Schematic For This Board

Schematic For This Board
ALLIED INNOVATIONS, LLC
Manufacturing the Product Lines of Len Gordon
7215 Bermuda Rd Las Vegas NV 89119-4304
BL-40 UNIVERSAL
CIRCUIT BOARD
REPLACEMENT KIT
IMPORTANT INSTALLATION INSTRUCTIONS - PLEASE READ!
The BL-40 Universal Circuit Board Replacement Kit replaces Catalina Controls Corporation models RC34, RC4,
RC4a, RC4Pa, RMQ4, RC7, RC7a, RC7E and Brett Aqualine models BL-40 and BL-40TC circuit boards. This
booklet contains installation instructions and wiring diagrams to assist you in installing the BL-40 circuit board.
Please review these instructions in advance to confirm that you have all necessary tools and components, which
may not be included in this kit. For any questions not covered, you may contact the Allied Innovations, LLC
Technical Service Department between 8:00 a.m. and 5:00 p.m. PST at (702) 361-0600 or e-mail
[email protected] Terminals 1 and 2 are for line voltage which can be 120V or 240V. The BL-40 Board
will automatically detect the voltage and adjust accordingly.
STEP ONE - CONFIGURE THE CIRCUIT BOARD (DIP SWITCH SETTINGS):
The BL-40 incorporates 8 mode selection (DIP) switches to configure the circuit board. The switches are located
on the circuit board (SW1) and are preset at the factory to the “OFF” (down) position. Each switch is assigned a
number from 1 through 8. To activate the desired mode, use a ball point pen and push the switch to the “ON” (up)
position. Factory DIP SWITCH setting: 2 & 6 ON; 1, 3, 4, 5, 7, 8 OFF.
“DIP” SWITCH SETTINGS
Select one of the following setup configurations listed below:
1
2
3
Single-speed pump(s) installed
Enable optional second light and aux pump
Select any of the following options listed below:
Disable 30 minute extended filtration feature
Enable thermostatic control of pump and heater
Disable heat if jets/blower is on (120V units)
5
ON
B
E
ON
ON
ON
6
7
8
OFF
M
U
S
T
Two-speed pump installed
For continuous circulation pump operation
4
N
O
T
ON
U
S
E
D
O
F
F
ON
NOTE: 1. If using a 2-speed pump, Dip Switch #6 must be “ON” for Filtering and Jets.
2. Switches “4" and “7" are not used and MUST be set to “OFF” position for proper operation.
3. If using a stand-alone heater, Dip Switch #5 (a separate gas or electric power source) should be “OFF”.
STEP TWO - INSTALL THE CIRCUIT BOARD:
WARNING: To prevent electric shock, make sure all power is off prior to attempting installation. Remove the
old circuit board (making note of where the wires are connected) and install the BL-40 universal replacement board.
Models with integral time clock may require the use of the four 1/4" standoff extensions provided for clearance
between the top of the circuit board and the bottom of the time clock.
STEP THREE - LOW VOLTAGE CONNECTIONS:
Using the “LOW VOLTAGE CONNECTION” table on the following page, reconnect all low voltage connections to
the BL-40 universal circuit board receptacles. IMPORTANT NOTE - DO NOT install freeze SENSORS or JUMPER
plugs from model RC4, RMQ4, or RC7 circuit boards to the BL-40 universal circuit board.
LOW VOLTAGE CONNECTIONS
From:
RC4, RC34
and RMQ4
P1
From:
RC7
From:
RC4a,
RC4Pa and
RC7a
Connect to
BL-40
Universal
Circuit
Board
COMMENTS
P1
‘SPA PNL’
‘RMT SPA
PANEL’
P1
Some older circuit boards use 8-pin spa-side connections. The BL-40 uses a 9-pin
spa-side connector. To use an existing 8-pin spa-side, shave off the plug ‘nub’ closest
to the green wire. The other ‘nub’ will act to align the connector correctly.
Some older circuit boards use 8-pin in-house connections. The BL-40 uses a 9-pin
Master panel connector. To use an existing 8-pin Master panel, shave off the plug
‘nub’ closest to the green wire. The other ‘nub’ will act to align the connector correctly.
Optional - Filtration time receptacle. Use terminal “P8" for low voltage clock
connection, or “P10" for high voltage (120 VAC or 240 VAC) clock connection. A
pigtail cable kit (Item# 060380) is available for high voltage connection to terminal
“P10".
P2
N/A
P2
‘RMT
MSTR
PANEL’
P2
N/A
P2
P13
‘DC TIME
IN’ P8 OR
‘AC CLK IN’
P10
N/A
P3
‘HEAT’
‘HEATER’
P11
N/A
P4
P12
‘OPTIONS’
P9
Optional - Heating timer receptacle. Note: ”P9" requires the use of a 9-pin connector.
Using the 9-pin connector and crimp-on splices provided in the kit, remove the 3-pin
plug, and splice wires to 9-pin connector (polarity is not important).
120/240 volt conversion jumper receptacle (not on all models).
P4
P5
‘TEMP’
‘WATER’
P3
Temperature Sensor Receptacle. A temperature sensor (Item# 070840 or 38-0400A)
must be connected to “P3” for heater operation. IMPORTANT: Older temperature
sensors may have reversed plug wiring and will not function with the BL-40. The
correct temperature sensor plug wiring is: pin one = cable shield (not used on all
models); pin two and three = sensor (reference point - pin one will be located adjacent
to nine pin receptacles P1 and P2). If temperature sensor plug wiring is not correct,
replace sensor or use a small flat blade screwdriver to pry wires one and three out of
plug and reverse. Use screwdriver to full reinsert wires into plug.
P5
P6
‘FLOW’
‘FLOW SW’
P4
Pressure/Flow Switch Receptacle. A pressure switch or flow switch, flow switch, or
bypass jumper must be installed for heater operation. IMPORTANT: If a pressure or
flow switch is not connected to this receptacle, a jumper plug (Item# 080040) must be
connected for heater operation.
P3
P7
---
‘FREEZE
1&2'
P6 AND P5
Optional Freeze SWITCH Receptacle. IMPORTANT: DO NOT move jumpers or
freeze SENSOR used on RC4, RMQ4, or RC7 circuit boards to the BL-40. Only use
optional freeze SWITCH (Item# 070120) if freeze protection is desired.
STEP FOUR - HIGH VOLTAGE CONNECTIONS:
Using the WIRING DIAGRAMS on the following pages, reconnect all high voltage-wiring connections to the BL-40
universal circuit board replacement terminal block. “Quick Disconnect” terminals are provided to replace model
RC7a circuit boards. Reapply power and check for proper operation.
NOTE: There are many possible wiring configurations. The attached diagrams show “typical” installations. Jumper
wires (not provided) may be required for terminal to terminal connections. Use minimum #14 AWG jumper wires
for this purpose. For common connections, such as multiple neutral connections, use wire nuts (not provided) or
other suitable connector approved for size and number of conductors being spliced together. All connections are
to be made in accordance with the National Electrical Code and local codes in effect at the time of installation.
TROUBLESHOOTING (Most common problems):
Heater Does Not Operate, no HEAT indicator light on spa side panel:
Make sure a pressure or flow switch or bypass jumper is connected to terminal P4. If a pressure or flow switch is
connected, ensure that the switch is operating correctly.
Make sure system is operating in a heat mode and the spa side control thermostat is set to HOT. If the system is
equipped with an optional in-house master control, ensure that this thermostat is also set to HOT.
Make sure temperature sensor is connected to terminal P3. Older temperature sensors may have reversed plug
wiring and will not function with the BL-40. The correct temperature sensor plug wiring is pin one = cable shield (not
used on all models); pin two and three = sensor (reference point - pin one will be located adjacent to nine pin
receptacles P1 and P2). If temperature sensor plug wiring is not correct, replace sensor or use a small flat blade
screwdriver to pry wires one and three out of plug and reverse. Use screwdriver to full reinsert wires into plug.
Heater does not operate, HEAT indicator light on spa side panel is illuminated:
Make sure the heater is operational.
Check wiring at high voltage terminals P11 and P12. The correct wiring will be power in (line) terminal 11 and power
out to heater (load) terminal 12.
Pump not operating correctly:
Make sure the DIP switch settings are correct for the type of pump used (single or two speed motor). Make sure the
high voltage wiring is connected properly (jumper wires must be installed between terminals 2, 3 and 6).
Pump runs continuously:
Make sure filtration timer is OFF.
Make sure the temperature sensor is connected to terminal P3. See Low Voltage Connections table for correct
temperature sensor wiring.
Remove any devices connected to ‘FREEZE 1 & 2', terminals P5 and P6. If the pump stops operating, the problem
may have been caused by a jumper or freeze sensor installed in these positions. Discard jumper or replace freeze
sensor installed in these positions with freeze switch (Item# 070120).
TEMPERATURE vs RESISTANCE TABLE
TEMP
(degrees F)
THERM
KOHM
TEMP
(degrees F)
THERM
KOHM
TEMP
(degrees F)
THERM
KOHM
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
32.7
31.8
30.9
30.0
29.2
29.4
27.6
26.8
26.1
25.4
24.7
24.0
23.3
22.7
22.1
21.5
20.9
20.4
19.8
19.3
18.8
18.3
17.8
17.3
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
16.9
16.5
16.0
15.6
15.2
14.8
14.5
14.1
13.7
13.4
13.1
12.7
12.4
12.1
11.8
11.5
11.2
11.0
10.7
10.4
10.2
9.95
9.71
9.48
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
9.25
9.03
8.82
8.61
8.41
8.22
8.03
7.84
7.66
7.48
7.31
7.14
6.98
6.82
6.67
6.52
6.37
6.23
6.09
5.96
5.83
5.70
5.57
5.45
5.33
105
5.22
the temperature sensor (by attaching the VOM
probes to the leads that correspond with the wire
connections on the temperature sensor).
TEMPERATURE SENSOR AND HIGH LIMIT
SENSOR CHECKOUT PROCEDURE
The temperature sensor and high limit sensor utilize a
thermistor which changes resistance as a function of
temperature. In order to troubleshoot the thermistor,
you must know what the resistance should be at a given
temperature
Use a standard VOM (Volt/Ohm Meter) set to read R
x 10,000:
"
"
Disconnect the sensor from
J2 (temperature sensor) or
J3 (high limit sensor) on the
Control circuit board.
Attach a 3 pin base to the
sensor plug to provide male
contact points for resistance
reading, or insert probe tips
into the back of plug until
contact is made.
Using the VOM, record the resistance reading of
"
Use an accurate thermometer and check the spa
water temperature. The acceptable range is 2EF
below the actual spa water temperature. See the
example below.
"
Refer to the Temperature vs Resistance Table
above and compare the spa water temperature to
determine if the resistance readings are within the
acceptable range.
Example: Temperature vs Resistance range
92
6.98
-2EF! 93
6.82
•
94
6.67
Acceptable
Water Temp! 95
6.52
Resistance
96
6.37
Range
+2EF! 97
6.23
–
98
6.09
WARRANTY
Allied Innovations, LLC warrants its products to be free from defects in workmanship and
material under normal use and conditions for a period of one year from the date of original
manufacture. Should repair be required by reason of any defect or malfunction during the
warranty period, Allied Innovations, LLC will repair, or at their discretion, replace this product
without charge, subject to verification of the defect or malfunction, upon delivery of the product
to the attention of:
Technical Service Department
Allied Innovations, LLC
7215 Bermuda Rd
Las Vegas, NV 89119-4304
If repair is required after the expiration date of the warranty period, Allied Innovations, LLC will
repair this product and bill for any necessary replacement parts, shipping and handling.
This warranty is void if: 1) the unit is not installed per the instructions; 2) is hooked up to
improper voltage; 3) is subjected to chemical corrosion; 4) is mechanically or electrically
altered in any way; 5) is subjected to water or immersion; 6) contacts show evidence of short
circuiting, or the unit has been visibly damaged by accident or misuse or which has been
damaged by wind, rain, lightning, freezing or other cause; or upon which the serial number or
manufacture date has been altered, effaced or removed. There is a charge for replacement
parts if the defective unit is returned for any of the reasons listed above.
Allied Innovations, LLC shall not be liable for any inconvenience, loss of time, or incidental
expenses incurred. Allied Innovations, LLC shall not be liable for any labor charges associated
with the removal or re-installation of any so-claimed defective products.
This is the only warranty expressed or implied by Allied Innovations, LLC. Warranties implied
under state law, including any implied warranty of merchantability or fitness for a particular
purpose, shall be limited to one year from the date of manufacture.
Allied Innovations, LLC disclaims any liability for any incidental or consequential damages.
Ship as follows:
1. Pack the unit in a well padded, heavy corrugated box.
2. Include name, return address, and daytime phone number
along with a short description of problem with control.
3. Mail the unit, prepaid, to the above address.
Some states do not allow the exclusion or limitation of incidental or consequential damages,
therefore the above limitation may not apply to you.
62580D-0
© 2002 Allied Innovations, LLC 02/02
ALLIED INNOVATIONS, LLC
Manufacturing the Product Lines of Len Gordon
7215 Bermuda Rd Las Vegas NV 89119-4304
This unit was shipped from the factory with a mini jumper (Item
#400190, shown at right) installed in the “Flow Switch” (P4)
receptacle. Make sure that this jumper is secure prior to installing
the unit. If a connection to an external pressure or flow switch is
desired, use optional Pressure/Flow Switch Cable (Item #070110)
in place of this jumper. The heater circuit will not operate
without this jumper or an external pressure or flow switch
connected to (P4) receptacle.
650080-0
© 2002 Allied Innovations, LLC 03/02
ATTENTION
INSTALLER
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