The Hayward HDF400 pool heater can be vented through a wall if installed according to the venting instructions. It requires a sealed stainless steel vent pipe, either single-wall or double-wall. Double-wall vent must be used in non-conditioned spaces. The vent pipe diameter must match the vent outlet on the heater, as specified in Table 8.

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Summary of Contents for Hayward HDF400

Page 1: Table Of Contents
This product must be installed and serviced by au- thorized personnel, qualified in pool/spa heater in- stallation. Improper installation and/or operation can create carbon monoxide gas and flue gases that can cause serious injury, property damage, or death. SAVE THESE INSTRUCTIONS ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 1 ...
Page 2: Getting Started
DISCONNECT IS POOL/SPA IN WATER PIPING TO NO CHEMICAL BALANCE? PRODUCT PRODUCT OPEN CONNECT WATER PIPING TO PRODUCT, BYPASS TO OPEN POSITION POOL/SPA SET BYPASS TO OPEN POSITION, IS HEATING/COOLING NO WATER DIVERTED NEEDED WITHIN 1 WEEK? FROM PRODUCT PRODUCT CLOSED BYPASS TO CLOSED POSITION, WATER DIRECTED TO PRODUCT POOL/SPA TURN ON ELECTRIC POWER AND GAS AS REQUIRED. START PRODUCT. PROGRAM REQUIRED WATER TEMPERATURE ON PRODUCT CONTROL PANEL. ENJOY YOUR POOL/SPA TURN OFF ELECTRIC IS HEATING/COOLING NO POWER AND GAS AS NEEDED FOR REST OF YEAR? REQUIRED 2 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 3 It can also make consumers aware of actions that are unpredictable and unsafe. NOTICE indicates special instructions that are important but not related to hazards. See product rating plate for manufacturer’s information. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 3 ...
Page 4 Figure 1: HEATER CONSTRUCTION AND SUB-ASSEMBLIES Control Access Panel Assembly Cabinet Top Control Assembly Exhaust Box Assembly Combustion Bower and Gas Manifold Assemblies Zero Clearance Panel (Both Sides) Burner Exhaust Side Panel Combustion Chamber Assembly Header Controls Cover Water Side Panels Cabinet Base 4 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 5  Integral water bypass to maintain correct water ﬂow through the heat exchanger. Maximum water ﬂow through the unit is 125 GPM. Model Gas Input Minimum Thermal Heater Heater Natural or Propane Water Flow Eﬃciency Width Weight Btu/hr GPM % in. lbs. HDF400 400,000 30 84 21 135 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 ...
Page 6 The unit wiring diagram is shown in Figure 2. A separate diagram is included in the electrical accessory kit supplied with your unit. This kit is located in the low voltage junction box on the exhaust side of the unit. For more detailed troubleshooting and service instructions. Please refer to HDF Service Kit Instructions supplied with any service part and available on Hayward’s website. 6 ...
Page 7 51300803801 REV B Figure 2: Wiring Diagram ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 7 ...
Page 8 Install two or more suction outlets per pump in accordance with latest ASME, APSP Standards and CPSC guidelines. Follow all applicable National, State, and Local codes.  Installation of a vacuum release or vent system, which relieves entrapping suction, is recommended. 8 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 9 GFCI is defective. If the GFCI interrupts power to the electrical equipment without the test button being pushed, a ground current is flowing, indicating the possibility of an electrical shock. Do not use this electrical equipment. Disconnect the electrical equipment and have the problem corrected by a qualified service representative before using. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 9 ...
Page 10 Inches of Mercury (inHg) is typically used with atmospheric pressure measurements. Pounds per square inch (PSI) is typically used with water “pressure”, “suction” or system measurements. Inches of Water (inwc) is typically used with gas or air pressure measurements (1.0 inHg = .49 PSI = 13.5inwc) 10 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 11: Installation
You may also consider protecting the unit by each of the four creating a physical barrier outside of the minimum clearances be- corners. (4) screws tween the unit and the prevailing beachfront wind. Damage caused total by sand or salt spray is not covered by the warranty. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 11 ...
Page 12: Locating The Heater
(consult NFGC) Table 3: Installation Required Clearances (in.) Heater Panel Outdoor Clearance Indoor Clearance Top Unobstructed 36 Front 18 18 (User Interface) Back* 0** 0** Water Side Connec on 12 12 Exhaust Side Connec on* 6 6 * If the heater is to be installed with vinyl siding behind or on the exhaust side of the heater, increase the clearance in Table 3 to 12 inches to avoid poten al discolora on of siding. ** While the heater is designed for no clearance to combus ble surfaces, it is recommended to leave a small gap for non‐binding removal of the top access panels. 12 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 13 3. Install the Tapcons® through the provided holes in the flanges of the heater feet with the washers on the top of the mounting flanges into the equipment pad. 4. Anchoring is completed when all (4) feet are secured to the pad with washers and Tapcons®. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 13 ...
Page 14 Because of this, observations of how much condensation is created by the unit will vary greatly. Consideration has gone into the design of Hayward’s HDF series pool heater to allow any moisture in the combustion chamber to drain out of the unit. Not allowing moisture to dwell in the unit will increase the life and reliability of your new pool heater.
Page 15: Gas Conversion Procedure
GAS CONVERSION PROCEDURE: These instructions are intended to be used only with the HDF gas pool heaters from Hayward. All HDF heaters are shipped from the factory ready to be installed and used with Natural Gas. If your application requires the use of propane gas (LP), the fuel/air mixer installed in the com- bustion blower inlet must be replaced with the fuel/air mixer designed for use with propane.
Page 16: Altitude Of Installation
51300803801 REV B ALTITUDE OF INSTALLATION: Hayward’s HDF heaters are rated for installations up to, and including, 2,000 ft above sea level. WARNING: Failure to comply with the appliance installation and service instructions in this manual may result in equipment damage, fire, asphyxiation, or carbon monoxide poisoning. Exposure to products of incomplete combustion (carbon monoxide) can cause cancer and birth defects or other reproductive harm.
Page 17 A) 1 sq. in. per 4,000 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 B) 1 sq. in. per 2,000 Btu/hr of total input ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 17 ...
Page 18: Flue Gas Venting
Material Requirement Vent pipe to be installed ac- Single or Double Vertical Vent- cording to the venting tables in Wall, Galvanized, HDF400 ing Applica- the National Fuel Gas Code Vertical Only Non-Sealed Vent tions (ANSI Z223.1/NFPA 54) for a Pipe Category I gas appliance.
Page 19 They can be ordered directly from the manufacturer, or one of their authorized dealers. To locate an authorized 1 45 dealer for venting parts, contact the appropriate manu- facturer at: 2 35 Selkirk Corpora on Hea ab Division 3 25 130 Industrial Blvd Turners Falls, MA 01376 (800) 772‐0739 www.hea ab.com Hea ab Saf‐T Vent EZ Seal (CI Plus) ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 19 ...
Page 20 Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat exchangers. Do not vent under a deck or large overhang. Recirculation could occur and cause performance or system problems. 3. 20 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 21 (2) In accordance with the current CAN/CSA B149.1, Natural Gas and Propane Installation Code For clearances not specified in ANSI Z223.1 / NFPA 54 or CAN/CSA B149.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 21 ...
Page 22: Gas Supply
Total piping length Distance from tank or length of First 100 to 150 regulator to gas valve Stage* inlet (ft) or 2nd stage 100 to 200 1-1/2 1-1/4 regulator 200 to 300 1-1/2 Second Stage** 0 to 10 22 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 23: Water Piping
Figure 13: Water Connections Figure 14: Bypass Valve(s) WARNING: EXPLOSION HAZARD Blockage of water flow from heater return to pool may result in fire or explosion caus- ing property damage, personal injury, or loss of life. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 23 ...
Page 24 Figure 15 illustrates a typical pool piping diagram and layout for the pool equipment. Figure 16 illustrates a multiple heater installation for very large pools with and without a manual bypass valve. Figure 15: Typical Plumbing to Pool or Spa Figure 16: Multiple Heater System 24 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 25: Electrical Connections
Risk of Electric Shock Review all safety information provided in the GETTING STARTED section of this manual prior to servicing. Always disconnect power circuit before servicing. This heater contains wiring that carries high voltage. Contact with these wires could result in death or personal injury. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 25 ...
Page 26 “Spa” the “SPA” LED will be illuminated and the water temperature will be displayed. The heater will use its internal thermostat to regulate the water temperature to the set point of the mode selected. 26 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 27 51300803801 REV B Figure 19: Location of Components (Top and Side Panels removed for Clarity) Control Panel Assembly (See Fig. 20) Gas Valve Gas Manifold Combustion Blower (see Fig. 22) Burner Igniter / Flame Sensor Header (See Fig. 21) ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 27 ...
Page 28 Figure 20: Control Assembly Components (Wiring Hidden for Clarity) Differential Pressure Switch Fuse Board Ignition Control Transformer Figure 21: Header Assembly Components Temperature Limits Water Pressure Integrated Bypass Switch Thermistor Outlet Header Inlet Header V-Header Pressure Relief Valve Port Drain Plug 28 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 29 51300803801 REV B Figure 22: Combustion Blower Assembly Components Combustion Blower Negative Pressure Tap Fuel/Air Mixer Reference Pressure Tap Blower Gasket Gas Manifold Assembly Burner 29 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 30: Check-Out & Start-Up
4 SEC. MAX properly. When the thermostat is satisfied and the call for heat ends, the control immediately de-energizes the gas valve and flame extinguishes. The control operates FLAME SENSED, the blower an additional 30 seconds as a post-purge. IGNITION SUCCESSFUL ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 30 ...
Page 31 AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resume operation as detailed in NORMAL OPERATION FOR POOL & SPA MODES. The heater can be manually reset using the keypad by cycling the mode button through “STANDBY” and back to the original operating mode (“SPA” or “POOL”). 31 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 32: Gas Testing
WARNING: EXPLOSION HAZARD Gas pressures in excess of those listed in Table 11 could cause a gas leak or dia- phragm rupture. Gas leakage could cause an explosion resulting in severe injury or death. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 32 ...
Page 33 -0.1 to -0.3 Pressure* Inlet Pressure, +4.0 +4.0 Minimum Inlet Pressure, +14.0 +14.0 Maximum Figure 26: Gas Valve Gas Inlet Pressure Tap ON / OFF Switch Vent Tap Pressure Tap Manifold pressure Electric adjustment under Terminals screw cap 33 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 34 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) ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 34 ...
Page 35 If the pump and piping arrangement are such that the required 1-pound minimum pres- sure cannot be obtained, do not attempt to operate the heater. Correct the installation. NOTICE: Heater installation, checkout, and start-up should now be completed. BE SURE to leave this manual with the pool owner. 35 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 36: Maintenance & Service
Use a 4- way pool/spa water test kit to check your water frequently (at least weekly). Use the guidelines in Table 15 to help maintain proper water chemistry: ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 36 ...
Page 37: Winterization
Turn the heater’s gas supply OFF at the main shut-off valve outside the heater cabinet. Be sure the circulating pump is OFF. Remove the drain plug (see Figure 26). Allow all water to drain from the heater. Re-install drain plug. 37 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 38: Spring Start-Up
Insufficient air supply; Inadequate venting; High or low gas pressure; Blockage of burner or orifices; Blockage of blower inlet; Low voltage supply causing blower to “spin” slower; Improper heater location / installation; Incorrect gas supply pipe size; Excessive water flow through heat exchanger; or an LP tank below 30% full level. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 38 ...
Page 39 Pull the flame sensor straight back until resistance is felt. Rotate the flame sensor 180° and lift up and out to remove it from the combus- tion chamber. Remove the old gasket from the front of the combustion chamber. 10. Replace the gasket, igniter, and flame sensor and reverse the above procedure to reassemble unit. 39 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 40 Verify manifold pressure after replacing the fuel/air mixer. Instructions for manifold pressure measurements can be found in the GAS TESTING section of this manual on page 31 and following. NOTICE: Do not enlarge orifice holes. NOTICE: All replacement wiring must be replaced with manufacturers supplied replacement parts. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 40 ...
Page 41: Troubleshooting
WARNING: UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNERS, BE USED OR STORED IN THE VICINITY OF THE HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE HEAT- ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 41 ...
Page 42 3 s of power-up or is lost for 30s during operation unit will shut down and error will be displayed. The error code will be cleared upon a valid data exchange between boards. EEPROM error An error was detected in the ignition control board. 42 ONLY USE GENUINE HAYWARD REPLACEMENT PARTS ...
Page 43 (5 °F or more) or a sensor “out of bounds” condition with either thermistor (less than 10°F or greater than180°F) will result in unit shut down and the error code displayed. Automatic restart is 2 minutes after the error is cor- rected. ONLY USE GENUINE HAYWARD REPLACEMENT PARTS 43 ...
Page 44: Service Parts
The following repair parts are available from Hayward and through your local distributor. When ordering parts, include the complete pool heater model number listed on the unit’s rating plate, located near the junction boxes on the exhaust side of the heater. (Example: HDF400) All ser- vice must be performed by a qualified technician.

Hayward HDF400 Installation & Operation Manual

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