Balboa Instruments ML400 User guide

GL2000 Mach 3 Tech Sheet
Balboa Instruments
System PN 55048-04
System Model # GL2-GL2000M3-RCA-3.0
Software Version # 32
EPN # 2833
Base PCBA – PN 53708-04
PCB GL2000 – PN 22898 Rev B, C, or D
HEX File – 10011932
Base Panels
ML900 – PN 52654-01
ML700 – PN 52649-01
ML400 – PN 52684
Template used: 40597-v32_A.pdf 04/15/2008
55048-04_97_A.pdf 05/06/2008
Page 1
55048-04_97_A
System Revision History
System PN EPN
55048-02
55048-03
55048-04
Date
Requested By
2130 12.06.2006 Balboa
n/a
07.23.2007 Balboa
2833 05.06.2008 Balboa
Changes Made
Software update to v28
Software update to v30
Software update to v32
Page 2
55048-04_97_A
Basic System Features and Functions
Power Requirements
Single Service [3 wires (line, neutral, ground)]
s 6!#(Z^!!#IRCUIT"REAKERRATING!!MAX
Dual Service [5 wires (line 1, neutral 1, line 2, neutral 2, ground)]
s 6!#(Z^X!#IRCUIT"REAKERRATING!MAXEACHSERVICE
0HASE3ERVICE;WIRESLINELINELINENEUTRALGROUND=
s 6!#(Z.^!#IRCUIT"REAKERRATING!MAXEACHPHASELINE
s )-0/24!.43ERVICEMUSTINCLUDEANEUTRALWIREWITHALINETONEUTRALVOLTAGEOF6!#
Setup 1 (As Manufactured)
s
s
s
s
s
s
s
60UMP3PEED
60UMP3PEED
6"LOWER3PEED
6/ZONE
63PA,IGHT
6AV (Stereo)
K7)NCOLOY(EATER
Optional Devices
s 6#IRC0UMP
(EATERWATTAGEISRATEDAT6
Additional Options
s &ULL&EATURE$OLPHIN2EMOTE
AND3PAONLY$OLPHIN2EMOTE
s 3PA-ONITOR
Connects to Main Panel terminal J70 or J71 or J72
s )2OR2&$OLPHIN2ECEIVER-ODULE
Connects to Remote terminal J20
s /ZONE'ENERATOR
Connects to terminal J9
s -OOD%&8,IGHTING
#ONNECTSTO3PA,IGHTTERMINAL*
s &IBER%&8,IGHTING
#ONNECTSTO3PA,IGHTTERMINAL*
s 3TEREO3YSTEM
Connects to A.V. terminal J4
J17
J72
TST
K1
MAIN
PANEL
J71
J2
G
W1
MAIN
PANEL
FUSE F3A 250V
F4
MAIN
PANEL
J10
J12
J70
N
G
N
J30 J31
AUX
PANEL
J91
J39
W2
J9
N
AUX
PANEL
J69
G
J20
RLY/TRIAC J6
J83
CFG
REMOTE
ADCM
J13
EXT 2S P3
Page 3
J15
J7
AUX F ALARM
J22
SEN A
J82
VAC
J24
SEN B
55048-04_97_A
Persistent Memory and Powering Up
Any time you change DIP Switches or Software Configuration Settings that
affect parameters the user can change (any filter settings, set temperature
default, Celsius vs Fahrenheit, 12-hour vs 24-hour time, reminders
suppression, etc), you must reset Persistent Memory for your DIP Switch or
Software Configuration Settings changes to take effect. You should also reset
Persistent Memory after loading a new file into a board (using the ESM,
purchased seperately).
To reset Persistent Memory:
s Power down.
s Set A12 ON (See illustration below).
s Power up.
s Wait until “ ” or “
” is displayed on your panel.
” appears see section below.
Note: If “
s Set A12 OFF. (This can be done safely with power on if you use a nonconductive tool such as a pencil to push the switch back to the OFF
position. Otherwise, power down before setting A12 OFF)
s Power up again (if you powered down in the previous step).
s For all other power ups, leave A12 OFF.
About Persistent Memory and Time of Day Retention:
This system uses memory that doesn’t require a battery to store a variety
of settings. What we refer to as Persistent Memory stores all the User
Preferences, as well as all the filter settings, the set temperature, and the
heat mode.
Persistent Memory is not used for Time of Day. Time of Day needs to be
“kept running” (not just stored) while the power is off, so a separate Real
Time Clock feature (on all models except the EL1000) keeps track of
Time of Day while the unit is off. Time of Day Retention, and Time of Day
Retention alone, is controlled by the J91 jumper. J91 must be set according
to main system panel used.
Switchbank A
J91
RTC
Enabled
(Not Jumpered)
Switchbank B
J91
RTC
Disabled
(Jumpered)
message on power up:
If “
” appears before (and instead of) “ ” or
”, you have not configured DIP Switches and/or
“
Software Configuration Settings in a valid manner. This must be corrected
before you can reset Persistent Memory.
The switch numbers, jumpers, or configuration settings displayed after
“
” are ones with which the system has found a configuration problem.
For example:
s “
” would mean that the combination of how you’ve set
A5 and how you’ve set B2 is not supported on this system.
s “
” would mean that there is a problem with jumper J99
s “
” would mean that the combination of how
you’ve set pump 3 for 1-speed and blower for 1-speed is not supported
on this system.
s “
” would mean that the combination of how you’ve
set DIP switches which have been assigned to pump 3 and blower is not
supported on this system.
Power Up Display Sequence
Upon power up, you should see the following on the display:
s Three numbers in a row, which are the SSID (the System Software
ID). The third display of these numbers is the Software Version, which
should match the version of your system. For example, if these three
, that is a Mach 3 EL8000 at version 26.
numbers are
s If there is a Configuration Error, the
message (see above) will
appear at this point (and none of the messages below will display).
Otherwise what comes next is:
s An indication of either the input voltage detected (EL1000/EL2000), or
the heater wattage range supported (EL8000/GL2000/GL8000).
s Heater wattage display: “ ” means the system supports a heater
” means the system supports a heater
from 1 kW to 3 kW. “
” means the system supports a 3 kW
from 3 kW to 6 kW. “
heater only. (These ranges may be modified slightly in the case of
special heaters, which the next bullet covers.)
s Input voltage display: A system showing “
” supports 3 kW
to 6 kW heaters. A system showing “ ” supports the very same
heaters, although at 120V those heaters will function at only 1/4 of
” or
their 240V rated wattage. (The system shows only either “
” as a general indication of input voltage; it does not show the
“
actual input voltage.)
s If your system is using a special type of heater, a display such as “ ”
may appear next. If your system is using the generic Balboa heater, no
heater type display will appear.
s “ ” or “
” will appear to signal the start of
Priming Mode.
At this point, the power up sequence is complete. Refer to the User Guide
for the ML Series panel on your system for information about how the spa
operates from this point on.
Page 4
55048-04_97_A
Wiring Configuration and DIP Settings
HIPot Testing Note:
Setup 1 (As Manufactured)
s 60UMP3PEED
s 60UMP3PEED
s 6"LOWER3PEED
s 63PA,IGHT
s 6/ZONE
s 6!<6(Stereo)
Disconnect slip terminal with green
wires from J90 prior to performing
HiPot test. Failure to disconnect will
cause a false failure of the test.
s K7)NCOLOY(EATER
s ML900 or ML700 Main Panel
s 6#IRC0UMPOPT
Reconnect terminal to J90 after
successful completion of HiPot test.
Use X-P CE or X-P231 CE
Expander for Pump 3 1-Speed
J3
J333
K7
K6
K8
J60
J57 J59 J58
J90
J101
SWITCHBANK A
SWITCHBANK B
J100
H 2
HTR
J72
J71
J70
J10
F4
Ozone
J68
W4
J9
K10
MAIN
PANEL
RTC
Enabled
J69
ADCM
CFG
J91
J26
K11
G
J96
G
J14
N
J28
J56
J12
Spa
Light
J55
W3
2-Spd P1
J95
FUSE T30A 480V
MAIN
PANEL
AUX
PANEL
J39
J1
W1
J30 J31
FUSE F3A 250V
J2
J27
J93
N
K9
K4
T1
F7
W2
J94
TB1
MAIN
PANEL
J2
G
Circ
N Pump
Balboa
J23
N
J53
J17
TST
K1
J45
G
J54
A.V.
N
J32
J8
3.0kW
J81
G
FUSE F10A 250V
J4
J99
BALBOA INSTRUMENTS, INC.
GL2000 TC MACH 3
P/N 22898 REV D
COPYRIGHT 2006
MADE IN U.S.A.
J36
J41
EXT I/O
Blower
N
W15
FUSE T30A 480V
F6
F2
FUSE T0.2A
240V
G
J97 F5
AUX
PANEL
REMOTE
J20
EXT RELAY J6
J83
K2
G
1-Spd
P2
N
K3
J79
J5
J98
J13
J15
J7
J22
J82
J24
H
HTR1
F1
3.0 kW
EXT 2S P3
AUX F ALARM
SEN A
VAC
SEN B
Heater rated @ 240V
J8 must be Jumpered
WARNING: Main Power to system should be turned OFF BEFORE adjusting DIP switches.
WARNING: Persistent Memory (A12) must be RESET to allow new DIP switch settings to take effect. (See Persistent Memory page)
Switchbank A
J83
When the Logic Jumper is not installed on J83 (CFG),
DIP Switch Settings are enabled.
DIP Switches will then operate as shown below.
CFG
RTC
Enabled
(Not Jumpered)
J91
SSID #
A7, Cleanup Cycle OFF
A8, 1Hr O3 Supress OFF
A9/A10,
No Circ Pump
A11, O3 w/ P1 Low
and P1 is 2-Spd
A12, Memory Retained
B1, Pump 2 2-Speed
1-Speed
B2, Pump 2 Disabled
Enabled
B3, Blower Disabled
Enabled
B4, No Fiber/Wheel
B5, Pump 3 Disabled
B6, Panel Scrunching OFF
Page 5
Neutral (Common) AC Connections
Special AC Connections
Line AC Connections
Switchbank B
10 Volt Connections
J8
3.0kW
Heater
A1, Test Mode OFF
A2, High
Low Amp
Amp
A3, Filter by Time
A4, 12 Hr Time
A5, Degrees C
F
A6, Short Timeouts
Wiring Color Key
100
119
32
Relay Control Wires
Board Connector Key
1
Typically Line voltage
2
Typically Line voltage for 2-speed pumps
3
Neutral (Common)
4
Ground
Note flat sides in connector
55048-04_97_A
DIP Switches and Jumpers Definitions
WARNING:
sSetting DIP switches incorrectly may cause abnormal system behavior and/or damage to system components.
sRefer to Switchbank illustration on Wiring Configuration page for correct settings for this system.
sContact Balboa if you require additional configuration pages added to this tech sheet.
DIP Switchbank A Key
A1
. . . . . . . . . . . . . . . . Test Mode (normally Off)
A2
. . . . . . . . . . . . . . . . In “ON” position, heater can run while any/all high-speed pumps or blowers are running
(High amperage)
. . . . . . . . . . . . . . . . In “OFF” position, heater is disabled while any high-speed pump or blower is running
(Low amperage)
A3
. . . . . . . . . . . . . . . . In “ON” position, filter cycles are programmed by duration for non-time capable panels
. . . . . . . . . . . . . . . . In “OFF” position, filter cycles are programmed to start and end times for time capable panels
A4*
. . . . . . . . . . . . . . . . In “ON” position, displays time in 24 hours (military\European time)
. . . . . . . . . . . . . . . . In “OFF” position, displays 12 hour time
A5*
. . . . . . . . . . . . . . . . In “ON” position, displays temperature in Celsius
. . . . . . . . . . . . . . . . In “OFF” position, displays temperature in Fahrenheit
* Sets default for user preferences - only applies when persistent memory is reset (A12 On) during power-up
A6
. . . . . . . . . . . . . . . . In “ON” position, Equipment timeout 30 minutes (4 hours for Pump 1-Low)
. . . . . . . . . . . . . . . . In “OFF” position, Equipment timeout 15 minutes (2 hours for Pump 1-Low)
A7
. . . . . . . . . . . . . . . . In “ON” position, Cleanup Cycle – 30 minutes after spa use/timeout, Pump 1-Low & Ozone or
Circ Pump and Ozone run for 1 hour
. . . . . . . . . . . . . . . . In “OFF” position, no Cleanup Cycle
A8
. . . . . . . . . . . . . . . . In "ON" position, Ozone suppression for one hour after pump/blower button press
A9 and A10. . . . . . . . . . . . . See Table for Circ Pump Behavior settings
A11
. . . . . . . . . . . . . . . . In “ON” position
Circ Pump
(non-circ mode operation) Pump 1 is two-speed, Ozone is
A9 A10
Behavior
ON in Filter & Cleanup Cycles only
OFF OFF
No Circ Pump
(in any circ mode) Pump 1 is one-speed, Ozone is ON with
or Circ Pump not
circ pump
plumbed w/heater
. . . . . . . . . . . . . . . . In “OFF” position
ON
OFF
24 Hours
(non-circ mode operation) Pump 1 is two-speed, Ozone is
OFF ON 24 Hr w/3°F Shut-Off
ON with Pump 1-Low
ON
ON Acts like Pump 1-Low
(in any circ mode) Pump 1 is two-speed, Ozone is ON with
(Filter Cycles, Polls)
circ pump
A12
. . . . . . . . . . . . . . . . Persistent memory reset (normally off) (used when spa is
powering up)
DIP Switchbank B Key
B1
. . . . . . . . . . . . . . . In “ON” position, single-speed Pump 2
. . . . . . . . . . . . . . . In “OFF” position, two-speed Pump 2
B2
. . . . . . . . . . . . . . . In “ON” position, Pump 2 enabled
. . . . . . . . . . . . . . . In “OFF” position, Pump 2 disabled
B3
. . . . . . . . . . . . . . . In “ON” position, Blower enabled
. . . . . . . . . . . . . . . In “OFF” position, Blower disabled
B4
. . . . . . . . . . . . . . . In “ON” position, Fiber and Wheel instead of Spa Light
(if A9 & A10 are both OFF, Fiber uses J2 connector; if either A9 or A10 is ON, X-FOW Kit required to run Fiber)
. . . . . . . . . . . . . . . In “OFF” position, Spa light enabled
B5
. . . . . . . . . . . . . . . In “ON” position, Pump 3 enabled (Jets 3 replaces Blower on Aux panel)
. . . . . . . . . . . . . . . In “OFF” position, Pump 3 disabled
B6
. . . . . . . . . . . . . . . In “ON” position, Alternate Panel layout (ML900 scrunching enabled - ML550 / 700 Jets 3 replaces Blower)
. . . . . . . . . . . . . . . In “OFF” position, Normal Panel layout
Jumpers
J8
Jumper on 1 Pin only when using 2.0kW or 1.0kW heater.
Jumper on Pins 1 and 2 when using 3.0kW heater.
J91
Jumper on 1 Pin only enables Real Time Clock function; use with time capable panels.
Jumper on Pins 1 and 2 disables RTC function; use with non-time capable panels.
Page 6
55048-04_97_A
Electrical Service Configuration Options
For DIP Switch Configured System
J32
F6
Single Service (1 x 16 Amp or 1 x 32 Amp)
J99
J53
MADE IN U.S.A.
J23
J94
Balboa
BALBOA INSTRUMENTS, INC.
GL2000 TC MACH 3
P/N 22898 REV D
COPYRIGHT 2006
TB1
F7
J2
J27
J93
J95
FUSE T30A 480V
W3
J28
J96
J26
L1
This option is configured and shipped as the default.
For 1 x 32 Amp Service:
DIP Switch A2 can be ON
For 1 x 16 Amp Service:
DIP Switch A2 must be OFF
J68
W4
K7
N1
J57 J59 J58
J101
J100
H 2
HTR
H
HTR1
F1
J32
F6
Dual Service Option (2 x 16 Amp)
J99
J53
J23
J94
Balboa
BALBOA INSTRUMENTS, INC.
GL2000 TC MACH 3
P/N 22898 REV D
COPYRIGHT 2006
MADE IN U.S.A.
TB1
Completely remove the white wire from J26 and J32.
F7
J2
J27
J93
L2
J95
FUSE T30A 480V
N2
W3
J28
J96
J26
L1
Note: J32 and J23 are electrically identical. The white
wire may be attached to either terminal before removal.
DIP Switch A2 must be ON
J68
W4
K7
N1
J57 J59 J58
J101
J100
H 2
HTR
H
HTR1
F1
3-Phase Service Option
IMPORTANT - Service MUST include a neutral wire,
with a line to neutral voltage of 230VAC.
J32
F6
J99
J53
MADE IN U.S.A.
J23
J94
Balboa
BALBOA INSTRUMENTS, INC.
GL2000 TC MACH 3
P/N 22898 REV D
COPYRIGHT 2006
TB1
Completely remove the white wire from J26 and J32.
F7
J2
J27
J93
L3
J95
FUSE T30A 480V
L2
J28
W3
J96
L1
J26
W4
N1
J68
K7
J57 J59 J58
J101
Completely remove the blue wire from J28 and J57.
Note: J57, J58 and J59 are electrically identical. The blue
wire may be attached to any of these terminals before
removal.
Move the brown wire from J23 or J32 to J28.
J100
H 2
HTR
Note: J32 and J23 are electrically identical. The white
wire may be attached to either of these terminals
before removal.
H
HTR1
F1
DIP Switch A2 must be ON
Page 7
55048-04_97_A
Ozone Connections
Note: A special tool is required to remove the pins from the connector body once they are snapped in
place. Check with your Balboa Account Manager for information on purchasing a pin-removal tool.
Balboa Ozone connector configuration for 230VAC 50Hz:
L
Black or Brown Line Conductor
Empty
White or Blue Neutral Conductor
Empty
N
Flat sides of sockets as shown
G
W1
MAIN
PANEL
J30 J31
FUSE F3A 250V
J10
MAIN
PANEL
AUX
PANEL
J91
J39
W2
J14
K10
J9
Line - Black or Brown conductor
Not used
Neutral - White or Blue conductor
Not used
J70
N
G
N
F4
J12
AUX
PANEL
J69
0
REMOTE
ADCM
CFG
EXT. RLY J6
J83
SWITCHBANK B
J20
J13
EXT 2S P3
J15
J7
AUX F ALARM
J22
SEN A
J82
VAC
J24
SEN B
Page 8
55048-04_97_A
Panel Configurations
Note: RTC jumper (J91) on Main PCBA must be OFF (1 pin only)
Time
Warm
Jets 1
Jets 2
Jets 3
Option
Mode/Prog
Cool
Invert
Fiber
Light
Blower
F1
F2
PL
TIME CAPABLE
TL
ML900
PN 52654-01 with Overlay PN 40026
s Connects to Main Panel terminal J70, J71, or J72
Time
Warm
Light
Blower
Mode/Prog
Cool
Jets 1
Jets 2
F1
F2
PL
TL
NON-TIME CAPABLE
ML700
PN 52649-01 with Overlay PN 11281
s Connects to Main Panel terminal J70, J71, or J72
Note: Connects to Main Panel terminal J70, J71, or J72
Note: RTC Jumper (J91) on Main PCBA must be ON (both pins
jumpered), unless a Time Capable panel is also used.
Heat
Jets
Aux
Temp
Light
ML400
PN 52684 with Overlay PN 11345
Page 9
55048-04_97_A