure resulting from improper flow, improperly balanced pool
water or the improper addition of sanitizers into the water is NOT covered under the terms of your warranty.
The following factors are critical to heat exchanger protec
tion. Follow these guidelines to help prevent pre-mature damage or failure to
your heater and heat exchanger.
1. WATER FLOW THROUGH HEATER
Water must be flowing through the heater at the minimum rated flow rate 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. The minimum rated flow rates are listed in the i
nstallation
manual on page 13. Some installations may require an adjustment to the water pressure switch for proper low-flow protection. Test
your system and if necessary, adjust the water pressure switch as described in the installation manual on page 32.
2. POOL/SPA WATER CHEMISTRY
The chemistry balance and mineral content of swimming pool water changes daily due to the addition of pool and san
itizing chemicals,
bather loads, rain, runoff and the amount of sun - to name a few. Improper chemistry balance and mineral content can cause scaling and
deposits to form on pool walls, in the filtration system, in the heat exchanger tubes and additionally can promote corrosive action to all
metals in the water path. Changing spa water regularly and maintaining the correct chemical balance in you
r pool/spa will keep the
pool/spa safe and sanitary, and will help protect the heat exchanger. Use a 4-way pool/spa water test kit to check your water frequently
(at least weekly). Use the following guidelines to help protect your heater's heat exchanger:
This additional information is intended to provid
e the most current and up-to-date information to the customer.
Please refer the the below text, in addition to the manual for information and warnings about your product.
Models H150, H200, H250, H300, H350, H400
Addendum to H-Series Heater Manual
Level
Chlorine
1 - 3 ppm
Bromine
2 - 4 ppm
swimmer irritation
reduced sanitizer effectiveness
large fluctuations in pH
Calcium Hardness
200 - 400 ppm corrosive to heat exchanger scaling of heat exchanger
WARNING:
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)
materials. The premium materials and the exacting processes used in the manufacture of the heat exchanger is state
of the art in pool heater design and manufacture. Yet, it remains vital that the heat exchanger be protected from damaging or corrosive chemicals, insufcient water ow or improperly balanced water chemistry. Heat exchanger damage or
failure resulting from improper ow, improperly balanced pool water or the improper addition of sanitizers into the water
is NOT covered under the terms of your warranty.
The following factors are critical to heat exchanger protection. Follow these guidelines to help prevent pre-mature damage or failure to your heater and heat exchanger.
1. WATER FLOW THROUGH HEATER
Water must be owing through the heater at the minimum rated ow rate during operation. Check that the pump is operating and the system is lled with water and purged of all air prior to starting the heater. The minimum rated ow rates
are listed on page 13 of this manual. Some installations may require an adjustment to the water pressure switch for
proper low-ow protection. Test your system and if necessary, adjust the water pressure switch as described on page
32 of this manual.
2. POOL/SPA WATER CHEMISTRY
The chemistry balance and mineral content of swimming pool water changes daily due to the addition of pool and
sanitizing chemicals, bather loads, rain, runoff and the amount of sun - to name a few. Improper chemistry balance and
mineral content can cause scaling and deposits to form on pool walls, in the ltration system, in the heat exchanger
tubes and additionally can promote corrosive action to all metals in the water path. Changing spa water regularly and
maintaining the correct chemical balance in your pool/spa will keep the pool/spa safe and sanitary, and will help protect
the heat exchanger. Use a 4-way pool/spa water test kit to check your water frequently (at least weekly). Use the following guidelines to help protect your heater’s heat exchanger:
3. SKIMMER CHLORINATION
Placing chlorine or bromine tablets directly into the skimmer may result in high chemical concentrations owing through
the heater. DO NOT place chlorine or bromine tablets in the skimmer.
4. CHLORINATOR INSTALLATION
Chlorinators must be installed downstream of the heater, and a check valve must be installed between the heater and
chlorinator to prevent high chemical concentrations from back owing into the heater. Make sure your piping arrangement meets the chlorinator installation requirements shown on page 14 of this manual.
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 ow through the heater and therefore the heat ex-
pH
Total Alkalinity
Salt
Recommended
80 - 120 ppm
2700 - 5000 ppm
2700 - 3400 ppm poor salt chlorinator performance corrosive to heat exchanger
changer. Close the bypass valve once the water is properly balanced. Failure to close the bypass valve when attempting to operate the heater will result in extensive damage to the heat exchanger. Ensure water ow 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. Refer to page 13 in this manual for further information.
7.4 - 7.6
Effect of Low Levels Effect of High Levels
hazy water, algea growth,
bacteria causing infections
corrosive to heat exchanger,
corrosive to heat exchanger,
swimmer irritation, bleaching of clothes/hair,
corrosive to heat exchanger
cloudy water, scaling of heat exchanger,
scaling of heat exchanger
3
SECTION 2. HEATER SIZING
H150 1,385 924 693 554 462 396
New Figure 2 for Manual 1302704001 rev F, page 4
VEW 2/7/2013
200 300 400 500 600 700 800 900 1,000
H400 9 14 19 23 28 33 37 42 47
H350 11 16 21 27 32 37 43 48 54
H300 12 19 25 31 37 44 50 56 62
H250 15 22 30 37 45 52 60 67 75
H210 17 26 35 44 52 61 70 78 87
H200 19 28 37 47 56 66 75 84 94
H150 25 37 50 62 75 87 100 112 125
VEW 2/7/2013
New Figure 3 for Manual 1302704001 rev F, page 4
Figure 3 - Recommended Heater Model
Selecting the correct size heater:
Factors inuencing heater sizing include pool/ spa size, average wind velocity, ambient temperature and desired increase in
temperature over ambient. A pool/spa in a warm area with little
or no wind will not require as large a heater as one in a cool,
windy location. Detailed sizing information is provided below.
For a swimming pool:
1. Determine pool’s surface area in square feet. For indoor pool
installations divide the pool’s surface area by 3.
Pool Surface Area:
Figure 1
2. Determine desired pool water temperature
(usually 78 -82°F).
3. Determine average air temperature of coldest month of use.
4. The temperature rise is the difference between
2 & 3.
5. Locate in Figure 2 the surface area equal to or just greater
than the pool’s surface area and the temperature degree rise
and select the appropriate heater model.
Figure 2 is based on 3 1/2 MPH wind velocity and elevation of
up to 2,000 feet above sea level.
When not in use, keep pool covered to reduce heat loss,
chemical usage and dirt load on the ltering system.
For a spa or hot tub:
Determine spa capacity in gallons (surface area x average
depth x 7 1/2).
The reference table lists the time required in minutes to raise
the temperature of the spa/hot tub by 30°F. Locate in the table
below the spa/hot tub size in gallons equal to or just greater than
the spa/hot tub size in gallons. Select the desired time to raise
the spa/hot tub temperature 30°F, read to the left and select the
appropriate heater model.
This guide can be adjusted for other temperatures rises. For
example, if a 15°F increase in temperature is desired, simply
divide the time for 30°F rise by the ratio of 30/15 = 2.
! NOTE: Heat losses and/or heat absorbed by spa walls
(such as concrete) or other objects will add to the heat-up time.
Spa sizing is based on an insulated and covered spa. Always
cover spa or hot tub when not in use to minimize heat loss and
evaporation.
Figure 2 - Recommended Heater Model
Temp. Rise °F 10° 15° 20° 25° 30° 35°
Model
H200 1,848 1,232 924 739 616 528
H210 1,988 1,326 994 795 663 568
H250 2,309 1,540 1,155 924 770 660
H300 2,771 1,848 1,386 1,109 924 792
H350 3,233 2,156 1,617 1,293 1,078 924
H400 3,695 2,463 1,848 1,478 1,232 1,056
Model
Time in Minutes to Raise Spa/Tub Temperature 30°F
Pool Surface Area in Square Feet
Spa/Hot Tub Size in Gallons
4
SECTION 3. INSTALLATION
Sea level/high altitude installation:
The H-Series heaters may be installed up to
2000 feet of elevation above sea level. For eleva-
tions from 2000 to 4500 feet above sea level,
heater shall be a high altitude model which has a
suffix "H" in the heater model designation (Example:
Model H400H1). For elevations above 4500 feet,
consult customer service at Hayward.
Location of heater:
Locate the pool/spa heater in an area where
leakage of 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 restrict air flow. .
This heater must be installed at least five feet
from the inside wall of a pool/spa unless separated
from the pool/spa by a solid fence, wall or other per-
manent solid barrier. This heater must be installed
also at least five feet from the wall of an above-
ground pool.
Flooring:
The H-Series pool/spa heaters must be
installed on a non-combustible floor or slab. Installa-
tion on other floors may be accomplished provided
the floor under the appliance is protected with
hollow masonry not less than 4 inches thick covered
with sheet metal of not less than 24 gauge. Such
masonry must be laid with ends unsealed and joints
matched in such a way as to provide a free circula-
tion of air from side to side through masonry. The
masonry must extend a minimum of 12 inches
beyond the heater to all sides. See Figure 4. In all
cases, floor protection is the responsibility of the
installer and the installer must check to be certain
that the floor is not exposed to excessive heat
during extended periods of operation.
12"
MiN.
12"
MIN.
Equipment inspection:
On receipt of the heater equipment, inspect the heater carton
and optional DHI or HWS vent (if used) carton for damage. If
any carton is damaged, note it when signing for it. Remove the
equipment from the carton(s) and advise the carrier of any dam-
ages at once.
Important notice:
The instructions herein are intended for the use of a qualied
technician, specically trained and experienced in the installation
of this type of heating equipment. Some states or provinces require that installation and service people performing the installa-
tion be licensed. If this is the case in the state or province where
heater is located the contractor must be properly licensed.
! WARNING; Failure to comply with the appliance and
vent package Installation Instructions and service instruc-
tions In this manual may result in equipment damage, re,
asphyxiation, or carbon monoxide poisoning. Exposure to
products of incomplete combustion (carbon monoxide) can
cause cancer and birth defects or other reproductive harm.
Conformance with codes:
The heater shall be installed in accordance with all local and
state codes. The heater installation and vent sizing, installation
and termination shall conform with the National Fuel Gas Code
ANSI Z223.1 (latest edition) and with the requirements of the
authority having jurisdiction. Design Certication in the United
States is in compliance with American National Standard Z21.56
(latest edition).
For Canadian installations, the heater is to be installed in
accordance with standards CAN/CGA -B149.1 and B149.2 - INSTALLATION CODES FOR GAS-BURNING APPLIANCES AND
EQUIPMENT and/or Local Codes, and, if applicable, Standard
CSA C22.1 - CANADIAN ELECTRICAL CODE, Part 1.
12”
MIN.
12”
MIN.
Sea level/high altitude installation:
The H-Series heaters may be installed up to 2000 feet of
elevation above sea level. For elevations from 2000 to 4500 feet
above sea level, heater shall be a high altitude model which has
a sufx “H” in the heater model designation (Example: Model
H400H1). For elevations above 4500 feet, consult customer
service at Hayward.
Location of heater:
Locate the pool/spa heater in an area where leakage of 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
restrict air ow.
This heater must be installed at least ve feet from the inside
wall of a pool/spa unless separated from the pool/spa by a solid
fence, wall or other permanent solid barrier. This heater must be
installed also at least ve feet from the wall of an above-ground
pool.
Flooring:
The H-Series pool/spa heaters must be installed on a noncombustible oor or slab. Installation on other oors may be
accomplished provided the oor under the appliance is protected
with hollow masonry not less than 4 inches thick covered with
sheet metal of not less than 24 gauge. Such masonry must be
laid with ends unsealed and joints matched in such a way as to
provide a free circulation of air from side to side through masonry. The masonry must extend a minimum of 12 inches beyond
the heater to all sides. See Figure 4. In all cases, oor protection
is the responsibility of the installer and the installer must check
to be certain that the oor is not exposed to excessive heat during extended periods of operation.
12”
MIN.
12”
MIN.
INSTALLATION ON CONCRETE SLAB
Figure 4
INSTALLATION ON BLOCKS
5
SECTION 3. INSTALLATION
Outdoor/Indoor vents:
The H-Series heaters may be installed
outdoors when equipped with the integral vent
(Figure 5) or the optional high wind HWS vent
(Figure 6). For indoor installations, a DHI vent
(Figure 7) must be used. All models except the
H210 may be installed indoor using a DHI vent.
The H210 cannot be installed indoor.
! NOTE: For Canadian indoor installations,
these heaters can only be installed in an enclosure that is not normally occupied and does not
directly communicate with occupied areas; i.e.
outdoor shelter.
Check to be sure that the vent supplied with
the heater is the correct one for the installation
location.
Outdoor heater-high
wind conditions:
Figure 5: Integral Vent
In areas where high winds are a daily occurrence, or where severe downdrafts are present
due to surrounding structures, it may be necessary to install the HWS high wind vent (Figure
6). Installation instructions are provided in the
carton with the HWS vent.
Figure 6: High Wind Vent (HWS) Figure 7: Indoor Drafthood (DHI)
6
SECTION 3. INSTALLATION
Reversible water connections:
The H-Series heater is designed so that it can be installed with
the water connections located on either the left or right side of the
heater. Heaters are shipped from the factory with the water con-
nections on the right side. To bring the water connections to the
left side, follow the step-by-step instructions below and refer to the
illustration in Figure 8. A trained service technician should perform
these procedures before the heater is installed.
1. Lift up and remove heater integral vent.
2. Remove screws from left and right side access panels and re-
move the panels.
3. Remove screws from rear heat shield and remove heat shield.
4. Remove screws from top rain guard and remove rain guard.
5. Disconnect high limit wires from the main harness and/or terminal
block. Pull the high limit wires through oval slot in the intermediate
panel. Disconnect wires from the pressure switch. Reroute the
disconnected main harness wires to opposite side of heater.
6. Remove the pressure switch tube and pull through oval slot in the
intermediate panel.
7. Millivolt Heaters Only - Remove the thermostat bulb from the
front header and reroute to opposite side of heater.
! NOTE: Using needle nose pliers to pull out copper strip makes
bulb removal easier. Pull thermostat capillary tube and bulb through
oval slots in the intermediate panel.
! CAUTION: Be careful not to crimp capillary tube as they could
break from mishandling.
8. Electronic Heaters Only - Disconnect thermistor leads from
control panel and pull through intermediate panel.
9. Remove the drain valve and brass plug from the front header and
save for reinstallation.
10. Remove the four screws from the ue collector and remove ue
collector from heater.
11. Remove 12 nuts retaining front header and carefully remove
header. CAUTION: By-pass and thermal governor may become
dislodged when removing front heater. They must be reinstalled
properly prior to reinstallation of front header. CAUTION: Header
O-rings may be reused if not permanently deformed. If installing
new O-rings, Jack’s 327 Lube may be liberally applied to O-rings
to keep them in place during header installation.
12. Lift out heat exchanger and rotate it 180 degrees horizontally.
CAUTION: DO NOT FLIP IT OVER. THE HEAT EXCHANGER
WILL BE DAMAGED IF INSTALLED INCORRECTLY. CAUTION: Care must be taken not to damage top corners of com-
bustion chamber panels.
13. Reinstall front header on heat exchanger (TOP marking on
header should now be on the bottom).
14. Torque nuts from 5 to 7 ft.-lbs. in the sequence shown in
Figure 8. Install drain previously removed into the bottom
header, and install brass plug into the top. Use new sealant on
the threads of these parts before reinstalling. Do over tighten.
15. Move the pressure switch tube over to the left side of the heater
and route through hole in the intermediate panel. Insert tube in
tting and tighten the ferrule down with the nut.
16. Replace the ue collector and secure with the four screws. Make
sure insulation strips on ue collector remain in place.
17. Millivolt Heaters Only - Carefully route the thermostat capillary
tube and bulb to the heater left side and route bulb through the
oval slot in the intermediate panel. Place thermostat bulb back in
the bulbwell using the copper strip to hold the bulbs all the way
into the bulb-well.
18. Electronic Heaters Only - Route thermistor leads through intermediate panel and plug into control panel.
19. Pull high limit wires through oval slot in the intermediate panel.
Reattach the main harness wires to the limit switches wires.
Reattach wires to pressure switch.
20. Replace the heater front door.
21. Replace the top rain guard and secure with screws removed in
step 4.
22. Replace the rear heat shield and secure with screws
removed in step 3.
23. Place access covers on the opposite sides and secure with
screws removed in step 2.
24. Replace heater top.
25. Check for any possible leaks after initial ltration system
start-up.
Heater
Top
Rain
Guard
Flue
Collector
101275
Hi-Limit
Wire Harness
Pressure
Switch Tube
Right Access
Panels
Thermostat
Bulbs
4
2
Heat
Exchanger
Left Access
Panel
1
3 9 11 8 6
Figure 8
7
SECTION 3. INSTALLATION
Outdoor installation and venting:
The following installation and service clearances must
be maintained from surfaces to provide adequate air ow to
the heater.
Outdoor Installations
Top - Open and unobstructed
Front - Unobstructed
Back - 6”
Non-combustible oor
Right side (Water side) - 12”
Left side - 6”
Figure 9
1. Outdoor models with integral vent or HWS vent are
self-venting and do 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. When locating an outdoor model consider that high winds can
roll over or deect off adjacent buildings, walls, and shrubbery
to create a negative draft causing ame rollout and sooting, reducing combustion efciency and damaging controls.
Normally, placing the heater at least 2 feet from any wall will
prevent this condition.
A venting system shall terminate at least 3 feet above any
forced air inlet located within 10 feet. See Figure 10.
! WARNING: (Canadian Installations Only) - The venting
system shall not be installed with the top of the vent assembly
within 10 feet below or to either side of any opening into the
building.
5. Do not install this appliance under an overhang less than 3
feet from the top of the appliance. The area under the over-
hang must be open on three sides.
6. Do not install heater directly under a roof overhang edge that
is not equipped with a rain gutter. Cascading rain water off the
roof edge could otherwise cause pilot outage or other operating problems.
7. Do not install heater where water spray from ground sprinklers
can contact heater. Sprinkler water could cause pilot outage
or other operating problems.
8. Do not install within 3 feet of an air conditioning condensing unit. Blown air from a condensing unit adjacent to heater
could cause pilot outage, poor combustion, or other operating
problems.
9. Do not install under a deck.
10. Any enclosure around the heater must provide a combustion
air vent commencing within 12 inches of the bottom of the
enclosure. The vent opening shall have a minimum free area
of 1 square inch per 4,000 BTU per hour of total input rating
of all heaters in the enclosure. See Figure 11.
4. The venting system shall terminate at least 4 feet below, 4
feet horizontally from, or 1 foot above any door, window, or
gravity air inlet into any building. The bottom of the vent terminal shall be located at least 12 inches above grade.
4’ MIN.
4’ MIN.
FORCED
AIR
3’ MIN.
INTAKE
10’
MIN.
OUTDOOR
EQUIPMENT ENCLOSURE
(BLOCK WALL
OR OTHER FENCING)
OPEN OR GRATED TOP
HEATER INSIDE ENCLOSURE
COMBUSTION
AIR VENT
12”
OR
LESS
Figure 10: Outdoor Installation Figure 11: Outdoor Enclosure
8
SECTION 3. INSTALLATION
Indoor installation and venting:
The following installation and service clearances must be
maintained from combustible materials.
Indoor Installations*
Top - 36”
Non-combustible oor
Front - Unobstructed
Vent - 6”
Back - 6”
Right side (Water side) - 12”
Left side - 6”
Figure 12
*Canada outdoor shelters
Do not Install In a closet!
Do not install an H210 indoor!
For alcove installations, the drafthood (DHI) shall be installed
so as to be in the same atmospheric pressure zone as the combustion air inlet to the pool heater.
Air supply:
Indoor installations and outdoor shelters must be provided
with adequate combustion and ventilation air vents to assure
proper heater operation. These vents must be sized according
to the requirements stated in A. and B. below and must never be
obstructed when heater is in operation.
When air blowers are used in spa/hot tub installations, caution must be observed to insure sufcient combustion air is available to the gas heater for proper combustion. A separate blower
air duct is recommended.
Equipment located in conned spaces:
A. All Air Supply From Inside The Building: The conned
space shall be provided with two permanent openings communicating directly with an additional room(s) of sufcient
volume so that the combined volume of all spaces meets the
criteria for an unconned space (a space whose volume is
not less than 50 cubic feet per 1000 BTUH). The total input
of all gas utilization equipment installed in the combined
space shall be considered in making this determination. Each
opening shall have a minimum free area of 1 square inch per
1,000 BTU per hour of the total input rating of all gas utilization equipment in the conned space, but not less than 100
square inches. See Figure 13. One opening shall be within
12 inches of the top and one within 12 inches of the bottom of
the enclosure.
B. All Air Supply From Outdoors: The conned space shall
be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within
12 inches of the bottom of the enclosure. The openings shall
communicate directly, or by ducts, with the outdoors or spac-
es (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening
shall have a minimum free area of 1 square inch per 4,000
BTU per hour of total input rating of all equipment in the enclosure. See Figure 13.
2. When communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 square
inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure. See Figure 13.
3. When communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1
square inch per 2,000 BTU per hour of total input rating of all
equipment in the enclosure. See Figure 13.
4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be
not less than 3 inches.
! NOTE: For more detailed methods of providing air for com-
bustion and ventilation, refer to latest edition of the National Fuel
Gas Code, ANSI Z223.1.
Free Area per Btu
Requirement
1 sq. in. per
1,000 btu/hr
(paragraph A)
1 sq. in. per
2,000 btu/hr
(paragraph B-3)
1 sq. in. per
4,000 btu/hr
(paragraph B-1)
1 sq. in. per
250 btu/hr
(below-ground
installation)
Total Input
(btu/hr)
150,000 150 150
200,000 200 200
250,000 250 250
300,000 300 300
350,000 350 350
400,000 400 400
150,000 75 75
200,000 100 100
250,000 125 125
300,000 150 150
350,000 175 175
400,000 200 200
150,000 37.5 37.5
200,000 50 50
250,000 62.5 62.5
300,000 75 75
350,000 87.5 87.5
400,000 100 100
150,000 600 600
200,000 800 800
250,000 1000 1000
300,000 1200 1200
350,000 1400 1400
400,000 1600 1600
Combustion Air
Free Area
Required
(sq. in.)
Figure 13
Ventilation Air
Free Area
Required
(sq. in.)
9
SECTION 3. INSTALLATION
INDOOR MODELS
TYPICAL INSTALLATION
VENTILATION
AIR
Figure 16: Vent Top Installation
VENT CAP
DOUBLE WALL
VENT PIPE
THRU APPROVED
ROOF JACK
VENTILATION
AIR
SEDIMENT TRAP
Figure 17: Indoor Installation
NATURAL GAS ONLY
BELOW GROUND
INSTALLATION
GRILL SIZE FOUR SQUARE INCHES
PER 1000 BTUH
FOR EACH GRILLE
DHI VENT BACKDRAFT
DIVERTER MUST BE INSTALLED
DIRECTLY ON HEATER
WATER CONNECTIONS
DO NOT RESTRICT
OR REDUCE PIPE SIZE
GAS SUPPLY
SEE CHART
FOR SIZE
SEDIMENT TRAP
CHECK VALVE
10’
2’
DRIP TEE
GAS COCK
VENTILATION
AIR
OUTLET
DRIP TEE
DHI VENT
BACKDRAFT
DIVERTER
DO NOT ALTER
OR CUT NECK
GAS COCK
VENT PIPE
DO NOT ALTER
OR CUT NECK
GAS COCK
(OPTIONAL)
GRADUAL RISE
OF ONE INCH
PER FOOT
LEVEL NON-COMBUSTIBLE
10’
2’
LEVEL
NON-COMBUSTIBLE
FLOORING OR SLAB
DHI VENT
BACKDRAFT
DIVERTER
DO NOT ALTER
OR CUT NECK
FLOORING OR SLAB
VENT CAP
GROUND LEVEL
RISE OF ONE
INCH PER FOOT
VENT CAP
DOUBLE WALL
VENT PIPE
THRU APPROVED
ROOF JACK
COMBUSTION
AIR
PLASTIC PIPE
(PVC, ETC.)
COMBUSTION
AIR
COMBUSTION
AIR
TO BASE
AIR DUCT
FROM GROUND
INLET
Venting:
Locate the pool/spa heater as close as practical to a chimney
or gas vent. See Figures 16,17 and 18. Do not alter back draft
diverter (DHI) in any way. Install draft diverter (DHI) on top of
heater.
Vent material should be of blued steel or galvanized steel
with double wall construction when passing through walls or a
ceiling. Vent size diameters for the H-Series heaters are as per
Figure 19.
Vent Size Diameters
Model Vent Diameter
H150 6”
H200 7”
H250 7”
H300 8”
H350 9”
H400 9”
Figure 19
The discharge opening of the vent must be at least three
feet above the roof surface and at least two feet higher than any
portion of a building within ten feet horizontally. The vent stack
shall be at least ve feet in height above the drafthood outlet.
The vent cap location shall have a minimum clearance of 4 feet
horizontally from electric meters, gas meters, regulators and
relief openings.
The weight of the vent or chimney must not rest on the heater
drafthood. Support must be provided in accordance with the applicable codes. The DHI drafthood must be easily removable for
maintenance and inspection. The vent pipe must be supported
to maintain proper clearances from combustibles.
Venting extending above the roof by more than ve feet
should be guyed or braced above or below the roof to protect
the vent from wind and/or snow damage.
SEDIMENT TRAP
LEVEL NON-COMBUSTIBLE
FLOORING OR SLAB
Figure 18: Below Ground Installation
10
SECTION 3. INSTALLATION
Model
btu/hr
Line
Material
Model
btu/hr
input
Line
Iron
Iron
Iron
Iron
Iron
Iron
Iron
¾" ⅞" ¾" ⅞" 1" 1⅛" 1" 1⅛" 1" 1⅛" 1" 1⅛" 1"
¾" 1⅛" 1" 1⅛" 1" 1⅛" 1" 1⅛" 1" 1¼" 1¼"
1" 1⅛" 1" 1¼" 1¼" 1¼" 1¼" 1¼"
1" 1¼" 1¼" 1¼" 1¼" 1¼" 1½"
Model
btu/hr
input
Line
Second
Stage**
Model
btu/hr
input
Line
Iron
Iron
Iron
Iron
Iron
Iron
Iron
½" ½" ½" ½" ½" ½" ½" ½" ½" ½" ½" ½" ½" ½"
½" ½" ½" ½" ½" ½" ½" ½" ½" ½" ½" ⅝" ½" ⅝"
½" ½" ½" ½" ½" ½" ½" ½" ½" ⅝" ½" ⅝" ½" ⅝"
Second
MetertoHeaterGas
H150
H200
H250
H300
H350
H400
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
1¼"
50to100ft
1"1"1¼"
1¼"
1¼"
1¼"
0to50ft
¾"1"1"
1¼"
1¼"
1½"
200to300ft
1¼"
1¼"
1½"2"2"
2"
100to200ft
1¼"
1¼"
1¼"
1½"
1½"
0to50ft
DistancefromTank
H150
H200
H250
H300
H350
H400
50to100ft
100to200ft
200to300ft
Baseduponaninletgaspressureof11inwcatapressuredropof0.5inwc
RegulatortoInletof
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
IronorPlastic
FirstStage
0to50ft
½"½"½"
½"
100to150ft
½"½"½"
½"
½"
½"
¾"¾"¾"
*Baseduponaninletgaspressureof2psigatapressuredropof1psi
**Baseduponaninletgaspressureof10inwcatapressuredropof0.5inwc
DistancefromTank
H150
H200
H250
H300
H350
H400
½"
H210
New Figure 20 for Manual 1302704001 rev F, page 11
VEW 2/7/2013
H210
IronorPlastic
1"
1¼"
1¼"
1½"
H210
FirstStage
0to50ft
50to100ft
100to150ft
*Baseduponaninletgaspressureof10psigatapressuredropof1psi
Gas supply and piping:
Refer to the charts on Figure 20 for gas pipe sizing for low pressure natural gas, low pressure single propane gas and high pressure two stage propane gas systems.
Gas Pipe Size: Follow local gas codes for proper gas Hoe material selection (copper, Iron or plastic pipe etc.)
Natural Gas Pipe Sizing, Low-Pressure, Single-Stage Regulation
DistancefromGas
ValveInlet
Baseduponaninletgaspressureof0.5psigorlessatapressuredropof0.5inwc
RegulatorOutletto
HeaterGasValve
Inlet
Distancefrom
Outletof1stStage
2ndStageRegulator
input
Material
Material
150,000 200,000 250,000 300,000 350,000 400,000
Pipe
Propane Gas Pipe Sizing, Low-Pressure, Single-Stage Regulation
150,000
Tubing
Pipe
H150 H200 H250 H300
150,000 200,000 250,000 300,000 350,000 400,000
Pipe
Pipe
200,000 250,000 300,000 350,000 400,000
Tubing
Pipe
Natural Gas Pipe Sizing, High-Pressure, 2-Stage Regulation
Pipe
210,000
Pipe
210,000
Pipe
H210
210,000
Pipe
Tubing
Pipe
Pipe
Pipe
Tubing
Pipe
Pipe
Pipe
Tubing
Pipe
Tubing
Pipe
H350 H400
Pipe
Pipe
Pipe
Tubing
Pipe
*
RegulatorOutletto
*
Stage**
**Baseduponaninletgaspressureof11inwcatapressuredropof0.5inwc
50to100ft ½" ½" ½" ½" ¾" ¾"
0to10ft ¾" ¾" ¾" ¾" ¾" ¾"
HeaterGasValve
Inlet
0to10ft
Material
150,000
Tubing
Pipe
½" ⅝" ½" ⅝" ½" ¾" ½" ¾" ¾" ¾" ¾" ⅞" ¾" ⅞"
½"
¾"
Propane Gas Pipe Sizing, High-Pressure, 2-Stage Regulation
200,000 250,000 300,000 350,000 400,000
Tubing
Pipe
Pipe
210,000
Tubing
Pipe
Tubing
Pipe
Tubing
Pipe
Tubing
Pipe
Tubing
11
SECTION 3. INSTALLATION
All gas installations:
The H-Series heater is to be installed with a gas connection
located on the left side (or right side, if necessary). Insert the
pipe to the gas valve through the star-slit black plastic cap in
the cabinet side. It is recommended that a ground-joint union be
installed inside (or outside if space does not allow) the heater
cabinet to facilitate servicing the burner assembly tray. See
Figure 21.
An A.G.A Certied main gas valve shutoff must be installed
outside of cabinet and within 6 feet of the heater. Gas shutoff
valve must have an l.D. large enough to supply the proper
amount of gas volume to the heater.
! NOTE: Apply joint compounds (pipe dope) sparingly and
only to the male threads of pipe joints. Do not apply joint compound to the rst two threads. Use joint compounds resistant to
the action of liqueed petroleum gas. Do not over tighten the gas
inlet pipe or damage may result. See Figure 21.
To prevent dirt and moisture from entering gas valve, a sediment trap should be installed in the gas line close to the valve.
See Figure 21.
6’ MAX.
GAS
GAS
SUPPLY
MANUAL
SHUT OFF
VALV E
UNION
3” TYPICAL
SEDIMENT
TRAP
SUBJECT TO
LOCAL CODES
HEATER CABINET
Figure 21: Sediment Trap
Do not use exible appliance connectors on any gas
connections unless the connector is A.G.A. approved for
outdoor installation, is marked with the BTUH capacity
(which must be equal to or greater than the heater rated
input), and the type of gas (Natural or LP) to be used.
Reduction of the 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”).
If more than one appliance is installed on the gas line, consult
the local gas company for the proper gas line size.
Any questions concerning the installation of the proper gas
line size can be directed to Hayward Technical Service. Tele-
phone numbers can be found in Troubleshooting Guide Section.
NATURAL GAS
The gas meter must have the capacity to supply enough
gas to the pool heater and any other gas appliances if they are
on the same pipe-line (Example: 225 meter = 225,000 BTUH).
VALV E
If doubt exists as to the meter size, consult local gas utility for
assistance. Hayward will not be responsible for heaters that
soot up due to improper meter and gas line sizing resulting in
improper gas volume.
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 edition) and applicable local codes. If propane gas tank is installed
underground, the discharge of the regulator vent must be above
the highest probable water level.
Propane tanks must be sufcient capacity to provide ad-
equate vaporization for the full capacity of the equipment at the
lowest expected temperatures. Consult a propane company
expert for correct sizing.
! NOTE: Whenever a high pressure double regulation system is utilized for propane gas, consult a propane professional
for accurate pipe and pressure sizing. Make sure that 1st and
2nd stage regulators are large enough to handle the BTUH input
listed for the heater(s) being used.
Hayward will not be responsible for heaters that soot up due
to improper gas line or Propane tank sizing resulting in improper
gas volume.
Water piping:
The H-Series heater is designed for use with pool and spa/
hot tub water only, as furnished by municipal water distribution
systems and puried by an automatic chlorinator or salt chlorine
generator. The warranty does not cover heater use with mineral
water, sea water, salt or other non-potable waters.
Do not install any restriction in the water pipe between heater
outlet and pool/spa with the exception of a three-way switching valve and an in-line chlorinator and associated check valve.
Blockage of water ow from heater return to pool may result in
re or explosion causing property damage, personal injury or
loss of life.
FRONT HEADER
O-RINGS
INLET - TOWARDS
FRONT OF HEATER
FLANGE PIPE
NIPPLES
Figure 22: Pipe Nipple Installation
OUTLET - TOWARDS
BACK OF HEATER
UNION NUTS
TURN CLOCKWISE
TO TIGHTEN. HAND
TIGHTEN ONLY.
12
Plumbing connections:
1. The H-Series heater is equipped with CPVC SCH-80
anged pipe nipples, union nuts, neoprene O-rings
for use with 2” pipe connections. Figure 22 shows the
method for installing these parts on the front header.
! NOTE: Assemble these parts to heater prior to plumb-
ing. Tighten union nuts securely before gluing ttings to
ends of pipe nipples.
2. The CPVC SCH-80 anged pipe nipples must be
installed on the heater inlet and outlet without modication. CPVC SCH-80 plastic has an ASTM rating of F441
and is NSF approved. The opposite ends of the pipe
nipples should be attached to the ltration system as
particular installation dictates.
3. Pipe, ttings, valves and any other element of the lter
system may be made of plastic materials, if acceptable
by the authority having jurisdiction. 1 1/2” plastic pipe if
used, will slide directly into the anged pipe ends.
4. Heat sinks (heat traps), reman switches and check
valves are not necessary on the H-Series heaters.
However, if there is any chance of “back-siphoning” of
hot water when the pump stops running, it is suggested
that a check valve be used on the heater inlet pipe.
5. The vari-o by-pass that is built into the front header
will maintain proper ow through the heat exchanger
if the ow rate is within the range for the heater. See
Figure 23.
RECOMMENDED FLOW RATE IN GPM
Model Minimum Maximum
H150-H400 25 125
Figure 23
SECTION 3. INSTALLATION
CONNECTION
TO HEATER
OUTLET
CONNECTION
TO HEATER
INTLET
FROM PUMP
AND FILTER
Figure 24: Manual By-pass Valve
TO POOL
MAIN
DRAIN
FROM
POOL
POOL
SPA
3-WAY
VALV E
Figure 25: Typical Plumbing To Pool
3-WAY VALVE
RELIEF
VALV E
OPTION
HEATER
BALANCING VALVES
FOR SKIMMER
AND DRAIN
FLOW METER
VALV E
RETURN TO
POOL/SPA
MANUAL
BY-PASS
VALV E
(if necessary)
FILTER
PUMP
6. If the normal pump and lter system ow rate exceeds
125 gpm then a manual by-pass valve, as shown in
Figure 24, must be installed as follows: Install a ow
meter on the outlet line of the heater. Adjust the manual
by-pass valve until the ow rate is within the rates re-
quired for the heater. Once the valve is set, the position
should be noted and the valve handle removed to avoid
further adjustment.
7. Figure 25 shows a typical pool piping diagram and layout for pool equipment. Figure 26 shows multiple heater
usage for very large pools with and without an external
by-pass (balancing) valve.
THERMOMETER
2”
FROM FILTER
THERMOMETER
2”
2”
2”
FROM FILTER
BALANCING VALVE
TO POOL
Figure 26: Multiple Heater Hookups
THERMOMETER
TO POOL
THERMOMETER
ADJUST
BALANCING VALVE
TO OBTAIN A
20ºF DIFFERENTIAL
ACROSS
THERMOMETERS
13
SECTION 3. INSTALLATION
Installation above pool/spa surface:
If heater is installed less than three (3) feet above the surface
of the pool/spa water, install eyeball ttings or directional ow ttings on the end of the return water line to the pool/spa to create
adequate back pressure at the heater to operate the pressure
safety switch when lter pump is running.
If heater is installed more than three (3) feet above surface of
pool/spa water, install a loop as shown on Figure 27 to prevent
drainage of water in heater during lter change.
For installation below pool/spa surface, refer to Section 4.
HIGHER THAN
TOP OF HEATER
HEATER
WATER LEVEL
If used, a chlorinator must be installed down stream from the
heater in the pool return line and at a lower elevation than the
heater outlet connection. See Figure 28. Install a separate positive seal, corrosion resistant check valve (EXAMPLE: Rainbow
Plastics #17288 or #172323) between the heater outlet and chlorinator to prevent highly concentrated sanitizers from back-siphoning into the heater. Back-siphoning usually occurs when the
pump is shut off and a pressure-suction differential is created.
Pressure relief valve:
It may be necessary to install a pressure relief valve to con-
form with local building codes. A 3/4” pressure relief valve with
a discharge capacity greater than or equal to the BTUH input of
the heater and a pressure relief rating less than the heater working pressure is recommended (see rating plate).
PRESSURE RELIEF VALVE
FRONT HEADER
DISCHARGE
CONNECTION
Figure 27: Heater Installation Above Pool
Automatic chlorinators and
chemical feeders:
TOP VIEW
PUMP
FILTER
FROM
POOL
SIDEVIEW
FROM
POOL
PUMP FILTER HEATER
Figure 28: Automatic Chlorinator
HEATER
CHECK
VALV E
CHECK VALVE
OPTIONAL (PREFERRED)
CHLORINATOR HOOKUP
CHECK
VALV E
CHLORINATOR
CHLORINATOR
RETURN
TO POOL
RETURN
TO POOL
PLUMBING
CONNECTIONS
Figure 29: Pressure Relief Valve
A 3/4” NPT connection is provided in the front header for
installation of a pressure relief valve. See Figure 29. The valve
shall be installed directly to the header in a vertical position. To
avoid scalding or water damage due to relief valve operation,
connect a drain pipe to the valve outlet and run the line to a safe
place of discharge. The drain pipe must be at least the same
size as the valve discharge connection throughout its entire
length and must pitch downward from the valve. No shutoff valve
or restriction shall be installed between the relief valve and the
discharge of the drainline. The valve lever should be lifted at
least once a year to ensure that the waterway is clear.
14
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