Hayward ED2 Administrator guide

Heater System Solving Guide FAULT CODE THUMBNAILS – PAGE F 1

FAULT CODE THUMBNAILS – PAGE F 1

Fault Code Thumbnails

FAULT CODE THUMBNAILS

Heater System Solving Guide FAULT CODE THUMBNAILS – PAGE F 2

FAULT CODE THUMBNAILS – PAGE F 2

Heater System Solving Guide

Fault Code Thumbnails AC Blower Vacuum Switch – Failed Closed

FAULT CODE THUMBNAILS AC BLOWER VACUUM SWITCH – FAILED CLOSED

UHS

BLOWER VACUUM SWITCH – FAILED CLOSED

If the blower vacuum switch is closed before blower start-up,

the control module will not start the blower.

Pre-check is executed by the control module.

PARTS THAT MAY BENEEDED

• Blower Vacuum Switch

• Control Module.

DIAGNOSTIC SEQUENCE

A. Disconnect the blower plug from the control module.

With the heater off, measure the control module receptacle’s

continuity across pins 1 and 2 (UHS, IDL2 & IDL) and pins 3 & 4

(IDL2 & IDL only). If either is closed, replace the control module.

B. If the relay is open, check the vacuum switch. If it is closed,

the blower vacuum switch failed and must be replaced.

IDL

IDL2

FAULT CODE THUMBNAILS – PAGE F 3

Heater System Solving Guide

Fault Code Thumbnails AO Blower Vacuum Switch – Failed Open

FAULT CODE THUMBNAILS AO BLOWER VACUUM SWITCH – FAILED OPEN

UHS

IDL2

IDL

BLOWER VACUUM SWITCH – FAILED OPEN

If the blower vacuum switch opens unexpectedly during operation, the

heater will shut down and attempt to re-light if there is still a call for

heat. If the blower vacuum switch does not close after the blower starts,

the control will stop the ignition trial & go into lockout. The blower will

continue to run for post-purge.

Automatic reset is immediate after the switch closes.

PARTS THAT MAY BENEEDED

• Blower • Control Module/Ignition Board

• Blower Vacuum Switch • Gray Vacuum Tubing

DIAGNOSTIC SEQUENCE

A. Check for faulty vacuum switch tubing and replace if necessary.

B. Check for faulty vacuum switch wiring or connection. Wire harness

terminals must be securely fastened to spade terminals on vacuum switch.

C. Check for faulty blower wiring or connection. Plug on blower must be

securely fastened to control module.

D. Check for defective vacuum switch by disconnecting blower plug

from control module. Measure resistance across blower windings.

Winding resistance across lead should be in the following range:

IDL: Black to White 30-45 ohms Red to White 90-130 ohms

IDL2: Black to White 10-14 ohms Red to White 18-22 ohms

UHS: Red to White 8-9 ohms

If measured values vary substantially from these values,

the blower is defective and should be replaced.

E. Check for a defective blower relay by disconnecting blower plug from

the control module. Place heater in Pool or Spa mode. Lower set point

temperature to generate call for heat. During pre-purge period, measure

for 120VAC across pins 1 and 2 (UHS & IDL2) or L1 & IND low (IDL).

If 120VAC is not present, the control module relay is defective, which

means the control module must be replaced.

F. If the above steps do not resolve the problem (the error still exists),

the vacuum switch is defective and must be replaced.

Heater System Solving Guide FAULT CODE THUMBNAILS – PAGE F 4

FAULT CODE THUMBNAILS – PAGE F 4

Heater System Solving Guide

Fault Code Thumbnails BD Bad Board or Secondary High Voltage Fault

FAULT CODE THUMBNAILS BD BAD BOARD OR SECONDARY HIGH VOLTAGE FAULT

UHS

IDL2

BAD BOARD

SECONDARY HIGH VOLTAGE FAULT

PARTS THAT MAY BENEEDED

• Control Module / Ignition Board

• Extra Fuses

• Fuse Board

• Wiring Harness

• Transformer

DIAGNOSTIC SEQUENCE

A. Verify that FC4 fuse on fuse board is not open. Remove FC from fuse-

holder. Measure continuity across fuse. If OK, reinstall fuse and proceed

to step 2. If fuse is open, proceed to section titled “Open FC4 Fuse”.

B. Verify high voltage output from fuse board. Disconnect plug from P6

connector of fuse board. Measure for 120VAC across pins 3 and 5 of

P6 receptacle on fuse board. If OK, reconnect plug and proceed to step

3. If not OK, go to step 4.

C. Check for defective wiring harness. Disconnect plug from E10 connector

of contol module. Measure for 120VAC across pins 1 and 3 of plug on

wiring harness. If OK, replace control module. If not OK, replace wiring

harness.

D. Check for defective transformer. Disconnect plug from P4 connector of

fuse board. Measure for 120VAC between pins 4 and 6 of plug from

transformer. If OK, proceed to step 5. If not OK, replace transformer.

E. If the above steps have not resolved the error condition, the fuse board

is defective and must be replaced.

NOTE: Red letters above correspond with adjacent illustrations.

FAULT CODE THUMBNAILS – PAGE F 5

Heater System Solving Guide

Fault Code Thumbnails BO Bypass Operation (for external controls)

FAULT CODE THUMBNAILS BO BYPASS OPERATION (FOR EXTERNAL CONTROLS)

BYPASS OPERATION (FOR EXTERNAL CONTROLS)

UHS, IDL2, IDL, ED2

The “bo” code is more of an information code than a fault code,

with the “bo” standing for Bypass Operation.

A “bo” code indicates the heater’s internal thermistor is disabled,

allowing the external thermostat control to operate.

This prevents any confusion between the two temperature-sensing

devices during heater operation — though the heater’s thermistor

will still prevent the heater for exceeding 104oF.

Heater System Solving Guide FAULT CODE THUMBNAILS – PAGE F 6

FAULT CODE THUMBNAILS – PAGE F 6

Heater System Solving Guide

Fault Code Thumbnails CE Communication Error

FAULT CODE THUMBNAILS CE COMMUNICATION ERROR

UHS

IDL2

COMMUNICATION ERROR

PARTS THAT MAY BENEEDED

• Control Module/Ignition Board

•. Display Board

• Membrane Switch/Keypad.

ERROR DETAIL: COMMUNICATION ERROR

BETWEEN CONTROL MODULE & DISPLAY INTERFACE ASSEMBLY

If communication between the ignition board and the display board is

not established within 3 seconds of power-up, an error will be displayed.

After communication is established, if it is lost for 30 seconds, the er-

ror will be displayed. The error code will be cleared upon a valid data

exchange between boards..

DIAGNOSTIC SEQUENCE

A. Power down heater and re-power. This is similar to rebooting a com-

puter.

B. If rebooting does not solve the problem, inspect the display interface

wiring. Ensure the display interface plug is securely attached to the

control module.

C. If steps A & B do not resolve the CE error, the control module and/or

display interface assembly are defective and must be replaced.

FAULT CODE THUMBNAILS – PAGE F 7

Heater System Solving Guide

Fault Code Thumbnails EE Electrical Error

FAULT CODE THUMBNAILS EE ELECTRICAL ERROR

ELECTRICAL ERROR

PARTS THAT MAY BENEEDED

• Control Module / Ignition Board

DIAGNOSTIC SEQUENCE

Replace the Control Module / Ignition Board.

UHS IDL2

Heater System Solving Guide FAULT CODE THUMBNAILS – PAGE F 8

FAULT CODE THUMBNAILS – PAGE F 8

Heater System Solving Guide

Fault Code Thumbnails HF NEW: Gas Valve Fault or OLD: Heater Flame Sensing Fault

FAULT CODE THUMBNAILS HF FLAME PRESENT WITH GAS VALVE CLOSED / HEATER FLAME SENSING FAULT

UHS

IDL2 ED2

IDL

HEATER FLAME SENSING FAULT

IDL, ED2

PARTS THAT MAY BENEEDED

• Ignitor / Flame Sensor

• Control Module / Ignition Board

DIAGNOSTIC SEQUENCE

A. Check all wiring and connections for Flame sensor.

B. Replace flame sensor (IDL) or ignitor (ED2).

C. Replace control module/ignition board if problem still exists.

FLAME PRESENT WITH GAS VALVE CLOSED

UHS, IDL2

PARTS THAT MAY BENEEDED

• Gas Valve

If flame is sensed without the gas valve energized, the control will go

into lockout.

DIAGNOSTIC SEQUENCE

• SHUT OFF GAS TO HEATER IMMEDIATELY.

• The gas valve is defective and needs to be replaced.

RIGHT: HF INDICATES AFLAME SENSING FAULT ON OLDER MODELS (IDL, ED2)

BELOW: HF INDICATES AGAS VALVE FAULT ON NEWER MODELS (UHS, IDL2)

FAULT CODE THUMBNAILS – PAGE F 9

Heater System Solving Guide

Fault Code Thumbnails HS Maximum Return Water Temp Exceeded

FAULT CODE THUMBNAILS HS MAXIMUM RETURN WATER TEMP EXCEEDED

MAXIMUM RETURN WATER TEMPERATURE EXCEEDED

UHS, IDL2, IDL, ED2

If water temperature exceeds 105°F, the heater will shut down and

go into lock-out.

Automatic restart is 2 minutes after water temp drops below 105°F.

PARTS THAT MAY BENEEDED

• Control Module

• External Thermostat (if system uses one)

NOTE: In most cases, no replacement part will be needed.

DIAGNOSTIC SEQUENCE

A. Verify water flow is adequate.

Low water flow will cause high temperature.

(Generally, 25 gpm is needed by smaller heaters, while 300,000 btu/h

heaters may require 40 gpm or more. See heater’s operating manual.)

B. Verify set point setting of remote thermostat us below 108°F. If external

control is used, verify that external thermostat is set below 104oF. (Exter-

nal thermostat may be faulty and need to be replaced.)

C. Verify integrity of exchanger.

D. Check for possible bad ignition/control module.

Heater System Solving Guide FAULT CODE THUMBNAILS – PAGE F 10

FAULT CODE THUMBNAILS – PAGE F 10

Heater System Solving Guide

Fault Code Thumbnails IF Ignition Failure

FAULT CODE THUMBNAILS IF IGNITION FAILURE (INSUFFICIENT FUEL)

IGNITION FAILURE

(INSUFFICIENT FUEL)

UHS, IDL2, IDL, ED2

REQUIRED DIAGNOSTIC TOOLS

• Manometer

• Multimeter

PARTS THAT MAY BENEEDED

• Flame Sensor

• Ignitor

• Ignition Board / Control Module

• Gas Valve

While IF actually stands for Ignition Failure, this code is often

referred to as the Insufficient Fuel code – since the most common

reason for an “IF” code is inadequate gas supply to the heater.

—————

“IF” occurs when the heater passes all safety checks but the heater fails to

ignite.

Without the proper gas/air mixture, the heater will not light. Since the

heater has gone through most of the steps within the Sequence of Op-

eration, the problem is most likely gas supply or a faulty ignition board,

flame sensor, ignitor or gas valve.

Investigate and ensure that the gas train is correct.

The source of an IF code is found in the gas train 90% of the time.

DIAGNOSTIC SEQUENCE

A. Ensure that main gas shutoff adjacent to heater is open. Ensure that

knob on gas valve inside unit is in ‘‘on’’ position. If OK, proceed to

next step.

B. Check for low gas supply pressure by ensuring inlet gas supply pres-

sure is between the minimum and maximum values indicated on rating

plate. If OK, proceed to next step.

C. Inspect flame sense wiring, and ensure wire harness terminals are se-

curely fastened to flame sense and to control module. If OK, proceed

to next step.

D. Inspect gas valve wiring, and ensure wire harness terminals are se-

curely fastened to spade terminals on gas valve. If OK, proceed to next

step.

E. Check for gas valve failure or gas valve relay failure.1. Measure volt-

age across gas valve during trial for igintion.

I. If 24VAC is present and gas valve does not open, gas valve is de-

fective and must be replaced.2.

II. If 24VAC is not present, gas valve relay on control module is defec-

tive, which means the control module must be replaced.

F. Inspect gas orifices for blockages that could prevent gas flow. Also re-

move and inspect burners for blockages.

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