Emerald Spas Balboa Service Manual
Contents
1. e Rotate the star wheel on the pressure switch clockwise until no continuity is shown on the meter e Turn on the high speed pumps and run for at least ten seconds You should again see continuity on your meter e Turn off all pumps and within four seconds continuity should no longer exist e If after four seconds you still see continuity on the meter attempt to recalibrate the pressure switch e Ifyou still have problems calibrating then replace the pressure switch Note The main reason for pressure switch failure is poor water chemistry Instruct the owner in proper water maintenance When the display is flashing FL this may indicate a flow restriction such as a dirty filter Another cause of the flashing FLO message could be a faulty or malfunctioned pressure switch When servicing a spa with a flashing FLO message e Set your voltmeter to ohms e Disconnect the pressure switch wire from the circuit board and turn on the low speed pump e Connect the pressure switch wire and voltmeter probes to the Balboa LJS At this point the pressure switch can be calibrated e Adjust the pressure switch by rotating the star wheel counter clockwise until continuity appears on the meter e Switch from low speed to high speed if available and run for ten seconds After ten seconds has passed turn off all pumps e After four seconds check the voltmeter and verify that there is no continuity showing e If there2. i fg ft Toia _ 4 a een i E rae ee Ozone Generator Hookup Perimeter Light Hookup pH Orp Sensor Input J11 Pump 1 Hookup Pump 2 Enable Jumper J10 Pump 2 Hookup Auxiliary Panel Input Serial Number Model Number Designations 50Hz 60Hz Jumper J25 Soldered in Fuse Spa Light Hookup Transformer Input 50A 20A Jumper J9 Battery Backup Enable Jumper J36 www balboa instruments com 23 Duplex Digital Super Duplex Circuit Board OO 20 Paan finni bi pum i Hii gmin Circuit Board Components 1 Blower Triac Use Screw For Heat Sink Only 15 Pump Low Relay Do Not Overtighten 16 Pump 2 Aux Relay 2 Blower Hookup 17 60Hz 50Hz Jumper J13 3 Control Panel Input 18 Serial Number Model Number Designations 4 Filter Select Jumper J19 19 Soldered in Fuse 5 Finger 5 20 Spa Light Hookup J10 6 Finger 6 21 Spa Light Relay 7 Flow Switch Input J9 22 Temp High limit Input J20 8 Freeze Control Sensor Input J22 23 Transformer Input 9 Heater Relay 24 20A 50A Jumper J8 10 Light Fuse 25 Pump 2 Enable Jumper J26 11 Main Processor with Software Number 12 Ozone Hookup J14 13 Ozone Generator Relay 14 Pump High Relay 24 X 800 645 3201
3. AE Vee HL _ e Ej Ce i OOOO Circuit Board Components a a wad ue i 1 Blower Triac TRC6 Use Screw For Heat Sink Only 15 Do Not Overtighten 16 2 Blower Hookup 17 3 Control Panel Input 18 4 Fan Battery Input J5 19 5 Finger 5 20 6 Finger 6 21 7 Filter Select Jumper Standard Only J7 22 8 Flow Switch Input J3 23 9 Freeze Control Sensor Input J15 24 10 Temp Hi limit Input J2 25 11 Light Fuse 12 Main Processor with Software Number 13 Ozone Enable Jumper J16 Ozone Generator Hookup ie ST Very FEF F O 06 Perimeter Light Hookup J14 pH Sensor Input J11 Pump 1 Hookup Pump 2 Enable Jumper J10 Pump 2 Hookup Auxiliary Panel Input Serial Number Model Number Designations Soldered in Fuse Spa Light Hookup Transformer Input 20A 50A Jumper J9 22 X 800 645 3201 Millennium Circuit Board Circuit Board Components 1 Blower Triac TRC6 Use Screw For Heat Sink Only Do Not Overtighten Blower Hookup Control Panel Input Fan Input J5 Finger 5 Finger 6 Filter Select Jumper Standard Only J7 Flow Switch Input J3 Aux Freeze Control Sensor Input J15 Temp High Limit Input J2 Light Fuse Main Processor with software number Orp Enable Jumper J24 Ozone Enable Jumper J16 SC a Sep ee Se eS eS BR wre RF oD 15 16 17 18 19 20 21 22 23 24 25 26 27 28 z it iG a J Pr 1 7 ee
4. Duplex Digital Super Duplex Circuit Board Duplex Digital Super Duplex Circuit Board 24 www balboa instruments com X 3 Balboa Control Service Checklist Preface This manual is provided to aid the qualified service technician in troubleshooting and correcting problems found in spas with control systems manufactured by Balboa Instruments Inc Tools Required e Ammeter 50A e Digital Multi meter e Balboa Six in one Screwdriver Includes Two Phillips Head and Two Flathead Screwdrivers Along with a 1 4 and gt Nut Driver e 5 16 Socket e 17 Open End Wrench e Small Wire Cutters e Pliers amp Needlenose Pliers e Quick Check Test Kit e Logic Jumper on a Sticl e Precision Thermometer Fever Type e Padlock to lock electri disconnect during servi e Plumber s Sealant Quick Check Test Kit System Components Required e Fuses 30 and 20A time delay plus 20 10 and 3A e System Transformers 120 V and 240 V plus a 120 V Duplex e System Sensor Assembly e System Panel s e System Circuit Board A 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 which is included with each system on the inside of the system box cover Use this diagram for voltage measurement points and for
5. e Ifyou still see symptoms of low voltage such as a blank or partially blank panel or if the display or the LED s do not function turn the power off and replace the circuit board Bulb Replacement Another panel problem found primarily on the Deluxe model may be burned out backlighting bulbs These bulbs can easily be replaced e With the power off gently pry up the topside control panel with a screwdriver Next locate the gray bulb holes in the back of the panel Use a screwdriver to turn the bulb approximately 1 4 to remove and replace the bulb Needlenose pliers may also be useful Remote Panel Troubleshooting Remote panel applications need special consideration where the panels connect to the circuit board If You are Working on a Spa With a Remote Panel e Before replacing the circuit board or any panel remove the gang connector from the system box and plug in each panel into the circuit board directly and individually Test all functions with each panel separately If a Remote Panel Doesn t Work e Remove the remote panel from its location e Be sure to secure the end of the panel cable e Plug the remote panel directly into the board This removes the extension loom with its one to one connector from the circuit board and will help you determine whether you have one panel with a problem a defective gang connector a bad extension loom a bad one to one connector or a circuit board prob
6. Wiring Checks Wiring Check Precautions 0 2 0000 System Box Wire Gauge Check 004 G F C I Wiring Check 6c ivaaeeida vie aeke ee ed G F C I Line in Wiring Check 0 00 G F C I Line out Wiring Check anuau 240 V Dedicated nnana 120 240 V Convertible nnana Voltage Checks Breaker Box Voltage Check 0004 G F C I Line in Voltage Check 240 V Dedicated ci roi ae cies Stes ate 120 240 V Convertible 0005 G F C I Load Out Voltage Check 000 240 V Dedicated 0 0 ccc eee 120 240 V Convertible 0000 System Box Check at TB1 000000 240 V Dedicated 0 eee ee ee 120 240 V Convertible 00 000 Peak Load Check 10 0 0 0 c cc cece eee ees Peak Load Check for 240 V Dedicated Peak Load Check for 120 240 V Convertible Wiring Schematic 00 000 10 Basic Control System Troubleshooting LOW VONAGE Sax wipig eran Mesto s tenn CAewON Ake 11 Brown Outs 2 eeraa aaa a eases battens 11 Checking the System Power Input Fuse 11 Deluxe or Standard Digital System 11 Duplex System nonon 11 To Determine if Fuse Replacement is Necessary 11 Test the System Pump Blower 11 Test the Amperage Draw 00000 eee 12 Test the Soldered in Fuse 00 0000 12 Transformer Installation Requirement 13
7. or pressure switch A Important Do not remove and replace the circuit board unless you have tested all other components and proven that the circuit board is actually causing the problem Temperature Sensor The temperature sensor is normally located in the tub wall or filter bucket but may be installed in the plumbing Its main function is to monitor the spa water temperature If this sensor reads a temperature above 112 F all output relays are opened and the spa is shut down The display will flash OH The spa will reset automatically at 110 E High limit Sensor at the heater Temperature Sensor in the spa High limit Sensor The high limit sensor is located on the heater Its main function is to detect both freeze and high limit conditions If the sensor reads a temperature below 40 F the system will automatically turn on all pumps to circulate the water The display will show ICE If the sensor reads a temperature above 118 F the high limit relays will open and the spa will shut down The display will flash GH This sensor must cool down to 110 F before the spa can be manually reset by touching a panel button www balboa instruments com Wiring Checks Safety is key when servicing any spa or spa control panel Remember safety comes first for you and your customer Please take all necessary precautions before attempting any repairs Wiring checks are the first step to ensure safety and proper functio
8. Confirm Transformer Connections 13 Topside Control Panel Preliminary Panel Check 0000 14 Bulb Replacement 05th leo eee 14 Remote Panel Troubleshooting 14 Panel Messages OH Mis UA AS Me a Ad Ad SB a AI ARIS A te a 15 SN E a A ee ae Gate aie E 16 SINS eles Sedara o aa A Pate ele a a a E E 16 FLO Continuous and Flashing 16 COON sche rod ore a San ree 17 MG eee O estas ae as ete weedeat cere ee een aca cesta 5 17 PD 2 uute a eaa e avian Sabie ds one 17 03 PETELE E ANL E EE EES EES 17 MOC Wma renter A OON aE e T ET 17 Pressure Switch Calibration 0 0000 17 800 645 3201 Table of Contents cont G F C I Troubleshooting If Correct Wiring is Verified 18 To Disconnect the Heater 020005 18 Testing the Circuit Board Output To use the Balboa Quick Check 19 Changing a System Circuit Board How to Remove a System Circuit Board 20 How to Replace a System Circuit Board 20 Filter Settings Filter Setting Information 04 21 Optional Features Ozone Generator Indicator 00 21 Pump 2 Enable trata cutans initia fehimenges 21 Heater Disable 0 0 0 ce eee ee eee 21 Deluxe Standard Circuit Board Deluxe Standard Circuit Board 22 Millennium Grcvit Board Millennium Circuit Board 00 23
9. fuse to blow However a lightning strike in the area is a possible though less likely cause of the failure Note These slow blow fuses are not always discolored when blown Always test continuity of a fuse with an ohmmeter If one or both fuses have blown and you have turned off all power at the house breaker box IMMEDIATELY check all wiring connections terminal block connections wire gauge type and check for shorts between the system box and the service disconnect Once you are confident that all wiring is correct replace the fuse Test the Soldered in Fuse e Fora class 2 transformer circuit UL requirements specify that a fuse must be permanently installed to protect the circuit board e Ifyou have determined that the system is getting proper voltage through the power input fuse then you must check to see if the soldered in fuse has blown e First turn off the power Next unplug the transformer from the circuit board then turn the power back on and probe from finger 5 to one side of the fuse e The voltage should read 120 V or 240 V depending on the system e Probe from finger 5 to the other side of the soldered in fuse The voltage should read 120 V or 240 V depending on the system e If either side has 0 voltage then the fuse is blown If so turn off the power and replace the circuit board See page 20 Note Another less likely reason for the soldered in fuse to blow is that a 240 V transforme
10. plug in the pump Note Be sure to test each device individually Test the Pump e Restore the power and activate the pump e If the fuse blows there is a pump problem e Ifthe fuse does not blow turn off the power Test the Blower e Plug in the blower e Power up the system and activate the blower e Ifthe fuse blows then there is a blower problem e Ifthe 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 e 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 www balboa instruments com 11 Troubleshooting cont Test the Amperage Draw e Turn off the power disconnect the blower make sure the pump is plugged in and restore power e Start the pump and switch to high speed if available this should draw the most current e Make sure all jets and valves are open e Check the amperage at the red pump wire Compare your reading with manufacturer specifications If the other plug in devices exist they should be tested in the same way e Ifthe 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 Miswiring of the spa is the most common reason for this
11. proper reconnection of wires A Important Be sure to bring the correct circuit board topside control panel components and tools A Safety Tips e Keep children and pets away e Be aware of your surroundings Standing in water while repairing a spa puts you at serious risk e Avoid working in cramped or crowded conditions DANGER SHOCK HAZARD DO NOT PROCEED IF UNQUALIFIED IN WORKING WITH HIGH VOLTAGE Ss 800 645 3201 System Description Highly advanced microprocessor technology has been combined with solid state electronic switches to produce the world s finest high quality state of the art digital control systems Balboa control systems are technologically sophisticated yet easy to understand use and troubleshoot Topside Control Panel The control panel activates functions at the touch of a button Each function will echo from the circuit board to the LCD in a corresponding manner The panel will also display diagnostic messages which enable the service technician to easily troubleshoot the system Circuit Board A typical circuit board has the following output capabilities e 240 VAC System e Two speed pump 240 VAC 60 Hz 2 HP e Single speed pump 240 VAC 60 Hz 2 HP e Blower 240 VAC 60 Hz 2 HP e Heater 240 VAC 60 Hz 5 5 kW e Light 12 V 12 W 60 Hz 1A or 120 V 100 W In addition to these outputs the board receives input from the spa temperature sensor high limit sensor and flow
12. Balboa Video Service Guide The Balboa Video Service Guide is the perfect companion to the Balboa Technical Service Manual You may obtain your copy of the video by contacting Balboa Direct at our toll free number 1 800 645 3201 The service video and technical service manual are designed to aid you in all your spa repair needs Video Service Guide All of the topics included in this manual are fully demonstrated in the video In addition to these materials Balboa offers several manufacturer seminars as well as seminars at most major trade shows Since Balboa is a leading spa control manufacturer a thorough knowledge of our controls will be a great benefit to you These seminars are another valuable way to get the most current information about servicing our products Feel free to call us with any questions or comments We are always available by phone or internet We also have an efficient fax back service that can get you technical data quickly and easily Thank you for using Balboa controls www balboa instruments com Table of Contents Balboa Control Service Checklist Preface 22 e422 aaaea alveolar e aie am tiers Tools Required occ aasae ok ereaaddrwaaeeake bs System Components Required 045 Safety PS e a a a ai System Description Topside Control Panel n n nnana Cit uit Boatd set Sonne haw atu en ante hee ree Temperature Sensor ses ouaa High limit Sensor Gs Gada aa bes es AE ee
13. Labeling these wires may help speed up reinstallation The wiring diagram should always be used to ensure proper wire placement e Remove all the screws which connect the wires to the terminal block e Remove all the screws which mount the board to the terminal block e Remove the board from the 3 plastic stand offs by gently squeezing the locking flange on each one with a pair of pliers The board should now be free and can be removed from the system box How to Replace a System Circuit Board e Check all jumpers on the new board Make sure the jumpers are in the same position as the old board e Make sure the new board snaps in place on the plastic board stand offs e Attach the screw to the blower triac TRC6 on the Millennium and Deluxe Standard boards being careful not to overtighten This screw serves as a heat sink only Replace all the screws on the terminal block fingers e Reconnect all the wires to the terminal block with the screws Follow the wiring diagram provided inside the cover of the system box e Reconnect all slip on connectors to the board relays and transformer Follow the wiring diagram provided inside the cover of the system box e Restore power to the spa at the main breaker e Test to make sure all functions work correctly See the photos on pages 22 23 and 24 for additional information about Balboa circuit boards 20 800 645 3201 Filter Settings e On the Deluxe Model the f
14. able G F C I may be acquired through your local distributor or Balboa Direct A Important Remember high voltage is still accessible in the house breaker box even though you have turned off the spa breaker G F C I Line in Wiring Check e Locate the proper circuit breaker and turn it off e Remove the cover from the house breaker box Check the main service amperage rating to the breaker box Note Typically a house circuit will require at least a 100 Amp service when a spa is installed e From the circuit breaker locate the red load wire and the black load wire e From the G F C I neutral bar locate the white load neutral and the green ground wire e Be sure there are no other appliances on the spa circuit If there are service must be re wired to supply the spa only e Make sure all four wires exit the house breaker box via conduit routed to the G F C I breaker box The black should be connected to the G F C I line in 1 The red should be connected to the line in 2 The white load neutral connects to the neutral bar The green ground wire should be attached securely to the ground lug inside the G F C I box G F C I Line out Wiring Check for 240 V Dedicated System 3 wire system induding ground wire The black wire should connect to load out 1 the red wire from load out 2 and the green ground wire should be attached securely to the ground lug inside the G F C I box All wires will exit the box via condui
15. abled until power returns to the unit The Panel Display Shows O 3 On the Deluxe Model with an ozone sensor this message will appear when the ozone generator is running On the Standard Model with an ozone sensor this message will flash alternately with current spa temperature when the ozone generator is not working The Panel Display flashes PH5G or PHAG On the Deluxe Model with a pH sensor refer to Note 9B in the Balboa Application Manual On the Deluxe Model without a pH sensor the jumper on positions 3 amp 4 of J20 is missing Add a jumper at J20 The Panel Display shows it BE or Other Unexplained Error Messages This rare message is only seen in older panels without telephone type panel connectors Optical Ozone Sensor e Usually appears when a certain device is faulty Often the ballast in an ozone generator can cause enough electrical noise in the circuit to cause this problem Pressure Switch Calibration When the display continually shows FL D this usually indicates that the pressure switch needs adjustment or has malfunctioned When servicing a spa with a solid FLO message e Disconnect the pressure switch wire at the circuit board The FLO message will disappear within five seconds At this point the pressure switch can be calibrated e Set your voltmeter to ohms e Attach the pressure switch wire and your voltmeter probes to the Balboa LJS You should see continuity at this point
16. em box 800 645 3201 Voltage Checks System Box G F C I Load Out Voltage Check 240 V Dedicated System Be sure the house breaker is on J Be sure the G F C I breaker is on Probe the black and red wires at the G F C I load out 1 and 2 The voltage should be 240 V Probe the black wire and the G F C I neutral bar The meter should read 120 V Probe the red wire and the G F C I neutral bar The voltage should read 120 V Probe the black load out wire and the box chassis ground lug The voltage should read 120 V Probe the red load out wire and the ground lug The voltage should be 120 V Recheck voltage under peak load conditions 120 240 V Convertible System Be sure the G F C I breaker is on Probe the black and red wires at G F C I load out 1 and 2 The voltage should be 240 V Probe the black and the white load neutral wires The meter should read 120 V Probe the red and white load neutral wires for 120 V Probe the red load out wire and the box chassis ground lug Your meter should read 120 V Probe the black load out wire and the ground lug The voltage should read 120 V Recheck voltage under peak load conditions A Important If the voltage is not within the acceptable range call an electrician or the local electric company to diagnose the problem System Box Check at TB1 240 V Dedicated System Check e Besure the G F C I breaker is on Probe the black and red wires Lo
17. ilter settings are completely programmable from the topside control panel e On the Deluxe Model if the filter settings have just been changed it takes 24 hours for the filter cycle to reflect the changes You may cycle the time clock forward 24 hours to put the new filter cycles immediately into effect e The low speed pump and ozone generator if installed will run during the filter cycles e The blower runs for 30 seconds at the start of each filter cycle This will maintain water quality in the air channel Optional Features A Important Please keep in mind the jumper positions indicated Ozone Generator Indicator below are specific to the Balboa generic models For service e On the Deluxe model short the wires on J16 with a on a custom unit please look for jumper names on the jumper or unplug the optical sensor if available 03 will circuit board be displayed on the panel whenever the ozone generator is enabled Pump 2 Enable e Short the post on the Pump 2 Enable with a jumper the i system is converted from a 2 pump to a 1 pump system Logic Jumper Feature Off Feature On Heater Disable When 50A 20A Jumper is in 20A position e The pump high or blower will turn off the heater e The blower if installed will go to low speed when the pump high is on Feature A Enabled Feature B Enabled www balboa instruments com X 21 Deluxe Standard Circuit Board OOO a T it a pi
18. in line fuse or the power input fuse is usually a symptom of a faulty pump blower or a short in the wiring to one of those devices e If the fuse is good then replace the output connector e Ifthe high speed pump comes on when the system calls for heat or when the system goes into a filter cycle the pump is most likely wired backwards Verify that the black low speed and red high speed wires are not switched in the amp connector or the pump itself e Always check to make sure all devices are plugged into the proper location Note If the spa light output is not detected with the Balboa Quick Check be sure to check continuity of the light fuse on the circuit board www balboa instruments com 19 Changing a System Circuit Board euverveeyvee Pe aa ie L mm Ss a A Important Be sure to turn the power off before replacing any component especially a circuit board A Important Do not remove and replace the circuit board unless the fault has positively been determined to be the circuit board How to Remove_a System Circuit Board e 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 e Remove the screw which mounts the blower triac TRC6 on the Millennium and Deluxe Standard boards e Disconnect all slip on connectors from the board relays and transformer Note
19. ing the above steps then replace the circuit board The Display Continually Shows FLU or the Status Heat LED is Flashing Briefly On Once a Second When this is happening the software is detecting pressure at the pressure switch without the pump running e Make sure the slice or ball valves are open If any valves are closed opening them may remove the error message from the display and the spa should operate normally e Ifthe spa does not operate normally disconnect the wire from the pressure switch e Ifthe spa operates normally turn OFF the spa system recalibrate the pressure switch if possible see page 17 If the pressure switch cannot be recalibrated replace the pressure switch Clean the area where the pressure switch is located with a metal brush Use plumber s sealant when installing a new pressure switch e Ifthe problem continues then replace the circuit board The Display is Flashing FLD When this is happening the software is detecting no pressure at the pressure switch with the pump running The following is a list of most probable causes of this message Check these first e Check the water level e Remove the filter cartridge then run the spa If the message disappears then clean or replace the filter cartridge e Check the slice or ball valves be sure they are open e Make sure the pump motor is functioning properly If not use the Balboa Quick Check or a multi meter to verify system box
20. is continuity adjust the star wheel lt Clockwise clockwise until there is no continuity Re lt Counter clockwi test with the low i a E r speed pump as i f before g a Adjusting Wheel e Ifthe pressure switch cannot be adjusted adequately replace it www balboa instruments com X 17 G F CI Troubleshooting Keep in mind that a majority of G F C I tripping problems can be attributed to incorrect wiring G F C I troubleshooting usually finds the problem if Correct Wiring is Verified Check to see if the proper G F C L is installed Check the label in the system box near TB1 to determine the maximum amperage draw for the system Be sure the G F C I is rated for more amperage than the system will draw For a 240 V dedicated system a 2 pole G F C I with no load neutral is acceptable For a 120 240 V system the G F C I must include a load neutral out If the white load neutral wire is routed from the G F C L neutral bar directly to TB1 in the system box then the G F C I will trip when a 120 V device is activated For a detailed wiring checklist please review the previous segment of this manual on proper G F C L wiring or the G F C I manufacturer s instructions If the wiring is correct and the G F C I will not reset then unplug the pump and try to reset the G F C I If the G F C I trips again then unplug the blower and push the reset button If the G F C I continues to
21. lem 14 800 645 3201 Panel Messages Panel Messages Panel messages are a quick clue toward solving a variety of problems Here are the most common messages and what they mean The Panel Display is Flashing GH or the Status Heat LED is Flashing 1 second on 1 second off This means that the control system is at a high limit condition and the spa is deactivated Note Overheating may occur if the low speed pump is set to operate for extended periods of time or if the incorrect pump is installed In rare cases usually warmer climates the circulation pump may also cause overheating The following is a list of most probable causes of this message Inspect these first e Check slice or ball valves Make sure that they are open e Make sure the correct pump and pressure switch are installed e Clean the filter skimmer if there is any blockage e Check heater element alignment e Check for debris on the heater element e In extremely hot weather check for proper cabinet ventilation e Make sure the temperature sensor is fully inserted into the sensor mount and that the sensor mount is properly insulated with foam Note Improper insulation is one of the most common causes of spa overheating Aerosol foam insulation is available at most hardware stores e Check for excessive filter duration Note On the Deluxe model a common programming mistake is overlapping filter times that may cause the spa to filter contin
22. n before beginning service on a unit A Wiring Check Precautions e When working in a system box always be aware that it may contain high voltage e 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 e All service calls no matter how minor should include a complete wiring check beginning with the house breaker e Keep in mind Balboa equipped spas only run on single phase electrical service Three phase power will not supply proper voltage to the system Three phase power may overheat the pumps and cause the G F C I to trip Check for Loose Connections or Damaged Wires e Make sure the power is off before you touch any wiring e Once the power is off carefully examine all wires for cuts or defects i 3 4 E ai FHT Wit TB1 in the System Box System Box Wire Gauge Check When inspecting the wiring for any control system note that connections for the incoming wires are clearly labeled at the main terminal block e 30A service minimum ten gauge copper wire e 40A service minimum eight gauge copper wire e 50A service minimum six gauge copper wire 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 A Important Using non copper wire can be danger
23. ok for 240 V Probe the black and green ground wires for 120 V Probe the red and green ground wires also 120 V Recheck voltage under peak load conditions 120 240 V Convertible System Check Be sure the G F C I breaker is on Begin the voltage check at TB1 Probe the black and red wires Your meter should read 240 V Probe the black and white wires Look for 120 V Probe the black and green ground wires also 120 V Probe the red and green ground wires again 120 V Probe the red and white load neutral wires This should read 120 V Probe the white neutral wire and the green ground wire This will show approximately 0 V Recheck voltage under peak load conditions Peak Load Check It is important to check the voltage again under peak load conditions To reach peak load turn on the blower heater light and all pumps Peak Load Check for 240 V System e Check the voltage between the black and red wires The acceptable voltage range is between 216 and 264 V e Probe the black and white neutral wires This voltage must be between 108 and 132 V Peak Load Check for 120 240 V Convertible System e Check the voltage between the black and red wires Acceptable range is between 216 and 264 V e Probe the black and the white load neutral wires The voltage must be between 108 and 132 V e Probe the red and the white load neutral wires The voltage must be between 108 and 132 V www balboa instrumen
24. ous 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 A Important This service must be single phase Any abnormal voltage reading requires an electrician Do not attempt to fix these types of problems yourself High voltage can seriously injure or kill G F C I Wiring Check If a Ground Fault Circuit Interrupter has recently been installed a majority of tripping problems can be attributed to incorrect wiring of the G F C L A clear understanding of the correct configuration is essential Please refer to the figure on page 10 as needed 800 645 3201 Wiring Check for G F CI Service Disconnect A Important The National Flectrical Code states that a service disconnect breaker bo a G F C I can be usec for this purpose must be located at least five feet away from the spa and should be conveniently located near the equipment bay If it is not in plain sight keep the disconnect padlocked when in the off position Precautions Effective January 1994 G F C I s are required for spa installations Prior to that G F C I s had been recommended for spa installations but were not mandatory If the spa you are servicing was not installed with a G F C L strongly urge your customer to improve safety and comply with current standards by installing one Note A suit
25. output to the pump e Check the floor suction grills for obstructions e Check the pump to be sure it is primed and pumping properly e Check the pressure switch wire for cuts e If all of these items are in working order attempt to recalibrate the pressure switch see page 17 If the pressure switch cannot be recalibrated replace the pressure switch Clean out the area where the pressure switch is located with a metal brush Use plumber s sealant when installing a new pressure switch e Ifthe problem continues then replace the circuit board The Panel Display Shows COOL This is a normal spa function no further action is necessary The water is more than 20 F cooler than the set temperature The heater will automatically activate to provide freeze protection The Panel Display Shows iCE This is a normal spa function no further action is necessary When the high limit sensor located at the heater or an optional freeze sensor reads below 40 F the system provides freeze protection It automatically activates all of the pumps to circulate water and warm the plumbing Note An optional freeze sensor located at the pumps or other plumbing is often used in colder climates to protect against freeze conditions 16 800 645 3201 Panel Messages cont The Panel Display Shows Pd Power has been cut off to the spa and it is using its battery backup to preserve its settings The control panel will be dis
26. panel is working properly but a pump blower or other device does not activate when its panel button is pressed further diagnosis is easily accomplished with the Balboa Quick Check Quick Check Test Kit To use the Balboa Quick Check e Turn off the power at the house breaker box e Unplug the device in question and plug the Quick Check in its place e Restore power to the spa and press the appropriate panel button again If the Quick Check s light appears the device in question is receiving voltage e An ordinary multi meter can also be used to check for proper output voltage except when working with a variable speed blower or a dimmable spa light In these cases a component on the circuit board called a triac needs to be under a small load to test output voltage e Even if the system is not equipped with a blower triac the best way to verify voltage output is with the Balboa Quick Check e Ifthe Quick Check light does not appear after pressing the appropriate panel button trace the wires from the corresponding connector in the system box back to the circuit board e Probe these connections at the circuit board after activating the function with the topside control panel e Ifyou do not have correct voltage double check the input voltage before you replace the circuit board e Ifyou do have correct voltage at the circuit board turn off the system power and check for a blown in line fuse Blowing the
27. r was replaced with a 120 V transformer by mistake e Make sure that the transformer is properly rated for the system The voltage reading between fingers 5 and 6 on the circuit board will determine the proper transformer input voltage for Deluxe and Standard models e Fora 120 V system the transformer should have two blue connectors e A 240 V transformer should have one blue connector e Ifyou determine that the soldered in fuse is not blown this means that the transformer is receiving voltage 12 800 645 3201 Troubleshooting cont Transformer Installation Requirement Some symptoms of low voltage may be caused by the transformer When working on a 120 V Deluxe or Standard system double check to make sure the transformer has two blue connectors A 240 V transformer with one blue connector may be installed by mistake in a 120 V system causing low voltage Confirm Transformer Connections Intermittent problems may occur when transformer connections are loose Make sure your fingers are away from exposed high voltage connections Wiggle the transformer wires near the connector on the circuit board This will determine if there is a loose transformer connection or bad pin on the circuit board e If the system intermittently turns on and off turn the power off e Plug in the test transformer restore the power and wiggle the transformer wires again e If there is no intermittent failure no further analy
28. sis is required e Turn off the power and replace the transformer e After installing your test transformer intermittent symptoms may still occur during the test e If so replace the circuit board see page 20 and install the original transformer A Important Be sure to turn the power off before replacing any component especially a circuit board Blue Connectors www balboa instruments com 13 Topside Control Panel Preliminary Panel Check e Ifthe problem is not obvious look on the topside control panel for diagnostic messages If no messages are seen run through all spa functions and note any inconsistent operation e If diagnostic messages appear on the topside control panel see page 15 for troubleshooting tips Once you have determined that proper voltage is running through the circuit board and transformer continue to the topside control panel A panel that is not functioning properly may include the following symptoms low voltage such as missing or scrambled segments missing icons on the LCD non functional LED s or nonfunctional buttons If any of these symptoms are present perform the following e Turn the power off and unplug the panel from the circuit board e Then plug in your test panel and restore power If everything functions normally replace the topside panel
29. sure the G F C L is off Carefully turn on the spa circuit breaker At the house breaker box probe the spa circuit breaker between the black and red wires Your meter should read 2 40 V Probe the black and green ground wires You should see 120 V Probe between the red and green ground wires You should also see 120 V The voltage between the white load neutral and the green ground wire should be approximately 0 V G F C I Line In Voltage Check 240 V Dedicated System Be sure the spa circuit breaker located in the house breaker box is on Make sure the G F C I is off Probe the black and red wires The meter should read 240 V Probe the black and green ground wires The meter should read 120 V Probe the red and green ground wires This should also read 120 V Turn on the G F C I breaker before continuing to the system box Note A white load neutral wire is not used in a 240 V dedicated system 120 240 V Convertible System Be sure the spa circuit breaker located in the house breaker box is on Make sure the G F C L is off Probe the black and red wires The voltage should be 240 V Probe the black and white load neutral wires The voltage should read 120 V Probe the red and the white load neutral wires The voltage should read 120 V The voltage between the white load neutral and the G F C I box ground lug should read approximately 0 V Turn on the G F C I breaker before continuing to the syst
30. t routed to the spa control system The white pigtail should be connected to the G F C I neutral bar All wires will exit the box via conduit routed to the spa control system If the system does not operate a 120 V component ozone music equipment etc then the white load neutral wire is not required G F C I Line out Wiring Check for 120 240 V Convertible System 3 4 wire system including ground wire If the spa is equipped with a 120 240 V control system an additional white load neutral wire must connect to the load neutral out This wire runs with the others to the system box Proper placement of this neutral wire is essential If miswired the G F C I will trip when a 120 V device is activated Once you have found all wiring correctly installed begin to check for proper voltage www balboa instruments com Voltage Checks Breaker Box G F CI When checking for proper voltage please keep in mind that the acceptable voltage range is 10 of the recommended voltage Acceptable voltage when 120 V is specified as the desired voltage is between 108 and 132 V Acceptable voliage when 240 V is specified as the desired voltage is between 216 and 264 V A Important This service must be single phase Any abnormal voltage reading requires an electrician Do not attempt to fix problems yourself High voltage can seriously injure or kill Breaker Box Voltage Check Set your multi meter or voltmeter for AC Volts Make
31. t the connections of both sensors on the circuit board The plugs must be clean e Unplug the sensor set at the temp high limit jumper and plug in the test sensor set Hang the test sensors over the spa side and into the water Keep in mind there is no high limit sensor protecting the heater during this test e Ifthe problem is solved replace the sensor set If the problem is not solved do not replace the sensor set www balboa instruments com X 15 Panel Messages cont e Plug in the original sensor set to verify that there is not a connection problem e Ifthe problem continues after following the above steps then replace the circuit board Note In rare cases rapid system overheat causes sensor error messages Be sure to rule out possible situations like no flow or no water The Panel Display Shows 53 or the Status Heat LED is Flashing Briefly Off Once a Second This indicates that the water temperature sensor is open or faulty The spa is deactivated e Unplug the sensor set at the temp high limit jumper and plug in the test sensor set Hang the test sensors over the spa side and into the water Keep in mind there is no high limit sensor protecting the heater during this test e Ifthe problem is solved replace the sensor set If the problem is not solved do not replace the sensor set e Plug in the original sensor set to verify that there is not a connection problem e Ifthe problem continues after follow
32. trip then do the same procedure for the ozone generator If the G F C I stops tripping after you unplugged one of the spa s components turn off the power to the spa then plug in each component except the one that tripped the G E C Power up the system If the G F C I no longer trips then you have correctly identified the problem Repair or replace the component as instructed by the spa manufacturer If you have unplugged all of the spa s components and the G F C L still doesn t reset then the problem is most likely a ground fault in the heater To Disconnect the Heater First turn off the main circuit breaker then remove both heater straps or wires from the terminal block not the heater itself After restoring the power try to reset the G F C I again If it no longer trips after the system calls for heat then replace the heater If the G F C I still trips look for pinched or shorted wires at the transformer Make sure that the screws that attach the transformer to the system box have not pinched or damaged the insulation of the transformer wires If the transformer wires are undamaged check for any other pinched wires Refer to the wiring diagram to verify the correct wiring of the control system If everything looks to be in perfect working order then the G F C I may be defective 18 800 645 3201 Testing the Circuit Board Output Testing the Circuit Board Output If your topside control
33. ts com X Wiring Schematic House Breaker Box RED HOT BLK HOT QODWOOOOOO G F C Breaker Box Bottom View of G F CI Square D Front View of G F C1 Square D RED HOT i BLK HOT WHT NEUTRAL GRN GROUND Spa Sy siem Box GRN GROUND ta WHITE NEUTRAL 2 BLK HOT 3 RED HOT 4 GREEN GROUND 5 my Note For a 240 V dedicated hookup the white neutral wire is not required between the G F C I and the system box GRN GROUND 110 5 ot 7s 10 xX 800 645 3201 Basic Control System Troubleshooting Low Voltage At Balboa it s been our experience that the majority of the problems associated with electronic control systems are due to low voltage Brown outs Brown outs can have an effect on the spa s operation in a variety of ways The control panel may go blank have scrambled messages on the LCD or only a few features will function e Ifthe system is getting the proper voltage at TB1 but still does not operate then measure fingers 5 and 6 of the circuit board You should see either 120 or 240 V depending upon the system configuration Checking the System Power Input Fuse Deluxe or Standard System e Ifyou determine that there is no voltage at fingers 5 and 6 then the system power input fuse needs to be replaced This fuse is located in the large fuse block inside the system box This configuration utilizes a 30A time dela
34. uously e Check the water level e Check the water temperature with an accurate temperature thermometer Remove the spa cover and allow the water to cool to below 110 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 If the Problem Recurs Test the Sensor Set e Check sensor wires for cracks or damage that may indicate the presence of a rodent e Inspect the connections of both sensors on the circuit board The plugs must be clean e Unplug the sensor set at the temp high limit jumper and plug in the test sensor set Hang the test sensors over the spa side and into the water Keep in mind there is no high limit sensor protecting the heater during this test e Ifthe problem is solved replace the sensor set If the problem is not solved do not replace the sensor set e Plug in the original sensor set to verify that there is not a connection problem e Ifthe problem continues after following the above steps then replace the circuit board Temperature Sensor in the spa High limit Sensor at the heater The Panel Display Shows Ant or the Status Heat LED is Flashing Briefly Off Once a Second This indicates that the high limit sensor is open or faulty The spa is deactivated e Check sensor wires for cracks or damage that may indicate the presence of a rodent e Inspec
35. y fuse Duplex System e Remember the system power input fuse may snap directly to the circuit board next to finger 6 e To check this fuse probe finger 5 and the side of the system power input fuse farthest away from finger 6 e If there is no voltage the 20A time delay fuse must be replaced Note In each situation the most likely reason for the system power input fuse to blow is a pump problem However on occasion a blower problem may also cause this fuse to blow if a 10A blower fuse is not built in Once the power input fuse has been changed e Check the voltage between the black and red wires again Acceptable voltage range is between 216 and 264 V e Probe the red and white neutral wires Again voltage must be between 108 and 132 V These readings should be taken under peak load conditions A Important If the voltage is not in the acceptable range call an electrician or the local electric company to diagnose the problem To Determine if Fuse Replacement is Necessary To determine if fuse replacement is necessary perform the following sequence of tests Test the System e Turn the power off e Be sure to replace the system power input fuse with the same type e Unplug the blower and all pumps e Restore the power and verify system operation e If the fuse blows then re check the internal system wires and connector for burns cracks or cuts in insulation e Ifthe fuse does not blow turn the power off and
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