410A-Service-Manual - GulfStream Heat Pumps
Contents
1. depending on unit and mode Note There is a 5 minute delay on make timer built into the control board so it will have a delay before starting Control Board Operation The control board has an LCD display and was kept as simple as possible for ease of customer use to minimize nuisance programming calls and to be able to handle most scenarios found in the field The board will display which mode it is in Pool Heat Spa Heat Simply raise or lower temp by pushing the Up or Down arrows To switch modes simply push the Mode button to toggle from pool to spa For Pool Cool there will be a Heat Cool setting in the service menu We also added Auto Feature so you may set temp at max temp and min temp and board will automatically heat or cool the pool spa The board also has the capability to control your solar system Control Board Hidden Menu All options and calibrations are in a hidden menu To access the hidden menu press and hold both up and down arrows simultaneously until first option appears on display The board will also rest to Pool Spa heat screen after 20 seconds of no activity Control Board Options Use Mode Button To Toggle Through Options 1 Option Language Select English Options are English Spanish French Portuguese German Use arrows to toggle to selection English is set as default Page 4 gt ATTENTION You will find the Pool Spa remote is no longer necessary the board is prog2. 318 6900 and we will fax or mail a copy to you Page 13 Pe A Il e e Legend Comp Compressor CC Compressor Capacitor DEF Defrost Temp Sensor FC Fan Capacitor FM Fan Motor HPS High Pressure Switch H20 WWater Temp Sensor LPS Low Pressure Switch M1 Main Contactor RY Reversing Valve T1 Transformer WPS Water Pressure Switch Blue A aba Ni 1 Field Connection Heater Vining Diagram 5 e connec Fi H Wiring br Remole Sealch or Obra om Tei Brown il Brown Ro d Enp Green white oer P T CR TLR POLPA Black SENSOR TST High Voltage Red Wii 220 240 1 50 Use for 208 Y 7 v Application E y Black i i j i Orange 230V Violet Violet SOLAR gs we Digital H20 DEF Control PUMP COMP Rw HPS LPS WPS Black ml dy R e d C wk k rez Oplonal 2 ue J lv Pink Fe HTH do n d Hires Ew Heal hed VV les Conhcbr Page 14 Bill of Materials DRAWING NO COMPONENT DESCRIPTION PART NO 3 CONTROL 1001003 6 contactor POLEA s capacitor soue srov e al capacrror zsur srov ooo BASE PAN 3003013 15 FRONT PANEL 3003015 EVAPORATOR 32 X 84 8008078 FILTER DRIER 8008052 Page 15 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 OHM 46225 44879 43577 42318 41099 39919 38777 37671 36601 35565 34561 33590 32648 31737 30853 29998 29169 28365 27587 26832 10K Sensor Ohms Chart 80
3. the defrost sensor 1s way out of calibration you should never see this code because of low ambient temperatures You should only see this code if there is a refrigerant leak Find and repair the leak Water Flow Lockout High Refrigerant pressure is 540 cut in is 360 This error code is almost always a lack of water flow so check everything under No Flow before putting on gauges or condemning High Pressure switch Evaporator Sensor Malfunction This is a 10k sensor If it is open or outside its range you ll get this error Check connections before replacing Water Sensor Malfunction This is also a 10k sensor If it is open or outside of its range you ll get this error Check connections before replacing ATTENTION gt This is a standard refrigeration system and most diagnostics are the same as air conditioners However you must keep in mind that the Heat Exchanger is the condenser and the large air coil around unit is the evaporator The system consists of a compressor water cooled condenser TXV and air heated evaporator gt ATTENTION gt Diagnosing the refrigeration system is something all A C technicians should know However there are a few points we would like to point out Page 7 Charge The system holds 4 pounds for Turbotec R 410A unit because the sub cooling amp super heat vary greatly with air and water temperature For field charging we use a condensing temperature of 24 degrees After power is o
4. 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 OHM 9297 9076 8861 8651 8447 8249 8056 7867 7684 7506 7333 7164 6999 6839 6683 6530 6382 6238 6097 5960 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 OHM 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 4664 4563 4464 4368 4274 4183 4094 4007 3922 3839 Page 16 WARNING Using any company that is not certified by G amp F Manufacturing will cause the warranty on the unit to void SERVICE All service must be handled by an Authorized Service Center Warranty may be void if a non authorized service representative does service Do not return the heater to your dealer as they do not provide service Before calling for assistance or service please check the Troubleshooting section of this manual or call your dealer This may save you the cost of a service call If you still need help follow the instructions below Service can be obtained by calling us at 954 318 6900 When asking for help or service please provide a detailed description of the problem your heater s complete serial number the purchase date and dealer purchased from This information will help us respond properly to your request Keep a copy of the sales receipt showing the date of purchase Proof of purchase will assure you of in warranty service MANUFACTURED BY G amp F MAN
5. G amp F Manufacturing Service Manual Version 2 0 April 2010 Table of Content Topics e Introduction to 410a e Sequence of operation e Control Board Operation e Control Board Service Menu e Service menu options Language Select Remote T Stat Pool Heat Cool Pool Cool Solar Control Time Delay Spa Timer Even Heat Temperature Scale Defrost Mode Evap Temp Calibration Water Temperature Calibration Load Defaults Board Diagnostic No Flow Defrost Low Refrigerant Pressure Water Flow Lockout Evaporator Sensor Malfunction Water Sensor Malfunction Components of Service Charge Thermal Expansion Valve Compressor Fan Remove and Replace Parts R amp R Compressor R amp R TXV and or Filter Dryer R amp R Heat Exchanger R amp R Water Temperature Sensor R amp R Defrost Evaporator Sensor R amp R Water Pressure Switch R amp R Hi Low Pressure Switch R amp R Control Board Installation of Heat Pump Direction Placement Air Flow Direction Electrical Diagram C C GC CN GC C UU R NNN d G G G OO 00 00 00 OO 10 10 10 12 12 12 12 13 13 13 14 Introduction This manual was put together to introduce you to G amp F Manufacturing s new R 410A Swimming Pool Heat Pump Please read the manual before you begin to service unit If you have any questions we have a dedicated service department to help you Only put your refrigerant gauges on these units as a last resort It is a package unit that has had many s
6. UFACTURING INC 7902 INTERSTATE COURT NORTH FORT MYERS FL 33917 dS R and Refrigeration Institute EM LID Air Conditioning Heating null BER Page 17
7. box and feed sensor wires out of control box On the suction line cut the cork tape and peel back exposing TX Y bulb and strap Loosen strap and slide old sensor out Reverse procedure to reinstall being sure to reinsulate and reinstall strain relief bushing R amp R Water Pressure Switch Turn off power Turn off water Remove front cover Remove wires from pressure switch Remove 2 screws holding control box back to coil on right side of control box Bend control box enough to get to back of flow switch Cut tubing as close to flow switch as possible Remove 1 2 nut holding flow switch to control box Install new switch and reverse procedure R amp R High or Low Pressure Switch Turn off power Remove front cover Cut high pressure switch wires near switch Unscrew HP switch using back up wrench Use leak lock when reinstalling switch Remove strain relief bushing where wires penetrate control box Feed old HP switch wires out and new HP switch wires in Reinstall strain relief bushing Install spades at HP terminals on control board Start and check unit operation Reinstall front cover R amp R Control Board Turn off power Remove front cover Loosen 4 screws holding control board to cover Remove control board and let hang on wires Push 4 screws through board and install new board Remove wires from old board and install on new board one at a time being sure to place wires from same terminals from old board to new board as you ar
8. e taking them off Turn power on Start unit check operation and reinstall front cover Page 12 Installation ATTENTION Before installing this heater there are several things to consider for performance serviceability and warranty Direction of Placement Access panel should always face out away from wall If you must face the service panel toward the wall leave a minimum of 24 between the wall and the unit ATTENTION gt You will not have a happy customer 1f they have to squeeze between the wall and the heater to use the controller Placement Airflow is critical to the performance and efficiency of a heater therefore leave as much space around and above heater as possible Installations under palm trees inside screened porches etc may help hide unit but will drastically reduce the performance of the unit You will not have a happy customer The unions were to the side of the unit to keep pipes out of the way of the control panel so that they are not stepped on while adjusting controls or WARNING Do not plumb the pipes back around front where pipes will be stepped on or prohibit access to the front panel Make sure unit is bonded and conduit is connected all the way up to the control box gt ATTENTION gt For a more detailed installation manual please visit our website Gulfstreamheatpump com and the manual will be there for you to download If no internet access call service department 954
9. iodically turn pool pump on according to delay setting Options are Off O Hr for testing 1 Hr 2 Hr 3 Hr 4 Hr Default is off 9 Option Temperature scale F Sets display for Centigrade or Fahrenheit Use arrows to toggle 10 Option Defrost Mode Air Defrost Options are Air Defrost and Reverse Cycle This option is set at the factory 11 Option Evaporator Temperature Calibration For calibrating the defrost sensor located on the suction line If this calibration is changed it will show by how much in plus or minus at bottom of display 12 Option Water Temperature Calibration This option is for calibrating the water temperature sensor and will show the amount of calibration in plus or minus at the bottom of display 13 Option Load Defaults In this mode you can reload all defaults by pressing the up arrow once Board Diagnostics The control board will alert you to most problems DISPLAY MESSAGES No Flow Means the water pressure switch is not closed Check water flow to heater Make sure any water bypass valves are not redirecting water around heater filter is clean pump is on and water level in pool is up in the middle of the pool tile this prevents skimmer from sucking air Defrosting Means the suction line has dropped to 28 degrees It will shut the unit down until it reaches 40 degrees and the system will run again Page 6 Low Refrigerant Pressure Low pressure cut out is 37 pounds cut in is 80 pounds Unless
10. n and water has been running through unit for at least 5 minutes your high side temperature should be 24 degrees above water temperature Read on control board Unless the ambient temperature is less than 62 degrees we expect a superheat of at least 15 degrees You may read the suction line temperature by pushing and holding the Up arrow on control board After about 15 seconds the board will display suction line temperature the board will read Evap and a temp Please wait for at least 10 minutes run time before checking superheat TXV Thermal Expansion Valve All units are manufactured with adjustable TXV s If you suspect the TXV needs to be adjusted please call 954 318 6900 from the jobsite and technical support will walk through it with you gt ATTENTION Check temperature on both sides of filter If more than 2 degrees different the filter is clogged Compressor Broken valves shafts not pumping and shorted to ground are obvious problems However no starts are commonly misdiagnosed Check the capacitor for correct MFD s Check connections voltage and open windings If open windings check to see if compressor is hot If so let it cool down or run cool water over it before condemning Check Ohm s common to run and common to start should equal run to start If everything above is correct then add hard start to capacitor Fan Please check connections and capacitor before condemning fan motor If you do have t
11. o change fan motor ALWAYS change capacitor also Page 8 ATTENTION gt Although the components of this system are the product of an engineer the design of the unit was created by a service technician of 35 years Therefore wherever possible the unit was put together with ease of service in mind Time is important to both your company and ours so when replacing refrigerant components please start with recovering refrigerant and then move on to disconnecting component Remove and Replace Parts R amp R Compressor Turn power to unit off Start recovery of refrigerant Remove the 4 screws holding the top on unit Cut wire tie on fan wire bundle outside of the control box Lift top of unit flip over and stand on end next to unit Bleed run capacitor Remove wires from compressor Note colors and positions Unbolt compressor from base Remove TXV bulb from suction line When recovery is done cut out filter Unsolder compressor and move through top Solder in new Filter Dryer Solder in compressor Pressurize system and check for leaks Start evacuation Rebolt compressor to base Rewire compressor and reinstall wire cover Reinstall TXV bulb Put top back on unit and rescreen Change Capacitor once system has reached 500 microns of vacuum then charge system to Turn power back on and check unit operation Reinstall front cover Page R amp R TXV and or Filter Turn off power Start refrigerant recovery Remove 4 screws h
12. olding top on unit Cut wire tie holding fan wires bundled at side of control box Lift top off flip over and lay on end next to unit After recovery has finished remove component from system Replace with new filter dryer Solder in new component Leak check start vacuum Replace top on unit After vacuum has reached 500 microns charge system to 4 lbs of R 410A for Turbotec Titanium unit Start unit and check operation Replace front cover gt ATTENTION Alwavs cut the filter out DO NOT UNBRAZE R amp R Heat Exchanger Turn off power Start recovery of refrigerant Cut wire tie holding fan wires bundled next to control box Remove 4 screws holding top on unit Lift top off flip top over and lay on end next to unit Cut or break female half of unions off back of unit Cut wire ties holding PVC ells to bottom of base When recovery is complete cut refrigerant filter out Unsolder and remove heat exchanger through top of unit Set new heat exchanger in base of unit Solder in heat exchanger Start system on vacuum Rebolt heat exchanger to base Restrap PVC ells to bottom of unit and glue on new female half of unions Reinstall top After system has reached 500 microns of vacuum charge system to 4 pounds R 410A Turn power on check system operation and reinstall front cover Page 10 WARNING DO NOT Cut old WTS wire and splice in new WTS R amp R Water Temp Sensor Turn off power Remove fr
13. ont cover Unscrew water temp sensor WTS and take out Screw in new WITS Take old WTS spade clips off of the back of the board Place new spade clip in same slot Close HP up ATTENTION The water temp probe is located on the lower water inlet elbow and is unserviceable Therefore when it s necessary to replace probe drill a 3 8 hole in upper elbow and install new probe there After it s installed wrap it once with cork tape then with closed cell insulation then again with cork tape R amp R Fan Motor Turn off power Remove front cover Disconnect fan wires from contactor capacitor and ground Remove strain relief bushing and holding wires where they penetrate control box Feed wires out of control box Cut wire ties holding wires in a bundle Remove plastic fan motor cap from fan guard Remove 4 screws holding top on unit and remove top Flip top over and lay on ground or on level surface Loosen setscrew and then remove fan blade Lift one side of top up to a 45 degree angle and remove 4 nuts holding fan motor to fan guard Lay top back down and remove motor Reverse procedure to install new motor Be sure to reinstall strain relief bushing where wires penetrate control box and replace fan motor capacitor Page 11 R amp R Defrost Sensor Turn off power Remove front cover Disconnect connectors from T 7 and T 8 on control board Remove strain relief bushing where wires penetrate side of control
14. rammed to automatically recognize the switch and self program 2 Option Remote T Stat Disable This option is used for external controller systems with its own thermostat such as an Aqua logic or Aqua link Default is disabled To enable push Up or Down arrows until display says Enable 3 Option Pool Heat Cool Disable Once this is enabled a Heat Cool setting will come up on display The board will recognize when the temp of the pool has raise or dropped by 1 and will heat or cool the pool until 1t reaches set point again This option is only for Heat Cool units 4 Option Pool Cool Disable Once this option is enabled it will give you a pool cool mode on display use Mode buttonto toggle This option is only for Heat Cool units 5 Option Solar Control Disable This option allows your pool heater with additional wiring to monitor the pool solar system s performance and will automatically control the temperature 6 Option Time Delay 5 Default is 5 minutes You may temporarily set to O for service purposes unit will reset to 5 Mins after 10 Mins have passed 7 Option Spa Timer Continuous This option 1s for rental properties or homeowners who do not want the spa left on indefinitely Options are Continuous Off or Up to 20 hours in 15 minute increments ini CAUTION nit Off will not allow spa to run Page 5 8 Option Even Heat Disabled Will per
15. teps taken at the factory to assure the system is contaminant free Almost all problems can be diagnosed without the use of gauges Check to see that the unit is bonded and that the electric conduit is connected to the electrical box inside the unit WARNING Only certified service providers to work on unit Anyone else will void warranty WARNING Turn off all electrical power to unit before servicing ATTENTION gt If you find that it is mis plumbed un bonded etc contact the warranty department and let them handle it Do not bad mouth an installation Attention Warning and Caution boxes have been place through out this manual to help point out important information to look out for Attention Points out important information to be aware of Warning Indicates an action that might void warranty LA 11 Caution Alerts service or user regarding safety issues Page 3 Sequence of Operation In order to properly diagnose a problem you must understand the sequence of operation When the pool pump comes on and the water flows through the heater the water pressure closes the normally open pressure switch When the switch closes the control board then checks the thermostat to see if the pool water temp is below the board set point If it 1s it checks the normally closed high and low pressure switches If both are closed it will then send 24v to the compressor fan contactor and the unit will start to heat or cool
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