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Universal heater
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- Contents
- Table of Contents
- Troubleshooting
- Bookmarks
Table of Contents
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Table of Contents
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ICB and Fuse Board Layout
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Sequence of Operation: Normal/Failure to Light
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Gas and Electrical Connections
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How to
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Change/Replace Gas Mixer
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Test/Adjust Gas Pressure
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Burner Inspection
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Change/Replace Combustion Chamber
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Troubleshooting
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Troubleshooting: (Cont.)
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Diagnostic Codes and Part Numbers
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Wiring Diagram
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Heater Not Powering up
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Open FC4 Fuse
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BD" Code
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EE" or "CE" Code
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IO" or "SB" Code
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SF" or "HS" Code
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PF" Code
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HF" Code
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LO: Code
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IF" Code
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AC" Code
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A1, A2, A3" Codes
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B1" Code
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B2" Code
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B3" Code
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B4" Code
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Universal HC Series Heater ®
Troubleshooting Guide
TSG-UHC21a
Copyright 2021 Hayward Holdings
Table ofContents
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Table of Contents
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Summary of Contents for Hayward HC Series
- Page 1 Universal HC Series Heater ® Troubleshooting Guide TSG-UHC21a Copyright 2021 Hayward Holdings...
- Page 2 Safety Precautions Warning High Voltage Electrocution Hazard Hazardous voltage can shock, burn, cause serious injury and or death. To reduce the risk of electrocution and or electric shock hazards: • Turn off power to unit before making repairs • Only qualified technicians should service heater •...
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Page 3: Table Of Contents
Table of Contents ICB and Fuse Board Layout Troubleshooting: (cont.) 27-57 5. “BD” Code Sequence of Operation: Normal/Failure to Light 6. "EE" or "CE" Code Gas and Electrical Connections 7. "IO" or "SB" Code How To: 8-26 8. "SF" or "HS" Code Program Heater Bypass &... -
Page 4: Icb And Fuse Board Layout
Integrated Control Board Layout (ICB) Remote Control: 24VAC (E1) Flame Sensor (E4) Temperature Sensor (E2) Display Output: 24VAC (E7) 3A Fuse (F1) Low Voltage R & C: 24VAC (E12, E13) Gas Valve & Safety Switches: 24VAC (E11) High Voltage: 120VAC (E10) Blower/Inducer (E6) Ignitor (E3) - Page 5 Field Wiring Panel Layout Transformer Secondary: 24VAC (right) & 120VAC (left) (P4) Voltage Selector 240 OR 120VAC determined by plug (P2): NOTE: 240VAC plug factory installed Fuse: 3a protects transformer high voltage secondary, will fail with blower, ignitor or ICB failure (FC4) Fuse: 3A protect primary input voltage, will fail with excessive voltage, improper wiring, shorted transformer or fuse...
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Page 6: Sequence Of Operation: Normal/Failure To Light
UHC Sequence of Operation: Normal The control continually compares the set temp to the actual water temp. When the water temp is 1º below the set point the following sequence starts:... -
Page 7: Gas And Electrical Connections
UHC Electrical & Gas Connection The low voltage and high/line voltage compartments can be reversed but NOT shared. Gas Port Alternate Gas Port 240V Low Voltage Factory Wired 120V See Manual High/Line Voltage Bonding Lug Low Voltage Wiring... -
Page 8: How To
Universal HC Series Heaters® How To:... -
How To: Program Heater Bypass Operation Follow the included steps to place the heater in bypass operation for external control. NOTE: the maximum temperature set point is 104° F. Step 1 Step 2 Press the ‘MENU ICON’ button to place the Press and hold the ‘MINUS’...
- Page 10 How To: Program Temperature Lock-Out Follow the included steps to lock the maximum temperature allowed. NOTE: The default Max temp set points are 90ºF (Pool) 104ºF (Spa). When setting the max temp lock-out set point, the LEDs & display should flash rapidly. Step 1 Step 2 Press the ‘MENU ICON’...
- Page 11 How To: Program Temperature Lock-Out (cont.) NOTE: The default Max temp set points are 90ºF (Pool) 104ºF (Spa). When setting the max temp lock-out set point, the LEDs & display should flash rapidly. Step 5 Step 6 Press the ‘MENU ICON’ button to toggle to the Raise or lower the temperature displayed ‘POOL’...
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Page 12: Change/Replace Gas Mixer
How To: Change/Replace Fuel/Air Mixer Remove screws from header cover Remove screws from control cover Step 1 Step 2 Turn power off, remove the 4 screws from the Lift the cabinet top slightly, then remove the 4 header controls cover and remove the panel. screws from the control cover and remove. -
Page 13: Test/Adjust Gas Pressure
How To: Test/Adjust Gas Pressure Turn off gas supply Inlet: Remove test plug from inlet Step 1 Step 2 Turn off gas supply to heater. Gas readings should Locate the inlet test port on the side of the gas be in line with the chart above. valve, and remove the 1/8”... - Page 14 How To: Test/Adjust Gas Pressure Turn off gas supply Locate test ports Step 1 Step 2 Turn off gas supply to heater. Remove 1/8” Allen Install barbed fitting from manometer in the plug from the pressure port on the gas valve. pressure port of the gas valve..
- Page 15 How To: Test/Adjust Gas Pressure (cont.) NOTE: IF incoming gas pressure is within range, then your manifold pressure should be correct per factory settings. Manometer Connected Verify Pressures are correct Step 5 Step 6 Once the manometer is connected, turn gas back on IF inlet pressures are correct AND the manifold &...
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Page 16: Burner Inspection
Clean/Replace Burner Remove screws from both sides Remove cabinet top Step 1 Step 2 Turn the Power and the gas off to the unit. Remove Carefully lift up on the top of the heater cover and the 2 top screws on each side of the heater as disconnect the ribbon cable from the display, then shown above. - Page 17 Clean/Replace Burner (cont.) Loosen flare nut Remove silicone tubing Step 5 Step 6 Loosen the flare nut from the gas manifold closest Remove the silicone tubing from both ports on the to the blower. Gently pull the manifold out of blower.
- Page 18 Clean/Replace Burner (cont.) Remove blower/burner assembly Remove blower nuts Step 9 Step 10 Remove the 4 each 7/16” nuts that hold the blower Slide left slightly and then lift the blower / burner assembly to the burner. assembly straight up out of the heater. Remove blower assembly Clean burner Step 11...
- Page 19 Clean/Replace Burner (cont.) Blow out burner Vacuum burner Step 13 Step 14 Using compressed air blow the burner out from the Turn the burner over and shake out any loose dirt front to the rear. Make sure that you blow around and debris.
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Page 20: Change/Replace Combustion Chamber
Change/Replace Combustion Chamber Disconnect gas & water unions Remove screw from Display Step 1 Step 2 Turn Power and gas off to unit, disconnect the gas Using a 5/16 nut driver or #2 Phillips Head line and plumbing unions from the heater. screwdriver, remove screw from below display. - Page 21 Change/Replace Combustion Chamber (cont.) Remove cabinet top Remove wiring cover Step 5 Step 6 Lift to remove top cover. Use caution when Remove screw from front wiring cover (shown left) removing, so you do not lose the screw tabs. Remove plastic wiring cover (shown right). Disconnect wiring Remove top plate Step 7...
- Page 22 Change/Replace Combustion Chamber (cont.) Remove exhaust side cover Remove water side cover Step 9 Step 10 Remove the 7 screws (left pic.). Lift up and then On the water side of the heater, remove the 5 pull out on the bottom of the panel and slide down screws from the top panel &...
- Page 23 Change/Replace Combustion Chamber (cont.) Remove front & rear panels Remove wires from limit switches Step 13 Step 14 Remove the 4 screws from the bottom of the front Use needle nose pliers to remove the 2 red wires and rear panels and pull up and out to remove from each of the high limit switches.
- Page 24 Change/Replace Combustion Chamber (cont.) Remove flame sensor Remove wire harness screw Step 17 Step 18 Remove the 2 screws from Ignitor pull out slightly Remove screw from the wire harness holder (left). then rotate 180 degrees then pull rest of way out. Remove wires from holder and set aside.
- Page 25 Change/Replace Combustion Chamber (cont.) Remove gas valve wiring Remove vent pipe Step 21 Step 22 Locate and remove the 4 screws (right) from the Using needle nose pliers, remove the black and vent pipe assembly and remove. white wire from the gas valve. Remove blower Step 23 Remove the 4 nuts from the bottom of the blower...
- Page 26 Change/Replace Combustion Chamber (cont.) Remove burner assembly Remove heat exchanger Step 25 Step 24 Remove the 6 screws at bottom of combustion Remove the 16 perimeter screws from the burner chamber. Remove 2, 7/16”nuts on each side of assembly. Lift up on the burner to remove chamber (right pics).
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Page 27: Troubleshooting
Universal HC Series Heater® Troubleshooting:... -
Page 28: Diagnostic Codes And Part Numbers
Diagnostic Codes Below is a list of all Diagnostic Codes for the HDF Heater. Troubleshooting Steps for each Code are covered on the following pages. Diagnostic Description Code Blower Vacuum Switch closed Air switch circuit open before ignitor warm-up Air switch circuit open after ignitor warm-up Air switch circuit open after post purge Ignition control board data error Gas valve sensed "ON"... - Page 29 Part Numbers Description The following outlines the various replacement parts required for this Service Kit SKU Description Service Kit SKU Cabinet Top HDXFTOP001 troubleshooting guide. Burner HDXFBRN001 Control Access Panel Assy. HDXFCAP001 Exhaust Pipe Assembly HDXFEXP001 Header Controls Cover HDXFHCC001 HDF Inlet/Outlet Header Kit HDXFIOH001 Water Side Trim Panels...
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Page 30: Wiring Diagram
Wiring Connection Diagram... -
Page 31: Heater Not Powering Up
1. Heater Not Powering Up Check Incoming Power Voltage selector plug Step 1A Step 1B IF voltage is present, go to step 1B. IF voltage is Verify selector plug matches incoming line power. incorrect, correct source power. IF it does not, power OFF & correct. IF OK, go to 1C. Inspect connections Test Fuses Step 1C... - Page 32 1. Heater Not Powering Up (cont.) Test transformer input Test transformer output Step 1E Step 1F Disconnect the P3 plug from field wiring panel Disconnect P4 plug from FWP. Verify 22-28VAC (FWP). Test 110-125VAC between pins 1&2 and between pins 1 & 2 (red wires), then 110-125VAC 3&4 on the board.
- Page 33 1. Heater Not Powering Up (cont.) Inspect wiring Test ICB input (low voltage) Step 1H Step 1I Inspect ICB wiring, ensuring all plugs are securely Disconnect and test the red and grey wires from fastened. IF wiring is OK go to Step 1I. IF NOT, the ICB.
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2. Open FC1 &/or F2 Fuse Verify voltage selector plug Inspect transformer wiring Step 2A Step 2B IF voltage selector plug matches voltage, go to step Inspect transformer wiring, ensuring the insulation 2B. IF not, power down, replace FC1 & FC2 fuses, & on the wiring is not damaged.
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3. Open F1 Fuse Inspect connections/high limits Inspect water pressure switch Step 3B Step 3A Power down and inspect all remote connections With power off, inspect the water pressure switch and high limit wiring for damage. IF damaged, wiring for damage. IF damaged, replace the wire repair/replace (pg.
- Page 36 3. Open F1 Fuse (cont.) When testing the gas valve, if continuity appears between any wires and ground, then this implies a short has occurred and the gas valve will need to be replaced. Verify gas valve is not shorted ICB wiring Step 3F Step 3E...
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Page 37: Open Fc4 Fuse
4. Open FC4 Fuse Ignitor and blower wiring Verify ignitor resistance Step 4B Step 4A Inspect the Ignitor & Blower wiring. Verify Disconnect ignitor from ICB & measure resistance insulation is not damaged. IF wires are damaged, of ignitor. Verify 8-25 ohms between 20°-140°F. IF replace the damaged part (pg. -
Page 38: Bd" Code
5. Service LED ON: ‘BD’ Code Verify transformer output Test the FC4 fuse (continuity) Step 5B Step 5A Disconnect P4 from fuse board. Verify 110-125VAC With power off, verify the FC4 fuse has continuity. between 4-6 (grey wires). IF OK, replace fuse IF fuse is good, go to 5B. -
Page 39: Ee" Or "Ce" Code
6. Service LED ON: “EE” OR “CE” Code “EE” Code “CE” Code Step 6B Step 6A “EE” error indicates the you have a defective ICB “CE” (communication error) indicates a problem board. IF this error appears, replace ICB (pg. 25). IF between the ICB &... -
Page 40: Io" Or "Sb" Code
7. Service LED ON: “IO” OR “SB” Code “IO” Code Inspect ignitor wires Step 7B Step 7A “IO” error indicates ignitor open. IF this error Verify ignitor is securely attached to ICB. If OK, appears, go to step 7B. IF “IO” does not appear, go inspect wires for damage. -
Page 41: Sf" Or "Hs" Code
8. Service LED ON: “SF” OR “HS” Code The “HS” (High Sense (water temperature)) will appear if the water sensor is reading above 105° OR if the sensor detects an increase of more than 6° with-in 60 seconds. Verify the pump is running & adequate water is flowing through heater. “SF”... -
Page 42: Pf" Code
9. Service LED ON: “PF” Code “Polarity Failure” This code will display if low voltage is detected, if the ground path is not sufficient, or the ICB is defective. Reset is immediate after error is corrected. Verify incoming power Line voltage connections Step 9A Step 9B Ensure voltage is within 10% + or –... -
Page 43: Hf" Code
10. Service LED ON: “HF” Code “HF” (heat or flame sensed) will occur if flame is sensed when the gas valve is off, the control will go into lockout. The blower will continuously run until corrected. When corrected, control will run blower for 5 seconds then restart heater after 2 minutes. Power cycle heater Call for heat and test gas valve Step 10A... -
Page 44: Lo: Code
11. Service LED ON: “LO” Code “LO” Code (Limit Open) may relate to water flow. Verify the pump is running & adequate water is flowing through heater. “LO” is NORMAL when the pump is turned off or there is insufficient water flow. Inspect water pressure switch Voltage test Step 11A... - Page 45 11. Service LED ON: “LO” Code “LO” Code (Limit Open) may relate to water flow. Verify the pump is running & adequate water is flowing through heater. “LO” is NORMAL when the pump is turned off or there is insufficient water flow. Test pressure switch voltage Test pressure switch voltage (cont.) Step 11C...
- Page 46 11. Service LED ON: “LO” Code (cont.) The water pressure switch should not need adjusting, some sites may require a water pressure switch adjustment Pressure switch adjustment Inspect and test high limits Step 11E Step 11F If adjustment is required refer to the water Inspect &...
- Page 47 11. Service LED ON: “LO” Code (cont.) Note: This exhaust gas limit switch is a one time safety. Once the switch has tripped then it NEEDS to be replaced and the combustion chamber should be inspected for soot or damage. Indoor/Outdoor Step 11G With one meter lead on the gas valve white wire (page 40, Step 11B), take other meter lead...
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Page 48: If" Code
12. Service LED ON: “IF” Code Inspect main gas supply Verify gas valve is ON Step 12B Step 12A IF “Ignition Failure”, Ensure main gas supply is in Verify that the gas valve, inside the heater, is in the the ON position. IF ON, go to step 12B. IF NOT, “ON”... - Page 49 12. Service LED ON: “IF” Code (cont.) Voltage/pressure off gas valve Verify correct flame sensor Step 12F Step 12E Verify 22-28VAC on gas valve (black & white wires) Verify that the installed flame sensor is clean and during ignition trial. IF present & no pressure free of any damage, if flame sensor is damaged (manometer attached), replace valve.
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Page 50: Ac" Code
13. Service LED ON: “AC” Code “AC” Code stands for “Air Switch Closed”. The differential pressure switch is closed, when it was expected to be open. Test differential pressure switch Verify blower operation Step 13B Step 13A With the heater off (in “Stand By”), IF the blower Isolate the diff. -
Page 51: A1, A2, A3" Codes
14. Service LED ON: “A1, A2, & A3” Code “A1” Code stands for “Air switch circuit open before ignitor warm up”. Differential Pressure Switch (DPS) open when expected closed. The switch circuit never closed when the blower turned on or re-opened within 10 seconds of blower starting. - Page 52 14. Service LED ON: “A1, A2, & A3” Code (cont.) Verify voltage selector plug Check blower tubing Step 14A Step 14B Verify selector plug matches incoming line power. Check blower tubing for damage/loose fit. IF IF it does not, power OFF & correct. IF OK, go to damaged, replace tubing (pg.
- Page 53 14. Service LED ON: “A1, A2, & A3” Code (cont.) Test blower Test differential pressure switch Step 14E Step 14D Test the blower for the proper resistance. Measure Verify diff. pressure switch is open when blower is for 3-5 ohms across red and white terminal wires. off, turn heater on and check to see if dps switch IF out-of-range, replace blower (pg.
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Page 54: B1" Code
15. Service LED ON: “b1” Code “b1” Code stands for “Ignition Control Board (ICB) data error”. If the ICB does not satisfy self-diagnostic on power up or initial trial for ignition, the ICB will lock out until error condition is corrected. Power cycle heater Test incoming power Step 15A... -
Page 55: B2" Code
16. Service LED ON: “b2” Code “b2” Code stands for “Gas valve sensed as “ON” error. If gas valve is powered when it should be off, the heater will shut down and go into lock out. The blower will operate until error condition is corrected. Power cycle heater Call for heat and test gas valve Step 16A... -
Page 56: B3" Code
17. Service LED ON: “b3” Code “b3” Code stands for “Gas valve sensed as “OFF” error. If gas valve is unpowered but flame is sensed, the blower will run for 5 seconds then start a new ignition sequence. If error occurs 10 times during a call for heat, the ICB will go into lockout. -
Page 57: B4" Code
18. Service LED ON: “b4” Code “b4” Code stands for “data retrieval error”. If input data values are corrupted on power up or initial trial for ignition, the ICB will lockout until error condition is corrected. Power cycle heater Test incoming power Step 18A Step 18B Power cycle heater, in an attempt to clear the “b4”...
This manual is also suitable for:
Hdf400Hdf275
