Hayward ABG135 User Manual

FOR YOUR SAFETY
WARNING: If the information in these
instructions is not followed exactly, a fi re or
explosion may result causing property damage,
injury, or death.
- Do not store or use gasoline or other fl am-
mable vapors or liquids in the vicinity of this
or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fi re department.
- Installation and service must be performed by
a qualifi ed installer, service agency, or the
gas supplier.
POOL AND SPA/HOT TUB HEATERS
H135ID & ABG135 MODELS
SERVICE & INSTALLATION MANUAL
FOR YOUR SAFETY
This product must be installed and serviced by authorized personnel, qualifi ed in pool/
spa heater installation. Improper installation and/or operation can create carbon monoxide gas
and fl ue gases that can cause serious injury, property damage, or death.
1301503701 Rev B 0917
See www.hayward-pool.com/patent for U.S. and
Canadian patent information
Unit must be installed outdoors only and below an
altitude of 2000 feet

Hayward ABG135 Specifications

General

Brand	Hayward
Model	ABG135
Category	Heater
Language	English

Summary

General Safety Information

Fire and Explosion Hazards

Details warnings about potential fire or explosion risks if instructions are not followed.

Gas Leak Procedures

Step-by-step instructions on what to do if you smell gas, emphasizing safety measures.

Professional Installation Requirement

Stresses that installation and service must be performed by qualified professionals.

Safety Information and Precautions

General Safety Guidelines

Electrical Safety and Bonding

Highlights requirements for licensed electricians, electrical wiring safety, and proper bonding procedures.

Installation and Usage Warnings

Electrician's Notes and Safety

Bonding and Grounding Procedures

Specific instructions for electricians regarding bonding lugs, conductors, and grounding requirements.

Suction Entrapment Hazard Prevention

Details suction entrapment hazards and essential safety measures to prevent injury or death.

Critical Safety Warnings

Entrapment and Flow Blockage Hazards

Warnings about risks from suction outlet blockages, improper valve operation, and pressure plug removal.

Pressure and Component Separation Hazards

Covers hazardous pressure risks and separation hazards related to pump components and circulation systems.

Fire, Burn, and Installation Hazards

Addresses fire hazards from motors, burn risks, and severe injury/death from improper installation.

Installation Procedures

Pre-Installation Checks and Requirements

Heater Location and Clearances

Gas Supply Installation Details

Gas Connection and Piping Practices

Water Piping and Connections

Water Connection Assembly

Ancillary Systems and Electrical Requirements

Electrical Specifications and Safety

Outlines electrical specifications and safety warnings related to wiring, grounding, and power connections.

Electrical Connections and Bonding

Heater Bonding Requirements

Explains the critical requirement for bonding the heater to a grounding grid using copper conductors.

Lighting and Operating Instructions

Pre-Lighting Safety Checks

Covers essential safety checks and warnings to be followed before lighting the heater.

Heater Operation and Shutdown Procedures

Provides step-by-step instructions for operating the heater and safely turning off the gas supply.

Installer Check-out and Start-up

General Procedures and Component Locations

Gas System Testing

Gas Line Leak Testing

Details the procedure for leak testing the gas supply line and connections to prevent explosions.

Gas Pressure Testing Procedure

Explains how to test gas pressure, its importance for burner operation, and the procedure for adjustment.

Gas Pressure Adjustment and Water Switch

Gas Pressure Regulator Adjustment

Water Pressure Switch Adjustment

Temperature Control and User Interface

Temperature Setting and Modes

Explains how to adjust temperature settings and navigate between STANDBY, SPA, and POOL modes.

Keypad Overview and Operation

Temperature Settings and Operation Modes

Temperature Lock-Out Feature

Error Handling and Keypad Input

Ignition Failure and Retry Logic

Explains the heater's response to ignition failures, including retry attempts and safety lockouts.

Loss of Flame and Recycle Logic

Details the procedure for handling a loss of flame, including attempts to re-ignite and safety lockouts.

Maintenance and Seasonal Procedures

Winterization Procedures

Heat Exchanger Draining and Spring Start-up

Draining the Heat Exchanger

Spring Start-Up Steps

Technician Maintenance and Servicing

General Maintenance and Safety Warnings

Heat Exchanger Inspection and Cleaning

Provides a detailed procedure for inspecting and cleaning the heat exchanger to remove soot accumulation.

Burner System Maintenance

Combustion Chamber and Burner Inspection

Burner Removal and Replacement

Component Replacement Procedures

Gas Valve Replacement

High Limit and Exhaust Gas Temperature Limit Replacement

Igniter Replacement

Thermistor and Water Pressure Switch Replacement

Troubleshooting and System Checks

General Troubleshooting Guidelines

Wiring, Reset, and Fuse Information

Error Code Reference

Error Code Descriptions and Information

Lists various error codes, their descriptions, and corresponding information for diagnosis.

Error Code Reference (Continued)

Additional Error Codes

Continues the list of error codes, providing descriptions and information for troubleshooting.

Troubleshooting Specific Faults

No Power and Low Voltage Faults

Addresses troubleshooting steps for issues like the heater not powering up and low voltage faults.

Board and Harness Faults

Supply Power Faults

Troubleshooting Specific Faults (Continued)

Igniter, Keypad, and Sensor Faults

Troubleshooting steps for igniter failures, keypad issues, and temperature sensor errors.

Flame and Gas Valve Faults

Covers troubleshooting flame presence issues and gas valve malfunctions.

Troubleshooting System Faults

Water Pressure Switch and Temperature Limit Faults

Guides on troubleshooting water pressure switch faults and temperature limit switch issues.

Exhaust Gas Temperature Limit Fault

Details troubleshooting for exhaust gas temperature limit trips, often indicating heat exchanger damage.

Troubleshooting Control and Bypass Faults

Ignition and Blower Vacuum Switch Faults

Covers troubleshooting ignition failures and blower vacuum switch issues.

Limited Heater Warranty

Warranty Terms and Coverage

Warranty Conditions and Exceptions

Warranty Limitations and Claims

Warranty Exceptions and Disclaimers