BWG 50Hz BP Troubleshooting Service Manual
Balboa's BP Troubleshooting & Service Manual
THIS MANUAL COVERS THE FOLLOWING:
SPA CONTROL SYSTEMS
PANELS
BP600
BP2100G1
TP900, TP800,
TP600, TP400
42217B
50 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 BP
Spa Control Systems, including but not limited to, accessories,
parts, or software relating 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.
RCD
It is strongly advised to install an RCD (Residual Current
Device) in the supply power to a spa. Also, an RCD should be
tested periodically. 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.
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.
Note: Follow all local electrical codes upon installation,
diagnosis, or testing of the RCD.
© 2013 Balboa Water Group. All Rights Reserved.
2
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.
5/02/13
Codes and Compliance
BP Diagnostic Service Manual
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.
This manual is for general servicing of BP Control systems,
and troubleshooting typical spa control system problems. For
detailed component settings and wiring configurations, service
technicians should obtain the latest technical manuals (Tech
Sheets) available.
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.
Contact your Balboa Water Group representative or BWG's
technical support for technical materials. Or, visit Balboa Water
Group at: http://www.balboawatergroup.com/
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 installing
into does not have these features, contact a licensed, qualified
electrician. Do not attempt to modify the wiring
yourself.
42217B
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.
5/02/13
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intellectual Property Advisement . . . .
End User Warning . . . . . . . . . . .
RCD . . . . . . . . . . . . . . . . .
Warnings: Danger! Risk of Electric Shock!
Codes and Compliance . . . . . . . . .
BP Diagnostic Service Manual . . . . .
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.2
.2
.2
.2
.3
.3
Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service Tools and Parts Checklist . . . . . . . . . . . . . . . . . . .
TP Panel Overview and User Guides . . . . . . . . . . . . . . . . . .
Product Identification . . . . . . . . . . . . . . . . . . . . . . . .
230 Volt / 50 Hz Residential Wiring Schematic with 2 Pole RCD Breaker Box
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.7
.8
.9
10
General Troubleshooting & Servicing of Spa's Electrical Equipment . . . . . . . . . . . . . . . 12
Basic Control System Troubleshooting . . . . .
Testing a System with Power . . . . . . . . .
230 Volt 50 Hz - Residual Current Devices (RCD’s)
Wiring Checks . . . . . . . . . . . . . . .
Wiring Check for RCD and Service Disconnect .
Troubleshooting Pumps, Problem & Cause . . .
Acceptable Ranges for Testing Equipment . . .
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13
15
17
18
19
20
21
Troubleshooting Using Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ohm’s Law . . . . . . . . . . . . . . . . . . . . . .
Testing a Fuse: Continuity . . . . . . . . . . . . . . .
Troubleshooting Heater Resistance . . . . . . . . . . .
Troubleshooting Heater Posts Resistance to Heater Housing
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22
23
24
25
Troubleshooting with Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Verifying Incoming Voltage at the Terminal Block - BP2100 & BP600 .
Testing Pump Fuses for Damage with Voltage On - BP2100 . . . . .
Testing Heater Voltage - All BP Systems . . . . . . . . . . . . .
A Safer Way to Test Heater Voltages . . . . . . . . . . . . . .
Testing Pump Fuses for Damage with Voltage On - BP600 . . . . .
Testing Heater Amperage . . . . . . . . . . . . . . . . . . .
Testing Low Speed and High Speed at the AMP Pump Connector . .
Testing the Sensor Set . . . . . . . . . . . . . . . . . . . . .
42217B
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27
28
29
30
31
32
33
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.
5
Table of Contents (cont.)
Component Failure and Replacement Testing . . . . . . . . . . . . . . . . . . . . . . . . . 36
Software Setups and Test Mode . . . . . . . . . . . . . . . .
Setup Changes with DIP Switch 1 ON - Using a TP600 or TP400 Panel
Setup Changes with DIP Switch 1 ON - Using a TP900 or TP800 Panel
Removing the Heater Assembly from a BP Spa System . . . . . . .
Remove and Replace a System Circuit Board . . . . . . . . . . .
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36
37
39
40
41
TP800, TP900 Panel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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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43
44
45
46
47
48
52
TP400, TP600 Standard Panel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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. .
TP400, TP600 Simplified and Standard Panel Main Menus
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53
54
55
56
59
60
61
62
Balboa Water Group BP Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Wiring Diagram - BP2100G1, Part Number 56389-01 .
Wiring Diagram - BP21MSSH, Part Number: 56381 .
Wiring Diagram - BP600, Setup 1-16 as Manufactured
Wiring Diagram - BP600, Setup 2-32 as Manufactured
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63
65
67
68
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Optional Balboa DolphinTM Remote. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Spa Guidelines to Keep in Mind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Index of Paragraph Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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.
5/02/13
Equipment Overview
-
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
COMMON FUSES USED ON SPA SYSTEMS
30074
30075
30122
30595
30076
30596
30142
30123
30137
21447
30136
Fuse 1 Amp Fast Blow Glass
Fuse 5 Amp Fast Blow Glass
Fuse 10a Blower
Fuse 10a Power Input
Fuse 15 Amp Fast Blow Ceramic
Fuse 15a Power Input
Fuse 20a Power Input
Fuse 20a Pump
Fuse 25a Power Input
Fuse 25a Power Input High Surge
Fuse 30a Power Input
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).
BP2100 Circuit Board
Heater Assembly
42217B
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: BP2000 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
J TS
S
AUX
X
LIGHT
LIGH
HEAT
HEAT
AT
TP400W
TP400T
UÊ User Guide 40940
User Interface and Programming Reference – Standard Menus
8
UÊ User Guide 42185; Ref. Card 40947
User Interface and Programming Reference – Simplified Menus
(See section TP400, TP600 Simplified vs. Standard 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.
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.
5/02/13
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
BP2100G1 – PN 56389-01
J43 TO J13 (BLOWER ON J14)
IN SETUPS 3, 5, 9, 11, 12, 17, 18
J51
J52
J98
J18
J20
AUX**
J34
MAIN
115V
J35
MAIN
J108 J107
J101
4
J45
J79
J54
J77
J75
J78
J53
4
J49
3
2
J44
J25
3
J15
J58
LIGHT
10
GND
J11
J23
SERIAL
ON S1
J40
J28
REMOTE
J17
J16
SENSOR B
3.0 kW HEATER
HEIZELEMENT
RADIATEUR
AUX
DEVICE
2 SPD*
PUMP 3
VOLTS
230V
AMPS
12A
MAX
FROM
W1 ON
EXPANDER
EXPANDER
X-P332
W1
J1
RIGHT
EXPANDER
BOARD
J7
TO
GROUP 2
J1
J5 (A1-A4)
OR
J8 (A5-A8)
FROM
J6 ON
EXPANDER
TO
GROUP 3
J53
NETZSTROMVERSORGUNG
2-GESCHW.-PUMPE 3*
ALIMENTATION POMPE 3
A 2 VITESSES*
J6
F1 30A
AUX
FRZ
230V
1þ
1x32A
SENSOR A
LOCATION
J1 ON RT
EXPANDER
J8
AUX
J31
J29
VAC
K7
F4 3A SLO-BLOW
J111
J27
WIFI
TRANSCEIVER
J34 OR J35
J26 J30
J48
J7
K5
J5
AUX
J91
J22
K3
2
J6
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
3
J110
J19
115V
TP (MAIN) PANELS
J34 OR J35
IR RECEIVER
OR
RF RECEIVER
J50
K8
230V
T1
F3 0.125A SLO-BLOW
K6
K1
2
GRN
J24
J109
1
BLU
K12
F8 30A
1
BRN
J43
24082_E
J14
J13
EXPANDER
J56
J57
J55
J59
J39
J10
J60 J41
J32
F7 10A 250VAC
K2
F6 30A
TB1
J21
K9
J81
J38
OZONE
J33
K4
CIRC PUMP
J46
F2 10A 250VAC
PUMP 1
J9
A/V HOT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
01-30-13
**J14 (AUX) IS:
2-SPEED PUMP 2 IN SETUPS 2-4, 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
*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
1-SPEED PUMP 2 IN SETUP 17, 18
UNUSED IN SETUPS 4, 10
PART A
42217B
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
230 Volt / 50 Hz Residential Wiring Schematic with 2 Pole RCD Breaker Box
9
OFF
ON
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
8
OFF
ON
ON
ON
ON
12
RCD Breaker Box
Neutral
+
Ground
230 VAC
“Live Wire”
230VAC House Breaker Box
7
6
ON
11
OFF
10
Outside Ground Rod
Correct
Voltage
0v
207V - 253V
10
When Probes Are Placed Across
[1 - 3] [4 - 7]
[5 - 9]
[10 - 11]
[1 - 2] [2 - 3]
[4 - 6] [5 - 8] [6 -7]
[8 - 9] [10 - 12] [11 - 12]
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.
5/02/13
PUMP 1
Spa System Box
J31=CE
HTR
SEL
J
J56
J57
J55
J59
K2
J 6
F6 30A
J60 J41
J51
J52
3
TB1
2
4
3
J36
J12
5
J37 J72
J4 J42
1
1
J10 J43
J51
J52
J98
TB1
J37 J72
J4 J42
J1 J3
J47 J61
J53 J58
J45
J79
J54
J77
J75
J78
J110
4
4
F7 10A 250VAC
J18
J20
AUX**
J34
MAIN
J35
MAIN
J108 J107
T1
3
J22
K3
2
J27
J23
SERIAL
J26 J30
J49 J44 J48
K5
J5
AUX
J91
J101
J8
AUX
J25 J31
3
J15
LIGHT
K7
F4 3A SLO-BLOW
J111
J11
J19
230V
K1
2
K6
J50
K8
115V 115V
F3 0.3A SLO-BLOW
J36
J12
J88
J62
3
J24
J109
1
2
K12
F8 30A
1
J
J13
10
GND
ON S1
J40
J29
VAC
J7
J60 J41
J6
F6 30A
J39
J32
OZONE
K9
J81
J38
CIRC PUMP
J33
K4
F2 10A 250VAC
J46
J56
J57
J55
J59
K2
PUMP 1
J9
A/V HOT
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
2
J53
5
9
4
7
5
8
0
4
1
J28
REMOTE
J17
J16
AUX
FRZ
1
2
3
K4 4
J32 J33
Test for Voltages by placing
probes on these locations
42217B
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
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
12
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.
5/02/13
Basic Control System Troubleshooting
Note: Local codes and laws vary. Use information below as a guide.
LOW VOLTAGE
CHECKING THE SYSTEM POWER INPUT FUSE
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 the system is getting the proper voltage at
TB1, but still doesn’t operate, then test for a
blown power input fuse.
WARNING
These procedures are performed while the system is
powered up and running under peak loads. Be careful.
Systems that use 230V peripheral devices (below):
UÊ Measure between the brown TB1 terminal and F6 power
input fuse at F6. You should see 230 volts.
UÊ If you determine that there is no voltage at this location,
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 of these 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. (cont. next page)
Once the power input fuse has been changed
UÊ Check the voltage between the black and red
wires again. Acceptable voltage range is between
216V and 264V.
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
J46
K4
J
J56
J57
J55
J59
K2
PUMP 1
J9
F6 30A
22117_B
F6 Fuse
GND
J24
J60 J41
TB1
1
BRN
J37 J72
J4 J42
TB1
2
BLU
J36
J12
3
BRN
4
4
GRN
L1
F6
J
K6
J45
J49 HTR A
L2
N
HTR B J44
J48
K3
T 150 m A 250V
J53
J45
J79
J54
J77
J75
J78
J110
GRN
BLU
K5
J15
J51
J52
N/A N
ADDED JUMPER FOR
CE INSTALLATIONS
UNFUSED
J1
J2
K1
F5 T 30A
J
Terminal Block & F6 Fuse on a
BP600 Power Board, 230V Setup
Terminal Block & F6
Fuse on a BP2100 Board
42217B
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
Basic Control System Troubleshooting (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, then re-check the internal system wires
and connector for burns, cracks or cuts in insulation.
UÊ If the fuse does not blow, turn the power off and plug in the
pump.
NOTE: Be sure to test each device individually.
TEST THE AMPERAGE DRAW
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 plugin 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: 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.
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
UÊ
UÊ
UÊ
Plug in the blower.
Power up the system and activate the blower.
If the fuse blows, then there is a blower problem.
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.
14
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.
5/02/13
Testing a System with Power
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.
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).
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.
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".
PRELIMINARY PANEL CHECK
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
42217B
JETS
AUX
UX
X
LIGHT
LIG T
HEAT
HEA
AT
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.
15
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
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.
5/02/13
230 Volt 50 Hz - Residual Current Devices (RCD’s)
A residual current device (RCD,) is the generic term for a
device that monitors the current in the line conductor and the
neutral conductor of a circuit in an earthed system.
Two Pole RCD
In a circuit that’s operating properly, the vector sum of the
live and neutral current values added together will be zero.
Current flowing to earth, due to a line earth fault, will return
via the earth conductor, and regardless of load conditions,
will be registered as a fault. This current flow will give rise to
a residual current that will be detected by the device. If the
residual current exceeds the rated sensitivity of the RCD, it
will automatically activate a tripping of the faulty circuit.
Typical specifications are as follows:
Residual Current Devices ( RCD’s ) range
Sensitivity - from 10 to 500mA
Voltage - 2 poles : 230V; 3/4 poles: 230/400V
Connection capacity
- 25A: 6/10 mm² (flexible/ rigid cable)
- 40,60A: 16/25 mm²
- 80,100A: 35/50 mm²
Four Pole RCD
42217B
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
Wiring Checks
WIRING CHECK PRECAUTIONS
CHECK FOR LOOSE CONNECTIONS OR
DAMAGED WIRES
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.
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.
SYSTEM BOX WIRE GAUGE CHECK
UÊ 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 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.
IMPORTANT -- USE OF NON-COPPER WIRE
TB1
Power System
Minimum wire size
Use Copper ONLY,
with 90 o C insulation
Ampere Rating of
RCD 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
Total Ampere Rating of
18
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.
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.
5/02/13
Wiring Check for RCD and Service Disconnect
IMPORTANT!
Remember, high voltage is still accessible in the house breaker
box even though you have turned off the spa breaker.
Keep in mind that a majority of R.C.D. tripping problems can be
attributed to incorrect wiring. R.C.D. troubleshooting usually
finds the problem.
RCD LINE-IN WIRING CHECK
UÊ œV>ÌiÊ̅iÊ«Àœ«iÀÊVˆÀVՈÌÊLÀi>ŽiÀÊ>˜`ÊÌÕÀ˜ÊˆÌʜvv°
UÊ ,i“œÛiÊ̅iÊVœÛiÀÊvÀœ“Ê̅iʅœÕÃiÊLÀi>ŽiÀÊLœÝ°Ê
…iVŽ
the main service amperage rating to the breaker box.
UÊ Àœ“Ê̅iÊVˆÀVՈÌÊLÀi>ŽiÀ]ʏœV>ÌiÊ̅iÊLÀœÜ˜Êœ>`Ê܈ÀiÊ>˜`Ê̅iÊ
blue neutral wire.
UÊ Àœ“Ê̅iÊ,°
°°Ê˜iÕÌÀ>ÊL>À]ʏœV>ÌiÊ̅iÊLÕiʏœ>`ʘiÕÌÀ>]Ê>˜`Ê
the green ground wire.
UÊ iÊÃÕÀiÊ̅iÀiÊ>ÀiʘœÊœÌ…iÀÊ>««ˆ>˜ViÃʜ˜Ê̅iÊë>Ê
circuit. If there are, service must be re-wired to supply the
spa only.
UÊ >ŽiÊÃÕÀiÊ>Ê̅ÀiiÊ܈ÀiÃÊi݈ÌÊ̅iʅœÕÃiÊLÀi>ŽiÀÊLœÝÊۈ>Ê
conduit, routed to the R.C.D. breaker box. The brown should
be connected to the R.C.D. line-in. The blue load neutral connects to the neutral in.
42217B
RCD LINE-OUT WIRING CHECK FOR 230 V DEDICATED
SYSTEM
The brown wire should connect to load out, the blue wire from
neutral out. All wires will exit the box via conduit routed to the
spa control system.
Once you have found all wiring correctly installed, begin
to check for proper voltage. If Correct Wiring is Verified,
check to see if the proper RCD 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 R.C.D. is rated for more amperage than the
system will draw.
UÊ For a 230 V dedicated system, a 2-pole or 4-pole R.C.D. with
no load neutral is acceptable.
UÊ For a detailed wiring checklist, please review the previous
segment of this manual on proper R.C.D. wiring or the R.C.D.
manufacturer’s instructions.
UÊ If the wiring is correct and the R.C.D. will not reset, then
unplug the pump and try to reset the R.C.D.
UÊ If the R.C.D. trips again, then unplug the blower and push
the reset button. If the R.C.D. continues to trip, then do the
same procedure for the ozone generator.
UÊ If the R.C.D. 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 R.C.D.
UÊ Power up the system. If the R.C.D. 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
R.C.D. still doesn’t reset, then the problem is most likely a
ground fault in the heater.
UÊ Disconnect the heater, and test.
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
20
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.
5/02/13
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
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
Black& Green
120 V
108 V - 132 V
Red & Green
120 V
108 V - 132 V
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
---
ACCEPTABLE HEATER OHM (Ω) 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.
Heater Type
Ohms (Ω)
5.5 kW @ 240 V
9.42 Ω -11.52 Ω
4 kW @ 240 V
12.96 Ω -15.84 Ω
1 kW @ 120 V
12.96 Ω - 15.84 Ω
TEMPERATURE & HIGH-LIMIT SENSOR OHM TABLE
Temp.
of Sensor
Ohms
(kΩ)**
Temp. of
Sensor
Ohms
(kΩ)**
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.
40° F
76.686 kΩ
90° F
22.117 kΩ
45° F
67.112 kΩ
100° F
17.636 kΩ
50° F
58.858 kΩ
105° F
15.788 kΩ
AMPERAGE DRAW RANGES
60° F
45.550 kΩ
110° F
14.158 kΩ
70° F
35.533 kΩ
115° F
12.716 kΩ
80° F
27.931 kΩ
120°F
11.439 kΩ
MOTOR AMPERAGE GUIDELINES
DEVICE
120 V DRAW
240 V DRAW
Pump low
2A-5A
2A-4A
Pump high
10 A - 14 A
8 A - 12 A
6A-8A
3A-4A
Blower
**Note: 1 kΩ = 1000 Ω :
kΩ 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
42217B
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.
21
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
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.
5/02/13
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.
A FUSE WITH THE
METER READING “BAD”
A FUSE WITH THE
METER READING “GOOD”
TESTING A FUSE: CHECK CONTINUITY
WITH THE FUSE REMOVED
FUSES INSTALLED IN THE SYSTEM
0.3 amp (part number 21581)
42217B
3 amp
(part number 20600)
10 amp
(part number 30122)
30 amp
(part number 30136)
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
Troubleshooting Heater Resistance
TEST IS WITH POWER OFF
TROUBLESHOOTING HEATER RESISTANCE
Release tab
Release tab
Locate the heater connector.
Pull the connector straight out.
Disconnect the connector by depressing the tab.
ACCEPTABLE HEATER OHM (Ω) RANGES
Heater Type
Ohms (Ω)
5.5 kW @ 240 V
9.42 Ω -11.52 Ω
4 kW @ 240 V
12.96 Ω -15.84 Ω
1 kW @ 120 V
12.96 Ω - 15.84 Ω
**Note: 1 kΩ = 1000 Ω :
kΩ may vary +/- 10% depending on the accuracy of
the meter used.
Place the meter probes on the heater terminals.
24
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.
5/02/13
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.
Pull the connector straight out.
Disconnect the connector by depressing the tab.
Measure resistance from a heater post to the
heater housing
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.
42217B
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).
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
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
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.
5/02/13
Verifying Incoming Voltage at the Terminal Block - BP2100 & BP600
CAUTION - TEST IS WITH POWER ON
VERIFYING INCOMING VOLTAGE AT THE TERMINAL BLOCK.
Brown to Blue Wires
on a 230V BP2100 System
Brown to Blue Wires
on a 230V BP600 System
NOTE THAT BROWN AND BLUE WIRE ORIENTATION IS
DIFFERENT ON THE TWO SYSTEMS SHOWN.
42217B
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
Testing Pump Fuses for Damage with Voltage On - BP2100
CAUTION - TEST IS WITH POWER ON
THERE ARE THREE 30A PUMP FUSES IN THE BP2100G1 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 BLUE
TEST THE VOLTAGE FROM THE
RIGHT SIDE OF THE FUSE
230V on each side
indicates a good fuse
230V 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
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.
5/02/13
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 (230V) post and
ground, severe arcing will occur. DEATH OR
SEVERE INJURY CAN OCCUR.
(continued on next page)
WRONG!
DO NOT MEASURE
ACROSS HEATER TERMINALS
42217B
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
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 230V system, the reading will be near
230V. (Allow for +/- 10% variance.)
5. When finished with testing, turn the power off before
removing the clamps from the terminal posts.
30
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.
5/02/13
Testing Pump Fuses for Damage with Voltage On - BP600
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.
42217B
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
Testing Heater Amperage
CAUTION - TEST IS WITH POWER ON
PLACE CLAMP AROUND ONE HEATER WIRE, AND THEN THE OTHER WIRE.
AMPERAGE HEATER TEST BP600
32
AMPERAGE HEATER TEST BP2100G1
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.
5/02/13
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. (230V)
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. (230V)
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
more information.
PUMP 1 AMP CORD
42217B
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
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)
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.
5/02/13
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 )
42217B
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
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)
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
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.
TIME OUTS
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
OTHER TEST MODE FEATURES:
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
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.
5/02/13
Setup Changes with DIP Switch 1 ON - Using a TP600 or TP400 Panel
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.
Note: All TP panels can be used with all BP systems. The setup change process below uses a
BP600 logic board for illustration. A BP2100 board setup is shown on the following pages.
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
BP600 BOARD
SETUP SWITCH
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.
42217B
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
Setup Changes with DIP Switch 1 ON - Using a TP600 or TP400 Panel (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.)
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.
5/02/13
Setup Changes with DIP Switch 1 ON - Using a TP900 or TP800 Panel
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.
Note: All TP panels can be used with all BP systems. The setup change process below uses a
BP2100 board for illustration. A BP600 board setup is shown on the preceding pages.
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.
J108 J107
T1
J101
SOFTWARE SETUPS (BP2100)
J22
K3
2
J6
J15
Set: 104°F
8:32 PM
Ozone
Filter 1
Spa
Shortcuts
Settings
Test
J8
AUX
J25 J31
3
LIGHT
K7
F4 3A SLO-BLOW
High Range
J27
J23
SERIAL
J26 J30
J49 J44 J48
10
GND
ON S1
J40
J29
VAC
J7
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.
102°F
J91
J28
REMOTE
J17
J16
AUX
FRZ
`
1
Ready in Rest Mode
Heating
10
ON
S1
Test
Back
42217B
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.
39
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.
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.
Remove both nuts that secure the element in place.
Locking nuts are in same location on BP models
30 - 35 in/lbs. torque when reinstalling.
4.
Remove the system door cover.
5. 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. The result will most likely be a
damaged terminal.
Avoid damaging the post. Reinforce the post, especially
when reinstalling the upper nut on a new heater.
Apply Loctite when reinstalling.
6.
Remove both 3/8" nuts that secure the element in place.
7.
Remove the heating assembly sensor wires and replace if
necessary.
8.
Remove the heater assembly.
9.
Reverse the procedure to reinstall the heater assembly.
Note:
UÊ Loctite should be applied to heater terminal threads
UÊ Heater terminal nuts require 30 - 35 in/lbs torque.
UÊ Heater element retainer nuts are also tightened to 30 - 35
in/lbs torque.
40
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.
5/02/13
Remove and Replace a System Circuit Board
IMPORTANT!
BE SURE TO TURN THE POWER OFF BEFORE
REPLACING ANY COMPONENT, ESPECIALLY A
CIRCUIT BOARD.
IMPORTANT!
Removing BP Expander Board, an Alternate Way
1
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.
42217B
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.
41
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.
J51
J52
J98
J72
J42
J3
J61
J53 J58
J45
J79
J54
J77
J75
J78
J110
4
4
F7 10A 250VAC
OZONE
J20
J18
J34
MAIN
230V
115V 115V
J35
MAIN
J108 J107
J101
K3
2
3
2
J5
AUX
J27
J23
SERIAL
J26 J30
J49 J44 J48
K5
J91
J22
J8
AUX
J25 J31
3
J15
LIGHT
K7
F4 3A SLO-BLOW
J111
J11
J50
J19
K1
J37
J4
J1
J47
J36
J12
J88
J62
3
J24
K6
K8
T1
F3 0.3A SLO-BLOW
1
2
K12
J109
1
TB1
J43
CIRC PUMP
J81
J10
F8 30A
24082_D
J14
J13
10
GND
ON S1
J40
J29
VAC
J7
J60 J41
J32
J6
F6 30A
J39
F2 10A 250VAC
J38
J21
K9
J56
J57
J55
J59
K2
J46
J33
K4
A/V HOT
J9
PUMP 1
BP2100 board
screw locations
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
J28
REMOTE
J17
J16
AUX
FRZ
BP2100 board
without wires
42
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.
5/02/13
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
42217B
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
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.
Exit
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.
44
– – –°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.
5/02/13
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.
42217B
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.
45
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.
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.
5/02/13
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
42217B
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.
47
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.
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.
5/02/13
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
The Utilities Menu contains the following:
Holding for 0:58
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
42217B
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
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.
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.
5/02/13
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.
Clean the filter
`
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
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
WATER TEMPERATURE IS UNKNOWN
Contact your dealer or service organization if this message appears on more than one power-up.
---˚F ---˚C
THE CLOCK HAS FAILED* – M020
After the pump has been running for 1 minute, the temperature
will be displayed.
CONFIGURATION ERROR - SPA WILL NOT START UP
POSSIBLE FREEZING CONDITION
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 WATER IS TOO HOT – M029
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.
THE GFCI TEST FAILED (SYSTEM COULD NOT TEST
THE GFCI) – M036
(North America Only) May indicate an unsafe installation.
A PUMP MAY BE STUCK ON – M034
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 – M015
The temperature sensors MAY be out of sync by 2°F or 3°F.
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
COMMUNICATIONS ERROR
The control panel is not receiving communication from the
System.
42217B
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
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.
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.
5/02/13
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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42217B
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
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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54
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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.
5/02/13
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.
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.
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 ºthe
pump and cause the system to energize the heater and go into
an overheat condition.
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-fl ow or no-fl ow 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.
42217B
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
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 44
M015 51, 58
M016 48, 57
M017 48, 57
M019 57
M019* 44
M020 51, 58
M021 51, 58
M022 51, 58
M026 51, 58
M027 48
M028 48, 57
M029 51, 57
M030 48, 57
M031 58
M031, Sensor A: 51
M032 58
M032, Sensor B: 51
M033 57
M034 51, 58
M035 51, 58
M036 51, 58
M037* 46
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.
A / B (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.
56
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.
5/02/13
TP400, TP600 Messages (cont.)
FALT LOG (FAULT LOG)
for extended pump operation or high ambient temp.
The Fault Log is a record of the last 24 faults that can be reviewed by a service tech.
SFTY TRIP -- -- -- -Safety Trip - Pump Suction Blockage* – M033
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 ----
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 -- -- -- --
PRIMING MODE – M019
Heater Flow is Reduced (HFL) – M016
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.
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.
-- -- --˚F -- -- -- ˚C
Water Temperature is Unknown
After the pump has been running for 1 minute, the temperature
will be displayed.
42˚F TOO COLD
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.
Too Cold - Freeze Protection
HTR TOO HOT -- -- -- --
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.
HTR is too Hot (OHH)* M030
WATR TOO HOT -- -- -- --
A Reset Message May Appear with other Messages.
Water is too Hot (OHS) – M029
Some errors may require power to be removed and restored.
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.
PRES BTTN TO RSET -- -- -- --
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
42217B
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
TP400, TP600 Messages (cont.)
FLOW-RELATED CHECKS
MEM RSET -- -- -- --
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.
Memory Warning - Persistent Memory Reset* – M021
102˚F SNSR BAL-- ANCE
Sensor Balance is Poor – M015
The temperature sensors MAY be out of sync by 2°F or 3°F.
SNSR SYNC -- -- -- -- CALL FOR SRVC -- -- -- -Sensor Balance is Poor* – M026
The temperature sensors ARE out of sync. The Sensor Balance is
Poor fault has been established for at least 1 hour.
SNSR A -- -- -- -- CALL FOR SRVC -- -- -- -SNSR B -- -- -- -- CALL FOR SRVC -- -- -- --
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.
CLOK FAIL -- -- -- -Memory Failure - Clock Error* – M020
Not Applicable on the BP1500.
CNFG FAIL -- -- -- -Configuration Error - Spa will not Start Up
GFCI FAIL -- -- -- -GFCI Failure - System Could Not Test/Trip the GFCI – M036
NORTH AMERICA ONLY. May indicate an unsafe installation.
Sensor Failure – Sensor A: M031, Sensor B: M032
A temperature sensor or sensor circuit has failed.
NO COMM
STUK PUMP -- -- -- -A Pump Appears to be Stuck ON – M034
No Communications
Water may be overheated. POWER DOWN THE SPA. DO NOT
ENTER THE WATER.
The control panel is not receiving communication from the
System.
HOT FALT -- -- -- -- CALL FOR SRVC -- -- -- --
BETA VER-- SION -- -- -- --
A Pump Appears to have been Stuck ON when spa was
last powered – M035
Pre-Production Software
POWER DOWN THE SPA. DO NOT ENTER THE WATER.
The Control System is operating with test software.
102˚T
°F or °C is replaced by °T
The Control System is in Test Mode.
MEM FAIL -- -- -- -Memory Failure - Checksum Error* – M022
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.
58
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.
5/02/13
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.
42217B
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
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.
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.
5/02/13
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), Setup 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 (full) menus by choosing
Setup 7, 8, or 9 respectively.
Headings of Setups 1, 2, & 3 in Tech Sheet SR240BP5 (12-05-12, Rv. A)
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
42217B
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
TP400, TP600 Simplified and Standard Panel Main Menus
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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Main Screen
A STANDARD MAIN MENU
(DOC NO. 40940I)
READY
RANGE FLTR1
SET
While the Temperature is
still flashing, press Light.
RANGE
Light Cycle if enabled
SET
Both panels can be navigated
using 2 or 3 buttons.
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.
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.
5/02/13
230V
1þ
1x32A
GRN
BRN
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 0.125A SLO-BLOW
J109
J43
J39
K9
F8 30A
J33
F2 10A 250VAC
3
J48
J20
GND
HEIZELEMENT
RADIATEUR
3.0 kW HEATER
2
J49
K3
J44
CIRC PUMP
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_E
**J14 (AUX) IS:
2-SPEED PUMP 2 IN SETUPS 2-4, 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
BLU
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 - BP2100G1, Part Number 56389-01
Balboa Water Group BP Wiring Diagrams
AMPS
12A
MAX
FROM
W1 ON
EXPANDER
TO
GROUP 2
J1
F1 30A
J6
RIGHT
EXPANDER
BOARD
J7
PART A
TO
GROUP 3
J53
NETZSTROMVERSORGUNG
2-GESCHW.-PUMPE 3*
ALIMENTATION POMPE 3
A 2 VITESSES*
*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
1-SPEED PUMP 2 IN SETUP 17, 18
UNUSED IN SETUPS 4, 10
J1
W1
EXPANDER
X-P332
FROM
J6 ON
EXPANDER
DEVICE
2 SPD*
PUMP 3
LOCATION
J1 ON RT
EXPANDER
J5 (A1-A4)
OR
J8 (A5-A8)
TP (MAIN) PANELS
J34 OR J35
AUX
VOLTS
230V
01-30-13
BP2100G1 – PN 56389-01
WIFI
TRANSCEIVER
J34 OR J35
IR RECEIVER
OR
RF RECEIVER
EXPANDER
42217B
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
NONE
NONE
NONE
NONE
NONE
NONE
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
FILTRATION
NONE
FILTRATION
FILTRATION
NONE
1
2
3
4
5‡
6
7
8
9
10
11‡
12‡
13
14
15‡***
16‡***
17
18
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
POLLING
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 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.
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
TORQUE RANGE FOR
MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS.
(31.1-34.5 kg cm)
INSTEAD OF
SETUP #1,
THIS SYSTEM IS
CONFIGURED IN
SETUP #:
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
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
°C
TEMP SCALE
12A MAX
S2
TO
J1 ON
EXPANDER
IN SETUPS 15, 16
S1 = PUMP 3
S3 = FUSED ADAPTER
IN SETUPS 5, 11, 12
S1 = PUMP 2
S3 = PUMP 3
SPLITTER OPTIONS:
12A MAX
S1
230V 1þ
1x32A
SWITCHBANK S1 ON
01-30-13
TO
S2
OFF
10A
4
3
2
1
TB1
***FUSED ADAPTER
A2
A5
J60 J41
4
1
SETUPS
15 & 16
ONLY
BLOWER
J53
J58
J6
J38
SPLITTER IS UNUSED
(REMOVED) IN
SETUPS 1-4, 6-10,
13, 14, 17, 18
3
2
J46
PART B
J1
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*
5 MIN HTR COOLDOWN (GAS)
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
BP2100G1 – PN 56389-01
GRN
3 BRN
BLU
2 BRN
1 BRN
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION.
230V 3þ
3x16A
*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
‡ OPTIONAL BP2X-WIRE KIT PN 30893
GREEN
***SETUPS 15 AND 16 REQUIRE ADDITIONAL FUSED ADAPTER FOR BLOWER OUTPUT
PUMP 1 LOW TIMEOUT IS 15 MINUTES.
‡SETUPS 5, 11, 12, 15 AND 16 REQUIRE BP2X-WIRE KIT PN30893
+ POLLING
+ POLLING
+
+
+
+
+
+
+
+
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
TO RED AC
(GROUP 2)
ON MAIN BOARD
BLACK
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
PROGRAMMABLE
CIRC PUMP
DEVICE
NETZSTROMVERSORGUNG 2-GESCHW.-PUMPE 1 ALIMENTATION POMPE 1 A 2 VITESSES 2-SPEED PUMP 1
AUX**
AUX LINE 1 CONNECTION
J19 to J43
10V BELEUCHTUNG ECLAIRAGE BAIN HYDRO SPA LIGHT
KREISLAUF PUMPE POMPE DE CIRCULATION CIRC PUMP
(SETUPS 7-14, 16)
OZONGENERATOR GENERATOROZONE OZONE GENERATOR
CIRC AND OZONE LINE 1 CONNECTION
J81 to J59
TV / AV
IR RECIEVER
AUX PANEL(S) - AX10, AX20, AX30, AX40
SETUP #
J33
J40
J5, J8
J15
J21
J32
LOCATION
J9
J14
J51
J52
J98
SINGLE SERVICE 230V 1þ / 1x32A, THREE-SERVICE 230V 1þ / 3x16A
WHITE
J37 J72
J4 J42
J1 J3
J47 J61
Wiring Diagram - BP2100G1, Part Number 56389-01 (cont.)
GREEN
J78
J45
J79
J54
J77
J75
WHITE
J36
J12
J88
J62
64
RED
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.
5/02/13
230V
1þ
1x32A
GRN
BRN
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
F2 10A 250VAC
K3
3
J48
J20
GND
3.0 kW HEATER
2
J49
J44
CIRC PUMP
K12
J32
OZONE
J19
K8
SENSOR B
ON S1
F4 3A SLO-BLOW
115V
230V
115V
LIGHT
J15
T1
J24
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
PUUMP 2
J21
F7 10A 250VAC
J9
PUMP 1
J45
J79
J54
J77
J75
J78
TB1
F6 30A
J110
J56
J57
J55
J59
J51
J52
J98
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
BLU
J25=HTR1
J26=HTR2
J27=HTR3
J30=TEST
J31=CE
HTR
SEL
J6
J18
Wiring Diagram - BP21MSSH, Part Number: 56381
J16
REMOTE
J40
J8
AUX
J23
SERIAL
J27
J5
AUX
K6
24082_E
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
PART A
TO
GROUP 3
J53
J5 (A1-A4)
OR
J8 (A5-A8)
TP (MAIN) PANELS
J34 OR J35
AUX
01-03-13
BP21MSSH – PN 56381
WiFi
Transceiver
J34 OR J35
IR Receiver
OR
RF Receiver
MICROSILK
42217B
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
FOR SUPPLY CONNECTIONS,
USE CONDUCTORS SIZED ON THE
BASIS OF 60°C AMPACITY BUT
RATED MINIMUM OF 90°C.
PUMP 1
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
2-SPEED
USE COPPER CONDUCTORS ONLY.
EMPLOYER UNIQUEMENT
DES CONDUCTEURS DE CUIVRE.
PUMP 1 LOW TIMEOUT IS 15 MINUTES.
CIRC PUMP
PROGRAMMABLE FILTRATION + POLLING
PROGRAMMABLE FILTRATION + POLLING
PROGRAMMABLE FILTRATION + POLLING
NONE
NONE
NONE
1
2
3
4
5
6
°C
°C
°C
°C
°C
°C
TEMP SCALE
TORQUE RANGE FOR
MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS.
(31.1-34.5 kg cm)
GRN
3 BRN
BLU
2 BRN
1 BRN
4
3
2
1
TB1
2-SPEED PUMP 1
2-SPEED PUMP 2
230V 3þ / 3x16A
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
1-SPEED
MicroSilk®
J55
POMPE 1 A 2 VITESSES
POMPE 2 A 2 VITESSES
J57
2-SPEED
1-SPEED
NONE
2-SPEED
1-SPEED
NONE
PUMP 2
DEVICE
NETZSTROMVERSORGUNG 2-GESCHW.-PUMPE 1 ALIMENTATION
NETZSTROMVERSORGUNG 2-GESCHW.-PUMPE 2 ALIMENTATION
PUMP 2 LINE 1 CONNECTION
J19 to
10V BELEUCHTUNG ECLAIRAGE BAIN HYDRO SPA LIGHT
KREISLAUF PUMPE POMPE DE CIRCULATION CIRC PUMP
OZONGENERATOR GENERATOROZONE OZONE GENERATOR
CIRC AND OZONE LINE 1 CONNECTION
J81 to
TV / AV
IR RECIEVER
AUX PANEL(S) - AX10, AX20, AX30, AX40
SETUP #
J33
J40
J5, J8
J15
J21
J32
LOCATION
J9
J14
J60 J41
PUMP 2
SETUPS
PUMP 2
SETUPS
PUMP 2
SETUPS
4
1
J53
J58
3
2
J46
IS 2-SPEED IN
1 & 4
IS 1-SPEED IN
2 & 5
IS NOT USED IN
3 & 6
J51
J52
J98
J37 J72
J4 J42
J1 J3
J47 J61
J36
J12
J88
J62
SINGLE SERVICE 230V 1þ / 1x32A, THREE-SERVICE 230V 1þ / 3x16A
Wiring Diagram - BP21MSSH, Part Number: 56381 (cont.)
J78
J45
J79
J54
J77
J75
J6
XP332
W1-XP332
J20
J38
230V 3þ
3x16A
230V 1þ
1x32A
J18
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.
5/02/13
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
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
SWITCHBANK S1 ON
01-03-13
BP21MSSH – PN 56381
SYSTEM WILL BE IN SETUP #1
UNLESS MARKED OTHERWISE
INSTEAD OF SETUP #1,
THIS SYSTEM IS CONFIGURED IN SETUP #:
PART B
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.
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
**SWITCH #
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION.
SWITCHBANK S1 OFF
**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
Wiring Diagram - BP600, Setup 1-16 as Manufactured
Boards Shown:
Power Board: 22117_B / 56284;
Logic Board: 22121_E / 56131-02
Power Requirements:
Single Service [3 wires (line, neutral, ground)]
230VAC, 50Hz, 1þ, 16A, (Circuit Breaker rating = 20A max.)
System Ouputs - 16A Service:
Pump 1
230VAC
2-Speed
7.5A max
30-minute timer for Low Speed, 15 Minutes for High Speed
This is the heater pump
Must deliver a minimum of 20 GPM through heater
Low Speed may not exceed 2A max
Pump 2
230VAC
Ozone
230VAC
Spa Light
10VAC
Heater
3kW @ 240VAC
1-Speed
On/Off
7.5A max
15-minute timer
.5A max
Uses the same relay as Pump 1 Low
1A max
4-Hour timer.
Wiring Diagram and Settings
J28
J30
J31
J32
J29
J45
J49 HTR A
HTR B J44
F6
J48
T 150 m A 250V
J1
UNFUSED
J2
DIP Switch Option
J46
K4
K3
F5 T 30A
RED AC
K1
K2
F3 10A 250V
J12
J8
GND
J20
J56
J14
F2 3A 250V
Orig. Setup 1
J22
GND
J21
J22
J15: SPA LIGHT
J33
BELEUCHTUNG
ECLAIRAGE BAIN HYDRO
10VAC 1A
J28 AUX FRZ
J29 VAC
6
J17
J16
S1
1
J5
J15
J31 HCE
J26 H2
J25 H1
J45
LIGHT
T1
J46
K7
J18 J19
L2
N
WS01CE
J30 TST
J27
H3
J16
L1
AUX
TO J5
22121_E
ON
GRN
K6
CONTROL PANEL
TO J33
J57
NOT USED
BLU
K5
WHT AC
J47
BRN
ADDED JUMPER FOR
CE INSTALLATIONS
SENSOR B
3.0 kW
HEATER
2S PUMP 1
N/A N
GND
SENSOR A
HEIZELEMENT
RADIATEUR
ALL UNUSED SWITCHES SHOULD BE OFF
J27
J25
J26
J23
J33
22117_B
USE COPPER CONDUCTORS ONLY
EMPLOYER UNIQUEMENT
DES CONDUCTEURS DE CUIVRE.
TORQUE RANGE FOR MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS. (31.1-34.5 kg cm)
J13
*SWITCH # 6 SHOULD BE SET TO OFF
UPON FINAL INSTALLATION.
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
OZONE
6
5
4
3
2
1
J15
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
FOR SUPPLY CONNECTIONS,
USE CONDUCTORS SIZED ON THE
BASIS OF 60°C AMPACITY BUT
RATED MINIMUM OF 90°C.
OFF POSITION
1S PUMP 2
S1 SWITCH #
J24
ON POSITION
F4 3A 250V
Changes to
Special Amperage Rule ON . . . . . . . . . . . . DIP Switch 5 OFF . . . . . . .DIP Switch 5 ON
Use this only in cases where there is an overcurrent condition due to pump size.
This setting will not allow Pump 1 High and Pump 2 to run at the same time.
42217B
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
Wiring Diagram - BP600, Setup 2-32 as Manufactured
Boards Shown:
Power Board: 22117_B / 56284;
Logic Board: 22121_E / 56131-02
Power Requirements:
Single Service [3 wires (line, neutral, ground)]
230VAC, 50Hz, 1þ, 32A, (Circuit Breaker rating = 40A max.)
System Ouputs - 32A Service:
Pump 1
230VAC
2-Speed
12A max
30-minute timer for Low Speed, 15 Minutes for High Speed
This is the heater pump
Must deliver a minimum of 20 GPM through heater
Pump 2
230VAC
Ozone
230VAC
Spa Light
10VAC
Heater
3kW @ 240VAC
Misc.
J2 & J32
1-Speed
On/Off
230VAC
12A max
15-minute timer
.5A max
Uses the same relay as Pump 1 Low
1A max
4-Hour timer.
4A max
Hot output (Stereo). Fused equipment or in-line fuse required.
Wiring Diagram and Settings
F5 T 30A
K1
K2
F3 10A 250V
J12
J8
GND
J20
J16
J56
J14
F2 3A 250V
J22
GND
J21
J22
J15: SPA LIGHT
J33
BELEUCHTUNG
ECLAIRAGE BAIN HYDRO
10VAC 1A
J28 AUX FRZ
J29 VAC
6
J17
J16
S1
1
J5
J15
J31 HCE
J26 H2
J25 H1
J45
LIGHT
T1
J46
K7
J18 J19
J28
J30
J31
J32
J29
J46
K4
K3
RED AC
ON
HTR B J44
F6
J48
T 150 m A 250V
J1
UNFUSED
J2
WS01CE
J30 TST
J27
H3
NOT USED
BLU
J45
J49 HTR A
AUX
TO J5
22121_E
J47
L2
N
CONTROL PANEL
TO J33
J57
OZONE
K6
L1
BRN
GRN
K5
WHT AC
SENSOR B
3.0 kW
HEATER
2S PUMP 1
N/A N
ADDED JUMPER FOR
CE INSTALLATIONS
SENSOR A
HEIZELEMENT
RADIATEUR
ALL UNUSED SWITCHES SHOULD BE OFF
GND
USE COPPER CONDUCTORS ONLY
EMPLOYER UNIQUEMENT
DES CONDUCTEURS DE CUIVRE.
TORQUE RANGE FOR MAIN TERMINAL BLOCK (TB1):
27-30 IN. LBS. (31.1-34.5 kg cm)
J27
J25
J26
J23
J33
22117_B
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
J13
*SWITCH # 6 SHOULD BE SET TO OFF
UPON FINAL INSTALLATION.
FOR SUPPLY CONNECTIONS,
USE CONDUCTORS SIZED ON THE
BASIS OF 60°C AMPACITY BUT
RATED MINIMUM OF 90°C.
OFF POSITION
J15
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
6
5
4
3
2
1
1S PUMP 2
S1 SWITCH #
J24
ON POSITION
F4 3A 250V
Configuration Changes based on Default
Feature
Orig. Setup 1
Changes to
J2 & J32 . . . . . . . . . . . . . . . . . . . . . . . Hot Output . . . . . . . . . . .Useable
DIP Switch Option
Orig. Setup 1
Changes to
Add 1 High Speed Pump with Heat . . . . . . DIP Switch 2 OFF . . . . . . .DIP Switch 2 ON
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.
5/02/13
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
10
J8
AUX
S1
SENSOR
LIGHT
HTR1
HTR2
HTR3
J15
J31
J38
A/V HOT
Dolphin
AUX
3A 250V
REMOTE
J30
J40
J36
MAIN
J14
PUMP 2
J18
42217B
Dolphin
Receiver
A
AUX
TEMP
SENSOR
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.
69
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)
Dolphin III CE (50212)
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 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
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.
5/02/13
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
42217B
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.
71
Glossary
CIRC PUMP (OR CIRCULATION PUMP)
WHAT PRIMING MODE DOES:
Low horse power pump designated especially for maintenance
of filtration and heating. It often runs all day.
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.
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
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.
72
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.
5/02/13
Index
Symbols
0.3 amp 23
1, DIP Switch 36
1, Switch 37
3 amp 23
6-pin connector J40 69
10 amp 23
30 - 35 in/lbs torque 40
30 amp 23
30A pump fuses 28
120V Amp Draw 21
120 V Draw 21
120V Watts 21
230V Amp Draw 21
230V Watts 21
240V Amp Draw 21
240 V Draw 21
240V Watts 21
20600, part number 23
21581, part number 23
22117_B 67, 68
22121_E 67, 68
30122, part number 23
30136, part number 23
42012, Document No. 70
42013, Document No. 70
50211, Document No. 70
50212, Document No. 70
56131-02 67, 68
56284 67, 68
---˚F ---˚C 51
°F or °C is replaced by °T 36
°T 38
°T, °F or °C is replaced by 36
A
A/B Sensor 36
A/B Sensor Temperatures 36
A/B Temps 49
Acceptable Heater Amperage Draw
Ranges 21
Acceptable Heater Ohm (Ω) Ranges 21, 24
Acceptable Ranges for Testing 21
42217B
Access, Test Menu 36
access to the power board 31
address, Assigning a new 70
Address, Dolphin 70
Addressing your Dolphin 70
Address, Spa 70
Adequate drainage 2
amp, 0.3 23
amp, 3 23
amp, 10 23
amp, 30 23
AMP cord 33
Amperage Draw Ranges 21
Amperage Heater Test 32
Amperage Heater Test BP2100G1 32
appliance, continuous duty 3
Apply Loctite 40
arrow, right 51
A, Sensor 36, 49
assembly, reinstall the heater 40
Assigning a new address 70
asterisk, message with an 44
Auxiliary freeze sensor 45
Avoid damaging the post. 40
A vs B or T vs H 34
B
background colors 52
ball valves 40
Blockage*, Pump Suction 57
Blower, Test the 14
board, access to the power 31
Board, Compatibility on Dual 42
board, expander 28, 41
board, isolate the logic 31
board, Logic 31
Board, Logic 31, 67, 68
board, newer revision 42
Board, Power 67, 68
board problem 35
board, reinstalling the 42
board, Torque main 42
BP500, Sensor Location 31
BP2000 board without wires 42
BP2100G1, Amperage Heater Test 32
breaker, GFCI 50
B, Sensor 36, 49
button, test 50
C
Calls, Service 7
Canadian Electric Code 3
Cause 20
changes, wiring 36
Change the setup 36
Checklist, Voltage 21
Checks, Flow-Related 58
Circ Pump 72
circulation pump 72
Circulation Pump Modes 45
cleanup cycle 46
Clean-up (or purge) Cycle 72
Code, Canadian Electric 3
Code, Fault Message 59
Code, Message 59
Code, National Electrical 3
Codes and Compliance 3
Code, Set Up 70
Codes, Fault Log Message 59
Codes, M0[XX] numbers are Message 44
Codes, Message 56
codes, set up 70
code, system 16
colder climates 45
colors, background 52
Compatibility on Dual Board 42
compatibility, software 8
Compliance, Codes and 3
condition, error 48
conditions, freezing 50
configuration, DIP switch for proper 41
Configuration Settings 36
Configuration Signature 56
configurations, setup 36
configuration, view the 36
connector, receiver’s 69
connector, sensor 31
connector, terminal 40
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
Index
continue monitoring temperature 48
continuous duty appliance 3
continuously, spa to filter 16
Control System 69
cord, AMP 33
Current Setup 36
cycle, cleanup 46
Cycle, Clean-up (or purge) 72
Cycle, Filtration 72
cycle, second filter 45
cycles, filtration 45
D
damaged terminal 40
DEMO (Demo Mode) 56
Demo Mode 36, 49
Depress sensor tab 31
Depress tab 34
Device, Residual Current 2
different, LCD readouts may look slightly
56, 57
DIP Switch 1 36
DIP switch for proper configuration 41
DIP switch positions of S1 56
discolored, slow-blow fuses are not
always 14
Document No. 42012 70
Document No. 42013 70
Document No. 50211 70
Document No. 50212 70
Dolphin 69
Dolphin Address 70
Dolphin, Addressing your 70
Dolphin II 69
Dolphin III manual 70
Dolphin receiver 69
DolphinTM Remote 69
Do not pry up 41
do not pull on the wires 41
down, spa is shut 57
dr 57
drainage, Adequate 2
Drain Mode 49
Draw, 120 V 21
Draw, 120V Amp 21
74
Draw, 230V Amp 21
Draw, 240 V 21
Draw, 240V Amp 21
Dry, Heater May be 57
duration 45
E
End User Warning 2
error condition 48
event, fault 59
exit Priming Mode 37
exit Test Mode 39
expander board 28, 41
F
failed, sensor circuit has 51
FALT LOG (Fault Log) 57
fault event 59
fault, ground 50
Fault Log 36, 47, 49, 59
Fault Log information 36
Fault Log Menu 59
Fault Log Message Codes 59
Fault Message Code 59
Fault, Sensor A 51
Fault, Sensor B 51
fault, Sensor Balance is Poor 58
faults, last 24 36
faults, Stray 34
Feature, GFCI Test 50
Filter Cycle 2 46
filtration 45
Filtration Cycle 72
filtration cycles 45
Filtration, Main 46
Filtration, Optional 46
flash, Heat LED will 15
Flashing Heat LED 15
flow problem 16
Flow-Related Checks 58
Four Pole RCD 17
freeze protection 45, 48
Freeze Protection 57, 72
freezing conditions 50
fuses, 30A pump 28
Fuses installed in the system 23
G
generator, ozone 45, 46
GFCI 72
GFCI breaker 50
GFCI should be reset immediately 50
GFCI should trip within several seconds
50
GFCI Test Feature 50
GFCI Trip Test 50
Glossary 72
GPM 71
ground fault 50
guard, VG Compliant suction 2
Guidelines, Motor Amperage 21
Guidelines, Spa 71
H
H, A vs B or T vs 34
Heater element retainer nuts 40
Heater Flow is Reduced 57
Heater Matrix 21
Heater May be Dry 57
heater, no voltage to the 15
heater, reinstalling the upper nut on a new
40
Heater Related Messages 48
Heater terminal nuts 40
Heater Type 21
Heater Voltage 56
Heater Wattage as Configured in Software
56
heater wires 40
heating assembly sensor wires 40
Heat LED will flash 15
Heat Waiting 15
HFL 16, 57
H _ (Heater Type) 56
High-Limit Sensor 21
High Temperature Range 43
Hot, HTR is too 57
Hot, Water is too 57
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.
5/02/13
Index
how to 50
HTR is too Hot 57
I
Identification, Software Self 72
ID, Software 48
ID, System Panel 72
immediately, GFCI should be reset 50
Information 47
information, Fault Log 36
Information, System 48
instructions, power connection 2
Interface, User 8
Invert 47
IR Receiver 69
isolate the logic board 31
L
last 24 faults 36
latest version 8
Law, Ohm’s 22
LCD readouts may look slightly different
56, 57
LED, Flashing Heat 15
lightning strike 14
Limit, Temp 36
Link the panel 37
Lock 47
Locking the Panel 47
Locking the Settings 47
Lock, Settings 47
Loctite, Apply 40
Loctite should be applied to heater terminal threads 40
Log, Fault 36, 47, 49, 59
Logic board 31
Logic Board 31, 67, 68
Low Temperature Range 43
M
M0[XX] numbers are Message Codes 44
M015 51, 58
M016 48, 57
M017 48, 57
42217B
M019 57
M019* 44
M020 51, 58
M021 51, 58
M022 51, 58
M026 51, 58
M027 48
M028 48, 57
M029 51, 57
M030 48, 57
M031 58
M031, Sensor A: 51
M032 58
M032, Sensor B: 51
M033 57
M034 51, 58
M035 51, 58
M036 51, 58
M037* 46
Main Filtration 46
manual, Dolphin III 70
Matrix, Heater 21
Menu, Fault Log 59
Menus, Simplified 8, 36, 61
Menus, Standard 8, 36
Menu, System Information 56
Menu, Test 59
Menu, TEST 36
Menu, Utilities 49
Message Code 59
Message Codes 56
Messages 43
messages can be reset from the panel 51
Messages, Heater Related 48
Messages, Scrolling TP400/TP600 57
Messages that can be reset 51
messages will scroll 57
message with an asterisk 44
Miswiring of the spa 14
Mode, Demo 36, 49
Mode, Drain 49
Mode, exit Priming 37
Mode, exit Test 39
Mode, Priming 57, 72
Mode, Ready 45
mode, test 15, 16
Mode, Test 36, 37, 38, 51
Mode., Test 16
MODL (System Model) 56
Motor Amperage Guidelines 21
N
National Electrical Code 3
newer revision board 42
no voltage to the heater 15
nuisance spike 14
Number, Setup 37
nuts, Heater element retainer 40
nuts, Heater terminal 40
O
OHH 57
OHH. 16
Ohms 21
Ohm’s Law 22
Ohm Table 21
OHS 57
ON, Switch 1 36
Operation, Restricting 47
Optional Filtration 46
Outs, Time 36
out, Water may splash 40
overlapping filter times 16
ozone generator 45, 46
P
panel, Link the 37
panel, messages can be reset from the 51
panel, software in the topside control 56
panel stops operating 36
panels, TP 8
panels, TP600/TP400 36
panels, TP900/TP800 36
Panel, Unlocking the 47
part number 20600 23
part number 21581 23
part number 30122 23
part number 30136 23
Parts, Recommended 7
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
Index
PASS should appear 50
period, time-out 45
Pins, Sensor 35
polling 45
post., Avoid damaging the 40
post, Reinforce the 40
Power Board 67, 68
power connection instructions 2
Preferences 72
pressure, Water under 40
prevent unwanted use 47
Priming Mode 57, 72
Problem 20
problem, board 35
problem, flow 16
problem, sensor 35
problem, suction 57
programmable circ pump 45
Programming 72
Programming Reference 8
properly reset the GFCI 50
protection, freeze 45, 48
Protection, Freeze 57, 72
Pump, Circ 72
pump, circulation 72
pump, programmable circ 45
Pumps, Troubleshooting 20
Pump Suction Blockage* 57
Pump, Test the 14
R
Range, High Temperature 43
Range, Low Temperature 43
Ranges, Acceptable Heater Amperage
Draw 21
Ranges, Acceptable Heater Ohm (Ω) 21,
24
Ranges, Amperage Draw 21
RCD 2
RCD, Four Pole 17
RCD should be tested 2
RCD, Two Pole 17
Ready Mode 45
76
receiver, Dolphin 69
Receiver, IR 69
Receiver, RF 69
receiver’s connector 69
Recommended Parts 7
Reduced, Heater Flow is 57
Ref. Card 40947 8
Reference, Programming 8
Reinforce the post 40
reinstalling the board 42
reinstalling the upper nut on a new heater
40
reinstall the heater assembly 40
release tab 41
REMOTE 69
Remote, DolphinTM 69
Replacement Sensor 35
Required, Service Tools 7
reset, Messages that can be 51
reset the GFCI 50
Residual Current Device 2
Resistance, Troubleshooting 24, 25
Restricting Operation 47
RF Receiver 69
right arrow 51
RUN PMPS PURG AIR ---- 57
S
S1 36
S1, DIP switch positions of 56
Safety Trip 57
Screen, Spa 45
Scrolling TP400/TP600 Messages 57
scroll, messages will 57
second filter cycle 45
Sensor A 36, 49
Sensor, A/B 36
Sensor A Fault 51
Sensor A: M031 51
sensor, Auxiliary freeze 45
Sensor B 36, 49
Sensor Balance is Poor fault 58
Sensor B Fault 51
Sensor B: M032 51
sensor circuit has failed 51
sensor connector 31
Sensor, High-Limit 21
Sensor Location BP500 31
Sensor Pins 35
sensor problem 35
Sensor, Replacement 35
sensor set 16, 35
sensor temperatures 16
Sensor Wires 7
sequence of tests 14
Service Calls 7
Service Tools Required 7
SETP (Current Setup) 56
set, sensor 16, 35
Set Temperature 47
Settings, Configuration 36
Settings Lock 47
setup, Change the 36
Set Up Code 70
set up codes 70
setup configurations 36
Setup, Current 36
Setup Number 37
Setups, Software 36
shimmer 15
SIG 56
Signature, Configuration 56
Simplified Menus 8, 36, 61
slice valves 40
slow-blow fuses are not always discolored 14
software compatibility 8
Software ID 48
software in the topside control panel 56
Software Self Identification 72
Software Setups 36
software, test 51, 58
Spa Address 70
Spa Guidelines 71
spa is shut down 57
spa, Miswiring of the 14
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.
5/02/13
Index
Spa Screen 45
spa to filter continuously 16
spike, nuisance 14
SSID 48, 72
SSID (Software ID) 56
Standard Menus 8, 36
Stray faults 34
suction problem 57
SW _ (Dip Switch Settings) 56
Switch 1 37
Switch 1 ON 36
system code 16
System, Control 69
system, Fuses installed in the 23
System Information 48
System Information Menu 56
System Panel ID 72
System, Test the 14
T
tab, Depress 34
tab, Depress sensor 31
Table, Ohm 21
tab, release 41
TB1 18
Tech Sheets 8
temperature, continue monitoring 48
temperature display will alternate 49
Temperatures, A/B Sensor 36
Temperature, Set 47
temperatures, sensor 16
Temp Limit 36
Temps, A/B 49
terminal connector 40
terminal, damaged 40
Test, Amperage Heater 32
test button 50
tested, RCD should be 2
Test, GFCI Trip 50
Testing, Acceptable Ranges for 21
Test Menu 59
TEST Menu 36
Test Menu Access 36
42217B
test mode 15, 16
Test Mode 36, 37, 38, 51
Test Mode. 16
test software 51, 58
tests, sequence of 14
Test the Blower 14
Test the ground fault circuit interrupter
2
Test the Pump 14
Test the System 14
threads, Loctite should be applied to
heater terminal 40
time-out period 45
Time Outs 36
times, overlapping filter 16
torque, 30 - 35 in/lbs 40
Torque main board 42
TP600/TP400 panels 36
TP900/TP800 panels 36
TP panels 8
Trip, Safety 57
Troubleshooting Pumps 20
Troubleshooting Resistance 24, 25
Two Pole RCD 17
Type, Heater 21
W
Waiting, Heat 15
Warning, End User 2
Water is too Hot 57
Water may splash out 40
Water under pressure 40
Watts, 120V 21
Watts, 230V 21
Watts, 240V 21
wires, BP2000 board without 42
wires, do not pull on the 41
wires, heater 40
wires, heating assembly sensor 40
Wires, Sensor 7
wiring changes 36
U
Unlocking the Panel 47
User Guide 40940 8
User Guide 40985 8
User Guide 42185 8
User Interface 8
Utilities 47
Utilities Menu 49
V
valves, ball 40
valves, slice 40
version, latest 8
VG Compliant suction guard 2
view the configuration 36
Voltage Checklist 21
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 of Paragraph Topics
3 amp
(part number 20600) . . . . . . . . . . . . . . . . . 23
Be sure that both clamps are not making contact with anything
below the insulating material on the terminal (arrows). . . . . 30
10 amp
(part number 30122) . . . . . . . . . . . . . . . . . 23
Be sure to set the Time-of-Day . . . . . . . . . . . . . . . . . 45
30 - 35 in/lbs. torque when reinstalling. . . . . . . . . . . . . 40
BE SURE TO TURN THE POWER OFF BEFORE REPLACING ANY
COMPONENT, ESPECIALLY A CIRCUIT BOARD. . . . . . . . . 41
0.3 amp (part number 21581) . . . . . . . . . . . . . . . . . 23
30 amp
(part number 30136) . . . . . . . . . . . . . . . . . 23
42˚F TOO COLD . . . . . . . . . . . . . . . . . . . . . . . . . 57
102˚F SNSR BAL-- ANCE . . . . . . . . . . . . . . . . . . . . 58
102˚T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
120 V Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
240 V Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A / B (A/B Sensor Temperatures) . . . . . . . . . . . . . . . . 56
A/B Temps . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
A/B Temps (A/B Sensor Temperatures) . . . . . . . . . . . . 36
Acceptable Heater Amperage Draw Ranges . . . . . . . . . . 21
Acceptable Heater Ohm (Ω) Ranges . . . . . . . . . . . . . . 21
Acceptable Heater Ohm (Ω) Ranges . . . . . . . . . . . . . . 24
A common programming mistake is overlapping filter times that
may cause the spa to filter continuously. . . . . . . . . . . . . 16
BETA VER-- SION -- -- -- -- . . . . . . . . . . . . . . . . . . . 58
BP600 board Setup switch . . . . . . . . . . . . . . . . . . . 37
BP2100 board screw locations . . . . . . . . . . . . . . . . . 42
BP2100 board without wires . . . . . . . . . . . . . . . . . . 42
BP2100 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 7
Brown Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brown to Blue Wires on a 230V BP600 System . . . . . . . . 27
Brown to Blue Wires on a 230V BP2100 System . . . . . . . . 27
CE Product: . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Changing Menus Through Configurations . . . . . . . . . . . 61
Check for Loose Connections or Damaged Wires . . . . . . . 18
Checking the System Power Input Fuse. . . . . . . . . . . . . 13
Circ Pump (or circulation pump) . . . . . . . . . . . . . . . . 72
A fuse with the meter reading “bad” . . . . . . . . . . . . . 23
Circulation Pump Modes . . . . . . . . . . . . . . . . . . . . 45
A fuse with the meter reading “good” . . . . . . . . . . . . . 23
Cleanup
All TP Panels have “Molex” Type Connectors . . . . . . . . . . 9
Cleanup Cycle (optional) . . . . . . . . . . . . . . . . . . . . 46
Always turn the power off when plugging and unplugging! . . 35
Clean-up (or purge) Cycle . . . . . . . . . . . . . . . . . . . . 72
A message with an asterisk [*] can be reset from the topside
panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CLOK FAIL -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . . 58
Amperage Draw Ranges . . . . . . . . . . . . . . . . . . . . 21
Color of Background . . . . . . . . . . . . . . . . . . . . . . 52
Amperage Heater Test BP600. . . . . . . . . . . . . . . . . . 32
Common Fuses Used on spa Systems . . . . . . . . . . . . . . 7
Amperage Heater Test BP2100G1 . . . . . . . . . . . . . . . 32
Communications error . . . . . . . . . . . . . . . . . . . . . . 51
Apply Loctite when reinstalling. . . . . . . . . . . . . . . . . 40
Compatibility on Dual Board Control Systems . . . . . . . . . 42
A Pump Appears to be Stuck ON – M034 . . . . . . . . . . . 58
Configuration Error - Spa will not Start Up . . . . . . . . . . . 51
A Pump Appears to have been Stuck ON when spa was last
powered – M035 . . . . . . . . . . . . . . . . . . . . . . . . 58
Configuration Error - Spa will not Start Up . . . . . . . . . . . 58
A pump may be stuck on – M034 . . . . . . . . . . . . . . . . 51
Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
A Reset Message May Appear with other Messages. . . . . . 57
Current Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A Simplified Main Menu (Doc No. 42185B). . . . . . . . . . . 62
DEMO (Demo Mode) . . . . . . . . . . . . . . . . . . . . . . 36
Assigning a new address to the Dolphin . . . . . . . . . . . . 70
DEMO (Demo Mode) . . . . . . . . . . . . . . . . . . . . . . 56
A Standard Main Menu (Doc No. 40940I) . . . . . . . . . . . 62
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Avoid damaging the post. Reinforce the post, especially when
reinstalling the upper nut on a new heater. . . . . . . . . . . 40
Depress sensor tab when removing . . . . . . . . . . . . . . 31
78
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CNFG FAIL -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . . 58
Configuration Signature . . . . . . . . . . . . . . . . . . . . 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.
5/02/13
Index of Paragraph Topics (cont.)
Depress tab when removing . . . . . . . . . . . . . . . . . . 34
Four Pole RCD . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Device
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Freeze condition . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . 48
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . 45
Disconnect the connector by depressing the tab. . . . . . . . 24
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . 72
Dolphin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fuses installed in the system . . . . . . . . . . . . . . . . . . 23
Dolphin II and Dolphin III (Applies to RF Dolphin only) . . . . 52
GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Dolphin III (50211) . . . . . . . . . . . . . . . . . . . . . . . 70
GFCI FAIL -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . . . 58
Dolphin III CE (50212) . . . . . . . . . . . . . . . . . . . . . . 70
GFCI Failure - System Could Not Test/Trip the GFCI – M036 . 58
Dolphin Manual . . . . . . . . . . . . . . . . . . . . . . . . 70
GFCI Test (Feature not available on CE rated systems.) . . . . 49
Dolphin Receiver . . . . . . . . . . . . . . . . . . . . . . . . 69
Ground in System Enclosure . . . . . . . . . . . . . . . . . . 12
Dolphin Remotes . . . . . . . . . . . . . . . . . . . . . . . . 70
Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7
Do not measure across heater terminals . . . . . . . . . . . . 29
Heater Element Specifications Are Shown on the Heater Tube
Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DO NOT REMOVE AND REPLACE THE CIRCUIT BOARD UNLESS
THE FAULT HAS POSITIVELY BEEN DETERMINED TO BE THE
CIRCUIT BOARD. . . . . . . . . . . . . . . . . . . . . . . . . 41
Heater Flow is Reduced (HFL) – M016 . . . . . . . . . . . . . 57
Heater Flow is Reduced (LF)* – M017 . . . . . . . . . . . . . 57
Drain Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Heater Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exiting Priming Mode . . . . . . . . . . . . . . . . . . . . . . 44
Heater May be Dry (dr)* – M028 . . . . . . . . . . . . . . . . 57
Exiting Priming Mode . . . . . . . . . . . . . . . . . . . . . . 55
Heater Related Messages . . . . . . . . . . . . . . . . . . . 48
F6 and F8 are on the main board. F1 is located on the expander
board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Heater Start Up Information . . . . . . . . . . . . . . . . . . 15
F6 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F6 to TB1 Blue . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FALT LOG (Fault Log) . . . . . . . . . . . . . . . . . . . . . . 36
FALT LOG (Fault Log) . . . . . . . . . . . . . . . . . . . . . . 57
Fault Log Message Codes: TP400, TP600 . . . . . . . . . . . . 59
Fault Log: tp800, tp900 . . . . . . . . . . . . . . . . . . . . . 49
-- -- --˚F -- -- -- ˚C . . . . . . . . . . . . . . . . . . . . . . . 57
---˚F ---˚C . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Filter Cycle 2 - Optional Filtration . . . . . . . . . . . . . . . . 46
Filtration and Ozone . . . . . . . . . . . . . . . . . . . . . . . 45
Filtration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 72
Flashing Heat LED on TP600 ("Heat Waiting") . . . . . . . . . 15
Flow-Related Checks . . . . . . . . . . . . . . . . . . . . . . 48
Flow-Related Checks . . . . . . . . . . . . . . . . . . . . . . 58
Forcing the GFCI Trip Test . . . . . . . . . . . . . . . . . . . . 50
°F or °C is replaced by °T . . . . . . . . . . . . . . . . . . . . 51
°F or °C is replaced by °T . . . . . . . . . . . . . . . . . . . . 58
42217B
Heater Type . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heater Voltage (Feature not used on CE rated systems.) . . . 48
Heater Voltage (Feature not used on CE rated systems) . . . . 56
Heater Wattage as Configured in Software (CE Systems Only) 48
Heater Wattage as Configured in Software (CE Systems Only) 56
Heat LED in Heat Waiting Mode, TP600 . . . . . . . . . . . . 15
H _ (Heater Type) . . . . . . . . . . . . . . . . . . . . . . . . 56
Hold Mode - M037* . . . . . . . . . . . . . . . . . . . . . . . 46
HOT FALT -- -- -- -- CALL FOR SRVC -- -- -- -- . . . . . . . . . 58
Hot fault – M035 . . . . . . . . . . . . . . . . . . . . . . . . 51
How the Dolphin Works . . . . . . . . . . . . . . . . . . . . . 69
htr flow fail -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . 57
htr flow loss -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . 57
HTR is too Hot (OHH)* M030 . . . . . . . . . . . . . . . . . . 57
HTR MAY BE DRY -- -- -- -- WAIT -- -- -- -- . . . . . . . . . . . 57
HTR TOO HOT -- -- -- -- . . . . . . . . . . . . . . . . . . . . . 57
If the problem stays with the same sensor (according to topside
messages) it's a board problem; if the problem moves to the other
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 of Paragraph Topics (cont.)
sensor it's a sensor problem. . . . . . . . . . . . . . . . . . 35
Observe safety at all times . . . . . . . . . . . . . . . . . . . 26
Important -- Use of non-copper wire . . . . . . . . . . . . . . 18
Ohm’s Law. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INFO (System Information sub-menu) . . . . . . . . . . . . . . 56
Once the power input fuse has been changed . . . . . . . . . 13
Installing a System Circuit Board . . . . . . . . . . . . . . . . 42
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
On Every System, an Identification Label Is Placed on Top of the
Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Locate the heater connector. . . . . . . . . . . . . . . . . . . 24
On Every System, a Wiring Diagram Is Placed Inside the Door . 9
Locate the heater connector. . . . . . . . . . . . . . . . . . . 25
Panel Version
Locking nuts are in same location on BP models . . . . . . . . 40
PANL (Panel Version) . . . . . . . . . . . . . . . . . . . . . . 56
Logic Board: 22121_E / 56131-02 . . . . . . . . . . . . . . . 67
Place clamp around one heater wire, and then the other wire. 32
Logic Board: 22121_E / 56131-02 . . . . . . . . . . . . . . . 68
Place the meter probes on the heater terminals. . . . . . . . 24
Logic Jumper, No. 20618 . . . . . . . . . . . . . . . . . . . . . 7
Possible freezing condition . . . . . . . . . . . . . . . . . . . 51
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Board: 22117_B / 56284; . . . . . . . . . . . . . . . 67
M0[XX] numbers are Message Codes. . . . . . . . . . . . . . 44
Power Board: 22117_B / 56284; . . . . . . . . . . . . . . . 68
M-7 Replacement Sensor . . . . . . . . . . . . . . . . . . . . 35
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Main Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . 46
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Measure resistance from a heater post to the heater housing 25
Preliminary Panel Check. . . . . . . . . . . . . . . . . . . . . 15
MEM FAIL -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . . 58
Preparation and Filling . . . . . . . . . . . . . . . . . . . . . 44
Memory Failure - Checksum Error* – M022 . . . . . . . . . . 58
Preparation and Filling . . . . . . . . . . . . . . . . . . . . . 55
Memory Failure - Clock Error* – M020 . . . . . . . . . . . . 58
Pre-Production Software . . . . . . . . . . . . . . . . . . . . 58
Memory Warning - Persistent Memory Reset* – M021 . . . . 58
PRES BTTN TO RSET -- -- -- -- . . . . . . . . . . . . . . . . . . 57
MEM RSET -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . . 58
Press-and-Hold . . . . . . . . . . . . . . . . . . . . . . . . . 43
Message Codes . . . . . . . . . . . . . . . . . . . . . . . . . 16
Priming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Message Codes . . . . . . . . . . . . . . . . . . . . . . . . . 56
Priming Mode – . . . . . . . . . . . . . . . . . . . . . . . . 44
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Priming Mode – M019 . . . . . . . . . . . . . . . . . . . . . 57
MODL (System Model) . . . . . . . . . . . . . . . . . . . . . 56
Priming Mode – M019* . . . . . . . . . . . . . . . . . . . . . 55
Most messages and alerts will appear at the bottom of the
normally used screens. . . . . . . . . . . . . . . . . . . . . . 51
Priming the Pumps . . . . . . . . . . . . . . . . . . . . . . . 44
Most Probable Overheating Causes, Inspect These First . . . . 16
Program memory failure* – M022 . . . . . . . . . . . . . . . 51
Motor Amperage Guidelines . . . . . . . . . . . . . . . . . . 21
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pull the connector straight out. . . . . . . . . . . . . . . . . . 24
NO COMM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Pull the connector straight out. . . . . . . . . . . . . . . . . . 25
No Communications . . . . . . . . . . . . . . . . . . . . . . . 58
Pump 1 AMP cord . . . . . . . . . . . . . . . . . . . . . . . . 33
Note: Be careful when removing a heater assembly from a spa
plumbing system. Water may splash out under pressure. . . . 40
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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 more information. . . . . . . . . . . 33
RCD Line-in Wiring Check . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 48
Priming the Pumps . . . . . . . . . . . . . . . . . . . . . . . 55
Purge Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
RCD Line-out Wiring Check for 230 V Dedicated System . . . 19
Recommended Parts to have For Service Calls . . . . . . . . . . 7
80
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.
5/02/13
Index of Paragraph Topics (cont.)
Release tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STUK PUMP -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . 58
Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SW _ (Dip Switch Settings) . . . . . . . . . . . . . . . . . . . 56
Remove both nuts that secure the element in place. . . . . . 40
System Box Wire Gauge Check . . . . . . . . . . . . . . . . . 18
Removing a System Circuit Board. . . . . . . . . . . . . . . . 41
System Information . . . . . . . . . . . . . . . . . . . . . . . 48
Removing BP Expander Board, an Alternate Way . . . . . . . 41
System Model . . . . . . . . . . . . . . . . . . . . . . . . . 48
Restricting Operation (Locking the Panel). . . . . . . . . . . . 47
TB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RUN PMPS PURG AIR ---- . . . . . . . . . . . . . . . . . . . 57
TB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Trip - Pump Suction Blockage* – M033 . . . . . . . . . 57
Temp Display . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Saving Settings . . . . . . . . . . . . . . . . . . . . . . . . . 45
Temperature & High-Limit Sensor Ohm Table . . . . . . . . . 21
Saving Your Dolphin Address . . . . . . . . . . . . . . . . . . 70
Temperature Sensors location (Wires removed) . . . . . . . . 34
Scrolling TP400/TP600 Messages . . . . . . . . . . . . . . . 57
Temp Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sensor A Fault, Sensor B Fault – Sensor A: M031, Sensor B: M032
51
Terminal Block & F6 Fuse on a BP600 Power Board, 230V Setup13
Sensor Balance is Poor – M015. . . . . . . . . . . . . . . . . 58
Testing a Fuse: Check continuity with the fuse removed . . . . 23
Sensor Balance is Poor* – M026 . . . . . . . . . . . . . . . . 58
Testing low speed and High Speed at the AMP Connector . . 33
Sensor Failure – Sensor A: M031, Sensor B: M032 . . . . . . 58
Testing Sensor Pins . . . . . . . . . . . . . . . . . . . . . . . 35
Sensor Location BP500, on Logic Board . . . . . . . . . . . . 31
Test Menu Access (S1, Switch 1 ON) . . . . . . . . . . . . . . 36
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. . . . . . . . . . . . 35
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Sensors are out of sync -- Call for service* – M026 . . . . . . 51
Test the Amperage Draw . . . . . . . . . . . . . . . . . . . . 14
Sensors are out of sync – M015 . . . . . . . . . . . . . . . . 51
Test the Blower . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service Tools Required . . . . . . . . . . . . . . . . . . . . . . 7
Test the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SETP (Current Setup) . . . . . . . . . . . . . . . . . . . . . . 56
Test the System . . . . . . . . . . . . . . . . . . . . . . . . . 14
sfty trip -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . . . 57
SIG (Configuration Signature) . . . . . . . . . . . . . . . . . . 56
The brown wire should connect to load out, the blue wire from
neutral out. All wires will exit the box via conduit routed to the spa
control system. . . . . . . . . . . . . . . . . . . . . . . . . . 19
Simplified Menus . . . . . . . . . . . . . . . . . . . . . . . . 61
The clock has failed* – M020 . . . . . . . . . . . . . . . . . 51
SNSR A -- -- -- -- CALL FOR SRVC -- -- -- -- . . . . . . . . . 58
SNSR B -- -- -- -- CALL FOR SRVC -- -- -- -- . . . . . . . . . . 58
The Control System is in Test Mode if 102˚T appears. (In this case
°F or °C is replaced by °T.) . . . . . . . . . . . . . . . . . . . 36
SNSR SYNC -- -- -- -- CALL FOR SRVC -- -- -- -- . . . . . . . . . 58
The DolphinTM Remote . . . . . . . . . . . . . . . . . . . . . 69
Software ID: (SSID) . . . . . . . . . . . . . . . . . . . . . . 48
The Fault Log . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Software Setups . . . . . . . . . . . . . . . . . . . . . . . . 36
The GFCI test failed (System Could Not Test the GFCI) – M036 51
Software Setups (BP2100) . . . . . . . . . . . . . . . . . . . 39
The Ground Fault Circuit Interrupter (GFCI) . . . . . . . . . . . 50
Some Troubleshooting Scenarios . . . . . . . . . . . . . . . . 16
The heater is dry* – M027 . . . . . . . . . . . . . . . . . . . 48
Spa Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
The heater is too hot* – M030 . . . . . . . . . . . . . . . . . 48
SSID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
The heater may be dry* – M028 . . . . . . . . . . . . . . . . 48
SSID (Software ID) . . . . . . . . . . . . . . . . . . . . . . . 56
The preferred way to check for fuse continuity is with the fuses
42217B
Terminal Block & F6 Fuse on a BP2100 Board . . . . . . . . . 13
Test software installed . . . . . . . . . . . . . . . . . . . . . 51
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 of Paragraph Topics (cont.)
removed from the circuit. . . . . . . . . . . . . . . . . . . . . 23
Water is too Hot (OHS) – M029. . . . . . . . . . . . . . . . . 57
There are three 30A pump fuses in the BP2100G1 spa control
system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Water Temperature is Unknown . . . . . . . . . . . . . . . . 51
These readings should be taken under peak load conditions. . 14
watr too hot -- -- -- -- . . . . . . . . . . . . . . . . . . . . . . 57
The settings have been reset (Persistent Memory Error)* – M021
51
What Priming Mode does: . . . . . . . . . . . . . . . . . . . 72
The Utilities Menu contains the following: . . . . . . . . . . . 52
The water flow has failed* – M017 . . . . . . . . . . . . . . 48
The water flow is low – M016 . . . . . . . . . . . . . . . . . 48
The water is too hot – M029 . . . . . . . . . . . . . . . . . . 51
Water Temperature is Unknown . . . . . . . . . . . . . . . . 57
Wiring Check Precautions . . . . . . . . . . . . . . . . . . . . 18
With the pump high speed ON, take a voltage reading at the AMP
receptacle on the PCB . . . . . . . . . . . . . . . . . . . . . . 33
With the pump low speed ON, take a voltage reading at the AMP
receptacle on the PCB . . . . . . . . . . . . . . . . . . . . . . 33
This would typically show high speed voltage for Pump one. (230V)
33
This would typically show low speed voltage for Pump one. (230V)
33
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Time Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Tip: If one sensor (A or B) seems to be having problems, swap the
cables of sensor A with sensor B. . . . . . . . . . . . . . . . 35
To Determine the Cause of a Blown Power Input Fuse . . . . . 14
Too Cold - Freeze Protection . . . . . . . . . . . . . . . . . . 57
TP400/TP600 error codes and fault messages are similar to TP800/
TP900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting Heater Posts Resistance to Heater Housing . 25
Troubleshooting heater Resistance . . . . . . . . . . . . . . . 24
Two Pole RCD . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unlocking the Panel . . . . . . . . . . . . . . . . . . . . . . . 47
Used for verifying a proper installation . . . . . . . . . . . . . 50
Utilities menu . . . . . . . . . . . . . . . . . . . . . . . . . 49
Verifying Incoming Voltage at the Terminal Block. . . . . . . . 27
Verify that there is no heater “leakage” . . . . . . . . . . . . 25
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). . . . . . . . . . . . . . . . . . 25
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. . . . . . . . . . . 25
Viewing Configuration Settings . . . . . . . . . . . . . . . . . 36
Voltage Checklist . . . . . . . . . . . . . . . . . . . . . . . . 21
82
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.
5/02/13
Notes
42217B
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
42217B May 2, 2013
Tustin Ca. 92780 (714) 384-0384
©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,
84
5/02/13
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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