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Y Series

Step-by-step field replacement

procedure

As part of our technical support services, this section

provides proper step-by-step methods to facilitate

the replacement of Y Series spa packs in the field

Tools needed:

• Phillips & flat screwdrivers

• Multimeter
• Open-ended adjustable wrench

• Scraper tool

• Pliers

• GFCI tester

All procedures described in this service manual

must only be performed by qualified personnel,

in accordance with the standards applicable in

the country of installation

Disconnect incoming
power lines by loosening
the screws on the
terminals of the terminal
block

Carefully revise the spa
plumbing schematics
and identify the spa

Flow

Shut Off Valves

Make

sure that both

Flow

Shut Off Valves,

which

control water inlet before
and after the heater, are
closed

Remove the cable strain
relief cover (3 screws)
and the cable strain relief
bracket (1 screw)

Unplug power cord by
squeezing the latches on
the side of each AMP plug
and pulling it from
its socket

Identify each output cord

Warning!

When replacing a
Y Series spa pack,
it's very important
to make sure to turn
power off before
proceeding

With a Phillips screwdriver
loosen the screws of
the spa pack cover and
remove it

How to remove a spa pack from the spa piping.

Step-by-step field replacement procedure

Содержание in.ye

Страница 1: ...hBook Gecko Alliance 450 des Canetons Quebec City Qc G2E 5W6 Canada 1 800 78 GECKO 9225 Stellar Court Corona CA 92883 USA 951 667 2000 www geckoalliance com Printed in Canada 9919 101184 C Rev 02 2014...

Страница 2: ...cable opening size 25 Output cable installation 25 AMP pins and housings 26 Y Series field programming options Custom configurations 27 Keypad overview Function description 30 Instructions 30 Typical...

Страница 3: ...THIS CONTROL SYSTEM READ AND FOLLOW ALL WIRING INSTRUCTIONS WHEN CONNECTING TO POWER SUPPLY THIS PACK CONTAINS NO USER SERVICEABLE PARTS CONTACT AN AUTHORIZED SERVICE CENTER FOR SERVICE ALL CONNECTIO...

Страница 4: ...wants an easy to understand multi application solution You don t have to wonder about compatibility instead there s just the comforting certainty that when you invest in the Y Series all spa configur...

Страница 5: ...Y Series systems boast a long list of technical features Each of them contributes to bringing the most advanced solutions available to Y Series equipped spa owners The in stik is a pen drive with an i...

Страница 6: ...utputs for all your spa needs Light outputs 1 direct 1 switched Main keypad connector Communications link Accessible bonding lugs Front view Side view 4 98 126 mm 2 51 mm 10 75 273 mm 16 55 420 mm 19...

Страница 7: ...in stik Enough outputs for all your spa needs Light outputs 1 direct 1 switched Main keypad connector Communications link Accessible bonding lugs Front view Side view 5 16 130 mm 2 51 mm 14 5 368 mm B...

Страница 8: ...me in contact with the enclosure must be carefully evaluated under end use conditions for compatibility Important Read before starting Please note that countersunk screws should not be used as they ca...

Страница 9: ...ch lower mounting holes on each side of the pack with the 2 remaining screws and 2 washers Lower mounting holes are 2 51 mm below upper holes Firmly attach one at a time upper mounting holes on each s...

Страница 10: ...ed Route the cable through one of the molded strain relief channels on the bottom right side of the spa pack as illustrated Fill the remaining space with the foam gaskets supplied Don t forget to repl...

Страница 11: ...essory wire must be moved See wiring diagram for details The heat wav heater is factory configured for 240 V 4 kW but it can be converted to a dedicated 120 V 1 kW by simply adding a cable connection...

Страница 12: ...N INPUT VOLTAGE HEATING ELEMENT HEATER GROUND L1 N L2 120V 240V A0 120V DIRECT K3 K4 K6 K7 K9 K10 P5 P17 P7 P22 P23 P28 P30 P33 P36 P37 P34 P18 P19 P6 P2 P3 P4 P8 P24 P29 P38 P41 P42 P45 P35 30A 480VA...

Страница 13: ...V Green ground P92 P92 Black line P133 P133 White common P86 P80 Pump 3 C3 in yt 7 and in yt 12 Voltage 120V 240V Green ground P94 P94 Black lowspeed K22 P K22 P Red high speed K21 P K21 P White commo...

Страница 14: ...230V Green ground P48 Black line K6 P White common P57 Pump 3 A4 in yt 5 ce only Voltage 230V Green ground P48 Black lowspeed K6 P White common P57 Circ pump A1 Voltage 230V Green ground P52 Black lin...

Страница 15: ...1 in ytonly Voltage 230V Green ground P92 Black line P133 White common P86 Pump 3 C3 in yt 7 and in yt 12 Voltage 230V Green ground P94 Black lowspeed K22 P Red high speed K21 P White common P88 Circ...

Страница 16: ...peed K3 P White common P60 Directoutput C1 Voltage 230V Green ground P92 Black line P133 White common P86 Pump 4 C3 in yt 7 Voltage 230V Green ground P94 Black lowspeed K22 P Red high speed K21 P Whit...

Страница 17: ...at screwdriver Loosen the screws of the spa pack cover and remove it Remove 5 1 2 142 mm of cable insulation Strip away 1 25 mm of each wire insulation Pull the cable through the cutout of the box and...

Страница 18: ...nnect PJ1 between P7 and P10 Connect PJ2 between P13 and P74 3 phase with single neutral L1 L2 L3 currents return through neutral Connect PJ1 between P7 and P10 Connect PJ2 between P11 and P13 2 phase...

Страница 19: ...ect PJ2 between P10 and P74 2 phase with single neutral L1 L2 currents return through neutral Connect PJ1 between P7 and P10 Connect PJ2 between P13 and P74 3 phase with single neutral L1 L2 L3 curren...

Страница 20: ...e Every OEM has its own preset configurations 98 It s important to specify the current rating of the GFCI used to ensure safe and efficient current management and reduce nuisance GFCI trippings Press...

Страница 21: ...a pack will upload all the different configurations from the in stik memory The unit will then enter the low level configuration menu The keypad display will show L xx where xx represents the previous...

Страница 22: ...evel and connector location Contact your OEM for specific configurations Model Quick Start Card Number in ye 3 9919 101202 in ye 3 ce 9919 101203 in ye 5 9919 101192 in ye 5 ce 9919 101193 in yt 7 991...

Страница 23: ...d P1 P1 2 spd A3 A3 A2 A1 A2 A1 A1 A4 FL A3 A2 P3 Di 1 120 V P2 P2 O3 CP O3 CP Individual configuration will depend on the low level selected Refer to low level table and wiring diagram in yt 7 P1 2 s...

Страница 24: ...eed Output 4 Output 5 P1 2 spd C2 CP O3 C1 Di P2 2 spd C3 P4 1 spd P3 1 spd A1 Output 2 P3 1 spd A1 A4 Output 3 O3 A4 Output 14 Di C1 CP Output 6 C2 P4 1 spd Output 8 C3 A3 A3 A2 P2 2 speed Output 1 O...

Страница 25: ...utput 12 Output 2 Output 4 on CE Output 5 Output 8 Output 9 Output 1 Output 6 Output 10 Output 3 Output 10 Output 4 Output 2 on CE Note If P4 2 speed is used AUX 1 can not be used P1 2 spd C2 CP P5 1...

Страница 26: ...25 For 14 3 18 3 cable size 0 305 to 0 375 For 14 3 18 3 cable size 0 305 to 0 375 For 14 3 18 3 cable size 0 305 to 0 375 For 14 4 14 3 cable size 0 365 to 0 425 For 14 4 14 3 cable size 0 365 to 0 4...

Страница 27: ...into 2 parallel outputs i e a single O3 output could be used for an ozonator and UV generator 03 or CP Both accessories driven must be of the same operating voltage 120 V or 240 V Pin 3 White Pin 3 W...

Страница 28: ...elay Output 12 Output 13 CP Accessory connected to the Direct Output 1 Output 14 CP Accessory connected to the Direct Output 2 Heater H Accessory connected to the heater relay CP usage CP Standard 0 C...

Страница 29: ...Output A current 0 to 15 amperes Current draw of Output 10 accessory Output B current 0 to 15 amperes Current draw of Output 11 accessory Output C current 0 to 15 amperes Current draw of Output 12 ac...

Страница 30: ...ain keypad functions Please refer to your own QRC for specific functions The Y Series spa pack is compatible with the following keypads in k200 in k300 in k400 in k450 in k500 in k600 streamlined K 4...

Страница 31: ...terminedperiod of time unlessithas been manuallydeactivated ThePump 2and orBlower indicatorlightsupwhen thecorrespondingoutput ison Note with dual speed pump the indicator will flash when Pump 2 is on...

Страница 32: ...Press Key 1 to reactivate the system before the expiration of the 30 minute delay While the Off mode is engaged the display will toggle between OFF and the water temperature Purge cycles To program th...

Страница 33: ...time If the readings received from the system are not valid blanks will be displayed until normal readings have been successfully recorded After verifying pump activation and taking a water temperatu...

Страница 34: ...to be corrected to ensure proper functioning of the system Both the error code and the water temperature are alternatively displayed Allerrorscodeswillbedisplayedon the keypaddisplay FLO The system di...

Страница 35: ...the spa pack and start stop all pumps and blower If error reappears replace the spa pack Verify if regulation probe located above the heater is properly connected Regulation probe Replace heater if pr...

Страница 36: ...ait until spa cools down add cold water if necessary Shut power off and power the spa up again to reset the system If reading is 119 F or higher and hot weather is not an issue Lower Set Point below c...

Страница 37: ...filter Make sure there is adequate flow minimum 18 GPM Make sure that no airlocks are trapped in the unit s plumbing pumps may make strange noises If airlocks are formed start the pump and slowly loos...

Страница 38: ...rature on display is correct above 108 F and weather is hot Remove spa cover and let spa cool down Add cold water and shorten filter cycle duration If problem persists replace spa pack If temperature...

Страница 39: ...display when you press Key 1 If Pump 1 does not work in either speed Replace appropriate Pump 1 fuse If replacing the fuse is not effective or if Pump 1 works in only one speed take a voltage reading...

Страница 40: ...If Pump 2 does not work in either speed Replace appropriate Pump 2 fuse If Pump 2 blower does not work works in one speed dual speed pumps or replacing the fuse did not work Turn Pump 2 to high speed...

Страница 41: ...rature 98 If you don t get a voltage reading Replace the accessory fuse If changing the fuse does not fix the problem replace the spa pack If voltageisasitshouldbe Replace circulation pump Take voltag...

Страница 42: ...in to resume cycle If not start up a filter cycle see Programming Filter Cycles section 98 If you don t get a voltage reading replace the accessory fuse If changing the fuse does not fix the problem r...

Страница 43: ...ldget240V Measure voltage between line 1 and neutral Youshouldget120V Measure voltage between line 2 and neutral Youshouldget120V For 120 V systems Measure voltage between line 1and neutral Youshouldg...

Страница 44: ...Call an electrician For 3 phase system Measure voltage between line 1 and neutral between line 2 and neutral and between line 3 and neutral You should get 230 V for each reading If you do not get goo...

Страница 45: ...replace spa pack In the case of the European model in yt ce only replace accessory fuse If voltage reading is as it should be verify that the heat wav power cable is properly connected to the terminal...

Страница 46: ...CD tripper circuit Verify that the GFCI RCD circuit is properly connected If it s not reconnect it Verify the spa pack wiring make sure that the neutral and the ground have not been inverted If the GF...

Страница 47: ...screws on the terminals of the terminal block Carefully revise the spa plumbing schematics and identify the spa Flow Shut Off Valves Make sure that both Flow Shut Off Valves which control water inlet...

Страница 48: ...ce that is done remove the old keypad from the spa Note the procedure on keypad replacement shown here is for educational purposes only It is not always necessary to replace the keypad unless it may b...

Страница 49: ...eypad Place a rubber 2 O ring gasket at the end of each heater nut to prevent water leakage between the heater nuts and the PVC heater tailpieces When installing the new spa pack slide the back side o...

Страница 50: ...ve and Ground Manually remove the HL probe Temp probe connector HL Probe Temp Probe Live Ground Return in flo Adjust the heater position and tighten the screws Plug the in flo connector back in socket...

Страница 51: ...r Manually remove the topside cable and the in link cables Using the Phillips screwdriver remove the strain relief bracket Remove the 2 screws from the assembly AMP bracket Remove the 2 screws of the...

Страница 52: ...om the assembly AMP bracket Remove the 2 screws of the shroud around the heater s connection post and remove it Do the same for the in link bracket Put the new PCB back in the enclosure Slide it downw...

Страница 53: ...ottom left side of the PCB Slide the circuit board downwards to disengage it from the upper PCB holder tab Put the new circuit board in place by engaging it into the PCB holder tab Secure the board wi...

Страница 54: ...eutral 16 A Max 60 Hz nominal 1 5 1 0 Hz Heat wav rating Voltage 120 or 240 V 60Hz Wattage 4 kW at 240 V 1 kW at 120 V Also available 5 5 kW at 240 V Flow rate Minimum of 18 GPM 68 LPM is required UL...

Страница 55: ...1 This model can be converted to a dedicated 120 V model 2 Pump 2 can only be installed if Pump 1 is a single speed pump 3 Total of Pump 1 low or Pumps 2 and O3 CP cannot exceed 15 FLA 4 Total of Pum...

Страница 56: ...an only be installed if Pump 1 is a single speed pump 2 Total of Pump 1 low or Pumps 2 and O3 CP cannot exceed 20 FLA 3 Total of Pump 2 and Pump 3 cannot exceed 20 FLA 4 Pump 3 can only be installed i...

Страница 57: ...hBook Gecko Alliance 450 des Canetons Quebec City Qc G2E 5W6 Canada 1 800 78 GECKO 9225 Stellar Court Corona CA 92883 USA 951 667 2000 www geckoalliance com Printed in Canada 9919 101184 C Rev 04 2014...

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