42211 C_BWG 60Hz BP Troubleshooting Service Manual_062213

42211 C_BWG 60Hz BP Troubleshooting Service Manual_062213
Balboa's BP Troubleshooting & Service Manual
THIS MANUAL COVERS THE FOLLOWING:
SPA CONTROL SYSTEMS
PANELS
BP500
BP2000G1
TP900, TP800,
TP600, TP400
42211 C
60 Hz
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
1
Introduction
Intellectual Property Advisement
Warnings: Danger! Risk of Electric Shock!
All Intellectual property, as defined below, owned by or which is
otherwise the property of Balboa Water Group or its respective
suppliers relating to the Balboa Water Group BP500 Spa Control,
including but not limited to, accessories, parts, or software
relating there to (the “System”), is proprietary to Balboa Water
Group and protected under federal laws, state laws, and
international treaty provisions. Intellectual Property includes,
but is not limited to, inventions (patentable or unpatentable),
patents, trade secrets, copyrights, software, computer programs,
and related documentation, and other works of authorship. You
may not infringe or otherwise violate the rights secured by the
Intellectual Property. Moreover, you agree that you will not (and
will not attempt to) modify, prepare derivative works of, reverse
engineer, decompile, disassemble, or otherwise attempt to create
source code from the software. No title to or ownership in the
Intellectual Property is transferred to you. All applicable rights of
the Intellectual Property shall remain with Balboa Water Group
and its suppliers.
UÊ All electrical work must be performed by a qualified electrician and must conform to all national, state, and local codes.
UÊ Before making any electrical connections, make certain that
the Main Power breaker from the house breaker box has
been turned off.
UÊ Do not attempt service of this control system. Contact your
dealer or service organization for assistance.
UÊ Do not permit any electric appliance, such as a light, telephone, radio, or television within 5’ (1.5m) of a pool or spa.
UÊ Follow all owner’s manual power connection instructions.
UÊ Installation must be performed by a licensed electrician and
all grounding connections must be properly installed.
UÊ No user serviceable parts.
UÊ Water temperature in excess of 38˚C may be injurious to
your health.
UÊ Disconnect the electrical power before servicing.
UÊ Keep access door closed.
End User Warning
This Installation Manual is provided solely to aid qualified spa
service technicians in installing spas with control systems
manufactured by Balboa Water Group. Balboa controls have
absolutely no end user serviceable parts. Balboa Water Group
does not authorize attempts by the spa owner/user to repair or
service any Balboa products. Non-qualified users should never
open or remove covers, as this will expose dangerous voltage
points and other dangerous risks. Please contact your dealer or
authorized repair center for service.
GFCI
It is required by code to install a Ground Fault Circuit Interrupter
(GFCI) in the supply power for a spa. This device will trip the
breaker if there is an unsafe electrical condition caused by a
malfunctioning component or even the slightest short to ground.
Note: Connect the control system only to a circuit protected
by a Class A GFCI mounted at least 5’ (1.52M) from the inside
walls of the spa/hot tub and in line of sight from the equipment
compartment.
Refer to NEC (National Electrical Code), 2005 Edition, Article
680 for more information.
2
CAUTION
UÊ Test the ground fault circuit interrupter before each use of
the spa.
UÊ Read the instruction manual.
UÊ Adequate drainage must be provided if the equipment is to be
installed in a pit.
UÊ To ensure continued protection against shock hazard, use
only identical replacement parts when servicing.
UÊ Install a VG Compliant suction guard that is suitably rated to
match the maximum flow rate marked.
WARNING:
UÊ Water temperature in excess of 38˚C may be injurious to
your health.
UÊ Disconnect the electrical power before servicing.
UÊ Keep access door closed.
© 2013 Balboa Water Group. All Rights Reserved.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Codes and Compliance
All of the electrical wiring methods and materials used to
complete the electrical installation of the BP control systems
must be in accordance with the National Electrical Code or the
Canadian Electric Code, as well as any local electrical codes in
effect at the time of installation.
The selection of electrical materials required to accomplish
this installation and the installation of the control system
must be made by, or be under the direct supervision of,
a qualified electrician.
The systems herein are classified as a “continuous duty
appliance” and is intended primarily for installation at a
single family dwelling. The installation recommendations and
instructions contained in this manual are directed solely toward
these issues.
WARNING!
If there is any doubt whether the system that you are repairing
does not have these features, contact a licensed, qualified
electrician. Do not attempt to modify the wiring yourself.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
3
Warning! Qualified Technician Required for Service and Installation
Basic Installation and
Configuration Guidelines
Use minimum 6AWG copper conductors only.
Torque field connections between 21 and 23 in lbs.
Readily accessible disconnecting means to be provided at time of installation.
Permanently connected.
Connect only to a circuit protected by a Class A Ground Fault Circuit
Interrupter (GFCI) or Residual Current Device (RCD) mounted at least 5’
(1.52M) from the inside walls of the spa/hot tub and in line of sight from
the equipment compartment.
CSA enclosure: Type 2
CSA Compliance/Conformité
Caution:
K'[email protected]?<B;13.B9A06?0B6A6;A2??B=A2?<[email protected] current device before
each use of the spa.
K%2.1A526;@A?B0A6<;:.;B.9
K12>B.A21?.6;.42:[email protected]/2=?<C612163A522>B6=:2;[email protected]</26;@A.9921
in a pit.
K<[email protected]<;9FD6A56;.;2;09<@B?2?.A21&;09<@B?2
K<;;20A<;9FA<.06?0B6A=?<A20A21/[email protected]@4?<B;13.B9A06?0B6A
interrupter or residual current device.
K'<2;@B?20<;A6;B21=?<A20A6<;.4.6;@[email protected]<[email protected]<;9F612;A60.9
replacement parts when servicing.
Refer to Wiring Diagram inside the cover of the control enclosure.
K;@[email protected]/[email protected]<;4B.?1A<:.A05A52:.E6:B:Jow rate
:.?821
Refer to Installation and Safety Instructions provided by the spa manufacturer.
Warning:
K*.A2?A2:=2?.AB?26;[email protected]@<3M:.F/26;7B?6<[email protected]<F<B?52.9A5
Warning: People with infectious diseases should not use a spa or hot
[email protected]<;;20AA522920A?60.9=<D2?/23<[email protected]?C606;4
tub.
Attention:
Warning: To avoid injury, exercise care when entering or exiting the spa
or hot tub.
K'<B7<[email protected]?6Ier l’efficacite du disjoncteur differentiel avant d’utiliser
differentiel avant d’utiliser le bain.
Warning: Do not use a spa or hot tub immediately following strenuous
K 6?29.;<A602A205;6>B2
exercise
K <[email protected]>[email protected];@A.9921.;@B;23<@@2<;1<[email protected]@B?2?B;
drainage adequat.
Warning: Prolonged immersion in a spa or hot tub may be injurious to
your health
Warning: Maintain water chemistry in accordance with the Manufacturers instructions.
Warning: The equipment and controls shall be located not less than 1.5
meters horizontally from the spa or hot tub.
K:=9<F2?B;6>B2:2;A.96;A2?62B?1B;209<AB?2&;09<@B?2
K<;;20A2?B;6>B2:2;A.B;06?0B6A=?<A242=.?B;[email protected]<;0A2B?16332?2;
tiel de Class A.
KI;[email protected]@B?2?B;2=?<A20A6<;=2?:.;2;A20<;A?2921.;[email protected]<08
electrique, lors de l’entretien employer seulement des pieces de rechange
identiques.
Warning! GFCI or RCD Protection.
K [email protected][email protected]@[email protected]=6?.A6<;1<6C2;A2A?22>[email protected][email protected]<;C2;.;A.B
debit maximal indique.
The Owner should test and reset the GFCI or RCD on a
regular basis to verify its function.
Avertissement:
[email protected]:[email protected]@[email protected]=2BC2;[email protected];A2?B;
danger pour la sante.
Warning! Shock Hazard!
No User Serviceable Parts.
Do not attempt service of this control system. Contact your
dealer or service organization for assistance. Follow all
owner’s manual power connection instructions. Installation
must be performed by a licensed electrician and all grounding connections must be properly installed.
4
K20<;;20A2?1B06?0B6A1.96:2;A.A6<;2920A?6>B2.C.;A292;A?2A62;
Warning/Advertissement:
[email protected]<;;20AA522920A?60=<D2?/23<[email protected]?C606;[email protected]@1<<?09<@21
K20<;;20A2?1B06?0B6A1.96:2;A.A6<;2920A?6>B2.C.;A92;A?2A62;
Garder la porte fermer.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intellectual Property Advisement . . . .
End User Warning . . . . . . . . . . .
GFCI . . . . . . . . . . . . . . . . .
Warnings: Danger! Risk of Electric Shock!
Codes and Compliance . . . . . . . . .
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.2
.2
.2
.2
.3
Service Tools and Parts Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TP Panel Overview and User Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Troubleshooting & Servicing of Spa's Electrical Equipment . . . . . . . . . . . . . . . 10
G.F.C.I. Troubleshooting . . . . . . . . . . . . .
120 Volt Residential Wiring Schematic with G.F.C.I. .
240 Volt Residential Wiring Schematic with G.F.C.I. .
Voltage Checks: Breaker Box, G.F.C.I. & System Box .
Wiring Checks . . . . . . . . . . . . . . . . .
Testing a System with Power . . . . . . . . . . .
Troubleshooting Pumps, Problem & Cause . . . . .
Acceptable Ranges for Testing Equipment . . . . .
Fuses: Devices, Locations, and Values . . . . . . .
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11
12
14
16
17
18
22
23
24
BP 60Hz Spa Control System Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wiring Diagram - BP500, Part Number 56278, Setup No. 1 (as manufactured)
Wiring Diagram - BP2000G1, Part Number 56377. . . . . . . . . . . . .
Wiring Diagram - BP2000G1, Part Number 56377-01 . . . . . . . . . . .
Wiring Diagram - BP20MSSH, Part Number: 56373 (MicroSilk) . . . . . .
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25
26
28
30
Troubleshooting Using Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Ohm’s Law . . . . . . . . . . . . . . . . . . . . . .
Testing a Fuse: Continuity . . . . . . . . . . . . . . .
Troubleshooting Heater Resistance . . . . . . . . . . .
Troubleshooting Heater Posts Resistance to Heater Housing
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32
33
34
35
Troubleshooting with Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Verifying Incoming Voltage at the Terminal Block - BP500, BP2000G1
Testing Pump Fuses for Damage with Voltage On - BP2000G1 . . .
Testing Heater Voltage - All BP Systems . . . . . . . . . . . . .
A Safer Way to Test Heater Voltages . . . . . . . . . . . . . .
Testing Pump Fuses for Damage with Voltage On - BP500 . . . . .
Testing Heater Amperage . . . . . . . . . . . . . . . . . . .
Testing Low Speed and High Speed at the AMP Pump Connector . .
42211 C
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37
38
39
40
41
42
43
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
5
Component Failure and Replacement Testing . . . . . . . . . . . . . . . . . . . . . . . . . 44
Software Setups and Test Mode . . . . . . . . . .
Setup Changes with DIP Switch 1 ON - BP500 . . . . .
Setup Changes with DIP Switch 1 ON - BP2500 . . . .
Testing the Sensor Set . . . . . . . . . . . . . . .
Remove and Replace a System Circuit Board . . . . .
Removing the Heater Assembly from a BP Spa System .
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44
45
47
48
50
52
TP800, TP900 Panel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
The Main Screen - Navigation . . . . . . . . . .
TP800, TP900 Priming Mode Start-up Sequence . . .
TP800, TP900 Spa Behavior . . . . . . . . . . . .
TP800, TP900 Adjusting Filtration . . . . . . . . .
TP800, TP900 Panel Lock & Unlock. . . . . . . . .
TP800, TP900 Sensor and System Related Messages.
TP800, TP900 Utilities Menu . . . . . . . . . . . .
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54
55
56
57
58
59
63
TP400, TP600 Standard Panel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Main Screen - Navigation . . . . . . . . . . . . .
TP400, TP600 Panel Utilities Menu . . . . . . . . . .
TP400, TP600 Preparation and Priming . . . . . . . .
TP400, TP600 Message Codes . . . . . . . . . . . .
TP400, TP600 Utilities Fault Log Menu . . . . . . . .
TP400, TP600 Utilities Menu - GFCI Test Feature . . . .
TP400, TP600 Simplified vs. Standard Panel Operations.
A Simplified Main Menu (Doc No. 42185B) . . . . . .
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.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
64
65
66
67
70
71
72
73
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Optional Balboa DolphinTM Remote. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Spa Guidelines to Keep in Mind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Index of Paragraph Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Service Tools and Parts Checklist
SERVICE TOOLS REQUIRED
UÊ
UÊ
UÊ
UÊ
UÊ
Ammeter (50A) with insulated clamps for probes
Screwdrivers, assorted flat and Phillips
Digital Multi-meter
Padlock (to lock electrical disconnect during service)
Pliers: Slip Joint & Needle nose
UÊ
UÊ
UÊ
UÊ
Precision Thermometer - Digital Fever Type
Silicone Tube
Small Wire Cutters
3/8” and 1/4" Open End Wrenches (Heater
wire nut removal)
Logic Jumper,
No. 20618
FUSES USED ON BP SPA SYSTEMS
Fuse
BWG Part Number
30A
30136
10A
30122
3A Slo-Blo
20600
0.3A Slo-Blo
21581
0.15A Slo-Blo
26281
0.125A Slo-Blo
26397
RECOMMENDED PARTS TO
HAVE FOR SERVICE CALLS
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
Extra Board(s)
Extra Panel(s)
Fuses
Jumpers
Heater Assemblies
Sensor Wires (No. 30344 sensor
wire for example).
BP2000 Circuit Board
Heater Assembly
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
7
TP Panel Overview and User Guides
TP900
System Models: BP2000G1 and other BP-Series Systems as
required.
Panel Model: TP900 Series, TP800 Series
Software Version(s): Software versions vary and are
constantly changing. See Tech Sheets for latest version and
software compatibility.
TP600
TP800
User Guide 40985
System Models: BP500 and other BP-Series Systems as required.
Panel Model: TP600 Series, TP400 Series
Software Version(s): Software versions vary and are
constantly changing. See Tech Sheets for latest version and
software compatibility.
JETS
TS
S
AUX
LIGHT
HEAT
HEAT
TP400
UÊ
User Guide 40940
User Interface and Programming Reference – Standard Menus
UÊ User Guide 42185; Ref. Card 40947
User Interface and Programming Reference – Simplified Menus
(See section TP400, TP600 Simplified Panel Operations for
more information.)
NOTE: All TP panels work with all BP Spa Control Systems. They
all have capabilities for navigation, setting functions and modes,
such as time, temperature, filter cycles, preferences, sensor
related messages, reminder messages, diagnostic messages, and
utilities such as fault logs.
8
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Product Identification
All TP Panels have
“Molex” Type
Connectors
On Every System, an Identification
Label Is Placed on Top of the Casing
Heater Element Specifications Are Shown
on the Heater Tube Label
On Every System, a Wiring Diagram
Is Placed Inside the Door
BP2000G1 – PN 56377-01
J43 TO J13 (BLOWER ON J14)
IN SETUPS 3, 5, 9, 11, 12, 17, 18
J45
J79
J54
J77
J75
J78
J53
4
J18
115V
J49
K5
3
2
J58
J44
J27
J23
SERIAL
LOCATION
J1 ON RT
EXPANDER
AUX
DEVICE
2 SPD*
PUMP 3
J15
LIGHT
F4 3A SLO-BLOW
10
GND
ON S1
J40
J29
VAC
K7
J28
EXPANDER
X-P332
J8
AUX
J25 J31
3
REMOTE
J17
VOLTS
240V
AMPS
12A
MAX
FROM
W1 ON
EXPANDER
TO
GROUP 2
J1
J5 (A1-A4)
OR
J8 (A5-A8)
FROM
J6 ON
EXPANDER
TO
GROUP 3
J53
J16
W1
J1
RIGHT
EXPANDER
BOARD
J7
J6
F1 30A
AUX
FRZ
SENSOR B
5.5 kW HEATER
**J14 (AUX) IS:
2-SPEED PUMP 2 IN SETUPS 1-4, 7-10, 15, 16
42211 C
WIFI
TRANSCEIVER
J34 OR J35
J26 J30
J48
SENSOR A
J5
AUX
J91
J22
J111
J11
J35
MAIN
J108 J107
K3
2
AUX**
J34
MAIN
J101
J6
4
J19
115V
TP (MAIN) PANELS
J34 OR J35
IR RECEIVER
OR
RF RECEIVER
J50
K8
230V
T1
240VAC
CIRC/O3
OPTION
K6
EXPANDER
J51
J52
J98
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
3
J20
J109
K1
2
J110
J24
F3 0.3A SLO-BLOW
1
GRN
K12
F8 30A
1
RED
BLK
WHT
J43
24082_D
J14
J13
J7
J56
J57
J55
J59
J39
J10
J60 J41
J32
F7 10A 250VAC
K2
F6 30A
TB1
J21
K9
OZONE
J38
CIRC PUMP
J33
K4
J81
J46
F2 10A 250VAC
PUMP 1
J9
A/V HOT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
01-29-13
*EXPANDER BOARD IS:
2-SPEED PUMP 3 IN SETUPS 1, 7
1-SPEED PUMP 3 (ONLY) IN SETUPS 2, 6, 8, 13, 14
1-SPEED PUMP 3 AND 1-SPEED BLOWER (WITH SPLITTER & IN-LINE FUSE)
IN SETUPS 15, 16
1-SPEED PUMP 2 AND 1-SPEED PUMP 3 IN SETUPS 5, 11, 12
2-SPEED PUMP 2 IN SETUPS 3, 9
UNUSED IN SETUPS 4, 10
1 SPEED PUMP 2 IN SETUPS 17 18
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
9
General Troubleshooting & Servicing of Spa's Electrical Equipment
HIGH VOLTAGE CAN SERIOUSLY INJURE OR KILL!
ONLY EXPERIENCED TECHNICIANS SHOULD SERVICE THIS EQUIPMENT.
DO NOT REMOVE THE PROTECTIVE COVERS FROM ANY ELECTRICAL ENCLOSURE, OR ATTEMPT TO SERVICE ANY RELATED ELECTRICAL DEVICE, UNLESS YOU ARE A QUALIFIED ELECTRICIAN OR SERVICE PROFESSIONAL.
DANGER
Risk of electric shock. Before working with any electrical
connections, make certain that the Main Power breaker from
the house breaker box has been turned off.
WARNING
ALL ELECTRICAL WORK MUST BE PERFORMED BY A
QUALIFIED ELECTRICIAN AND MUST CONFORM TO ALL
LOCAL CODES.
IMPORTANT
DUE TO THE DANGER OF SEVERE ELECTRICAL SHOCK,
LOCATE ALL POWER DISCONNECTS BEFORE SERVICING A SPA. PRECAUTIONS MUST BE TAKEN WHENEVER
WORKING WITH BREAKER BOXES, G.F.C.I.’S, OR SERVICE
DISCONNECTS.
Always refer to the wiring diagram that is included with each
system on the inside of the system box cover. Use this diagram
for voltage measurement points, and for proper reconnection
of wires.
A terminal marked “GROUND” is provided
within the System Control Center enclosure.
To reduce the risk of electrical shock, connect
this terminal to the grounding
terminal of the electric supply
panel with a continuous
green insulated copper wire
equivalent in size to the circuit
conductors supplying this
equipment, but no smaller than
#12 AWG.
Ground in System Enclosure
UÊ
UÊ
UÊ
UÊ
10
SAFETY TIPS
Keep children and pets away.
Be aware of your surroundings. Standing in water while
repairing a spa puts you at serious risk.
Avoid working in cramped or crowded conditions.
Consider placing a padlock on the service panel to lock
out anyone who might power up the system.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
G.F.C.I. Troubleshooting
Keep in mind that a majority of G.F.C.I. tripping problems can be attributed to incorrect wiring. G.F.C.I. troubleshooting
usually finds the problem.
IF CORRECT WIRING IS VERIFIED
TO DISCONNECT THE HEATER
UÊ Check to see if the proper G.F.C.I. is installed.
UÊ Check the label in the system box near TB1 to determine the
maximum amperage draw for the system.
UÊ Be sure the G.F.C.I. is rated for more amperage than the
system will draw.
UÊ For a 240 V dedicated system, a 2-pole G.F.C.I. with no load
neutral is acceptable.
UÊ For a 120/240 V system, the G.F.C.I. must include a load
neutral out.
UÊ If the white load neutral wire is routed from the G.F.C.I.
neutral bar directly to TB1 in the system box, then the G.F.C.I.
will trip when a 120 V device is activated.
UÊ For a detailed wiring checklist, please review the previous segment of this manual on proper G.F.C.I. wiring or the
G.F.C.I. manufacturer’s instructions.
UÊ If the wiring is correct and the G.F.C.I. will not reset, then
unplug the pump and try to reset the G.F.C.I.
UÊ If the G.F.C.I. trips again, then unplug the blower and reset
the G.F.C.I.. If the G.F.C.I. continues to trip, then do the same
procedure for the ozone generator.
UÊ If the G.F.C.I. stops tripping after you unplugged one of the
spa’s components, turn off the power to the spa then plug in
each component except the one that tripped the G.F.C.I.
UÊ Power up the system. If the G.F.C.I. no longer trips, then you
have correctly identified the problem.
UÊ Repair or replace the component as instructed by the spa
manufacturer.
UÊ If you have unplugged all of the spa’s components and the
G.F.C.I. still doesn’t reset, then the problem is most likely a
ground fault in the heater.
UÊ First, turn off the main circuit breaker, then remove both
heater straps or wires from the system heater output, not
the heater itself.
UÊ After restoring the power, try to reset the G.F.C.I. again. If it
no longer trips after the system calls for heat, then replace
the heater.
UÊ If the G.F.C.I. still trips, look for pinched or shorted wires at
the transformer. Make sure that the screws that attach the
transformer to the system box have not pinched or damaged
the insulation of the transformer wires.
UÊ If the transformer wires are undamaged, check for any other
pinched wires. Refer to the wiring diagram to verify the
correct wiring of the control system.
UÊ If everything looks to be in perfect working order, then the
G.F.C.I. may be defective.
Ground-Fault Circuit
Interrupter/Circuit
Breaker (G.F.C.I.)
WARNING: THE OWNER SHOULD TEST AND RESET
THE G.F.C.I. ON A REGULAR BASIS TO VERIFY ITS
FUNCTION.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
11
120 Volt Residential Wiring Schematic with G.F.C.I.
G.F.C.I Breaker Box
120 VAC
Neutral
120 VAC
House Breaker Box
8
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
10
OFF
ON
ON
OFF
OFF
OFF
ON
OFF
6
5
ON
ON
11
ON
ON
7
9
4
Outside Ground Rod
Correct
Voltage
0v
108V - 132V
12
When Probes Are Placed Across
[2 - 3] [4 - 6] [4 - 7] [5 - 8] [9-10]
[1 - 2} [1 - 3] [4 - 5] [4 - 8] [5 - 6]
[5 - 9] [6 - 8] [7 - 8] [9 - 11] [10 - 11]
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Note: This applies to all Domestic BP Systems.
A BP2000 System is shown for illustrative purposes.
Bottom view of G.F.C.I
J 6
PUMP 1
J31=CE
HTR
SEL
J56
J57
J55
J59
K2
J
F6 30A
J51
J52
J60 J41
TB1
1
White White
J37 J72
J4 J42
Black (Hot)
2
5
3
J36
J12
3
J53
5
9
4
7
5
8
0
4
1
2
J
Green Ground Wire
to Ground Bar
J60 J41
J51
J52
J98
J18
AUX**
J50
K8
J19
J34
MAIN
230V
115V 115V
T1
J101
J53 J58
J22
K3
2
J5
AUX
J8
AUX
J25 J31
3
J15
J7
2
K5
3
J27
J23
SERIAL
J26 J30
J49 J44 J48
J6
J37 J72
J4 J42
J1 J3
J47 J61
4
J91
F3 0.3A SLO-BLOW
J36
J12
J88
J62
3
J14
J35
MAIN
J108 J107
K1
2
K6
J24
J109
1
LIGHT
J40
J29
VAC
K7
REMOTE
F4 3A SLO-BLOW
J45
J79
J54
J77
J75
J78
J110
J21
K12
F8 30A
1
TB1
J13
OZONE
J81
J39
J10 J43
F6 30A
J32
F7 10A 250VAC
K9
CIRC PUMP
J38
F2 10A 250VAC
K4
J20
J33
J46
J56
J57
J55
J59
PUMP 1
J9
K2
A/V HOT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
4
J111
J11
10
J17
GND
ON S1
J28
J16
AUX
FRZ
1
2
Black
3
White
4
K4
Test for Voltages by placing
probes on these locations
J32 J33
Electric Installation 120VAC_with 56405_sunrise_board_030613.ai
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
13
240 Volt Residential Wiring Schematic with G.F.C.I.
G.F.C.I Breaker Box
10
120 VAC
Neutral
120 VAC
House Breaker Box
11
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
13
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
14
8
7
ON
15
ON
ON
9
6
12
5
Outside Ground Rod
Correct
Voltage
0v
14
When Probes Are Placed Across
[3 - 4] [5 - 8]
[5 - 9]
[12 - 13]
108V - 132V
[1 - 3] [5 - 6]
[2 - 3] [5 - 7]
[5 - 10]
[5 - 11]
[12 - 14]
[12 - 15]
216V - 264V
[1 - 2] [6 - 7]
[10 - 11]
[14 - 15]
[13 - 14]
[13 - 15]
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Note: This applies to all Domestic BP Systems.
A BP2000 System is shown for illustrative purposes.
Bottom view of G.F.C.I
J 6
PUMP 1
J31=CE
HTR
SEL
J56
J57
J55
J59
K2
J
F6 30A
J51
J52
J60 J41
TB1
Black (Hot)
White White
2
Red (Hot)
6
3
4
J36
J12
7
J37 J72
J4 J42
1
J53
5
9
4
7
5
8
0
4
1
2
3
J
Green Ground Wire
to Ground Bar
J60 J41
J51
J52
J98
J18
AUX**
J34
MAIN
115V 115V
J35
MAIN
J108 J107
T1
J101
J53 J58
J22
K3
2
J5
AUX
J8
AUX
J25 J31
3
J15
J7
2
J27
J23
SERIAL
J26 J30
J49 J44 J48
K5
3
J6
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
4
J91
F3 0.3A SLO-BLOW
K1
3
LIGHT
J40
J29
VAC
K7
REMOTE
F4 3A SLO-BLOW
J45
J79
J54
J77
J75
J78
J110
J19
230V
J24
J109
1
2
K6
J50
K8
K12
F8 30A
1
TB1
J14
J13
OZONE
J81
J39
J10 J43
F6 30A
J21
J32
F7 10A 250VAC
K9
CIRC PUMP
J38
F2 10A 250VAC
K4
J20
J33
J46
J56
J57
J55
J59
K2
PUMP 1
J9
A/V HOT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
4
J111
J11
10
J17
GND
ON S1
J28
J16
AUX
FRZ
1
Red
2
Black
3
White
4
K4
Test for Voltages by placing
probes on these locations
J32 J33
42211 C
Electric Installation 240VAC_with 56405_sunrise_board_030613.ai
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
15
Voltage Checks: Breaker Box, G.F.C.I. & System Box
UÊ
UÊ
UÊ
UÊ
When checking for proper voltage, keep in mind that the acceptable voltage range is +/- 10% of the recommended voltage.
Acceptable voltage when 120 V is specified is between 108 and 132 V.
Acceptable voltage when 240 V is specified is between 216 and 264 V.
Diagrams are on the following pages.
VOLTAGE VERIFICATION - MOST G.F.C.I. PROBLEMS ARE DUE TO LOW VOLTAGE
IMPORTANT:
IF THE VOLTAGE IS NOT WITHIN THE ACCEPTABLE RANGE, CALL AN ELECTRICIAN
OR THE LOCAL ELECTRIC COMPANY TO DIAGNOSE THE PROBLEM.
CHECK THE VOLTAGES AT:
1. Breaker Box Voltage Check
2. G.F.C.I. Line-In Voltage Check.
3. G.F.C.I. Load Out Voltage Check
4. System Box Check At Tb1
120 Volt Systems - 120V ± 10% - 108V - 132V
240 Volt Systems - 240V ± 10% - 216V - 264V
No More Than 2% (5 Volt AC) Difference Between Voltage
at the Breaker Panel And Voltage at the System.
CHECK UNDER PEAK LOADS -- TWO TYPES OF PEAK LOADS
1. Spa System Peak Loads - Pumps, Heater, Blower & Light On
2. Household Peak Loads - May Be In Afternoon On Hot Day
Use Recording Meter If Possible - Records Max & Min Volts
UÊ
-/,Ê
" /,"ÊSYSTEM RELATED ISSUES
Communication Between Topside & System Board In Most Systems
Press Button - Message Sent To System Board
System Board Performs - Message Sent Back To Topside & Relay Opens or Closes
LED or Icon Is Turned On or Off - Hear Or See Relay Open Or Close
In Most Cases, If This Happens, There Is No Problem With The Topside Panel or System Board
UÊ
8*ÊʇÊÊ-*Ê/Ê-Ê "/Ê7", ÊʇÊÊÓÊ",ÊÎÊ-9Ê-/*-Êt
1. Press Light Button
Light LED or Icon Turns ON, But Spa Light Is NOT ON
Topside & Board Are Good, Check Downstream
Light LED or Icon Is NOT ON
Topside Or System Board May Be Bad, Continue
2. Plug In Spare Topside Panel - Easier To Check For Bad Topside
Light LED or Icon Now Turns ON
Original Topside Is Bad - R&R Topside Panel
Light LED or Icon Is NOT ON
Original Topside Is Good, Do Not Replace
System Board Is Bad - R&R System Board
3. Spa Light Is Still NOT ON - Check Downstream
Same Procedure For Other Functions
Jets, Blower, Heater, Time, Program, Mode, etc.
16
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Wiring Checks
WIRING CHECK PRECAUTIONS
SYSTEM BOX WIRE GAUGE CHECK
UÊ When working in a system box always be aware that it may
contain high voltage.
UÊ Always keep your fingers and hand tools away from any
wiring or circuit board when the power is on. Touching anything in these areas can result in serious injury.
UÊ All service calls, no matter how minor, should include a
complete wiring check, beginning with the house breaker.
When inspecting the wiring for any control system, note that
connections for the incoming wires are clearly labeled at the
main terminal block.
UÊ 30A service – minimum ten gauge copper wire.
UÊ 40A service – minimum eight gauge copper wire.
UÊ 50A service – minimum six gauge copper wire.
CHECK FOR LOOSE CONNECTIONS OR DAMAGED
WIRES
These wires must connect the house breaker box, through the
local disconnect, to the main terminal block. The wiring diagram
inside the system box shows the main terminal block as TB1.
UÊ Make sure the power is off before you touch any wiring.
UÊ Once the power is off, carefully examine all wires for cuts or
defects.
IMPORTANT
Using non-copper wire can be dangerous, and also can be the
cause of a spa’s malfunction. If non-copper wire is used at any
point, we do not recommend servicing the spa until an electrician replaces it with the proper gauge copper wire.
IMPORTANT
This service must be single phase. Any abnormal voltage reading requires an electrician. Do not attempt to fix these types of
problems yourself. High voltage can seriously injure or kill.
TB1
42211 C
TOTAL
T Ampere Rating of
Power System
Minimum wire size
Use Copper ONLY,
L
o
with 90 C insulation
Ampere Rating of
G.F.C.I. Circuit-breaker
0 A to 16 A
#12 AWG
20
16 A to 20 A
#10 AWG
25
20 A to 24 A
#10 AWG
30
24 A to 28 A
#8 AWG
35
28 A to 32 A
#8 AWG
40
32 A to 36 A
#6 AWG
45
36 A to 40 A
#6 AWG
50
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
17
Testing a System with Power
LOW VOLTAGE
At Balboa, it’s been our experience that the majority of the
problems associated with electronic control systems are due to
low voltage.
BROWN OUTS
“Brown outs” can have an effect on the spa’s operation in a
variety of ways. The control panel may go blank, have scrambled
messages on the LCD, or only a few features will function.
If your system uses 240V peripheral devices (below):
UÊ Measure between the red TB1 terminal and power input
fuse. You should see 240 volts. Measure the other side of
the input fuse. You should also see 240 volts.
UÊ If you determine that there is no voltage at both locations,
then the system power input fuse needs to be replaced.
Only use a fuse of the same type and amp rating when you
replace any fuse.
UÊ NOTE FOR ALL SYSTEMS: In each situation, the most
likely reason for the system power input fuse to blow is a
pump problem. However, on occasion, a blower problem
may also cause this fuse to blow if a 10A blower fuse is not
built in.
Once the power input fuse has been changed
CHECKING THE SYSTEM POWER INPUT FUSE
WARNING
THESE PROCEDURES ARE PERFORMED
WHILE THE SYSTEM IS POWERED UP AND
RUNNING UNDER PEAK LOADS.
UÊ Probe the red wire and the white neutral wire. Again,
voltage must be between 108 and 132 V.
UÊ Check the voltage between the black and red wires again.
Acceptable voltage range is between 216 and 264 V.
If the system is getting the proper
voltage at TB1, but still doesn’t operate,
then test for a blown power input fuse.
(See section: Testing Pump Fuses for Damage)
UÊ Measure between the white TB1 terminal and power input
fuse. You should see 120 volts.
UÊ If the system is equipped with the additional power input
fuse, measure additional power input fuse in the same
manner. You should also see 120 volts.
WHT AC
J24
GND
N
K5
K6
J15
WHITE
J27
J25
J26
J23
J33
22117_B
L1
BLACK
J28
J30
J31
J32
J29
F6 Fuse
2S PUMP1
J45
J49 HTR A
L2
RED
HTR B J44
J48
UNFUSED
K4
K3
F6 0.3A 250V
J1
J2
K1
F5 30A
K2
F3 10A 250V
Terminal Block 1 & F5 Fuse on a
BP500 Power Board, 240V Setup
18
J12
J13
GRN
TB1 Marking
on Board
J
F2 3A
Terminal Block 1 & F6
Fuse on a BP2000 Board
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing a System with Power (cont.)
THESE READINGS SHOULD BE TAKEN UNDER
PEAK LOAD CONDITIONS.
IMPORTANT
If the voltage is not in the acceptable range, call
an electrician or the local electric company to diagnose
the problem.
TO DETERMINE THE CAUSE OF A BLOWN POWER INPUT
FUSE
Perform the following sequence of tests.
Test the System
UÊ Turn the power off.
UÊ Be sure to replace the system power input fuse with the
same type.
UÊ Unplug the blower and all pumps.
UÊ Restore the power and verify system operation.
UÊ If the fuse blows, power down the system and then re-check
the internal system wires and connector for burns, cracks or
cuts in insulation.
UÊ Or, if the fuse does not blow, turn the power off and plug in
the pump.
TEST THE AMPERAGE DRAW
UÊ Turn off the power, disconnect the blower, make sure the
pump is plugged in, and restore power.
UÊ Start the pump and switch to
high speed (if available), this
should draw the most current.
UÊ Make sure all jets and valves
are open.
UÊ Check the amperage at the
red pump wire. Compare your
reading with manufacturer
specifications. (If the other
plug-in devices exist, they
should be tested in the
same way.)
UÊ If the amperage draw for
each device is within manufacturer’s specifications, the
problem could be a nuisance spike in the pump, or water in
the blower.
NOTE: These slow-blow fuses are not always discolored when
blown. Always test continuity of a fuse with an ohmmeter.
NOTE: Be sure to test each device individually.
Test the Pump
UÊ Restore the power and activate the pump.
UÊ If the fuse blows, there is a pump problem.
UÊ If the fuse does not blow, turn off the power.
Test the Blower
UÊ Plug in the blower.
UÊ Power up the system and activate the blower.
UÊ If the fuse blows, then there is a blower problem.
UÊ If the fuse does not blow, the combined pump and blower
amperage may be excessive. To verify this, first check
with your spa manufacturer for amperage draw limits on
each device.
UÊ Since the blower should now be running, you can check
the amperage draw with an ammeter by measuring around
the black blower wire and compare with manufacturer’s
specifications.
42211 C
NOTE: Miswiring of the spa is the most common reason for this
fuse to blow. However, a lightning strike in the area is a possible,
though less likely, cause of the failure.
ELECTRICAL PROTECTION
1.
Local Disconnect:
A local disconnect (sometimes referred to as an “electrical
disconnect”) is installed apart from the main service panel.
The local disconnect must be installed where readily accessible and within sight of the spa, but at least 5’ (1.5 meters)
from the inside wall of the spa.
2. GFCI:
It is required by code to install a Ground Fault Circuit Interrupter (GFCI) in the supply power for a spa.
NOTE: A GFCI power cord is included with a 120VAC spa. This
can be used for a cord-connected 120V setup only, and only in
place of a stand-alone GFCI.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
19
Testing a System with Power (cont.)
See manufacturer’s owners manual or reference card for general information on operating the spa, including
programming filters and other settings that are changed from the topside control panel.
SAFETY AND ELECTRICAL SYSTEMS
PRELIMINARY PANEL CHECK
UÊ Use minimum 6AWG copper conductors only.
UÊ Torque field connections between 21 and 23 in-lbs.
UÊ Connect only to a circuit protected by a Class A Ground Fault
Circuit Interrupter (GFCI) CSA enclosure: Type 2.
UÊ The BP Spa Control Systems are classified as a “continuous
duty appliance” and is intended primarily for installation at
a single family dwelling. The installation recommendations
and instructions contained in this manual are directed solely
toward these issues.
UÊ If the problem is not obvious, look on the topside control
panel for diagnostic messages.
UÊ If no messages are seen, run through all spa functions and
note any inconsistent operation.
UÊ Most error messages are stored in the fault log. To view the
fault log, the spa must be in test mode and the spa light
must be turned on.
Once you have determined that proper voltage is running through
the circuit board and transformer, continue to the topside control
panel. A panel that is not functioning properly may include the
following symptoms: low voltage such as missing or scrambled
segments, missing icons on the LCD, non-functional LED’s, or
nonfunctional buttons. If any of these symptoms are present,
perform the following:
UÊ Turn the power off and unplug the panel from the
circuit board.
UÊ Then, plug in your test panel and restore power. If everything functions normally, replace the topside panel.
UÊ Disconnect ozone generator (if applicable).
UÊ If you still see symptoms of low voltage, such as a sluggish,
blank or partially blank panel, or if the display or the LED’s
do not function at all, turn the power off; unplug the ozone
generator (if equipped); then restore power to the system.
If the problem persists, turn off the power and replace the
circuit board.
WARNING!
If there is any doubt whether the system that you are installing
into does not have these features, contact a licensed, qualified
electrician. Do not attempt to modify the wiring yourself.
HEATER START UP INFORMATION
On M-7 systems, the heater goes through a testing phase every
time it starts up to assure that there is adequate water flow. This
provides sophisticated dry fire and low flow protection. It can be
confusing if you don't know what to expect. Step by step, here is
what happens. (Note that the timing/temperature details may be
slightly different on some older M7 systems.)
UÊ Prior to heating, the pump is run for at least two minutes,
and then the temperature difference between the sensors
is assessed. It must be 2°F/1.0°C or less for heating to
proceed, otherwise an error is issued.
UÊ The heater turns on for 6.5 to 18 seconds (depending on
heater voltage and wattage). At this point, the heat indicator
on the panel is "solid". During this time the panel is not
immediately responsive.
UÊ The heater turns off for 90 seconds, making sure that the
water flow keeps the temperature rise small and short.
(Abnormal water flows, or lack of water, will produce a large
and/or long temperature rise, and the system faults in that
situation.) At this point, the heat indicator on the panel may
appear to "shimmer" or "dim" (on some panels this may be
less obvious from certain angles and more obvious from
other angles, or in different lighting).
UÊ If the dry fire test has passed, heating turns back on to heat
the spa. The heat indicator on the panel returns to "solid".
UÊ During spa heating, a difference between the sensors
of 2°F/1.0°C, or perhaps 3°F/1.5°C (at least with 4-6kW
240V heaters), is considered normal. A significantly higher
difference, however, is usually indicative of a flow problem,
and will cause a fault which disables the heating for at least
a minute (and then restarts the whole above process).
20
FLASHING HEAT LED ON TP600 ("HEAT WAITING")
When there is a call for heat, the system will start the heater for
a few seconds and the Heat LED will light. After a few seconds
of heat, the heater will shut off for 90 seconds and the system will look at the sensors to be sure they are within the M7
parameters for flow and a safe environment to run the heater.
During this 90 second wait time, the Heat LED will flash quickly,
or "shimmer", until the heater comes on again to heat. There is
no voltage to the heater during this cycle. This is normal for M7.
Once the heater comes back on, the LED will be on without shimmering. On the TP800 and TP900 panels, the screen will display
"Heat Waiting".
JETS
JETTS
AUX
LIGHT
HEAT
HEAT
Heat LED in Heat Waiting Mode, TP600
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing a System with Power (cont.)
MOST PROBABLE OVERHEATING CAUSES, INSPECT
THESE FIRST
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
Check slice or ball valves. Make sure that they are open.
Make sure the correct pump is installed.
Clean the filter/skimmer if there is any blockage.
Check heater element alignment.
Check for debris on the heater element.
In extremely hot weather, check for proper cabinet ventilation.
Make sure the temperature sensor is fully inserted into the
sensor fitting on the heater.
Check for excessive filter duration.
Check the water level.
Check the water temperature with an accurate temperature
thermometer. Remove the spa cover and allow the water to
cool to below 108° F. Adding cool water may be necessary.
Touch any button to reset the system. If the water is still
hotter than the set temperature, press the blower button (if
applicable) to cool the spa.
UÊ If the Problem Recurs, test the Sensor Set.
NOTE:
A common programming mistake is overlapping filter
times that may cause the spa to filter continuously.
If alternating with temperature, it may just be a temporary
condition. If flashing by itself, spa is shut down.
If the panel also displays “Service Req” spa is shut down.
If the spa shuts down due to this error, one (or both) of the
sensors are probably reading several degrees off. If the problem
recurs, test the sensor set.
FREEZE CONDITION
When either sensor reads below 40°F (4°C), the system provides
freeze protection. It automatically activates the pump (and the
heater if necessary) to circulate the water and warm the plumbing. The equipment stays on until the sensors detect that the
spa temperature has risen to within 15°F of the set temperature.
The other pumps and the blower will purge for 30 seconds to 2
minutes at the end of the freeze condition. If pump 1 was turned
on due to this reason alone, this message will appear for up to
two minutes right after very cold water is detected.
work properly if placed inside the spa skirt in the coldest area.
All spa models are different in shape and size and have different
thermal characteristics; therefore, Balboa Water Group cannot
be held responsible for freeze damage to the spa’s plumbing.
Testing is the responsibility of the spa manufacturer and must be
done to determine the best location for the freeze sensor.
SOME TROUBLESHOOTING SCENARIOS
You find out the system is in “OHH”. This alone doesn't explain a
lot. What led up to the “OHH” is much more important. If it's a
Prestige, review the fault log carefully. Otherwise, see if the user
has any additional information (for example, how long before
the “OHH” was the spa panel last checked, and how hot was
the water then). If the spa has cooled, see whether the problem
can happen again, this time watching carefully to see if there
are additional clues leading to the “OHH” (for example, other
messages that appear shortly before the “OHH” happens).
You find out the system keeps showing “HFL,” or is now in “LF,”
or is shut down due to a "dry" fault. Put the spa in test mode
with the light on, so that you see the two sensor temperatures.
Are they normal (within 1°F/0.5°C) when not heating? How far
apart are they when heating? “HFL” happens when they are
6°F/3°C apart (4°F/2°C on 120V and other low-heater-wattage
systems), see how quickly that happens after heating starts. If
it's getting close to that right away, it's probably a consistent
flow problem, but if it's nowhere close to the “HFL”-causing
temperature difference, the flow problem may be intermittent or
only occur in certain specific situations.
TEST MODE
Test modes vary for different systems and configurations. Please
refer to the specific Tech Sheet applicable.
MESSAGE CODES
Refer to Tech Sheets for each system code. Or, a general set of
codes for BP systems is found under the sectionTP400, TP600
Message Codes in this manual. Message codes are the same
for all TP panels.
NOTE: Internal freeze protection only functions when there
is proper power running to the spa, and the control system is
operational. Using an optional freeze sensor may be necessary
in extreme climates to prevent plumbing damage, but will only
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
21
22
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
O-ring over / under tightened,
pinched, improperly seated
Pipe inlet higher than water line
Pump jammed with debris
Pump not installed at correct level
Suction cover/guard, impeller, or
filter may be clogged
Water level too low
Bearings bad
Open air control valves
X
Low water
pressure /
flow
X
Water
leakage
f/ unions
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
No air
Contact qualified Pump
mixed
electrician for
hums,
into water service
noisy
X
X
Jets not fully
functioning
X
X
X
Pump not
pumping
properly
X
Pump will not
turn off
X
Pump motor
does not
start
Air button, or switch on pump defecX
tive
Air tube blocked, kinked, or disX
lodged
Jets are closed
Leaks / loss of prime
Low voltage; is there proper
voltage?
Motor burnt, flooded by water
X
GFCI / Fuse
No incoming power
Thermal overload tripped
Cause
Problem
Troubleshooting Pumps, Problem & Cause
Acceptable Ranges for Testing Equipment
VOLTAGE CHECKLIST
ACCEPTABLE HEATER AMPERAGE DRAW RANGES
All voltages specified as 120 V or 240 V, may show an
acceptable variance of +/- 10%.
Voltage Ranges
Heater Type
120V Amp Draw
240V Amp Draw
5.5 kW @ 240 V
10.42 A - 12.74 A
20.83 A - 25.48 A
4 kW @ 240 V
7.58 A - 9.26 A
15.15 A -18.52 A
1 kW @ 120 V
7.58 A - 9.26 A
-
Wire Combo
Voltage +/- 10% Range
Black & Red
240 V
216 V -264 V
Black & White
120 V
108 V -132 V
Red & White
120 V
108 V - 132 V
Heater Type
Ohms (1)
Black& Green
120 V
108 V - 132 V
5.5 kW @ 240 V
9.42 1 -11.52 1
Red & Green
120 V
108 V - 132 V
4 kW @ 240 V
12.96 1 -15.84 1
1 kW @ 120 V
12.96 1 - 15.84 1
ACCEPTABLE HEATER OHM (ȍ) RANGES
Green & White 0 V
*
*
* Depending on variables such as length of run,
type of wire and temperature, small voltage readings may
sometimes occur between ground and neutral.
MOTOR AMPERAGE GUIDELINES
TEMPERATURE & HIGH-LIMIT SENSOR OHM TABLE
Temp.
of Sensor
Ohms
(k1)**
Temp. of
Sensor
Ohms
(k1)**
40° F
76.686 k1
90° F
22.117 k1
The following ranges represent general parameters
for many different motors and applications. Check the
device label or with the spa manufacturer to get accurate
amperage draws.
45° F
67.112 k1
100° F
17.636 k1
50° F
58.858 k1
105° F
15.788 k1
110° F
14.158 k1
AMPERAGE DRAW RANGES
70° F
35.533 k1
115° F
12.716 k1
80° F
27.93J k1
120°F
11.439 k1
DEVICE
120V DRAW
240V DRAW
Pump low
2A-5A
2A-4A
Pump high
10 A - 14 A
8 A - 12 A
6A-8A
3A-4A
Blower
60° F
**Note: 1 k1 = 1000 1 :
k1 may vary +/- 10% depending on the accuracy of the thermometer and meter used.
HEATER MATRIX
Heater Type
Ohms
5.5Kw @ 240V
10.472
11.458
1.37Kw
22.916
5.2Kw @ 240V
11.076
10.834
1.3Kw
4Kw @ 240V
14.4
8.333
3Kw @ 240V
19.2
2Kw @ 240V
1Kw @ 120V
42211 C
120V Amp Draw 120V Watts 240V Amp Draw 240V Watts
230V Amp Draw
230V Watts
5.5Kw
21.961
5.05Kw
21.666
5.2Kw
20.765
4.8Kw
1Kw
16.666
4Kw
15.972
3.7Kw
6.25
750W
12.5
3Kw
11.979
2.8Kw
28.8
4.166
500W
8.333
2Kw
7.986
1.8Kw
14.4
8.333
1Kw
N/A
N/A
N/A
N/A
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
23
Fuses: Devices, Locations, and Values
Fuses:
BP500 series (UL),
BP600 Series (CE)
Fuse
Fuse Current Rating
Protects device on output #
Device - depending on system set up
F2
3A 250VAC
J22
Ozonator
F3
10A 250VAC
J14 (option)
Blower fuse only. Jumped out for Pump 2.
F4
3A 250VAC
J15
Spa Light
F5
30A, Class G, 250V
All, Except Heater
Input power ( Line 1)
F6
0.3A, Slo-Blo
BP500 (UL)
120VAC Transformer Input
F6
0.15A, Slo-Blo
BP600 (CE)
230VAC Transformer Input
Fuse
Fuse Current Rating
Protects device on output #
Device - depending on system set up
F2
10A 250VAC
J32, J21
Ozonator, Circ Pump
F3
0.3A Slo-Blo
BP2000 (UL)
120VAC Transformer Input
F3
0.125A Slo-Blo
BP2100 (CE)
230VAC Transformer Input
F4
3A Slo-Blo
J15
Spa Light
F6
30A
J9, J33
Pump 1, AV (Audio), .250 spades
F7
10A
J14
Blower fuse only. Jumped out for Pump 2.
F8
30A
Typically J14
Floating - Typically J14 (P2, Blower, etc.)
F1
30A
J1
Pump 2, Pump 3, Microsilk, etc.
Fuse
BWG Part Number
30A
30136
10A
30122
3A Slo-Blo
20600
0.3A Slo-Blo
21581
0.15A Slo-Blo
26281
0.125A Slo-Blo
26397
Fuses:
BP2000 series (UL),
BP2100 series (CE)
24
On Expander
Board
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
BP 60Hz Spa Control System Wiring Diagrams
Wiring Diagram - BP500, Part Number 56278, Setup No. 1 (as manufactured)
Power Requirements:
240VAC, 60Hz, 40A, Class A GFCI-protected service (Circuit Breaker rating = 50A max.)
4 wires (Hot–Line 1, Hot–Line 2, Neutral, Ground)
System Ouputs:
Pump 1
240VAC
2-Speed
12A max
30-minute timer for Low Speed, 15 Minutes for High Speed
This is the heater pump and must be the same voltage as the Ozone
Must deliver a minimum of 20 GPM through heater
Pump 2
240VAC
Ozone
240VAC
.5A max
Uses the same relay as Pump 1 Low
Must be the same voltage as heater pump
Spa Light
12VAC
Heater
4kW @ 240VAC
Misc.
J23 & J32
1-Speed
12A max
On/Off
120VAC
15-minute timer
1A max
4-Hour timer.
4A max
Hot output (Stereo). Fused equipment or in-line fuse required.
Wiring Diagram and Settings
S1 SWITCH #
6
5
4
3
2
1
OFF POSITION
STORE SETTINGS*
SPECIAL AMPERAGE RULE OFF
DON’T ADD 4 HS PUMPS W/HTR
DON’T ADD 2 HS PUMPS W/HTR
DON’T ADD 1 HS PUMP W/HTR
TEST MODE OFF
*SWITCH # 6 SHOULD BE SET TO OFF
UPON FINAL INSTALLATION.
AUX
TO J5
K4
K3
J1
J2
K1
F5 30A
K2
F3 10A 250V
J12
J8
J22
GND
J20
J14
F2 3A 250V
J22
J27
H3
J5
J33
J15
J56
J31 HCE
J26 H2
J25 H1
J45
LIGHT
T1
GND
J21
J28 AUX FRZ
J29 VAC
6
J17
J16
S1
1
J46
K7
J18 J19
J28
J30
J31
J32
J29
J46
HTR B J44
J48
J30 TST
ON
J15
J45
J49 HTR A
L2
RED AC
NOT USED
K6
J16
K5
L1
F6 0.3A 250V
42211 C
CONTROL PANEL
TO J33
22121_E
J47
J24
N
UNFUSED
SENSOR B
J57
OZONE
GRN
WHT AC
GND
1S PUMP 2
RED
SENSOR A
2S PUMP 1
BLACK
ALL UNUSED SWITCHES
SHOULD BE OFF
4.0 kW
22117_B
WHITE
WS01
J27
J25
J26
J23
J33
MEMORY RESET*
SPECIAL AMPERAGE RULE ON
ADD 4 HS PUMPS WITH HEAT
ADD 2 HS PUMPS WITH HEAT
ADD 1 HS PUMP WITH HEAT
TEST MODE ON
J13
ON POSITION
F4 3A 250V
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
25
GRN
TB1
F6 30A
4
3
2
1
K2
J46
4
K4
J38
J60 J41
1
A/V HOT
J53
J58
J11
J111
J10
J81
3
2
SENSOR A
K5
K1
F3 0.3A SLO-BLOW
J109
J43
J39
K9
F8 30A
J33
CIRC PUMP
F2 10A 250VAC
J44
3
J48
J20
GND
5.5 kW HEATER
2
J49
K3
240VAC
CIRC/O3
OPTION
K12
J32
J13
J24
J19
K8
SENSOR B
K7
J14
10
J25
J29
VAC
AUX
FRZ
J31
J26 J30
J22
J17
J101
J91
J50
J35
MAIN
J108 J107
J34
MAIN
J28
J7
J16
REMOTE
J40
J8
AUX
J23
SERIAL
J27
J5
AUX
K6
24082_D
**J14 (AUX) IS:
2-SPEED PUMP 2 IN SETUPS 1-4, 7-10, 15, 16
1-SPEED PUMP 2 IN SETUPS 5, 6, 11–14
1-SPEED BLOWER IN SETUPS 3, 5, 9, 11, 12
ON S1
F4 3A SLO-BLOW
115V
230V
115V
LIGHT
J15
T1
OZONE
J21
F7 10A 250VAC
J9
PUMP 1
J45
J79
J54
J77
J75
J78
RED
BLK
WHT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
J110
J56
J57
J55
J59
J51
J52
J98
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
AUX**
J43 TO J13 (BLOWER ON J14)
IN SETUPS 3, 5, 9, 11, 12
J6
J18
Wiring Diagram - BP2000G1, Part Number 56377
AMPS
12A
MAX
FROM
W1 ON
EXPANDER
TO
GROUP 2
J1
F1 30A
J6
RIGHT
EXPANDER
BOARD
J7
*EXPANDER BOARD IS:
2-SPEED PUMP 3 IN SETUPS 1, 7
1-SPEED PUMP 3 (ONLY) IN SETUPS 2, 6, 8, 13, 14
1-SPEED PUMP 3 AND 1-SPEED BLOWER (WITH SPLITTER & IN-LINE FUSE)
IN SETUPS 15, 16
1-SPEED PUMP 2 AND 1-SPEED PUMP 3 IN SETUPS 5, 11, 12
2-SPEED PUMP 2 IN SETUPS 3, 9
UNUSED IN SETUPS 4, 10
J1
W1
EXPANDER
X-P332
FROM
J6 ON
EXPANDER
DEVICE
2 SPD*
PUMP 3
LOCATION
J1 ON RT
EXPANDER
PART A
TO
GROUP 3
J53
J5 (A1-A4)
OR
J8 (A5-A8)
TP (MAIN) PANELS
J34 OR J35
AUX
VOLTS
240V
10-23-12
BP2000G1 – PN 56377
WIFI
TRANSCEIVER
J34 OR J35
IR RECEIVER
OR
RF RECEIVER
EXPANDER
26
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
DEVICE
VOLTS
MAX AMPS
2-SP PUMP 1
240V
12A MAX
AUX
240V
12A MAX
AUX LINE 1 CONNECTION J19
SPA LIGHT
12V
1A
CIRC PUMP
120V*
2A MAX
OZONE
1A
CIRC AND OZONE LINE 1 CONNECTION
TV / AV
120V
3A
HEATER
240V
5.5 kW
J79-GROUP 4
J59
J45-GROUP 4
J81
J38
TO
J72-GROUP 2
J3-GROUP 2
J20
FROM
J46
J18
J43
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
NONE
NONE
NONE
NONE
NONE
NONE
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
NONE
FILTRATION
CIRC PUMP
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
+ POLLING
+
+
+
+
+
+
+
+
PUMP 1
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
1-SPEED
2-SPEED
1-SPEED
2-SPEED
2-SPEED
INSTEAD OF
SETUP #1,
THIS SYSTEM IS
CONFIGURED IN
SETUP #:
PUMP 1 LOW TIMEOUT IS 15 MINUTES.
‡SETUPS 5, 11, 12, 15 AND 16 REQUIRE BP2X-WIRE KIT PN30893
1
2
3
4
5‡
6
7
8
9
10
11‡
12‡
13
14
15‡
16‡
SETUP #
2-SPEED
2-SPEED
2-SPEED
2-SPEED
1-SPEED
1-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
2-SPEED
2-SPEED
PUMP 2
* FOR 240V CIRC PUMP AND OZONE, CONNECT J20 TO J42 (IN GROUP 2)
J33
J44
J15
J21
J32
LOCATION
J9
J14
WHITE
GREEN
BLACK
GREEN
WHITE
RED
2-SPEED
1-SPEED
NONE
NONE
1-SPEED
1-SPEED
2-SPEED
1-SPEED
NONE
NONE
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
PUMP 3
NONE
NONE
1-SPEED
NONE
1-SPEED
NONE
NONE
NONE
1-SPEED
NONE
1-SPEED
1-SPEED
NONE
NONE
1-SPEED
1-SPEED
BLOWER
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
TEMP SCALE
TO S2
SPLITTER IS UNUSED
(REMOVED) IN
SETUPS 1-4, 6-10,
13, 14,
IN SETUPS 15, 16
S1 = PUMP 3
S3 = FUSED ADAPTER
IN SETUPS 5, 11, 12
S1 = PUMP 2
S3 = PUMP 3
SPLITTER OPTIONS:
BLOWER
SETUPS 15 AND 16 REQUIRE THE ADDITIONAL
FUSED ADAPTER FOR BLOWER OUTPUT
SETUPS
15 & 16 ONLY
12A MAX
S2
12A MAX
S1
FUSED ADAPTER
‡ OPTIONAL BP2X-WIRE KIT PN 30893
TO RED AC
(GROUP 2)
ON MAIN BOARD
TO
J1 ON
EXPANDER
Wiring Diagram - BP2000G1, Part Number 56377 (cont.)
10A
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
27
SWITCHBANK S1 ON
TEST MODE ON
ADD 1 HS PUMP WITH HEAT
ADD 2 HS PUMPS WITH HEAT
ADD 4 HS PUMPS WITH HEAT
SPECIAL AMPERAGE RULE A
MEMORY RESET**
5 MIN HTR COOLDOWN (GAS)
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION.
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
10-23-12
BP2000G1 – PN 56377
PART B
TOTAL OUTPUT AMP DRAW NOT TO EXCEED MAX INPUT RATING OF SPA
USE EARTH GROUND CONNECTIONS AS INDICATED INSIDE THE SYSTEM ENCLOSURE
A DISCONNECTING MEANS MUST BE INSTALLED WITHIN SIGHT FROM
THE EQUIPMENT AND AT LEAST 5 FEET (1.52 M) FROM THE
INSIDE WALLS OF THE POOL, SPA, OR HOT TUB.
CONNECT ONLY TO CIRCUITS PROTECTED BY A CLASS A GFCI.
TORQUE RANGE FOR MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS. (31.1-34.5 kg cm)
FOR SUPPLY CONNECTIONS, USE CONDUCTORS SIZED ON THE BASIS OF
60°C AMPACITY BUT RATED MINIMUM OF 90°C.
USE COPPER CONDUCTORS ONLY.
EMPLOYER UNIQUEMENT DES CONDUCTEURS DE CUIVRE.
#6 AWG MIN. WIRE = 90°
** SWITCH #
TEST MODE OFF
DON’T ADD 1 HS PUMP W/HTR
DON’T ADD 2 HS PUMPS W/HTR
DON’T ADD 4 HS PUMPS W/HTR
SPECIAL AMPERAGE RULE A
STORE SETTINGS**
1 MIN HTR COOLDOWN (ELEC)
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
SWITCHBANK S1 OFF
GRN
TB1
F6 30A
4
3
2
1
K2
J46
4
K4
J38
J60 J41
1
A/V HOT
J53
J58
J11
J111
J10
3
2
SENSOR A
K5
K1
F3 0.3A SLO-BLOW
J109
J43
J39
K9
F8 30A
J33
CIRC PUMP
F2 10A 250VAC
K3
J44
3
J48
J20
GND
5.5 kW HEATER
2
J49
240VAC
CIRC/O3
OPTION
K12
J32
J13
J24
J19
K8
SENSOR B
K7
J14
J7
J28
10
J25
J29
VAC
AUX
FRZ
J31
J26 J30
J22
J17
J101
J91
J50
J35
MAIN
J108 J107
J34
MAIN
J18
J16
REMOTE
J40
J8
AUX
J23
SERIAL
J27
J5
AUX
K6
24082_D
**J14 (AUX) IS:
2-SPEED PUMP 2 IN SETUPS 1-4, 7-10, 15, 16
1-SPEED PUMP 2 IN SETUPS 5, 6, 11–14
1-SPEED BLOWER IN SETUPS 3, 5, 9, 11, 12, 17, 18
ON S1
F4 3A SLO-BLOW
115V
230V
115V
LIGHT
J15
T1
OZONE
J21
F7 10A 250VAC
J9
PUMP 1
J45
J79
J54
J77
J75
J78
RED
BLK
WHT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
J110
J56
J57
J55
J59
J51
J52
J98
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
AUX**
J43 TO J13 (BLOWER ON J14)
IN SETUPS 3, 5, 9, 11, 12, 17, 18
J6
J81
Wiring Diagram - BP2000G1, Part Number 56377-01
AMPS
12A
MAX
FROM
W1 ON
EXPANDER
TO
GROUP 2
J1
F1 30A
J6
RIGHT
EXPANDER
BOARD
J7
*EXPANDER BOARD IS:
2-SPEED PUMP 3 IN SETUPS 1, 7
1-SPEED PUMP 3 (ONLY) IN SETUPS 2, 6, 8, 13, 14
1-SPEED PUMP 3 AND 1-SPEED BLOWER (WITH SPLITTER & IN-LINE FUSE)
IN SETUPS 15, 16
1-SPEED PUMP 2 AND 1-SPEED PUMP 3 IN SETUPS 5, 11, 12
2-SPEED PUMP 2 IN SETUPS 3, 9
UNUSED IN SETUPS 4, 10
1-SPEED PUMP 2 IN SETUPS 17, 18
J1
W1
EXPANDER
X-P332
FROM
J6 ON
EXPANDER
DEVICE
2 SPD*
PUMP 3
LOCATION
J1 ON RT
EXPANDER
PART A
TO
GROUP 3
J53
J5 (A1-A4)
OR
J8 (A5-A8)
TP (MAIN) PANELS
J34 OR J35
AUX
VOLTS
240V
01-29-13
BP2000G1 – PN 56377-01
WIFI
TRANSCEIVER
J34 OR J35
IR RECEIVER
OR
RF RECEIVER
EXPANDER
28
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
DEVICE
VOLTS
MAX AMPS
PUMP 1
240V
12A MAX
AUX
240V
12A MAX
AUX LINE 1 CONNECTION J19
SPA LIGHT
12V
1A
CIRC PUMP
120V*
2A MAX
OZONE
1A
CIRC AND OZONE LINE 1 CONNECTION
TV / AV
120V
3A
HEATER
240V
5.5 kW
J79-GROUP 4
J59
J45-GROUP 4
J81
J38
TO
J72-GROUP 2
J3-GROUP 2
J20
FROM
J46
J18
J43
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
NONE
NONE
NONE
NONE
NONE
NONE
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
NONE
FILTRATION
FILTRATION
NONE
CIRC PUMP
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
+ POLLING
+ POLLING
+
+
+
+
+
+
+
+
PUMP 1
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
1-SPEED
2-SPEED
1-SPEED
2-SPEED
2-SPEED
1-SPEED
2-SPEED
PUMP 1 LOW TIMEOUT IS 15 MINUTES.
‡SETUPS 5, 11, 12, 15 AND 16 REQUIRE BP2X-WIRE KIT PN30893
1
2
3
4
5‡
6
7
8
9
10
11‡
12‡
13
14
15‡
16‡
17
18
SETUP #
WHITE
GREEN
BLACK
GREEN
WHITE
RED
2-SPEED
1-SPEED
NONE
NONE
1-SPEED
1-SPEED
2-SPEED
1-SPEED
NONE
NONE
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
NONE
NONE
PUMP 3
NONE
NONE
1-SPEED
NONE
1-SPEED
NONE
NONE
NONE
1-SPEED
NONE
1-SPEED
1-SPEED
NONE
NONE
1-SPEED
1-SPEED
1-SPEED
1-SPEED
BLOWER
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
TEMP SCALE
S2
TO S2
SPLITTER IS UNUSED
(REMOVED) IN
SETUPS 1-4, 6-10,
13, 14, 17, 18
IN SETUPS 15, 16
S1 = PUMP 3
S3 = FUSED ADAPTER
IN SETUPS 5, 11, 12
S1 = PUMP 2
S3 = PUMP 3
SPLITTER OPTIONS:
BLOWER
SETUPS 15 AND 16 REQUIRE THE ADDITIONAL
FUSED ADAPTER FOR BLOWER OUTPUT
SETUPS
15 & 16 ONLY
12A MAX
S1
12A MAX
FUSED ADAPTER
‡ OPTIONAL BP2X-WIRE KIT PN 30893
TO RED AC
(GROUP 2)
ON MAIN BOARD
TO
J1 ON
EXPANDER
INSTEAD OF
SETUP #1,
THIS SYSTEM IS
CONFIGURED IN
SETUP #:
2-SPEED
2-SPEED
2-SPEED
2-SPEED
1-SPEED
1-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
2-SPEED
2-SPEED
1-SPEED
1-SPEED
PUMP 2
* FOR 240V CIRC PUMP AND OZONE, CONNECT J20 TO J42 (IN GROUP 2)
J33
J44
J15
J21
J32
LOCATION
J9
J14
Wiring Diagram - BP2000G1, Part Number 56377-01 (cont.)
10A
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
29
SWITCHBANK S1 ON
TEST MODE ON
ADD 1 HS PUMP WITH HEAT
ADD 2 HS PUMPS WITH HEAT
ADD 4 HS PUMPS WITH HEAT
SPECIAL AMPERAGE RULE A
MEMORY RESET**
5 MIN HTR COOLDOWN (GAS)
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION.
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
01-29-13
BP2000G1 – PN 56377-01
PART B
TOTAL OUTPUT AMP DRAW NOT TO EXCEED MAX INPUT RATING OF SPA
USE EARTH GROUND CONNECTIONS AS INDICATED INSIDE THE SYSTEM ENCLOSURE
A DISCONNECTING MEANS MUST BE INSTALLED WITHIN SIGHT FROM
THE EQUIPMENT AND AT LEAST 5 FEET (1.52 M) FROM THE
INSIDE WALLS OF THE POOL, SPA, OR HOT TUB.
CONNECT ONLY TO CIRCUITS PROTECTED BY A CLASS A GFCI.
TORQUE RANGE FOR MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS. (31.1-34.5 kg cm)
FOR SUPPLY CONNECTIONS, USE CONDUCTORS SIZED ON THE BASIS OF
60°C AMPACITY BUT RATED MINIMUM OF 90°C.
USE COPPER CONDUCTORS ONLY.
EMPLOYER UNIQUEMENT DES CONDUCTEURS DE CUIVRE.
#6 AWG MIN. WIRE = 90°
** SWITCH #
TEST MODE OFF
DON’T ADD 1 HS PUMP W/HTR
DON’T ADD 2 HS PUMPS W/HTR
DON’T ADD 4 HS PUMPS W/HTR
SPECIAL AMPERAGE RULE A
STORE SETTINGS**
1 MIN HTR COOLDOWN (ELEC)
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
SWITCHBANK S1 OFF
GRN
TB1
4
3
2
1
K2
J46
PUMP 1
4
K4
J38
J60 J41
1
A/V HOT
J53
J58
J11
J111
J10
J81
3
2
SENSOR A
K5
K1
F3 0.3A SLO-BLOW
J109
J43
J39
K9
F8 30A
J33
F2 10A 250VAC
K3
3
J48
J20
GND
5.5 kW HEATER
2
J49
J44
CIRC PUMP
K12
J32
OZONE
J24
J19
K8
SENSOR B
ON S1
F4 3A SLO-BLOW
115V
230V
115V
LIGHT
J15
T1
J13
K7
J7
J28
10
J25
J29
VAC
AUX
FRZ
J31
J26 J30
J22
J17
J101
J91
J50
J35
MAIN
J108 J107
J34
MAIN
J14
PUMP 2
J21
F7 10A 250VAC
J9
J51
J52
J98
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
F6 30A
J110
J56
J57
J55
J59
J45
J79
J54
J77
J75
J78
RED
BLK
WHT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
J6
J18
J16
REMOTE
J40
J8
AUX
J23
SERIAL
J27
J5
AUX
K6
24082_D
Wiring Diagram - BP20MSSH, Part Number: 56373 (MicroSilk)
AMPS
12A
MAX
FROM
W1 ON
EXPANDER
TO
GROUP 2
J1
F1 30A
J6
MICROSILK IS A REGISTERED TRADEMARK
OF JASON INTERNATIONAL
J1
W1
EXPANDER
X-P331
J7
FROM
J6 ON
EXPANDER
DEVICE
VOLTS
1 SPD
240V
MICROSILK®
LOCATION
J1 ON RT
EXPANDER
TO
GROUP 3
J53
J5 (A1-A4)
OR
J8 (A5-A8)
TP (MAIN) PANELS
J34 OR J35
AUX
01-03-13
BP20MSSH – PN 56373
WiFi
Transceiver
J34 OR J35
IR Receiver
OR
RF Receiver
MICROSILK
30
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
31
DEVICE
VOLTS
MAX AMPS
2-SP PUMP 1
240V
12A MAX
2-SP PUMP 2
240V
12A MAX
PUMP 2 LINE 1 CONNECTION
SPA LIGHT
12V
1A
CIRC PUMP
120V*
2A MAX
OZONE
1A
CIRC AND OZONE LINE 1 CONNECTION
TV / AV
120V
3A
HEATER
240V
5.5 kW
J79-GROUP 4
J59
J78-GROUP 4
J81
J38
TO
J72-GROUP 2
J3-GROUP 2
J10
J20
FROM
J46
J18
J19
1
2
3
4
5
6
INSTEAD OF
SETUP #1,
THIS SYSTEM IS
CONFIGURED IN
SETUP #:
PUMP 1 LOW TIMEOUT IS 15 MINUTES.
CIRC PUMP
PROGRAMMABLE FILTRATION + POLLING
PROGRAMMABLE FILTRATION + POLLING
PROGRAMMABLE FILTRATION + POLLING
NONE
NONE
NONE
SETUP #
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
PUMP 1
2-SPEED
1-SPEED
NONE
2-SPEED
1-SPEED
NONE
PUMP 2
* FOR 240V CIRC PUMP AND OZONE, CONNECT J20 TO J42 (IN GROUP 2)
J33
J44
J15
J21
J32
LOCATION
J9
J14
°F
°F
°F
°F
°F
°F
TEMP SCALE
MICROSILK IS A REGISTERED TRADEMARK
OF JASON INTERNATIONAL
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
MICROSILK®
SYSTEM WILL BE IN
SETUP #1
PUMP 2 IS 2-SPEED IN SETUPS 1 & 4
PUMP 2 IS 1-SPEED IN SETUPS 2 & 5
PUMP 2 IS NOT USED IN SETUPS 3 & 6
Wiring Diagram - BP20MSSH, Part Number: 56373 (MicroSilk, cont.)
SWITCHBANK S1 ON
TEST MODE ON
ADD 1 HS PUMP WITH HEAT
ADD 2 HS PUMPS WITH HEAT
ADD 4 HS PUMPS WITH HEAT
SPECIAL AMPERAGE RULE B
MEMORY RESET*
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION.
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
01-03-13
BP20MSSH – PN 56373
PART B
TOTAL OUTPUT AMP DRAW NOT TO EXCEED MAX INPUT RATING OF SPA
USE EARTH GROUND CONNECTIONS AS INDICATED INSIDE THE SYSTEM ENCLOSURE
A DISCONNECTING MEANS MUST BE INSTALLED WITHIN SIGHT FROM
THE EQUIPMENT AND AT LEAST 5 FEET (1.52 M) FROM THE
INSIDE WALLS OF THE POOL, SPA, OR HOT TUB.
CONNECT ONLY TO CIRCUITS PROTECTED BY A CLASS A GFCI.
TORQUE RANGE FOR MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS. (31.1-34.5 kg cm)
FOR SUPPLY CONNECTIONS, USE CONDUCTORS SIZED ON THE BASIS OF
60°C AMPACITY BUT RATED MINIMUM OF 90°C.
USE COPPER CONDUCTORS ONLY.
EMPLOYER UNIQUEMENT DES CONDUCTEURS DE CUIVRE.
#6 AWG MIN. WIRE = 90°
*SWITCH #
TEST MODE OFF
DON’T ADD 1 HS PUMP W/HTR
DON’T ADD 2 HS PUMPS W/HTR
DON’T ADD 4 HS PUMPS W/HTR
SPECIAL AMPERAGE RULE A
STORE SETTINGS*
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
SWITCHBANK S1 OFF
Troubleshooting Using Resistance - Ohm’s Law
OHM’S LAW
The direct current flowing in a conductor is directly proportional to the potential difference between its ends. It is usually
formulated as V=IR, where V is the potential difference, or voltage, I is the current, and R is the resistance of the conductor.
CONTINUITY
32
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing a Fuse: Continuity
NOTE: THERE ARE NO SERVICEABLE PARTS ON THE PCB.
THE PREFERRED WAY TO CHECK FOR FUSE CONTINUITY IS WITH
THE FUSES REMOVED FROM THE CIRCUIT.
TESTING A FUSE: CHECK CONTINUITY
WITH THE FUSE REMOVED
A FUSE WITH THE
METER READING “GOOD”
A FUSE WITH THE
METER READING “BAD”
FUSES USED ON BP SPA SYSTEMS
42211 C
Fuse
BWG Part Number
30A
30136
10A
30122
3A Slo-Blo
20600
0.3A Slo-Blo
21581
0.15A Slo-Blo
26281
0.125A Slo-Blo
26397
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
33
Troubleshooting Heater Resistance
TEST IS WITH POWER OFF
TROUBLESHOOTING HEATER RESISTANCE
Release tab
Release tab
Locate the heater connector.
Disconnect the connector by depressing the tab.
Pull the connector straight out.
ACCEPTABLE HEATER OHM (ȍ) RANGES
Heater Type
Ohms (1)
5.5 kW @ 240 V
9.42 1 -11.52 1
4 kW @ 240 V
12.96 1 -15.84 1
1 kW @ 120 V
12.96 1 - 15.84 1
**Note: 1 k1 = 1000 1 :
k1 may vary +/- 10% depending on the accuracy of
the meter used.
Place the meter probes on the heater terminals.
34
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Troubleshooting Heater Posts Resistance to Heater Housing
TEST IS WITH POWER OFF
TROUBLESHOOTING HEATER POSTS RESISTANCE TO HEATER HOUSING
VERIFY THAT THERE IS NO HEATER “LEAKAGE”
Release tab
Release tab
Locate the heater connector.
Disconnect the connector by depressing the tab.
Pull the connector straight out.
Measure resistance from a heater post to the
heater housing
Verify there is NO continuity from the heater post to
the ground/earth. On the resistance scale, the a digital
meter should read OL (indicating infinite resistance).
Verify there is NO continuity from the heater post
to the heater housing or heater current collector
connection. The meter reading shown is OL,
indicating infinite resistance.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
35
Troubleshooting with Voltage
IMPORTANT!
BEFORE TESTING A SPA CONTROL SYSTEM FOR VOLTAGE OR
AMPERAGE, BE SURE OF THE FOLLOWING DANGERS:
HIGH AND LOW VOLTAGE CAN KILL.
QUALIFIED TECHNICIANS SHOULD BE PERFORMING THESE TESTS
OR
WHEN TESTING VOLTAGE
WHEN TESTING AMPERAGE
OBSERVE SAFETY AT ALL TIMES
36
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Verifying Incoming Voltage at the Terminal Block - BP500, BP2000G1
CAUTION - TEST IS WITH POWER ON
VERIFYING INCOMING VOLTAGE AT THE TERMINAL BLOCK (240V SYSTEM)
BP2000 SHOWN (BP500 SYSTEM IS SIMILAR)
Red to Black Wires = 240V
White to Red Wires = 120V
White to Black Wires = 120V
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
37
Testing Pump Fuses for Damage with Voltage On - BP2000G1
CAUTION - TEST IS WITH POWER ON
THERE ARE THREE 30A PUMP FUSES IN THE BP2000G1 SPA CONTROL SYSTEM.
F6 AND F8 ARE ON THE MAIN BOARD. F1 IS LOCATED ON THE EXPANDER BOARD.
TEST THE VOLTAGE FROM THE
LEFT SIDE OF THE FUSE
F6 TO TB1
RED
TEST THE VOLTAGE FROM THE
RIGHT SIDE OF THE FUSE
240V on each side
indicates a good fuse
240V on one side and
0V on the other side
indicates a bad fuse
Then continue
measuring the other
two fuses: F8, F1
F6
F8
F1
38
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing Heater Voltage - All BP Systems
CAUTION - TEST IS WITH POWER ON.
AVOID TOUCHING THE HEATER ASSEMBLY
WHILE PERFORMING THIS TEST.
THE HEATER IS ATTACHED TO GROUND.
Testing at the heater terminal verifies that
there is not a broken line to the heater. It
may also indicate problems that may not
be apparent visually, such as corrosion or
a damaged heater terminal post.
However, before you do test, read on...
Many people use probes to test live heater voltages
from TB1 to a heater post, or across both posts.
DON'T.
There is danger in measuring voltages across
heater posts. Some of the common problems in
testing spa systems are that:
1. The area is often tight and confined.
2. The area is often not well lit.
3. Spa control systems are usually placed at near
ground level, which makes measuring with
meter probes awkward or difficult. The probes
may have a tendency to slip or not touch the
designated point of test. If a probe slips and
simultaneously contacts a hot (240V) post and
ground, severe arcing will occur. DEATH OR
SEVERE INJURY CAN OCCUR.
(continued on next page)
WRONG!
DO NOT MEASURE
ACROSS HEATER TERMINALS
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
39
A Safer Way to Test Heater Voltages
Equipment needed:
UÊ Insulated clamps for your voltmeter probes
Suggested attire:
UÊ Safety glasses
UÊ Rubber gloves (when measuring live electrical wires)
1. Turn the power OFF to the spa control system.
2. Set voltmeter for AC high voltage reading. Set
clamps onto terminals securely. Be sure that both
insulated boots fully cover the clamps. Be sure that
both clamps are not touching each other and that
they are not making contact with anything below
the insulating material on the terminal. (See photo
below.)
3. Turn on power to the spa. Do not disturb the voltmeter
or clamps until the power is turned off.
4. With the system operating and the panel display set
for the need for heat, verify the voltage at the heater
posts. On a 240V system, the reading will be near
240V. (Allow for +/- 10% variance.)
5. When finished with testing, turn the power off before
removing the clamps from the terminal posts.
40
Be sure that both clamps are not making
contact with anything below the insulating
material on the terminal (arrows).
Note: Black boot removed below to show
detail.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing Pump Fuses for Damage with Voltage On - BP500
Due to the design of the BP500, the upper Logic board must be
moved out of the way to test most of the power board fuses.
To gain access to the power board:
1. Power down the system.
2. Remove the sensor wires from the logic board. Be sure to
depress the release tab on the sensor connector. Do not pull
on the wire.
3. Remove the four corner retaining screws.
4. Place the Logic board out of the way of any metal or points
of system voltage or grounding areas once the system is
powered up.
Note: One consideration to isolate the logic board from the
metal chassis is to place a non-conductive material separating
the components (below).
Sensor Location BP500, on Logic Board
Also, if you must move the components around for testing, add
or remove sensors or wires, take a few moments to power down
the system.
Depress sensor tab
when removing
For safety, an antistatic bag, a piece of cardboard (as shown here), or any other insulator should be used to separate the chassis
ground from the logic board.
The Logic board must not be in contact with
any hot spots, chassis ground, or floor of the
spa area when the system is powered up for
testing. Be especially careful if the surrounding floor area is wet.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
41
Testing Heater Amperage
CAUTION - TEST IS WITH POWER ON
PLACE CLAMP AROUND ONE HEATER WIRE, AND THEN THE OTHER WIRE.
AMPERAGE HEATER TEST BP2000G1
AMPERAGE HEATER TEST BP500
ACCEPTABLE HEATER AMPERAGE DRAW RANGES
42
Heater Type
120V Amp Draw
240V Amp Draw
5.5 kW @ 240 V
10.42 A - 12.74 A
20.83 A - 25.48 A
4 kW @ 240 V
7.58 A - 9.26 A
15.15 A -18.52 A
1 kW @ 120 V
7.58 A - 9.26 A
-
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing Low Speed and High Speed at the AMP Pump Connector
TESTING LOW SPEED AND HIGH SPEED AT THE AMP CONNECTOR
CAUTION - TEST IS WITH POWER ON
Board Connector Key
Ground
Neutral (Common)
Typically Line voltage for 2-speed pumps
Typically Line voltage
Note flat sides in connector
WITH THE PUMP LOW SPEED ON,
TAKE A VOLTAGE READING AT THE
AMP RECEPTACLE ON THE PCB
THIS WOULD TYPICALLY SHOW LOW
SPEED VOLTAGE FOR PUMP ONE. (240V)
WITH THE PUMP HIGH SPEED ON,
TAKE A VOLTAGE READING AT THE
AMP RECEPTACLE ON THE PCB
THIS WOULD TYPICALLY SHOW HIGH
SPEED VOLTAGE FOR PUMP ONE. (240V)
Note: These are typical settings only.
Voltages may be different depending
on the configuration that the system is
set to. See the system's Tech Sheet for
complete information.
PUMP 1 AMP CORD
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
43
Component Failure and Replacement Testing - Software Setups and Test Mode
All BP systems have the capability for Test Mode. Test Mode is
used when changing setup configurations through the panel,
which also means that wiring changes may be necessary. (See
the specific spa control system Tech Sheet for more details.)
Note: Although Test Mode allows access to certain utility features, most Utilities are available without entering Test Mode.
A/B Sensor Temperatures and Fault Log information are presented here since they appear on the Test menu screen (see below).
DANGER! HIGH VOLTAGE WILL BE ACCESSIBLE!
SERVICE TECHNICIAN ONLY!
TEST MENU ACCESS (S1, SWITCH 1 ON)
OTHER TEST MODE FEATURES:
A/B TEMPS (A/B SENSOR TEMPERATURES)
When this is set to On, the temperature display will alternate to
display temperature from Sensor A and Sensor B in the heater.
FALT LOG (FAULT LOG)
The Fault Log is a record of the last 24 faults that can be
reviewed by a service tech.
DEMO (DEMO MODE)
Demo Mode is not always enabled, so it may not appear. This
is designed to operate several devices in a sequence in order to
demonstrate the various features of a particular hot tub.
SOFTWARE SETUPS
Under the TEST Menu, the Setup screen will allow changing the
Setup from 1 to any number established by the manufacturer.
Changing the Setup may require wiring changes as well.
1. While the system is running, move DIP Switch 1 (on S1 on
the Main circuit board) to ON.
2. The system will enter Test Mode. On the home screen
(below) will appear the word TEST.
3. Change the setup to the desired setup configuration number
(depending on DIP switch or wires changes, if any).
(Test Mode On) Test > Setup
4. Moving DIP Switch 1 to OFF will exit Test Mode
The Control System is in Test Mode if 102˚T appears.
(In this case °F or °C is replaced by °T.)
1
Used only by the manufacturer for specific tests.
TEMP LIMIT
Used only by the manufacturer for specific tests.
VIEWING CONFIGURATION SETTINGS
There are times when a technician may want to view the configuration settings (or, config. setup) before working on a system.
View the configurations in the following way:
TP900/TP800 panels: System Information > Current Setup
TP600/TP400 panels: UTIL > INFO > SETP (Standard Menus)
TP600/TP400 panels with Simplified Menus can only access
the configuration setup when in test mode.
Note: In the event that a panel stops operating, a good working
panel plugged into the system will reveal the config. settings as
they are held in memory.
ON
102°F
10
TIME OUTS
S1
Set: 104°F
8:32 PM
Ozone
Filter 1
Test
High Range
Spa
Shortcuts
Settings
Test
Back
`
Setup
A/B Temps
Fault Log
Timeouts
Temp Limit
1 `
Off
`
Normal
Yes
Ready in Rest Mode
Heating
44
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Setup Changes with DIP Switch 1 ON - BP500
Note: For complete variations of equipment configurations and setups, the latest Tech Sheet should be obtained on the
system you're working on. The information for setup changes is included here in the event you have wiring diagrams available,
and to facilitate a better understanding of how setup changes are made.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE BEGINNING THIS PROCESS.
Know the Setup Number you want before you power up the spa and wait to power up the spa until you’re ready to change the
Setup Number.
The system must be in Test Mode, so move Switch 1 to the ON position. The Test Menu will then be available.
Power up the spa, and press any button once to Link the panel. (Note: Switch 1 can be moved to the ON position immediately
after power-up, if preferred - Danger! High Voltage will be present!)
You will have 1 minute to complete the setup change after you manually exit Priming Mode. (Once familiar with the process, the
Setup change should take less than 15 seconds.)
J28 AUX FRZ
J29 VAC
6
J17
J16
S1
1
ON
As soon as Switch #1 is placed
in the ON position,
The temperature will show
“T” after it instead of F or C,
indicating the System is
in Test Mode
When the panel displays RUN PMPS PURG AIR, press any Temperature button ONCE to exit Priming Mode.
You should see “---T” where the T indicates the system is in Test Mode.
READY
RANGE
Continued on Next Page.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
45
Setup Changes with DIP Switch 1 ON - BP500 (cont.)
Again, You will have 1 minute to complete the setup change after you manually exit Priming Mode.
Immediately after exiting Priming Mode, press this sequence of buttons: Warm*, Light, Warm, Warm, Warm, Warm. Continue
to press Warm until the display shows the Setup Number (S-01, S-02, etc.) you want to switch to. When the correct setup
number is showing, press Light once, and the system will reset, using the newly-selected Setup from that point on.
Move DIP Switch 1 to the OFF position to take the spa out of Test Mode. °F or °C will replace °T.
Using a permanent marker, write the Setup number on the Setup label mounted inside the system lid (right). This is very
important to any service person in the future who may need to replace a circuit board or system and needs to
change the Setup on a replacement part while in the field.
THIS SYSTEM IS
CONFIGURED AS
SETUP #
NOTE: Changing the Setup may require wiring changes as well - refer to the wiring diagram or wiring diagram
addendum.
Key
Indicates Flashing or Changing Segment
Indicates Alternating or Progressive Message - every 1/2 second
A temperature button, used for “Action”
Light or dedicated “Choose” button, depending on control panel configuration
Waiting time - varies depending on function
Main Screen
READY
RANGE FLTR1
SET
The System will reset and go into Priming Mode if the Light Button
is pressed while anything other than the current setup is flashing.
If there is no change to the Setup Number (S-01, S-02, etc.),
the display returns to the SETP screen.
While the Set Temperature is
still flashing, press Light
TEST will now appear in
the LCD first.
RANGE
SET
SET
SET
SET
Several Setups can
exist in in this string
A dash (--) indicates the current Setup.
SET
When set to ON, Panel will display
alternate readings from
Senor A and Sensor B
on Main Screen
Displays Fault Log
or
SET
SET
SET
SET
Approx.
5 sec.
SET
or
SET
SET
SET
Approx.
5 sec.
SET
Main Screen
READY
RANGE FLTR1
*If the Control Panel does not have a Warm (Up) button, but rather a single Temp button, use the Temp button in place of the Warm
button in the instruction above. (The flow chart assumes a single Temperature Button.)
46
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Setup Changes with DIP Switch 1 ON - BP2500
Note: For complete variations of equipment configurations and setups, the latest Tech Sheet should be obtained on the
system you're working on. The information for setup changes is included here in the event you have wiring diagrams available,
and to facilitate a better understanding of how setup changes are made.
TEST MENU ACCESS (S1, SWITCH 1 ON) SERVICE TECHNICIAN ONLY.
DANGER! HIGH VOLTAGE WILL BE ACCESSIBLE! SERVICE TECHNICIAN ONLY!
While the system is running, move DIP Switch 1 (on S1 on the Main circuit board) to ON.
The system will enter Test Mode.
Moving DIP Switch 1 to OFF will exit Test Mode.
SOFTWARE SETUPS (BP2500)
Under the TEST Menu, the Setup screen will allow changing the Setup from 1 to any number established by the
manufacturer. Changing the Setup may require wiring changes as well.
1
102°F
Set: 104°F
8:32 PM
Ozone
Filter 1
ON
High Range
10
Spa
Shortcuts
Settings
Test
S1
`
Ready in Rest Mode
Heating
Test
Back
42211 C
Setup
A/B Temps
Fault Log
Timeouts
Temp Limit
1 `
Off
`
Normal
Yes
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
47
Testing the Sensor Set
1.
Begin the diagnosis with the power off. Check sensor
wires for cracks or damage that may indicate the
presence of a rodent.
2. Inspect the connections of both sensors on the circuit
board. The plugs must be clean.
3.
If the sensors are not totally failing but are showing
excessive (2° F/1.0 °C or more) difference between the
two sensors when not heating (a possible cause of
Sn/SnS/SENSOR SYNC, HL/HFL/HTR FLOW LOW, and
LF/LOW/FLOW/messages), do the following:
UÊ Note which sensor is reading consistently higher
(A vs B or T vs H).
4.
Depress tab
when removing
Unplug the two sensors from the circuit board and
exchange their positions (i.e., plug the one that was in
the “Sen. A” jack into the “Sen. B” jack and vice versa).
Note: When removing a sensor wire from the board,
depress the tab. Do not pull on the wire.
5. Press a panel button if any "stray" faults appeared
during the process. (Stray faults are normal when
sensors are unplugged then plugged back in while the
system is running.)
6.
Within a minute or so, see if the same or other sensor is
now reading consistently higher:
UÊ If the same sensor (A vs B or T vs H) is reading higher
after the sensor interchange, the problem is on the
circuit board. Replace the circuit board.
UÊ If the opposite sensor is now reading higher, the
problem is with the sensor(s). Replace the sensor set.
*If you wait more than 2 minutes after plugging the
sensors back in, heating may start (even outside a filter
in Economy or Sleep mode) due to a stray Cd/CLd/COLD
WATER condition usually detected when sensors are
being plugged in while the system is running.
TEMPERATURE SENSORS LOCATION
(WIRES REMOVED)
48
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Testing the Sensor Set (cont.)
7. If there is a message indicating an open or faulty sensor:
UÊ Unplug the sensor set (but leave the original sensors in the
heater) and plug in the test sensor set. Put both sensors
into the same cup of warm water (ideally above the set
temperature, so the spa won't try to heat during this test, as
there is no heater protection during this test) and verify that
they read the same temperature (within 1°F/0.5°C).
UÊ If the problem is solved, replace the sensor set. If the
problem is not solved, do not replace the sensor set.
UÊ Plug in the original sensor set to verify that there is not a
connection problem.
UÊ If the problem continues after following the above steps,
then replace the circuit board.
TESTING SENSOR PINS
ALWAYS TURN THE POWER OFF
WHEN PLUGGING AND UNPLUGGING!
Sensor Pins: At times, a protective coating may on
accident coat the sensor pins during manufacturing.
Those pins may need to be scraped and the sensors
plugged back in.
Tip: If one sensor (A or B) seems to be having problems,
swap the cables of sensor A with sensor B.
If the problem stays with the same sensor (according to
topside messages) it's a board problem; if the problem
moves to the other sensor it's a sensor problem.
M-7 Replacement Sensor
M-7 REPLACEMENT SENSOR
HEATER
METAL
TUBE
NUT
STAINLESS WASHER
ORING
SENSOR
SENSOR HOUSING MOUNT
(Sample Board Shown )
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
49
Remove and Replace a System Circuit Board
IMPORTANT!
BE SURE TO TURN THE POWER OFF BEFORE
REPLACING ANY COMPONENT, ESPECIALLY A
CIRCUIT BOARD.
IMPORTANT!
DO NOT REMOVE AND REPLACE THE CIRCUIT
BOARD UNLESS THE FAULT HAS POSITIVELY BEEN
DETERMINED TO BE THE CIRCUIT BOARD.
REMOVING A SYSTEM CIRCUIT BOARD
UÊ Shut OFF line power to the spa at the main circuit breaker
panel. Do not attempt to service a spa without shutting off
the power. Serious injury or damage may result. Consider
placing a padlock on the main service disconnect box while
working on the spa.
UÊ Before you begin, consider labeling all wires that will
be removed from the board. This may help speed up
reinstallation. Other technicians prefer to take the board
out with wires intact, place both defective and new board
side by side on a bench, then swap wires, recheck the logic
jumpers, and DIP switch for proper configuration. Whatever
technique is used, a wiring diagram should always be used
to ensure proper wire placement.
UÊ Remove the sensor wire connectors at the board, and the
J44 heater connector on the BP2000 Board (located to the
left of the transformer). Be sure to use the release tab on
the connectors; do not pull on the wires.
UÊ Some BP spa control systems use an expander board.
Removing the expander board first simplifies the process.
To remove it, remove the screw, and then gently squeeze
the locking flange on each standoff with needle nose pliers
while lifting the board out. Some technicians, after removing
the screw (and if the standoffs allow it), gently pry the board
up where there’s a plastic stand off. Do not use excessive
force if the standoff will not yield. Do not pry up directly into
the board as damage to the board may result.
UÊ Remove the seven screws (if BP2000, see illustration).
UÊ The board should now be free and can be removed from the
system box.
50
Removing BP Expander Board, an Alternate Way
1
2
3
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Remove and Replace a System Circuit Board (cont.)
INSTALLING A SYSTEM CIRCUIT BOARD
COMPATIBILITY ON DUAL BOARD CONTROL SYSTEMS
When reinstalling the board:
UÊ Torque main board hold down screws to 8-10 in/lbs.
Do not over tighten as damage to the board may result.
UÊ Reconnect all wires and slip-on connectors.
UÊ Restore power to the spa at the main breaker.
UÊ Test to make sure all functions work correctly.
System BP600 has two boards: a power board and logic board. If
one board is found to be defective and is replaced with a newer
revision board, it will still be compatible with the other, older
system board.
J10
F6 30A
J60 J41
J51
J52
J98
J18
OZONE
J20
K6
J50
K8
J19
J34
MAIN
K12
230V
J35
MAIN
J24
115V 115V
J109
J108 J107
T1
J101
K1
2
4
J5
AUX
J53 J58
3
3
J15
J7
2
J8
AUX
J25 J31
K5
J27
J23
SERIAL
J26 J30
J49 J44 J48
J6
J72
J42
J3
J61
J36
J12
J88
J62
3
J22
K3
J37
J4
J1
J47
2
J91
F3 0.3A SLO-BLOW
1
LIGHT
J40
J29
VAC
K7
REMOTE
F4 3A SLO-BLOW
J45
J79
J54
J77
J75
J78
J110
J13
F8 30A
1
TB1
J43
24082_D
J14
J32
F7 10A 250VAC
J39
CIRC PUMP
J38
J81
A/V HOT
J46
J21
K9
J56
J57
J55
J59
K2
J33
K4
F2 10A 250VAC
J9
PUMP 1
BP2100 board
screw locations
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
4
J111
J11
10
J17
GND
ON S1
J28
J16
AUX
FRZ
BP2100 board
without wires
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
51
Removing the Heater Assembly from a BP Spa System
Note: Be careful when removing a heater assembly from
a spa plumbing system. Water may splash out under
pressure. See next page for more illustrations.
Water under pressure in the plumbing may splash out, and onto
the system’s electronic board. Do not remove the system door
until the water has been drained from the heater assembly
housed in the system.
1.
Turn off the main power.
2. Close off the slice valves (or, ball valves) adjacent to the
heater assembly.
3.
Once the valves are closed, slowly crack the heater
assembly end tubes until water flows out. If the connectors
are on too tight, it may be necessary to loosen the Phillips
screws that hold the connectors together. Once the water
has been drained, continue.
4.
Remove the system door cover.
Heater Connector on BP2000/BP2100 Series
5. If you received the heater kit with wires (BP2000/
BP2100 Series systems, see right):
Depress the tab on the heater connector to remove it.
6.
If you received a heater without the wire kit or if you
need to replace the heater wires (see next page):
a) Remove the nuts securing the heater wires to the
heater assembly’s terminal connectors. Be sure to use a
supporting end wrench on the lower nut. (Upper nut is
3/8"; lower nut is 1/4".) If a lower end wrench is not used
to hold the terminal in a fixed position when removing or
installing the upper nut, excessive torque will transfer to
the terminal connector and will probably damage it.
7.
Replace the heater sensor wires as necessary.
8.
Remove both 3/8" nuts that secure the element in place.
9.
Remove the heater assembly.
Side View: Depress Tab to Unlock Connector
10. Reverse the procedure to reinstall the heater assembly.
Note: Heater terminal nut installation is 30 - 35 in lbs. torque.
52
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Removing the Heater Assembly from a BP Spa System (cont.)
Remove both nuts that secure the
element in place.
Locking nuts are in the same
location on other BP models
Avoid damaging the post. Use an end wrench
on the lower nut to reinforce the post when
removing the upper nut.
SENSOR A
SENSOR B
J15
GND
J20
2S PUMP 1
HTR B J44
J48
UNFUSED
K4
K3
J1
J2
K1
F5 30A
K2
F3 10A 250V
J12
J13
GRN
J16
J46
RED
J8
J56
J14
F2 3A 250V
J22
GND
J47
J45
J49 HTR A
L2
RED AC
OZONE
L1
J57
NOT USED
K6
WHITE
F6 0.3A 250V
42211 C
K5
1S PUMP 2
N
BLACK
The Logic Board must be
removed to acess and remove
the heater wires, shown in red.
WHT AC
GND
J27
J25
J26
J23
J33
22117_B
J24
Heater Wires on a BP500/BP600
Series system are connected to
the lower Power Board.
J28
J30
J31
J32
J29
4.0 kW
J21
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
53
TP800, TP900 Panel Operations - The Main Screen - Navigation
SPA STATUS
NAVIGATION
Important information about spa operation can be seen quickly
from the Main Screen. The most important features, including
Set Temperature adjustment, can be accessed from this screen.
Navigating the entire menu structure is done with the 5 buttons
on the control panel.
When a text item changes to white during navigation, that indicates the item is selected for action.
Operating or changing a selected item is generally done with the
center or “Select” button.
The actual water temperature can be seen in large text and the
desired, or Set Temperature, can be selected and adjusted.
Time-of-day, Ozone operation and Filter Operation status is available, along with other messages and alerts
.
High Temperature Range vs. Low Temperature Range is indicated
in the upper right corner
.
The Jets Icon in the center will spin on a TP900 if any pump is
running and changes color when the heater is on. (The icon does
not spin on a TP800, but still indicates pump and heater function)
A Lock icon is visible if the panel or settings are locked.
The Menu choices on the right can be selected and the screen
will change to show more detailed controls or programming
functions.
Water Temperature
Desired Temperature
Temperature Range
The only item that can be changed on the left side of the Main
Screen is the Set Temperature. Press the Left Arrow button to
change the Set Temperature number to white. The Set Temperature can then be adjusted with the up and down buttons.
Pressing the Select button or the Right Arrow button will save
the new set temperature.
On the right side of the screen, the menu selections can be
selected with the Up and Down Buttons. Use the Select Button
to choose an item. Selecting one of these items will change to a
different screen with additional controls.
PRESS-AND-HOLD
If an Up or Down button is pressed and held when the Set
Temperature is selected, the temperature will continue to change
until the button is released, or the Temperature Range limits are
reached.
MESSAGES
At the bottom of the screen, messages may appear at various
times. Some of these messages must be dismissed by the user.
Pump and Heat
Status
102°F
Set: 104°F
8:32 PM
Ozone
Filter 1
High Range
Spa
Shortcuts
Settings
Ready in Rest Mode
Heating
Messages
Menus
Lock Indicator
54
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP800, TP900 Priming Mode Start-up Sequence
PREPARATION AND FILLING
PRIMING THE PUMPS
Fill the spa to its correct operating level. Be sure to open all
valves and jets in the plumbing system before filling to allow
as much air as possible to escape from the plumbing and the
control system during the filling process.
After turning the power on at the main power panel, the top-side
panel will display a splash, or startup screen.
As soon as the Priming Mode screen appears on the panel,
select the “Jets 1” button once to start Pump 1 in low-speed and
then again to switch to high-speed. Also, select the other pumps,
to turn them on. The pumps should be running in high-speed to
facilitate priming. If the pumps have not primed after 2 minutes,
and water is not flowing from the jets in the spa, do not allow
the pumps to continue to run. Turn off the pumps and repeat the
process.
Back
Jets 1
Jets 2
Jets 3
Circ
Priming Mode
PRIMING MODE –
After the initial start-up sequence, the control will enter Priming
Mode and display a Priming Mode screen. Only pump icons appear on the priming mode screen. The system will automatically
return to normal heating and filtering at the end of the priming
mode, which lasts 4-5 minutes.
During the priming mode, the heater is disabled to allow the
priming process to be completed without the possibility of energizing the heater under low-flow or no-flow conditions. Nothing
comes on automatically, but the pump(s) can be energized by
selecting the “Jet” buttons.
Note: Turning the power off and back on again will initiate a
new pump priming session. Sometimes momentarily turning the
pump off and on will help it to prime. Do not do this more than
5 times. If the pump(s) will not prime, shut off the power to the
spa.
Important: A pump should not be allowed to run without priming for more than 2 minutes. Under NO circumstances should a
pump be allowed to run without priming beyond the end of the
4-5 minute priming mode. Doing so may cause damage to the
pump and cause the system to energize the heater and go into
an overheat condition.
EXITING PRIMING MODE
You can manually exit Priming Mode by navigating to the “Back”
button on the Priming Mode Screen. Note that if you do not
manually exit the priming mode as described above, the priming
mode will be automatically terminated after 4-5 minutes. Be sure
that the pump(s) have been primed by this time.
Once the system has exited Priming Mode, the top-side panel
will display the Main Screen, but the display will not show the
temperature yet, as shown below. This is because the system
requires approximately 1 minute of water flowing through the
heater to determine the water temperature and display it.
If the spa has a Circ Pump, it can be turned on and off by pressing the “Circ Pump” button during Priming Mode. In addition, if
the spa has a Circ Pump, it can be activated by pressing the dedicated “Light” button during Priming Mode when using a TP800.
Manually exit Priming Mode by pressing the “Exit” Button.
42211 C
– – –°F
– – –°C
UÊ
M0[XX] numbers are Message Codes.
UÊ
A message with an asterisk [*] can be reset from the
topside panel.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
55
TP800, TP900 Spa Behavior
BE SURE TO SET THE TIME-OF-DAY
Setting the time-of-day is important for determining filtration
times and other background features. “Set Time” will appear on
the display if no time-of-day is set in the memory.
On the Settings Screen, select the Time-of-Day line. On the Timeof-Day screen, simply navigate right and left to select the Hour,
Minutes, AM/PM and 12/24 Hour segments. Use the Up and
Down Buttons to make changes.
SAVING SETTINGS
The Time-of-Day screen is a simple, editable screen that illustrates a feature of the control that applies to all other editable
screens as well.
When changes are made, the icon to go “Back” changes to
“Save” and a new icon for “Cancel” appears under the Save icon.
Navigating to the left will highlight the Save icon, and navigating down from there will allow the user to cancel the pending
change. Pressing the “Select” button will save or cancel the
changes and go back to the previous screen.
NOTE: If power is interrupted to the system, Time-of-Day will be
maintained for several days.
PUMPS
On the Spa Screen, select a “Jets” button once to turn the pump
on or off, and to shift between low- and high-speeds if equipped.
If left running, the pump will turn off after a time-out period. The
pump 1 low-speed will time out after 30 minutes. The high-speed
will time-out after 15 minutes.
On non-circ systems, the low-speed of pump 1 runs when the
blower or any other pump is on. If the spa is in Ready Mode,
Pump 1 low may also activate for at least 1 minute every 30
minutes to detect the spa temperature (polling) and then to heat
to the set temperature if needed. When the low-speed turns on
automatically, it cannot be deactivated from the panel, however
the high speed may be started.
CIRCULATION PUMP MODES
Some spas may be manufactured with Circ Pump settings that
allow programming filtration cycle duration. Some circ Modes
are pre-programmed to operate 24 hours a day and are not
programmable.
56
If your system is equipped with a circ pump, it may be configured
to work in one of three different ways:
1. The circ pump operates continuously (24 hours) with the
exception of turning off for 30 minutes at a time when the
water temperature reaches 3°F (1.5°C) above the set temperature (most likely to happen in very hot climates).
2. The circ pump stays on continuously, regardless of water
temperature.
3. A programmable circ pump will come on when the system
is checking temperature (polling), during filter cycles, during
freeze conditions, or when another pump is on.
UÊ The specific Circulation Mode that is used has been determined by the Manufacturer and cannot be changed in the
field.
UÊ Other device options may be available, like Blower, Light,
Mist, etc.
FILTRATION AND OZONE
On non-circ systems, Pump 1 low and the ozone generator will
run during filtration. On circ systems, the ozone will generally run
with the circ pump, but can be limited to filtration cycles.
The system is factory-programmed with one filter cycle that will
run in the evening (assuming the time-of-day is properly set)
when energy rates are often lower. The filter time and duration
are programmable.
A second filter cycle can be enabled as needed.
At the start of each filter cycle, the water devices like blower,
mist device (if these exist) and other pumps will run briefly to
purge the plumbing to maintain good water quality.
FREEZE PROTECTION
If the temperature sensors within the heater detect a low
enough temperature, then the water devices automatically
activate to provide freeze protection. The water devices will run
either continuously or periodically depending on conditions.
In colder climates, an optional additional freeze sensor may
be added to protect against freeze conditions that may not be
sensed by the standard sensors. Auxiliary freeze sensor protection acts similarly except with the temperature thresholds
determined by the switch. See your dealer for details.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP800, TP900 Adjusting Filtration
CLEANUP CYCLE (OPTIONAL)
When a pump or blower is turned on by a button press, a cleanup cycle begins 30 minutes after the pump or blower is turned
off or times out. The pump and the ozone generator will run for
30 minutes or more, depending on the system. On some systems,
you can change this setting. (See the Preferences section.)
Filter Cycles
Back
Filter Cycle 1
Starts at 12:00 AM
Runs 0 HR 0 Min
Ends at 12:00 AM
Filter Cycle 2 No
Starts at 12:00 AM
Runs 0 HR 0 Min
Ends at 12:00 AM
MAIN FILTRATION
Using the same navigation and adjustment as Setting the Time,
Filter Cycles are set using a start time and a duration. Each setting can be adjusted in 15-minute increments. The panel calculates the end time and displays it automatically.
FILTER CYCLE 2 - OPTIONAL FILTRATION
Filter Cycle 2 is OFF by default.
Simply navigate to the Filter Cycle 2 line by pressing the Right
Navigation Button, and when “NO” is highlighted, press Up or
Down to toggle Filter Cycle 2 on and off. When Filter Cycle 2 is
ON, it can be adjusted in the same manner as Filter Cycle 1 by
navigating to the right.
Filter Cycles
Back
Cancel
It is possible to overlap Filter Cycle 1 and Filter Cycle 2, which
will shorten overall filtration by the overlap amount.
PURGE CYCLES
Filter Cycle 1
Starts at 6:15 AM
Runs 3 HR 0 Min
Ends at 9: 15 AM
Filter Cycle 2 No
Starts at 12:00 AM
Runs 0 HR 0 Min
Ends at 12:00 AM
In order to maintain sanitary conditions, as well as protect
against freezing, secondary water devices will purge water from
their respective plumbing by running briefly at the beginning of
each filter cycle.
If the Filter Cycle 1 duration is set for 24 hours, enabling Filter
Cycle 2 will initiate a purge when Filter Cycle 2 is programmed
to begin..
HOLD MODE - M037*
Hold Mode is used to disable the pumps during service functions
like cleaning or replacing the filter. Hold Mode will last for 1 hour
unless the mode is exited manually. If spa service will require
more than an hour, it may be best to simply shut down power to
the spa.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
57
TP800, TP900 Panel Lock & Unlock
RESTRICTING OPERATION (LOCKING THE PANEL)
Lock
Back
Settings
Panel
Main Screen > Settings > Lock
OFF
OFF
UÊ The control can be restricted to prevent unwanted use or
temperature adjustments.
UÊ Locking the Panel prevents the controller from being used,
but all automatic functions are still active.
UÊ Locking the Settings allows Jets and other features to be
used, but the Set Temperature and other programmed settings cannot be adjusted.
UÊ Settings Lock allows access to a reduced selection of menu
items. These include Set Temperature, Invert, Lock, Utilities, Information and Fault Log. They can be seen, but not
changed or edited.
UNLOCKING THE PANEL
100°F
Set: 104°F
10:00 PM
Ozone
Filter 1
High Range
A: 99 B:100
Unlock
Main Screen > Unlock > [Right] > [Select] > [Select] > [Down]
UÊ Unlocking the panel is accomplished from within the Lock
Screen. The Unlock Sequence is the same for both Panel
Lock and Settings Lock. However, the Panel must be unlocked before the Settings is unlocked.
UÊ NOTE: When inside the Lock Screen, be sure that “Settings”
or “Panel” is highlighted and not “Back” before using the key
sequence below.
Ready Mode
Check Filter
Lock
Back
58
Settings
Panel
OFF
ON
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP800, TP900 Sensor and System Related Messages
SYSTEM INFORMATION
The System Information Menu displays various settings and
identification of the particular system. As each item in the menu
is highlighted, the detail for that item is displayed at the bottom
of the screen.
SOFTWARE ID: (SSID)
Displays the software ID number for the System.
System Information
Back
Software ID (SSID)
System Model
Current Setup
Configuration Signature
Heater Voltage
Heater Type
Software ID (SSID):
M100_101 V0.6
SYSTEM MODEL
Displays the Model Number of the System.
CURRENT SETUP
Displays the currently selected Configuration Setup Number.
CONFIGURATION SIGNATURE
Displays the checksum for the system configuration file.
HEATER RELATED MESSAGES
THE WATER FLOW IS LOW – M016
There may not be enough water flow through the heater to carry
the heat away from the heating element. Heater start up will
begin again after about 1 min. See “Flow Related Checks” below.
THE WATER FLOW HAS FAILED* – M017
There is not enough water flow through the heater to carry the
heat away from the heating element and the heater has been
disabled. See “Flow Related Checks” below. After the problem
has been resolved, you must press any button to reset and begin
heater start up.
THE HEATER MAY BE DRY* – M028
Possible dry heater, or not enough water in the heater to start
it. The spa is shut down for 15 min. Press any button to reset the
heater start-up. See “Flow Related Checks” below.
THE HEATER IS DRY* – M027
There is not enough water in the heater to start it. The spa
is shut down. After the problem has been resolved, you must
clear the message to restart heater start up. See “Flow Related
Checks” below.
THE HEATER IS TOO HOT* – M030
One of the water temp sensors has detected 118°f (47.8°C) in the
heater and the spa is shut down. You must clear the message
when water is below 108°f (42.2°C). See “Flow Related Checks”
below.
HEATER VOLTAGE (FEATURE NOT USED ON CE
RATED SYSTEMS.)
FLOW-RELATED CHECKS
Displays the operating voltage configured for the heater.
Check for low water level, suction flow restrictions, closed
valves, trapped air, too many closed jets and pump prime.
HEATER WATTAGE AS CONFIGURED IN SOFTWARE
(CE SYSTEMS ONLY)
Displays a heater kilowatt rating as programmed into the control
system software (1-3 or 3-6).
Note: On some systems, even when spa is shut down by an error
condition, some equipment may occasionally turn on to * or if
freeze protection is needed.
HEATER TYPE
Displays a heater type ID number.
DIP SWITCH SETTINGS
Displays a number that represents the DIP switch positions of S1
on the main circuit board.
PANEL VERSION
Displays a number of the software in the topside control panel.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
59
TP800, TP900 Sensor and System Related Messages (cont.)
DRAIN MODE
System Hold
Main Screen > Settings > Hold > Drain
Drain Off
Some spas have a special feature that allows Pump 1 to be
employed when draining the water.
When available, this feature is a component of Hold mode.
Exit
UTILITIES MENU
Main Screen > Settings > Utilities
Holding for 0:58
The Utilities Menu contains the following:
A/B TEMPS
When this is set to On, the temperature display will alternate to
display temperature from Sensor A and Sensor B in the heater.
Utilities
Back
A/B Temps
Demo Mode
Fault Log
GFCI Test
Off
Off
DEMO MODE
Main Screen > Settings > Utilities > Demo Mode
Demo mode is not always enabled, so it may not appear. This is
designed to operate several devices in a sequence in order to
demonstrate the various features of a particular hot tub.
FAULT LOG: TP800, TP900
Main Screen >Settings > Utilities > Fault Log
The Fault Log is a record of the last 24 faults that can be reviewed by a service tech.
Utilities
Back
Demo Mode
Fault Log
GFCI Test
Off
GFCI TEST (FEATURE NOT AVAILABLE ON CE RATED
SYSTEMS.)
GFCI Test is not always enabled, so it may not appear. This
screen allows the GFCI to be tested manually from the panel and
can be used to reset the automatic test feature. If the GFCI Test
Feature is reset, the device will trip within 7 days.
Fault Log
Entry 2
Message Code 19
1 Days Ago 2:21PM
Rest Mode
High Range
Set Temp 104°F
Sensors: A: 100 B: 96
Message:
Sensors are out of sync
Back
60
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP800, TP900 Sensor and System Related Messages (cont.)
THE GROUND FAULT CIRCUIT INTERRUPTER (GFCI)
Settings
Back
Light Cycle
Invert Panel
Lock
Hold
Utilities
Preferences
Information
Normal
USED FOR VERIFYING A PROPER INSTALLATION
Your spa may be equipped with a GFCI Protection feature. If your
spa has this feature enabled by the manufacturer, the GFCI Trip
Test must occur to allow proper spa function.
Utilities
Back
A/B Temps
Demo Mode
Fault Log
GFCI Test
Off
Off
GFCI Status - Passed
Back
Test
Reset
The Ground Fault Circuit Interrupter (GFCI) or Residual Current
Detector (RCD) is an important safety device and is required
equipment on a hot tub installation. (The GFCI Test Feature is
not available on CE rated systems.)
Within 1 to 7 days after startup, the spa will trip the GFCI to test
it. (The number of days is factory programmed.) The GFCI must
be reset once it has tripped. After passing the GFCI Trip Test,
any subsequent GFCI trips will indicate a ground fault or other
unsafe condition and the power to the spa must be shut off until
a service person can correct the problem.
FORCING THE GFCI TRIP TEST
The installer can cause the GFCI Trip Test to occur sooner by
initiating it using the above menu.
The GFCI should trip within several seconds and the spa should
shut down. If it does not, shut down the power and have a qualified person verify that the GFCI breaker is installed and that the
circuit and spa are wired correctly. Verify the function of the GFCI
with its own test button. Restore power to the spa and repeat
the GFCI Trip Test.
Once the GFCI is tripped by the test, reset the GFCI and the spa
will operate normally from that point. You can verify a successful
test by navigating to the above menu. PASS should appear after
a temp button is pressed from the GFCI Screen.
WARNING:
UÊ The end-user must be told to expect this one-time test to
occur and how to properly reset the GFCI.
UÊ If freezing conditions exist, the GFCI should be reset immediately or spa damage could result.
CE PRODUCT:
UÊ CE registered systems do not have an RCD Test Feature due
to the nature of the electrical service.
UÊ Some UL registered systems do not have the GFCI Test
Feature activated.
UÊ The end-user must be trained how to properly test and reset
the RCD.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
61
TP800, TP900 Sensor and System Related Messages (cont.)
MOST MESSAGES AND ALERTS WILL APPEAR AT
THE BOTTOM OF THE NORMALLY USED SCREENS.
Several alerts and messages may be displayed in a sequence.
Some messages can be reset from the panel. Messages that
can be reset will appear with a “right arrow” at the end of the
message. This message can be selected by navigating to it at
pressing the Select button.
COMMUNICATIONS ERROR
The control panel is not receiving communication from the
System.
TEST SOFTWARE INSTALLED
The Control System is operating with test software.
°F OR °C IS REPLACED BY °T
The Control System is in Test Mode.
PROGRAM MEMORY FAILURE* – M022
Clean the filter
`
WATER TEMPERATURE IS UNKNOWN
---˚F ---˚C
After the pump has been running for 1 minute, the temperature
will be displayed.
POSSIBLE FREEZING CONDITION
At Power-Up, the system has failed the Program Checksum Test.
This indicates a problem with the firmware (operation program)
and requires a service call.
THE SETTINGS HAVE BEEN RESET (PERSISTENT
MEMORY ERROR)* – M021
Contact your dealer or service organization if this message appears on more than one power-up.
THE CLOCK HAS FAILED* – M020
CONFIGURATION ERROR - SPA WILL NOT START UP
A potential freeze condition has been detected, or the Aux Freeze
Switch has closed. All water devices are activated.
In some cases, pumps may turn on and off and the heater may
operate during Freeze Protection. This is an operational message,
not an error indication.
THE GFCI TEST FAILED (SYSTEM COULD NOT TEST
THE GFCI) – M036
THE WATER IS TOO HOT – M029
A PUMP MAY BE STUCK ON – M034
The system has detected a spa water temp of 110°F (43.3°C) or
more, and spa functions are disabled. System will auto reset
when the spa water temp is below 108°F (42.2°C). Check for
extended pump operation or high ambient temp.
SENSORS ARE OUT OF SYNC – M015
The temperature sensors MAY be out of sync by 2°F or 3°F.
(North America Only) May indicate an unsafe installation.
Water may be overheated. POWER DOWN THE SPA. DO NOT
ENTER THE WATER.
HOT FAULT – M035
A Pump Appears to have been Stuck ON when spa was last
powered. POWER DOWN THE SPA. DO NOT ENTER THE
WATER.
SENSORS ARE OUT OF SYNC -- CALL FOR SERVICE*
– M026
The temperature sensors ARE out of sync. The fault above has
been established for at least 1 hour.
SENSOR A FAULT, SENSOR B FAULT – SENSOR A:
M031, SENSOR B: M032
A temperature sensor or sensor circuit has failed. Call for Service
62
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP800, TP900 Utilities Menu
THE UTILITIES MENU CONTAINS THE FOLLOWING:
PREFERENCES
The Preferences Menu allows the user to change certain parameters based on personal preference.
TEMP DISPLAY
Change the temperature between Fahrenheit and Celsius.
TIME DISPLAY
Change the clock between 12 hr and 24 hr display.
REMINDERS
Turn the reminder messages (like “Clean Filter”) On or Off.
CLEANUP
Cleanup Cycle Duration is not always enabled, so it may not appear. When it is available, set the length of time Pump 1 will run
after each use. 0-4 hours are available.
DOLPHIN II AND DOLPHIN III (APPLIES TO RF
DOLPHIN ONLY)
When set to 0, no addressing is used. Use this setting for a
Dolphin II or Dolphin III which is factory set for no
address by default. When set between 1 and 7, the number is the
address. (See Optional Balboa Dolphin Remote within this
manual, or the Dolphin III domestic manual for details, Doc. No.
50211.)
COLOR OF BACKGROUND
Pressing the Select Button when Color is highlighted will cycle
through 5 background colors available in the control.
LANGUAGE
Change the language displayed on the panel.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
63
TP400, TP600 Standard Panel Operations - Main Screen - Navigation
Note: TP400 menu structure is similar to the TP600. This section is only for quick reference as it applies to troubleshooting.
For complete menu operations, please refer to BWG user guide, document No. 40940 or user guide 42185 for simplified menus.
TP400/TP600 error codes and fault messages are similar to TP800/TP900.
Navigation
Navigating the entire menu structure is done with 2 or 3 buttons on the control panel.
Some panels have separate WARM (Up) and COOL (Down) buttons, while
others have a single Temperature button. In the navigation diagrams
Temperature buttons are indicated by a single button icon.
Panels that have two Temperature buttons (Warm and Cool) can
use both of them to simplify navigation and programming where
a single Temperature icon is shown.
The LIGHT Button is also used to
choose the various menus and navigate each section.
Typical use of the Temperature button(s) allows changing the
Set Temperature while the numbers are flashing in the LCD.
Pressing the LIGHT button while the numbers are flashing will
enter the menus.
The menus can be exited with certain button presses. Simply waiting for
several seconds will return the panel operation to normal.
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64
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP400, TP600 Panel Utilities Menu
If the system can power up, you have access to the Utilities and Fault Log menus.
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42211 C
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Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
65
TP400, TP600 Preparation and Priming
PREPARATION AND FILLING
Fill the spa to its correct operating level. Be sure to open all
valves and jets in the plumbing system before filling to allow
as much air as possible to escape from the plumbing and the
control system during the filling process.
ing for more than 2 minutes. Under NO circumstances should a
pump be allowed to run without priming beyond the end of the
4-5 minute priming mode. Doing so may cause damage to ºthe
pump and cause the system to energize the heater and go into
an overheat condition.
After turning the power on at the main power panel, the top-side
panel display will go through specific sequences. These sequences are normal and display a variety of information regarding the
configuration of the hot tub control.
PRIMING MODE – M019*
This mode will last for 4-5 minutes or you can manually exit
the priming mode after the pump(s) have primed. Regardless of
whether the priming mode ends automatically or you manually
exit the priming mode, the system will automatically return to
normal heating and filtering at the end of the priming mode. During the priming mode, the heater is disabled to allow the priming
process to be completed without the possibility of energizing the
heater under low-flow or no-flow conditions. Nothing comes on
automatically, but the pump(s) can be energized by pushing the
“Jet” buttons. If the spa has a Circ Pump, it can be activated by
pressing the “Light” button during Priming Mode.
PRIMING THE PUMPS
As soon as the above display appears on the panel, push the
“Jet” button once to start Pump 1 in low-speed and then again
to switch to high-speed. Also, push the Pump 2 or “Aux” button,
if you have a 2nd pump, to turn it on. The pumps will now be
running in high-speed to facilitate priming. If the pumps have not
primed after 2 minutes, and water is not fl owing from the jets in
the spa, do not allow the pumps to continue to run. Turn off the
pumps and repeat the process.
EXITING PRIMING MODE
You can manually exit Priming Mode by pressing a “Temp” button
(Up or Down). Note that if you do not manually exit the priming
mode as described above, the priming mode will be automatically terminated after 4-5 minutes. Be sure that the pump(s) have
been primed by this time.
Once the system has exited Priming Mode, the top-side panel
will momentarily display the set temperature but the display will
not show the temperature yet, as shown below. This is because
the system requires approximately 1 minute of water flowing
through the heater to determine the water temperature and
display it.
or
READY
RANGE
READY
RANGE
Note: Turning the power off and back on again will initiate a
new pump priming session. Sometimes momentarily turning the
pump off and on will help it to prime. Do not do this more than
5 times. If the pump(s) will not prime, shut off the power to the
spa.
Important: A pump should not be allowed to run without prim-
66
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP400, TP600 Message Codes
The following are messages and features that can appear on the TP400 and TP600 panels.
NOTE: LCD readouts may look slightly different than shown on screen.
MESSAGE CODES
DEMO (DEMO MODE)
(Found on the pages listed)
M0[XX] numbers are Message Codes 55
M015 62, 69
M016 59, 68
M017 59, 68
M019 68
M019* 55
M020 62, 69
M021 62, 69
M022 62, 69
M026 62, 69
M027 59
M028 59, 68
M029 62, 68
M030 59, 68
M031 69
M031, Sensor A: 62
M032 69
M032, Sensor B: 62
M033 68
M034 62, 69
M035 62, 69
M036 62, 69
M037* 57
Demo Mode is not always enabled, so it may not appear. This
is designed to operate several devices in a sequence in order
to demonstrate the various features of a particular hot tub.
INFO (SYSTEM INFORMATION SUB-MENU)
The System Information Menu displays various settings and
identification of the particular system. As each item in the
menu is highlighted, the detail for that item is displayed at the
bottom of the screen.
SSID (SOFTWARE ID)
Displays the software ID number for the System.
MODL (SYSTEM MODEL)
Displays the Model Number of the System.
SETP (CURRENT SETUP)
Displays the currently selected Configuration Setup Number.
SIG (CONFIGURATION SIGNATURE)
Displays the checksum for the system configuration file.
HEATER VOLTAGE (FEATURE NOT USED ON CE
RATED SYSTEMS)
Displays the operating voltage configured for the heater.
HEATER WATTAGE AS CONFIGURED IN SOFTWARE
(CE SYSTEMS ONLY)
Displays a heater kilowatt rating as programmed into the
control system software (1-3 or 3-6).
H _ (HEATER TYPE)
Displays a heater type ID number.
SW _ (DIP SWITCH SETTINGS)
Displays a number that represents the DIP switch positions of
S1 on the main circuit board.
PANL (PANEL VERSION)
Displays a number of the software in the topside control panel.
GFCI (GFCI Test) (Feature not available on CE rated systems.)
GFCI Test is not always enabled, so it may not appear. This
screen allows the GFCI to be tested manually from the panel
and can be used to reset the automatic test feature. If the GFCI
Test Feature is reset, the device will trip within 7 days.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
67
TP400, TP600 Messages (cont.)
A / B (A/B SENSOR TEMPERATURES)
WATR TOO HOT -- -- -- --
When this is set to On, the temperature display will alternate to
display temperature from Sensor A and Sensor B in the heater.
Water is too Hot (OHS) – M029
FALT LOG (FAULT LOG)
The Fault Log is a record of the last 24 faults that can be reviewed by a service tech.
One of the water temp sensors has detected spa water temp
110°F (43.3°C) and spa functions are disabled. System will auto
reset when the spa water temp is below 108°F (42.2°C). Check
for extended pump operation or high ambient temp.
SFTY TRIP -- -- -- -SCROLLING TP400/TP600 MESSAGES
The following messages will scroll across the TP400/TP600 panels. NOTE: LCD readouts may look slightly different than shown
on screen.
RUN PMPS PURG AIR ---PRIMING MODE – M019
Each time the spa is powered up, it will enter Priming Mode. The
purpose of Priming Mode is to allow the user to run each pump
and manually verify that the pumps are primed (air is purged)
and water is flowing. This typically requires observing the output
of each pump separately, and is generally not possible in normal
operation. Priming Mode lasts 4 minutes, but you can exit it
earlier by pressing any Temp button. The heater is not allowed to
run during Priming Mode.
NOTE: If your spa has a Circ Pump, it will turn on with Jets 1 in
Priming Mode. The Circ Pump will run by itself when Priming
Mode is exited.
-- -- --ÝF -- -- -- ÝC
Water Temperature is Unknown
After the pump has been running for 1 minute, the temperature
will be displayed.
42ÝF TOO COLD
Too Cold - Freeze Protection
A potential freeze condition has been detected, or the Aux Freeze
Switch has closed, and all pumps and blower are activated. All
pumps and blower are ON for at least 4 minutes after the potential freeze condition has ended, or when the aux freeze switch
opens. In some cases, pumps may turn on and off and the heater
may operate during Freeze Protection. This is an operational
message, not an error indication.
68
Safety Trip - Pump Suction Blockage* – M033
The Safety Trip error message indicates that the vacuum switch
has closed. This occurs when there has been a suction problem
or a possible entrapment situation avoided. (Note: not all spas
have this feature.)
HTR FLOW LOSS -- -- -- -Heater Flow is Reduced (HFL) – M016
There may not be enough water flow through the heater to carry
the heat away from the heating element. Heater start up will
begin again after about 1 min. See “Flow Related Checks” below.
HTR FLOW FAIL -- -- -- -Heater Flow is Reduced (LF)* – M017
There is not enough water flow through the heater to carry the
heat away from the heating element and the heater has been
disabled. See “Flow Related Checks” below. After the problem
has been resolved, you must press any button to reset and begin
heater start up.
HTR MAY BE DRY -- -- -- -- WAIT -- -- -- -Heater May be Dry (dr)* – M028
Possible dry heater, or not enough water in the heater to start
it. The spa is shut down for 15 min. Press any button to reset the
heater start-up. See “Flow Related Checks” below.
HTR TOO HOT -- -- -- -HTR is too Hot (OHH)* M030
One of the water temp sensors has detected 118°f (47.8°C) in the
heater and the spa is shut down. You must press any button to
reset when water is below 108°f (42.2°C). See “Flow Related
Checks” below.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
PRES BTTN TO RSET -- -- -- --
MEM FAIL -- -- -- --
A Reset Message May Appear with other Messages.
Memory Failure - Checksum Error* – M022
Some errors may require power to be removed and restored.
At Power-Up, the system has failed the Program Checksum Test.
This indicates a problem with the firmware (operation program)
and requires a service call.
FLOW-RELATED CHECKS
Check for low water level, suction flow restrictions, closed
valves, trapped air, too many closed jets and pump prime.
On some systems even when spa is shut down, some equipment
may occasionally turn on to continue monitoring temperature or
if freeze protection is needed.
MEM RSET -- -- -- -Memory Warning - Persistent Memory Reset* – M021
Sensor Balance is Poor – M015
Appears after any system setup change. Contact your dealer
or service organization if this message appears on more than
one power-up, or if it appears after the system has been running
normally for a period of time.
The temperature sensors MAY be out of sync by 2°F or 3°F.
CLOK FAIL -- -- -- --
SNSR SYNC -- -- -- -- CALL FOR SRVC -- -- -- --
Memory Failure - Clock Error* – M020
Sensor Balance is Poor* – M026
Not Applicable on the BP1500.
The temperature sensors ARE out of sync. The Sensor Balance is
Poor fault has been established for at least 1 hour.
CNFG FAIL -- -- -- --
SNSR A -- -- -- -- CALL FOR SRVC -- -- -- -SNSR B -- -- -- -- CALL FOR SRVC -- -- -- --
GFCI FAIL -- -- -- --
Sensor Failure – Sensor A: M031, Sensor B: M032
GFCI Failure - System Could Not Test/Trip the GFCI – M036
A temperature sensor or sensor circuit has failed.
NORTH AMERICA ONLY. May indicate an unsafe installation.
NO COMM
STUK PUMP -- -- -- --
No Communications
A Pump Appears to be Stuck ON – M034
The control panel is not receiving communication from the
System.
Water may be overheated. POWER DOWN THE SPA. DO NOT
ENTER THE WATER.
BETA VER-- SION -- -- -- --
HOT FALT -- -- -- -- CALL FOR SRVC -- -- -- --
Pre-Production Software
A Pump Appears to have been Stuck ON when spa was
last powered – M035
102˚F SNSR BAL-- ANCE
The Control System is operating with test software.
Configuration Error - Spa will not Start Up
POWER DOWN THE SPA. DO NOT ENTER THE WATER.
102ÝT
°F or °C is replaced by °T
The Control System is in Test Mode.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
69
TP400, TP600 Utilities Fault Log Menu
THE FAULT LOG
FAULT LOG MESSAGE CODES: TP400, TP600
The Fault Log stores up to 24 events in memory and they can be
reviewed under the Fault Log Menu. The Fault Log is a record of
the last 24 faults that can be reviewed by a service tech.
UÊ
UÊ
UÊ
UÊ
UÊ
UÊ
Each event captures a Fault Message Code, how many days have
passed since the fault, Time of the fault, Set Temperature during
the fault, and Sensor A and B temperatures during the fault. The
Fault Log is also available from the Test Menu (in Test Mode).
UÊ Pressing TEMP at any fault event reveals a Message Code
UÊ Continuing to press TEMP reveals additional information for
that specified numbered fault event.
UÊ Waiting 30 seconds inside the fault log menu allows the
screen to return to normal operation.
MXXX: Fault Message Code
DZZZ: How many days have passed since the fault
Time of the fault
Set Temperature during the fault
Sensor A Temperature during the fault
Sensor B Temperature during the fault
Key
Indicates Flashing or Changing Segment
Indicates Alternating or Progressive Message - every 1/2 second
A temperature button, used for “Action”
Light or dedicated “Choose” button, depending on control panel configuration
Waiting time - varies depending on function
Main Screen
READY
RANGE FLTR1
SET
RANGE
While the Temperature is
still flashing, press Light
repeatedly until UTIL (Utilities)
appears in the LCD.
Indicates a Menu Item that
Depends on a Manufacturer
Configuration and
may or may not appear.
Press Light
repeatedly until FALT LOG
appears in the LCD.
To FIRST item in
Main Menu
(TEMP Range)
M: Message Code
READY
READY
RANGE
RANGE
D: Days Ago
SET
Only if DEMO Mode
is enabled
M:
READY
READY
RANGE
RANGE
Time
24 Fault messages is the maximum.
Fewer messages may be displayed.
READY
RANGE
P
Set Temperature
M:
READY
RANGE
Sensor A Temp
M:
The Fault Log is also available from the
Test Menu (in Test Mode).
READY
RANGE
Sensor B Temp
Waiting several seconds inside the Fault Log Menu will allow the screen to return to normal operation.
70
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
TP400, TP600 Utilities Menu - GFCI Test Feature
Not Available on CE Rated Systems.
A GFCI is an important safety device and is required equipment on a hot tub installation.
Your spa may be equipped with a GFCI Protection feature. (UL rated systems only.) If your spa has this feature enabled by
the manufacturer, the GFCI Trip Test must occur to allow proper spa function.
Within 1 to 7 days after startup, the spa will trip the GFCI to test it. (The number of days is factory programmed.) The GFCI
must be reset once it has tripped. After passing the GFCI Trip Test, any subsequent GFCI trips will indicate a ground fault or
other unsafe condition and the power to the spa must be shut off until a service person can correct the problem.
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Forcing the GFCI Trip Test
The installer can cause the GFCI Trip Test to occur sooner by initiating it using the above menu.
The GFCI should trip within several seconds and the spa should shut down. If it does not, shut down the power and manually verify that a GFCI breaker is installed and that the circuit and spa are wired correctly. Verify the function of the GFCI
with its own test button. Restore power to the spa and repeat the GFCI Trip Test.
Once the GFCI is tripped by the test, reset the GFCI and the spa will operate normally from that point. You can verify a successful test by navigating to the above menu. PASS should appear after a temp button is pressed from the GFCI screen.
The end-user must be trained to expect this one-time test to occur and how to properly reset the GFCI.
Warning:
If freezing conditions exist, a GFCI should be reset immediately or spa damage
could result. The end user should always trained to test and reset the
GFCI on a regular basis.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
71
TP400, TP600 Simplified vs. Standard Panel Operations
SIMPLIFIED MENUS
CHANGING MENUS THROUGH CONFIGURATIONS
Simplified Menus is an option that manufacturers (OEM's) offer
to their end users in order to provide an easier to navigate
menu. A simplified menu structure does not have extended
features such as Utilities, Restricting Operation, Unlocking, and
so on; yet, provides basic spa operations that satisfy the needs
of end users. Navigating the menu structure is similar for both
standard and simplified menus, which is done using two or
three buttons on the control panel.
If the option of an alternate menu structure is available, then it
is possible to change the simplified menu to a standard menu,
and vice versa. A technician must refer to the Tech Sheet of that
particular system to see what configuration (if any) is available.
All TP600 and TP400 panels are compatible with simplified
menus and standard menus, and can access Test Mode.
Regardless of menu structure, test modes have full functionality.
The control panel user guides for standard and simplified menus
are different: Balboa user guide 40940 describes standard
menus; user guide 42185 describes simplified menus.
Menu attributes are embedded within the spa control system
at the factory. Swapping out one panel with another will not
change a simplified menu to a standard menu, and vice versa.
For the system to be changed from one menu structure to
another is dependent on whether that option was programed
into the system at the time of manufacturing.
For instance, if a technician plans to install or modify a Sunrise
Spas BP 240V system (in this example), and that system has
standard menus that he wishes to change to simplified menus,
he would refer to Tech Sheet SR240BP5 (No. 56415-97, Rev. A).
Page two provides information in the System Revision History:
"240V-only version with both Simplified Menus and Full Menus".
The next giveaway of dual menu options is the section headers
on the following pages. See below.
UÊ Page 3: An option is given to use Setup 1, or Setup 7.
UÊ Below that, an option is given to use Setup 2, or Setup 8.
UÊ Page 4: An option is given to use Setup 3, or Setup 9.
In these three examples (out of six possible dual menu options
available for this system), Setups 1, 2, or 3 could be chosen for
a simplified menu. Of course, the option is open to configure a
counterpart control system to standard menus by choosing Setup
7, 8, or 9 respectively.
Headings of Setups 1, 2, & 3 in Tech Sheet SR240BP5 (12-05-12, Rv. A)
72
Page 3:
Setup 1 – Simplified Menu (with Flip) Setup 7 – Full Menu
Page 3:
Setup 2 – Simplified Menu (with Flip) Setup 8 – Full Menu
Page 4:
Setup 3 – Simplified Menu (with Flip) Setup 9 – Full Menu
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
A Simplified Main Menu (Doc No. 42185B)
Main Menus
Navigation
Navigating the entire menu structure is done with 2 or 3 buttons on the control panel.
Some panels have separate WARM (Up) and COOL (Down) buttons, while
others have a single Temperature button. In the navigation diagrams
Temperature buttons are indicated by a single button icon.
Panels that have two Temperature buttons (Warm and Cool) can
use both of them to simplify navigation and programming where
a single Temperature icon is shown.
The LIGHT Button is also used to
choose the various menus and navigate each section.
Typical use of the Temperature button(s) allows changing the
Set Temperature while the numbers are flashing in the LCD.
Pressing the LIGHT button while the numbers are flashing will
enter the menus.
The menus can be exited with certain button presses. Simply waiting for
several seconds will return the panel operation to normal.
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A STANDARD MAIN MENU (DOC NO. 40941I)
Main Screen
READY
Both panels can be navigated
using 2 or 3 buttons.
RANGE FLTR1
SET
While the Temperature is
still flashing, press Light.
RANGE
Light Cycle if enabled
SET
RANGE
SET READY
SET
1
P
SET
If Time of Day is not set
“SET TIME” will
appear in this menu.
2
Main Screen
READY
RANGE FLTR1
Waiting Several Seconds in the Main Menu
will allow the display to revert to the Main Screen.
Most changes are not saved unless Light
is pressed.
Refer to Key above.
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
73
Supplemental Information - Optional Balboa DolphinTM Remote
THE DOLPHINTM REMOTE
The Dolphin Remote works much the same way as your entertainment remote at home does; yet, it’s designed to control
pumps, blowers, and any option that you have on your pool or
spa--including entertainment equipment.
HOW THE DOLPHIN WORKS
The Dolphin communicates with a Dolphin RF Receiver (or IR
Receiver). The receiver is wired into the Control System.
1. Mount the Dolphin receiver module in a vertical position
with the molded arrow pointing up.
2. Plug the receiver’s connector into the 6-pin connector J40
labeled REMOTE located within the Control System box.
3. In order for the Dolphin to communicate, it must be assigned
an “address” that the Control Center and Dolphin recognize, and allows both the Dolphin and specific equipment
(blower, jets, or stereo for example) to “talk” to each other.
(The factory default is zero, or no address.)
4. When set to 0, no addressing is used. Use this setting for
a Dolphin III, which is factory set for no address by default.
The Dolphin has a total of eight addresses: zero, and 1-7.
J8
J8
J8
J8
AUX
10
S1
SENSOR
LIGHT
HTR1
HTR2
HTR3
J15
J38
J31
REMOTE
J30
J40
J36
MAIN
J14
PUMP 2
J18
A
AUX
TEMP
SENSOR
A/V HOT
Dolphin
AUX
3A 250V
74
Dolphin
Receiver
J29
J28
AUX FRZ
J23
SERIAL
J34
MAIN
J108
RLY 9/10
J35
MAIN
J107
RLY 7/8
B
BP SPA
CONTROL SYSTEM
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Optional Balboa DolphinTM Remote (cont.)
ASSIGNING A NEW ADDRESS TO THE DOLPHIN
Preferences
Back
Temp Display
Time Display
Reminders
Cleanup
Dolphin
Color
Language
F
12 HR
On
0.5 HR
0
Blue
English
Dolphin Address
Back
5
In some instances you may want to reset the address of your
Dolphin. You’ll need to match that new address in the control
system and that of your Dolphin.
Step 1: Addressing your Colossus through your control
panel:
Main Screen > Settings (scroll to Preferences) > Preferences >
Dolphin > Dolphin Screen
Use the arrow key to change the address to 5 (in this example).
Exit with Arrow Left key.
Step 2: Addressing your Dolphin:
1. a) Press the SPA Button on the Dolphin once.
b) Press and hold SETUP until the LED blinks once.
c) Hold it until it blinks twice.
2. Enter one of the set up codes below:
Set Up Code = [Spa Address]
0000 = [0] (no address)
0008 = [1]
0080 = [2]
0088 = [3]
0800 = [4]
0808 = [5]
0880 = [6]
0888 = [7]
3. If the code is entered correctly, the LED will blink twice.
(Refer to the Dolphin manuals for more details.)
SAVING YOUR DOLPHIN ADDRESS
Dolphin III (50211)
For future reference, make a note of the address for your records.
Keep in mind that you may have to change the address if there
are conflicts with your equipment. Also, the address may have to
be reentered after servicing.
Dolphin III CE (50212)
DOLPHIN MANUAL
Dolphin III manuals can be found on our site: www.balboawatergroup.com
Click on “Spa Products” > “Wireless Remotes”
UÊ Dolphin III manual (domestic) Document No. 42012
UÊ Dolphin III manual (CE) is Document No. 42013
DOLPHIN REMOTES
UÊ Dolphin III (domestic), Document No. 50211
UÊ Dolphin III, CE (no RF), Document No. 50212
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
75
Spa Guidelines to Keep in Mind
Below are guidelines when designing replacing an older control system, or if designing a new spa system.
This information is included in order to offer more insight into spa plumbing and mechanics.
1.
The heater requires at least 20 Gallons per Minute (GPM) of
flow for proper function.
2. Some systems may require at least 25 GPM.
3. The suction system for the 2-speed pump or for the circ
pump must be dedicated. There must not be any other
pumps connected to this suction system.
4. The suction system for the 2-speed pump or for the circ
pump must include the following:
a. 2 suction fittings, or
b. 1 suction fitting and a skimmer.
5. If the suction system for the 2-speed pump or for the circ
pump includes a filter, it is desirable that the filter incorporate a by-pass around the filter cartridge that opens
when the cartridge gets dirty. (Spring tension holding the
by-pass valve closed must be overcome by the vacuum
of the pump.) This by-pass should be capable of flowing
a minimum of 20 GPM during the low speed operation of
the 2-speed pump or during circ pump operation with the
cartridge 100% blocked. The inclusion of a suction fitting
appropriately plumbed into the suction circuit in conjunction with a vacuum filter may also meet this requirement.
6. The pressure system for the 2-speed pump or for the circ
pump must be dedicated. There must not be any other
pumps connected to this pressure system.
7. The pressure system for the 2-speed pump or for the circ
pump must discharge water freely into the spa.
8. If the pressure system for the 2-speed pump includes
a diverter valve, or a diverter jet, there must not be an
“off” position that would stop water flow from the pump
or any other position that would throttle or reduce water
flow from the pump.
9. If the pressure system for the 2-speed pump includes
flow adjustable jets that can be 100% closed, at least 2
non-adjustable jets must be included in each possible
inlet circuit so that a minimum of 20 GPM can flow
during low pump operation with all the jets closed. Any
other means of by-passing flow around the closed jets is
acceptable as long as the by-pass means is down stream
from the heater and allows a minimum of 20 GPM to
flow through the heater during low speed operation.
10. If the pressure system for the 2-speed pump includes
flow adjustable jets that do not close 100%, at least 20
76
11.
12.
13.
14.
15.
16.
17.
18.
GPM must flow during low speed operation through each
possible inlet circuit with all the jets closed.
If the pressure system for a 2-speed pump or for a circ pump
includes a filter, the filter must be equipped with a by-pass
around the cartridge that opens when the cartridge gets
dirty. (Spring tension holding the by-pass valve closed must
be overcome by the pressure of the pump.) This by-pass
must be capable of flowing a minimum of 20 GPM during
low pump operation with the cartridge 100% blocked.
If the pressure system for a 2-speed pump or for a circ pump
includes branch circulation lines such as circuits intended
to operate ozone injection systems, these branch circulation
lines must be connected downstream from the heater.
Avoid inter-connection of the plumbing circuits for the
2-speed pump or for the circ pump with other pumps in the
spa plumbing system for the purpose of freeze protection.
The Colossus control system will provide freeze protection.
There is also provision for remote sensing freeze protection
if required.
Position inlets and jets in the spa so that they do not direct
water flow towards suction fittings or skimmers. This will
avoid a “thermal short circuit” and prevent excessive heater
and pump cycling.
If service valves are a part of the circulation system for the
2-speed pump or for the circ pump, be sure to use valves
that incorporate a means of “locking” in the open position.
If the 2-speed pump or the circ pump is replaced in the field
by service personnel, the replacement used must equal or
exceed the hydraulic specifications of the original pump.
To assure adequate performance, the spa plumbing must be
1-1⁄2” minimum. The use of 2” is highly recommended. Either
schedule 40 or flexible PVC pipe is acceptable.
It is recommended that shut-off valves be installed in the
suction and discharge lines.
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Glossary
CIRC PUMP (OR CIRCULATION PUMP)
Low horse power pump designated especially for maintenance
of filtration and heating. It often runs all day.
CLEAN-UP (OR PURGE) CYCLE
An action designed to circulate water to maintain sanitary conditions. Pumps or blowers purge standing water to prevent the
water from becoming stagnant.
FILTRATION CYCLE
purpose of Priming Mode is to allow the user to run each pump
and manually verify that the pumps are primed (air is purged)
and water is flowing. This typically requires observing the output
of each pump separately, and is generally not possible in normal
operation. Priming Mode lasts 4 minutes, but you can exit it
earlier by pressing any Temp button. The heater is not allowed to
run during Priming Mode. NOTE: If your spa has a Circ Pump, it
will turn on with Jets 1 in Priming Mode. The Circ Pump will run
by itself when Priming Mode is exited.
Period of time designated to filter the system. Oftentimes there
are two filter cycles, 12 hours apart, and designated as F1 and F2.
FREEZE PROTECTION
A safety feature detecting water or air temperature approaching
freezing. Once a set low temperature is reached, an action is
often initiated automatically. Oftentimes pumps will start to keep
water circulating in all plumbing and the heater may operate.
GFCI
A device intended to protect people in the event of an electrical
malfunction. Spa owners should know how to test the GFCI as
routine maintenance.
PREFERENCES
Programmed events according to personal preferences.
SSID
Software Self Identification (or, System Panel ID)
PROGRAMMING
Setting an order and time for planned events, such as filter
times, clean-up cycle, etc.
PRIMING MODE
Act of water flow through the plumbing to purge air from the
spa system. Normally, priming mode can be bypassed. The priming mode is necessary only if the spa is refilled and if there’s the
possibility of air being in the system.
WHAT PRIMING MODE DOES:
Each time the spa is powered up, it will enter Priming Mode. The
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
77
Index
Symbols
1, DIP Switch 44
1, Switch 45
6AWG copper conductors 20
6-pin connector J40 74
30 - 35 in lbs. torque 52
30A pump fuses 38
120V Amp Draw 23, 42
120V Draw 23
120V Watts 23
230V Amp Draw 23
230V Watts 23
240V Amp Draw 23, 42
240V Draw 23
240V Watts 23
30344 sensor wire 7
42012, Document No. 75
42013, Document No. 75
50211, Document No. 75
50212, Document No. 75
---˚F ---˚C 62
°F or °C is replaced by °T 44
°T 46
°T, °F or °C is replaced by 44
A
A / B (A/B Sensor Temperatures) 68
A/B Sensor 44
A/B Sensor Temperatures 44
A/B Temps 60
Acceptable Heater Amperage Draw
Ranges 23
Acceptable Heater Ohm (1) Ranges 23,
34
Acceptable Ranges for Testing 23
Access, Test Menu 44
access to the power board 41
address, Assigning a new 75
Address, Dolphin 75
Addressing your Dolphin 75
Address, Spa 75
Adequate drainage 2
Always test continuity of a fuse 19
78
ammeter, amperage draw with an 19
AMP cord 43
amperage at the red pump wire 19
amperage draw limits 19
Amperage Draw Ranges 23
amperage draw with an ammeter 19
Amperage Heater Test BP500 42
Amperage Heater Test BP2000 42
appliance, continuous duty 3
arrow, right 62
A, Sensor 44, 60
Assigning a new address 75
asterisk, message with an 55
Auxiliary freeze sensor 56
A vs B or T vs H 48
B
background colors 63
ball valves 52
black blower wire 19
Blockage*, Pump Suction 68
blower problem 19
board, access to the power 41
Board, Compatibility on Dual 51
board, expander 38, 50
Board, Expander 24
board, isolate the logic 41
board, Logic 41
Board, Logic 41
board, newer revision 51
board problem 49
board, reinstalling the 51
board, Torque main 51
BP500, Amperage Heater Test 42
BP500, Sensor Location 41
BP2000, Amperage Heater Test 42
BP2000 board without wires 51
BP2000/BP2100, Heater Connector on 52
BP, TP panels work with all 8
breaker, GFCI 61
B, Sensor 44, 60
button, test 61
C
Calls, Service 7
Canadian Electric Code 3
Cause 22
changes, wiring 44
Change the setup 44
Checklist, Voltage 23
Check Under Peak Loads 16
Circ Pump 77
Circuit, Class A Ground Fault 20
circulation pump 77
Circulation Pump Modes 56
Class A GFCI 2
Class A Ground Fault Circuit 20
cleanup cycle 57
Clean-up (or purge) Cycle 77
Code, Canadian Electric 3
Code, Fault Message 70
Code, Message 70
Code, National Electrical 3
Codes and Compliance 3
Code, Set Up 75
Codes, Fault Log Message 70
Codes, M0[XX] numbers are Message 55
Codes, Message 67
codes, set up 75
code, system 21
colder climates 56
colors, background 63
Compatibility on Dual Board 51
Compliance, Codes and 3
condition, error 59
conditions, freezing 61
conductors, 6AWG copper 20
configuration, DIP switch for proper 50
Configuration Settings 44
Configuration Signature 67
configurations, setup 44
configuration, view the 44
connector, receiver’s 74
connector, sensor 41
connector, terminal 52
Connector, Unlock 52
continue monitoring temperature 59
continuous duty appliance 3
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Index
continuously, spa to filter 21
Control System 74
cord, AMP 43
cord, GFCI power 19
Current Setup 44
cycle, cleanup 57
Cycle, Clean-up (or purge) 77
Cycle, Filtration 77
cycle, second filter 56
cycles, filtration 56
D
DEMO (Demo Mode) 67
Demo Mode 44, 60
Depress sensor tab 41
Depress tab 48
different, LCD readouts may look slightly
67, 68
DIP Switch 1 44
DIP switch for proper configuration 50
DIP switch positions of S1 67
disconnect, electrical 19
disconnect, local 19
Disconnect, Local 19
Document No. 42012 75
Document No. 42013 75
Document No. 50211 75
Document No. 50212 75
Dolphin 74
Dolphin Address 75
Dolphin, Addressing your 75
Dolphin II 74
Dolphin III manual 75
Dolphin receiver 74
DolphinTM Remote 74
Do not pry up 50
do not pull on the wires 50
down, spa is shut 68
dr 68
drainage, Adequate 2
Drain Mode 60
Draw, 120V 23
Draw, 120V Amp 23, 42
Draw, 230V Amp 23
Draw, 240V 23
42211 C
Draw, 240V Amp 23, 42
Draw, Heater Amperage 42
Draw, Test the Amperage 19
Dry, Heater May be 68
duration 56
freezing conditions 61
fuse, Always test continuity of a 19
fuses, 30A pump 38
fuses, slow-blow 19
fuse, system power input 18
E
G
electrical disconnect 19
Electrical Protection 19
End User Warning 2
error condition 59
event, fault 70
exit Priming Mode 45
exit Test Mode 47
expander board 38, 50
Expander Board 24
generator, ozone 56, 57
GFCI 19, 77
GFCI breaker 61
GFCI, Class A 2
GFCI power cord 19
GFCI should be reset immediately 61
GFCI should trip within several seconds 61
GFCI Test Feature 61
GFCI Trip Test 61
Glossary 77
GPM 76
ground fault 61
guard, VG Compliant suction 2
Guidelines, Motor Amperage 23
Guidelines, Spa 76
F
failed, sensor circuit has 62
FALT LOG (Fault Log) 68
fault event 70
fault, ground 61
Fault Log 44, 58, 60, 70
Fault Log information 44
Fault Log Menu 70
Fault Log Message Codes 70
Fault Message Code 70
Fault, Sensor A 62
Fault, Sensor B 62
fault, Sensor Balance is Poor 69
faults, last 24 44
faults, Stray 48
Feature, GFCI Test 61
Filter Cycle 2 57
filtration 56
Filtration Cycle 77
filtration cycles 56
Filtration, Main 57
Filtration, Optional 57
flash, Heat LED will 20
Flashing Heat LED 20
flow problem 21
freeze protection 56, 59
Freeze Protection 68, 77
H
H, A vs B or T vs 48
Heater Amperage Draw 42
Heater Connector on BP2000/BP2100 52
Heater Flow is Reduced 68
heater kit with wires 52
Heater Matrix 23
Heater May be Dry 68
heater, no voltage to the 20
Heater Related Messages 59
heater, removing a 52
heater sensor wires 52
Heater terminal nut installation 52
Heater Type 23
Heater Voltage 67
Heater Wattage as Configured in Software
67
heater wires 52
Heat LED will flash 20
Heat Waiting 20
HFL 21, 68
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
79
Index
H _ (Heater Type) 67
High-Limit Sensor 23
High Temperature Range 54
Hot, HTR is too 68
Hot, Water is too 68
how to 61
HTR is too Hot 68
I
Identification, Software Self 77
ID, Software 59
ID, System Panel 77
immediately, GFCI should be reset 61
Information 58
information, Fault Log 44
Information, System 59
installation, Heater terminal nut 52
instructions, power connection 2
Interface, User 8
Invert 58
IR Receiver 74
isolate the logic board 41
Issues, System Related 16
L
last 24 faults 44
latest version 8
Law, Ohm’s 32
LCD readouts may look slightly different
67, 68
LED, Flashing Heat 20
limits, amperage draw 19
Limit, Temp 44
Link the panel 45
Loads, Check Under Peak 16
Loads, Two Types of Peak 16
local disconnect 19
Local Disconnect 19
Lock 58
Locking the Panel 58
Locking the Settings 58
Lock, Settings 58
Log, Fault 44, 58, 60, 70
Logic board 41
80
Logic Board 41
Low Temperature Range 54
M
M0[XX] numbers are Message Codes 55
M015 62, 69
M016 59, 68
M017 59, 68
M019 68
M019* 55
M020 62, 69
M021 62, 69
M022 62, 69
M026 62, 69
M027 59
M028 59, 68
M029 62, 68
M030 59, 68
M031 69
M031, Sensor A: 62
M032 69
M032, Sensor B: 62
M033 68
M034 62, 69
M035 62, 69
M036 62, 69
M037* 57
Main Filtration 57
manual, Dolphin III 75
Matrix, Heater 23
Menu, Fault Log 70
Menus, Simplified 8, 44, 72
Menus, Standard 8, 44
Menu, System Information 67
Menu, Test 70
Menu, TEST 44
Menu, Utilities 60
Message Code 70
Message Codes 67
Messages 54
messages can be reset from the panel 62
Messages, Heater Related 59
Messages, Scrolling TP400/TP600 68
Messages that can be reset 62
messages will scroll 68
message with an asterisk 55
Miswiring of the spa is the most common
reason 19
Mode, Demo 44, 60
Mode, Drain 60
Mode, exit Priming 45
Mode, exit Test 47
models, TP panels work with both Revolution 8
Mode, Priming 68, 77
Mode, Ready 56
mode, test 20, 21
Mode, Test 44, 45, 46, 62
Mode., Test 21
MODL (System Model) 67
Motor Amperage Guidelines 23
N
National Electrical Code 3
NEC (National Electrical Code) 2
newer revision board 51
no voltage to the heater 20
nuisance spike 19
Number, Setup 45
O
OHH 68
OHH. 21
Ohms 23
Ohm’s Law 32
Ohm Table 23
OHS 68
ON, Switch 1 44
Operation, Restricting 58
Optional Filtration 57
Outs, Time 44
out, Water may splash 52
overlapping filter times 21
ozone generator 56, 57
P
panel, Link the 45
panel, messages can be reset from the 62
panel, software in the topside control 67
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Index
panel stops operating 44
panels, TP600/TP400 44
panels, TP900/TP800 44
Panel, Unlocking the 58
Parts, Recommended 7
PASS should appear 61
period, time-out 56
Pins, Sensor 49
polling 56
power connection instructions 2
Preferences 77
pressure, Water under 52
prevent unwanted use 58
Priming Mode 68, 77
Problem 22
problem, blower 19
problem, board 49
problem, flow 21
problem, pump 19
problem, sensor 49
problem, suction 68
programmable circ pump 56
Programming 77
Programming Reference 8
properly reset the GFCI 61
Protection, Electrical 19
protection, freeze 56, 59
Protection, Freeze 68, 77
Pump, Circ 77
pump, circulation 77
pump problem 19
pump, programmable circ 56
Pumps, Troubleshooting 22
Pump Suction Blockage* 68
R
Range, High Temperature 54
Range, Low Temperature 54
Ranges, Acceptable Heater Amperage
Draw 23
Ranges, Acceptable Heater Ohm (1) 23,
34
Ranges, Amperage Draw 23
42211 C
Ready Mode 56
reason, Miswiring of the spa is the most
common 19
receiver, Dolphin 74
Receiver, IR 74
Receiver, RF 74
receiver’s connector 74
Recommended Parts 7
red TB1 terminal 18
Reduced, Heater Flow is 68
Ref. Card 40947 8
Reference, Programming 8
reinstalling the board 51
release tab 50
REMOTE 74
Remote, DolphinTM 74
removing a heater 52
Replacment Sensor 49
Required, Service Tools 7
reset, Messages that can be 62
reset the GFCI 61
Resistance, Troubleshooting 34, 35
Restricting Operation 58
RF Receiver 74
right arrow 62
RUN PMPS PURG AIR ---- 68
S
S1 44
S1, DIP switch positions of 67
Safety Trip 68
Screen, Spa 56
Scrolling TP400/TP600 Messages 68
scroll, messages will 68
second filter cycle 56
Sensor A 44, 60
Sensor, A/B 44
Sensor A Fault 62
Sensor A: M031 62
sensor, Auxiliary freeze 56
Sensor B 44, 60
Sensor Balance is Poor fault 69
Sensor B Fault 62
Sensor B: M032 62
sensor circuit has failed 62
sensor connector 41
Sensor, High-Limit 23
Sensor Location BP500 41
Sensor Pins 49
sensor problem 49
Sensor, Replacment 49
sensor set 21, 49
sensor temperatures 21
Sensor Wires 7
Service Calls 7
Service Tools Required 7
SETP (Current Setup) 67
set, sensor 21, 49
Set Temperature 58
Settings, Configuration 44
Settings Lock 58
setup, Change the 44
Set Up Code 75
set up codes 75
setup configurations 44
Setup, Current 44
Setup Number 45
Setups, Software 44
shimmer 20
SIG 67
Signature, Configuration 67
Simplified Menus 8, 44, 72
slice valves 52
slow-blow fuses 19
software compatability 8
Software ID 59
software in the topside control panel 67
Software Self Identification 77
Software Setups 44
software, test 62, 69
Spa Address 75
Spa Guidelines 76
spa is shut down 68
Spa Screen 56
spa to filter continuously 21
spike, nuisance 19
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
81
Index
SSID 59, 77
SSID (Software ID) 67
Standard Menus 8, 44
Stray faults 48
suction problem 68
SW _ (Dip Switch Settings) 67
Switch 1 45
Switch 1 ON 44
system code 21
System, Control 74
System Information 59
System Information Menu 67
System Panel ID 77
system power input fuse 18
System Related Issues 16
T
tab, Depress 48
tab, Depress sensor 41
Table, Ohm 23
tab, release 50
TB1 17
Tech Sheets 8
temperature, continue monitoring 59
temperature display will alternate 60
Temperatures, A/B Sensor 44
Temperature, Set 58
temperatures, sensor 21
Temp Limit 44
Temps, A/B 60
terminal connector 52
terminal, red TB1 18
test button 61
Test, GFCI Trip 61
Testing, Acceptable Ranges for 23
Test Menu 70
TEST Menu 44
Test Menu Access 44
test mode 20, 21
Test Mode 44, 45, 46, 62
Test Mode. 21
test software 62, 69
Test the Amperage Draw 19
82
Test the ground fault circuit interrupter
2
time-out period 56
Time Outs 44
times, overlapping filter 21
torque, 30 - 35 in lbs. 52
Torque main board 51
TP600/TP400 panels 44
TP900/TP800 panels 44
TP panels work with all BP 8
TP panels work with both Revolution
models 8
Trip, Safety 68
Troubleshooting Pumps 22
Troubleshooting Resistance 34, 35
Two Types of Peak Loads 16
Type, Heater 23
Watts, 230V 23
Watts, 240V 23
wire, 30344 sensor 7
wire, amperage at the red pump 19
wire, black blower 19
wires, BP2000 board without 51
wires, do not pull on the 50
wires, heater 52
wires, heater kit with 52
wires, heater sensor 52
Wires, Sensor 7
wiring changes 44
U
Unlock Connector 52
Unlocking the Panel 58
User Guide 40940 8
User Guide 40985 8
User Guide 42185 8
User Interface 8
Utilities 58
Utilities Menu 60
V
valves, ball 52
valves, slice 52
version, latest 8
VG Compliant suction guard 2
view the configuration 44
Voltage Checklist 23
W
Waiting, Heat 20
Warning, End User 2
Water is too Hot 68
Water may splash out 52
Water under pressure 52
Watts, 120V 23
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Index of Paragraph Topics
0.3A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
All TP Panels have “Molex” Type Connectors . . . . . . . . . . 9
0.3A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
All voltages specified as 120 V or 240 V, may show an acceptable
variance of +/- 10%. . . . . . . . . . . . . . . . . . . . . . . 23
0.15A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
0.15A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . 33
0.125A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . 7
0.125A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . 33
3A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3A Slo-Blo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A message with an asterisk [*] can be reset from the topside
panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Amperage Draw Ranges . . . . . . . . . . . . . . . . . . . . 23
Amperage Heater Test BP500. . . . . . . . . . . . . . . . . . 42
Amperage Heater Test BP2000G1 . . . . . . . . . . . . . . . 42
A Pump Appears to be Stuck ON – M034 . . . . . . . . . . . 69
10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A Pump Appears to have been Stuck ON when spa was last
powered – M035 . . . . . . . . . . . . . . . . . . . . . . . . 69
30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A pump may be stuck on – M034 . . . . . . . . . . . . . . . . 62
30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A Reset Message May Appear with other Messages. . . . . . 69
120V Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assigning a new address to the Dolphin . . . . . . . . . . . . 75
240V Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
A Standard Main Menu (Doc No. 40941I) . . . . . . . . . . . 73
20600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Avoid damaging the post. Use an end wrench on the lower nut to
reinforce the post when removing the upper nut. . . . . . . . 53
20600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
21581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
26281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
26281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
26397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
26397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
30122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
30136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A / B (A/B Sensor Temperatures) . . . . . . . . . . . . . . . . 68
A/B Temps . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
A/B Temps (A/B Sensor Temperatures) . . . . . . . . . . . . 44
Acceptable Heater Amperage Draw Ranges . . . . . . . . . . 23
Acceptable Heater Amperage Draw Ranges . . . . . . . . . . 42
Acceptable Heater Ohm (ȍ) Ranges . . . . . . . . . . . . . . 23
Acceptable Heater Ohm (ȍ) Ranges . . . . . . . . . . . . . . 34
A common programming mistake is overlapping filter times that
may cause the spa to filter continuously. . . . . . . . . . . . . 21
A fuse with the meter reading “bad” . . . . . . . . . . . . . 33
A fuse with the meter reading “good” . . . . . . . . . . . . . 33
42211 C
Be sure that both clamps are not making contact with anything
below the insulating material on the terminal (arrows). . . . . 40
Be sure to set the Time-of-Day . . . . . . . . . . . . . . . . . 56
BE SURE TO TURN THE POWER OFF BEFORE REPLACING ANY
COMPONENT, ESPECIALLY A CIRCUIT BOARD. . . . . . . . . 50
BP500 BP2000G1 . . . . . . . . . . . . . . . . . . . . . . . . . 1
BP2000 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 7
BP2100 board screw locations . . . . . . . . . . . . . . . . . 51
BP2100 board without wires . . . . . . . . . . . . . . . . . . 51
Brown Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BWG Part Number. . . . . . . . . . . . . . . . . . . . . . . . . 7
BWG Part Number. . . . . . . . . . . . . . . . . . . . . . . . 33
CE Product: . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
changing menus through configurations . . . . . . . . . . . . 72
Check for Loose Connections or Damaged Wires . . . . . . . 17
Checking the System Power Input Fuse. . . . . . . . . . . . . 18
Circ Pump (or circulation pump) . . . . . . . . . . . . . . . . 77
Circulation Pump Modes . . . . . . . . . . . . . . . . . . . . 56
Cleanup
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cleanup Cycle (optional) . . . . . . . . . . . . . . . . . . . . 57
Clean-up (or purge) Cycle . . . . . . . . . . . . . . . . . . . . 77
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
83
Index of Paragraph Topics (cont.)
Color of Background . . . . . . . . . . . . . . . . . . . . . . 63
Fault Log: tp800, tp900 . . . . . . . . . . . . . . . . . . . . . 60
Communications error . . . . . . . . . . . . . . . . . . . . . . 62
---˚F ---˚C . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Compatibility on Dual Board Control Systems . . . . . . . . . 51
Filter Cycle 2 - Optional Filtration . . . . . . . . . . . . . . . . 57
Configuration Error - Spa will not Start Up . . . . . . . . . . . 62
Filtration and Ozone . . . . . . . . . . . . . . . . . . . . . . . 56
Configuration Error - Spa will not Start Up . . . . . . . . . . . 69
Filtration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 77
Configuration Signature . . . . . . . . . . . . . . . . . . . . 59
Flashing Heat LED on TP600 ("Heat Waiting") . . . . . . . . . 20
Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Flow-Related Checks . . . . . . . . . . . . . . . . . . . . . . 59
Current Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Flow-Related Checks . . . . . . . . . . . . . . . . . . . . . . 69
DEMO (Demo Mode) . . . . . . . . . . . . . . . . . . . . . . 44
Forcing the GFCI Trip Test . . . . . . . . . . . . . . . . . . . . 61
DEMO (Demo Mode) . . . . . . . . . . . . . . . . . . . . . . 67
°F or °C is replaced by °T . . . . . . . . . . . . . . . . . . . . 62
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
°F or °C is replaced by °T . . . . . . . . . . . . . . . . . . . . 69
Depress sensor tab when removing . . . . . . . . . . . . . . 41
Freeze condition . . . . . . . . . . . . . . . . . . . . . . . . . 21
Depress tab when removing . . . . . . . . . . . . . . . . . . 48
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . 56
Device
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . 59
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dolphin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fuses Used on BP spa Systems . . . . . . . . . . . . . . . . . . 7
Dolphin II and Dolphin III (Applies to RF Dolphin only) . . . . 63
Fuses Used on BP spa Systems . . . . . . . . . . . . . . . . . 33
Dolphin III (50211) . . . . . . . . . . . . . . . . . . . . . . . 75
GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Dolphin III CE (50212) . . . . . . . . . . . . . . . . . . . . . . 75
GFCI Failure - System Could Not Test/Trip the GFCI – M036 . 69
Dolphin Manual . . . . . . . . . . . . . . . . . . . . . . . . 75
GFCI Test (Feature not available on CE rated systems.) . . . . 60
Dolphin Receiver . . . . . . . . . . . . . . . . . . . . . . . . 74
Ground-Fault Circuit Interrupter/Circuit Breaker (G.F.C.I.) . . . 11
Dolphin Remotes . . . . . . . . . . . . . . . . . . . . . . . . 75
Ground in System Enclosure . . . . . . . . . . . . . . . . . . 10
Do not measure across heater terminals . . . . . . . . . . . . 39
Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7
DO NOT REMOVE AND REPLACE THE CIRCUIT BOARD UNLESS
THE FAULT HAS POSITIVELY BEEN DETERMINED TO BE THE
CIRCUIT BOARD. . . . . . . . . . . . . . . . . . . . . . . . . 50
Heater Connector on BP2000/BP2100 Series . . . . . . . . . . 52
Drain Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Heater Flow is Reduced (HFL) – M016 . . . . . . . . . . . . . 68
Electrical Protection . . . . . . . . . . . . . . . . . . . . . . . 19
Heater Flow is Reduced (LF)* – M017 . . . . . . . . . . . . . 68
Exiting Priming Mode . . . . . . . . . . . . . . . . . . . . . . 55
Heater Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exiting Priming Mode . . . . . . . . . . . . . . . . . . . . . . 66
Heater May be Dry (dr)* – M028 . . . . . . . . . . . . . . . . 68
F6 and F8 are on the main board. F1 is located on the expander
board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Heater Related Messages . . . . . . . . . . . . . . . . . . . 59
F6 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F6 to TB1 Red . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FALT LOG (Fault Log) . . . . . . . . . . . . . . . . . . . . . . 44
FALT LOG (Fault Log) . . . . . . . . . . . . . . . . . . . . . . 68
Fault Log Message Codes: TP400, TP600 . . . . . . . . . . . . 70
84
Heater Element Specifications Are Shown on the Heater Tube
Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heater Start Up Information . . . . . . . . . . . . . . . . . . 20
Heater Type . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Heater Voltage (Feature not used on CE rated systems.) . . . 59
Heater Voltage (Feature not used on CE rated systems) . . . . 67
Heater Wattage as Configured in Software (CE Systems Only) 59
Heater Wattage as Configured in Software (CE Systems Only) 67
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Index of Paragraph Topics (cont.)
Heat LED in Heat Waiting Mode, TP600 . . . . . . . . . . . . 20
Note: These are typical settings only. Voltages may be different
depending on the configuration that the system is set to. See the
system's Tech Sheet for complete information. . . . . . . . . 43
H _ (Heater Type) . . . . . . . . . . . . . . . . . . . . . . . . 67
Observe safety at all times . . . . . . . . . . . . . . . . . . . 36
Hold Mode - M037* . . . . . . . . . . . . . . . . . . . . . . . 57
Ohm’s Law. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hot fault – M035 . . . . . . . . . . . . . . . . . . . . . . . . 62
Once the power input fuse has been changed . . . . . . . . . 18
How the Dolphin Works . . . . . . . . . . . . . . . . . . . . . 74
On Every System, an Identification Label Is Placed on Top of the
Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heater Wires on a BP500/BP600 Series system are connected to
the lower Power Board. . . . . . . . . . . . . . . . . . . . . 53
HTR is too Hot (OHH)* M030 . . . . . . . . . . . . . . . . . . 68
If Correct Wiring is Verified . . . . . . . . . . . . . . . . . . . 11
If the problem stays with the same sensor (according to topside
messages) it's a board problem; if the problem moves to the other
sensor it's a sensor problem. . . . . . . . . . . . . . . . . . 49
On Every System, a Wiring Diagram Is Placed Inside the Door . 9
On Expander Board . . . . . . . . . . . . . . . . . . . . . . . 24
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Panel Version
. . . . . . . . . . . . . . . . . . . . . . . . . 59
INFO (System Information sub-menu) . . . . . . . . . . . . . . 67
PANL (Panel Version) . . . . . . . . . . . . . . . . . . . . . . 67
Installing a System Circuit Board . . . . . . . . . . . . . . . . 51
Place clamp around one heater wire, and then the other wire. 42
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Place the meter probes on the heater terminals. . . . . . . . 34
Locking nuts are in the same location on other BP models . . 53
Possible freezing condition . . . . . . . . . . . . . . . . . . . 62
Logic Jumper, No. 20618 . . . . . . . . . . . . . . . . . . . . . 7
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
M0[XX] numbers are Message Codes. . . . . . . . . . . . . . 55
Preliminary Panel Check. . . . . . . . . . . . . . . . . . . . . 20
M-7 Replacement Sensor . . . . . . . . . . . . . . . . . . . . 49
Preparation and Filling . . . . . . . . . . . . . . . . . . . . . 55
Main Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . 57
Preparation and Filling . . . . . . . . . . . . . . . . . . . . . 66
Measure resistance from a heater post to the heater housing 35
Pre-Production Software . . . . . . . . . . . . . . . . . . . . 69
Memory Failure - Checksum Error* – M022 . . . . . . . . . . 69
Press-and-Hold . . . . . . . . . . . . . . . . . . . . . . . . . 54
Memory Failure - Clock Error* – M020 . . . . . . . . . . . . 69
Priming Mode – . . . . . . . . . . . . . . . . . . . . . . . . 55
Memory Warning - Persistent Memory Reset* – M021 . . . . 69
Priming Mode – M019 . . . . . . . . . . . . . . . . . . . . . 68
Message Codes . . . . . . . . . . . . . . . . . . . . . . . . . 21
Priming Mode – M019* . . . . . . . . . . . . . . . . . . . . . 66
Message Codes . . . . . . . . . . . . . . . . . . . . . . . . . 67
Priming the Pumps . . . . . . . . . . . . . . . . . . . . . . . 55
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Priming the Pumps . . . . . . . . . . . . . . . . . . . . . . . 66
MODL (System Model) . . . . . . . . . . . . . . . . . . . . . 67
Program memory failure* – M022 . . . . . . . . . . . . . . . 62
Most messages and alerts will appear at the bottom of the
normally used screens. . . . . . . . . . . . . . . . . . . . . . 62
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Most Probable Overheating Causes, Inspect These First . . . . 21
Pull the connector straight out. . . . . . . . . . . . . . . . . . 35
Motor Amperage Guidelines . . . . . . . . . . . . . . . . . . 23
Pump 1 AMP cord . . . . . . . . . . . . . . . . . . . . . . . . 43
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
No Communications . . . . . . . . . . . . . . . . . . . . . . . 69
Purge Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Note: Be careful when removing a heater assembly from a spa
plumbing system. Water may splash out under pressure. See
next page for more illustrations. . . . . . . . . . . . . . . 52
Recommended Parts to have For Service Calls . . . . . . . . . . 7
42211 C
Pull the connector straight out. . . . . . . . . . . . . . . . . . 34
Red to Black Wires = 240V . . . . . . . . . . . . . . . . . . . 37
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
85
Index of Paragraph Topics (cont.)
Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remove both nuts that secure the element in place. . . . . . 53
TB1 Marking on Board . . . . . . . . . . . . . . . . . . . . . 18
Removing a System Circuit Board. . . . . . . . . . . . . . . . 50
Temp Display . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removing BP Expander Board, an Alternate Way . . . . . . . 50
Temperature & High-Limit Sensor Ohm Table . . . . . . . . . 23
Restricting Operation (Locking the Panel). . . . . . . . . . . . 58
Temp Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Safety and Electrical Systems . . . . . . . . . . . . . . . . . 20
Safety Trip - Pump Suction Blockage* – M033 . . . . . . . . . 68
Terminal Block 1 & F5 Fuse on a BP500 Power Board, 240V Setup
18
Saving Settings . . . . . . . . . . . . . . . . . . . . . . . . . 56
Terminal Block 1 & F6 Fuse on a BP2000 Board . . . . . . . . 18
Saving Your Dolphin Address . . . . . . . . . . . . . . . . . . 75
Testing a Fuse: Check continuity with the fuse removed . . . . 33
Scrolling TP400/TP600 Messages . . . . . . . . . . . . . . . 68
Testing low speed and High Speed at the AMP Connector . . 43
Sensor A Fault, Sensor B Fault – Sensor A: M031, Sensor B: M032
62
Testing Sensor Pins . . . . . . . . . . . . . . . . . . . . . . . 49
Sensor Balance is Poor – M015. . . . . . . . . . . . . . . . . 69
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sensor Balance is Poor* – M026 . . . . . . . . . . . . . . . . 69
Test software installed . . . . . . . . . . . . . . . . . . . . . 62
Sensor Failure – Sensor A: M031, Sensor B: M032 . . . . . . 69
Test the Amperage Draw . . . . . . . . . . . . . . . . . . . . 19
Sensor Location BP500, on Logic Board . . . . . . . . . . . . 41
The clock has failed* – M020 . . . . . . . . . . . . . . . . . 62
Sensor Pins: At times, a protective coating may on accident coat
the sensor pins during manufacturing. Those pins may need to be
scraped and the sensors plugged back in. . . . . . . . . . . . 49
The Control System is in Test Mode if 102˚T appears. (In this case
°F or °C is replaced by °T.) . . . . . . . . . . . . . . . . . . . 44
Sensors are out of sync -- Call for service* – M026 . . . . . . 62
The Fault Log . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Sensors are out of sync – M015 . . . . . . . . . . . . . . . . 62
SETP (Current Setup) . . . . . . . . . . . . . . . . . . . . . . 67
The following ranges represent general parameters for many
different motors and applications. Check the device label or with
the spa manufacturer to get accurate amperage draws. . . . 23
Side View: Depress Tab to Unlock Connector . . . . . . . . . 52
The GFCI test failed (System Could Not Test the GFCI) – M036 62
SIG (Configuration Signature) . . . . . . . . . . . . . . . . . . 67
The Ground Fault Circuit Interrupter (GFCI) . . . . . . . . . . . 61
Simplified Menus . . . . . . . . . . . . . . . . . . . . . . . . 72
The heater is dry* – M027 . . . . . . . . . . . . . . . . . . . 59
Software Setups . . . . . . . . . . . . . . . . . . . . . . . . 44
The heater is too hot* – M030 . . . . . . . . . . . . . . . . . 59
Software Setups (BP2500) . . . . . . . . . . . . . . . . . . . 47
The heater may be dry* – M028 . . . . . . . . . . . . . . . . 59
Some Troubleshooting Scenarios . . . . . . . . . . . . . . . . 21
The Logic Board must be removed to acess and remove the heater
wires, shown in red. . . . . . . . . . . . . . . . . . . . . . . 53
Service Tools Required . . . . . . . . . . . . . . . . . . . . . . 7
Spa Control Systems . . . . . . . . . . . . . . . . . . . . . . . 1
Spa Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SSID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Test Menu Access (S1, Switch 1 ON) . . . . . . . . . . . . . . 44
The DolphinTM Remote . . . . . . . . . . . . . . . . . . . . . 74
The preferred way to check for fuse continuity is with the fuses
removed from the circuit. . . . . . . . . . . . . . . . . . . . . 33
SSID (Software ID) . . . . . . . . . . . . . . . . . . . . . . . 67
There are three 30A pump fuses in the BP2000G1 spa control
system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SW _ (Dip Switch Settings) . . . . . . . . . . . . . . . . . . . 67
These readings should be taken under peak load conditions. . 19
System Box Wire Gauge Check . . . . . . . . . . . . . . . . . 17
System Information . . . . . . . . . . . . . . . . . . . . . . . 59
The settings have been reset (Persistent Memory Error)* – M021
62
System Model . . . . . . . . . . . . . . . . . . . . . . . . . 59
The Utilities Menu contains the following: . . . . . . . . . . . 63
The water flow has failed* – M017 . . . . . . . . . . . . . . 59
86
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
6/22/13
Index of Paragraph Topics (cont.)
The water flow is low – M016 . . . . . . . . . . . . . . . . . 59
Wiring Check Precautions . . . . . . . . . . . . . . . . . . . . 17
The water is too hot – M029 . . . . . . . . . . . . . . . . . . 62
With the pump high speed ON, take a voltage reading at the AMP
receptacle on the PCB . . . . . . . . . . . . . . . . . . . . . . 43
This would typically show High speed voltage for Pump one. (240V)
43
This would typically show low speed voltage for Pump one. (240V)
43
With the pump low speed ON, take a voltage reading at the AMP
receptacle on the PCB . . . . . . . . . . . . . . . . . . . . . . 43
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Time Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Tip: If one sensor (A or B) seems to be having problems, swap the
cables of sensor A with sensor B. . . . . . . . . . . . . . . . 49
To Determine the Cause of a Blown Power Input Fuse . . . . . 19
To Disconnect the Heater . . . . . . . . . . . . . . . . . . . . 11
Too Cold - Freeze Protection . . . . . . . . . . . . . . . . . . 68
TP400/TP600 error codes and fault messages are similar to TP800/
TP900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
TP900, TP800, TP600, TP400 . . . . . . . . . . . . . . . . . . . 1
Troubleshooting Heater Posts Resistance to Heater Housing . 35
Troubleshooting heater Resistance . . . . . . . . . . . . . . . 34
Unlocking the Panel . . . . . . . . . . . . . . . . . . . . . . . 58
Used for verifying a proper installation . . . . . . . . . . . . . 61
Verifying Incoming Voltage at the Terminal Block (240V system)
BP2000 shown (BP500 system is similar) . . . . . . . . . . . 37
Verify that there is no heater “leakage” . . . . . . . . . . . . 35
Verify there is NO continuity from the heater post to the ground/
earth. On the resistance scale, the a digital meter should read OL
(indicating infinite resistance). . . . . . . . . . . . . . . . . . 35
Verify there is NO continuity from the heater post to the heater
housing or heater current collector connection. The meter reading
shown is OL, indicating infinite resistance. . . . . . . . . . . 35
Viewing Configuration Settings . . . . . . . . . . . . . . . . . 44
Voltage Checklist . . . . . . . . . . . . . . . . . . . . . . . . 23
Warning: The Owner should test and reset the G.F.C.I. on a regular
basis to verify its function. . . . . . . . . . . . . . . . . . . . 11
Water is too Hot (OHS) – M029. . . . . . . . . . . . . . . . . 68
Water Temperature is Unknown . . . . . . . . . . . . . . . . 62
Water Temperature is Unknown . . . . . . . . . . . . . . . . 68
What Priming Mode does: . . . . . . . . . . . . . . . . . . . 77
White to Black Wires = 120V . . . . . . . . . . . . . . . . . . 37
White to Red Wires = 120V . . . . . . . . . . . . . . . . . . . 37
42211 C
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
87
Tustin Ca. 92780 (714) 384-0384
©2013 Balboa Water Group. All rights reserved.
42211 C June 22, 2013
Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,
6/22/13
88
Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.
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