Technical Service Manual
Contents
1. FLO Error Condition 4e If problem has not been solved lower Set Point at 60 by pressing on Down arrow key and turning pump off then short two pres aati switch terminals with jumper cable 5e An FLC error condition should occur FLC error condition identifies pressure switch as source of problem Try readjust pressure switch If this isnt possible replace switch Refer to How to Adjust the Pressure Switch section of this manual 6 IfFLC error condition does not occur problem may be either with switch cable or board Replace Spa Pack 19 SSPA Spa Pack Service M anual FLC Flow Chart If FLC error condition occurs follow Troubleshooting Flow Chart below to identify problem usually pressure switch problem pump is off but water pressure is detected yes Bm mv Disconnect pressure switch cable on pressure switch Does FLO error condition occur when pump is on Adjust pressure switch Replace Replace pressure switch Spa Pack if FLC error condition persists when you start or stop pump 21 SSPA Spa Pack Service M anual FLC Error Condition An FLC error condition indicates a pressure switch problem If system detects any pressure when pump is off an FLC error condition will occur _ ___c _ _____ Power may remain On when the following steps are carried out 1 Disconnect pressure switch cable 22. he E Far Pa T Sua Tm fry E 2 If light still isnt working verify if Light indicator appears on keypad display when you press Light key 3 If Light indicator doesn t appear use a spare keypad to verify if soa keypad is defective If it is replace keypad If not replace Spa Pack SSPA Spa Pack Service M anual 4 5 6 If Light indicator appears but light still isn t working remove plastic cover and measure voltage between two light wires on the board If you get 12 VAC replace light socket Light fuse If you aren t getting a voltage reading replace light fuse on the board If problem persists replace Spa Pack 46 Qzonator Flow Chart If the ozonator is not working follow Troubleshooting Flow Chart below to identify the problem e Ozonator output will be shut down when Pump J Pump 2 or blower have been turned on manually yes B mv E Has Filter Cycle indicator appeared on E keypad display Start up a filter cycle yes Do you read 20 VAC for a 20 VAC ozonator or 240 VAC for 240 VAC on the board yes lt H 0 Is Pump 1 working Replace Phen Spa Pack Refer to ozonator if you stil Pump 1 does aren t getting not Work a voltage reading section 47 SSPA Spa Pack Service M anual Ozonator Does Not Work If ozonator isn t working carry out the following tests to correct th
3. Jumper Positions Certain SSPA spa pack parameters can be modified by changing the position of jumpers on the board To access jumpers first remove SSPA power box cover In some cases jumper functions may differ from the following Please check wiring diagram on power pack box cover to verify specific functions for your pack Position 1 Position 2 ts Ep Jumpers l Jumpers are located in the lower 2 To change a setting simply pull cover right section of the board off and replace in desired position Jumper I Current Limiting Option Jumper 1 is used to limit amount of current drawn when the 2 pumps are on Position 1 HC System turns heater off when the two pumps are on at high speed Position 2 LC System turns heater on when one pump is on at high Mandatory for 20 VAC systems speed The H eater icon flashes on display indicating that more heat is requested but heater is not allowed to start Jumper 2 Temperature Unit Jumper 2 is used to select the temperature unit Position 1 Temperature will be displayed in Fahrenheit degrees Position 2 Temperature will be displayed in Celsius degrees Jumper 3 Pumps SSPA Spa Pack Service M anual 10 Flashing Dots Flow Chart If 3 flashing dots appear on keypad display follow Troubleshooting Flow Chart below to identify the problem 2 3 flashing dots appear on the display FLO FLC or HL errors
4. SSPA Spa Pack Service M anual 26 HL Error Condition If digital thermometer water temperature reading is 119 F or higher and keypad display indicates correct temperature carry out the following tests If weather is very hot le Remove spa cover even during the night Start blower if spa Is equipped with one Wait until spa cools down add cold water if necessary If hot weather is not a factor 2 Lower Set Point below current water temperature The H eater indicator should disappear from keypad display 3 Remove plastic cover W ith a voltmeter read voltage between the two heater wires on the board 4e Ifyou do not read 240 VAC pump may be overheating water during filter cycle Shorten filter cycle duration 27 To shorten filter cycle duration De Press and hold Light key for ere 5 seconds tT D isplay will R show a value 4 that represents the filter cycle duration in hours Use Down arrow key to lower the number of hours 0 no filtration 12 continuous filtration When the desired setting IS displayed press Light key again The filter 4 cycle will start immediately If you do read 240 VAC replace Spa Pack Ei EELE SSPA Spa Pack Service M anual HL Error Condition If digital thermometer water temperature reading is 119 F or higher and keypad display isn t showing correct temperature carry out the foll
5. Technical Service Manual OPA amp SSPA M P SPA PACKS SERVICE MANUAL by Gecko Electronics Inc Visual step by step guide to easily identify amp correct technical problems Table of Contents Topics covered in this manual are as follows Power amp Ground Check Electrical W iring 6 GFCI 7 qa _ _ Programming Jumper Positions 10 e _ _ _ _ _ _ Error Conditions 3 Flashing D ots Appearing on Keypad D isplay 11 D isplay Is Flashing 13 Wrong Temperature Appearing on Keypad D isplay 15 FLO 17 FLC 21 Prr 23 HL 25 a Oo Troubleshooting N othing Seems to Work 29 Spa Does N ot H eat 33 Pump 1 Does N ot Work 37 Pump 2 or Blower Does N ot Work 41 Light D oes N ot Work 45 O zonator Does N ot Work 47 Keys Do N ot Work 49 O How to Replace The Spa Pack 51 Adjust The Pressure Switch 54 a Miscellaneous Parts List 57 W iring D iagrams 58 Professional Repair Kit Info 60 O In an attempt to make this manual as useful as possible it has been presented in two formats Problem solving solutions are described with Troubleshooting Flow C harts and also with Step by Step Procedures The two formats together should provide an overall complete explanation with flow charts providing an overview of specific problems and step by step procedures giving more detailed information Tools amp Parts Tools te
6. yes gt Remove pack cover Is board LED on Flashing dots indicate an hi limit H L condition Refer to HL pages of this manual to correct the problem Turn off pump that heats water circulation pump or Pump 1 B ys Qe mv 1 Are dots still flashing 1 It s an FLC It s an FLO problem problem Refer to FLC Refer to FLO pages of this pages of this manual to manual to correct the correct the problem problem 11 SSPA Spa Pack Service M anual Display Flashing Flow Chart On SSPA NE packs if system detects temperature at 112 F or higher the display will start flashing Follow Troubleshooting Flow Chart below to identify the problem yes m yes lt Q m WA Press any key A power failure has occurred Has display stopped flashing System works fine water temperature reading on the display no Are you getting correct ES Verify if E temperature probe is touching water Verify if ys lt Q 10 or if cold air from _ temperature probe back can affect is properly connected Is weather reading very hot Ifso replace probe o and reset breaker Remove spa cover even during 1 __ the night Replace board if yes gt no _ bower f L t point Eea 2 ower set poin ists stings __ below actual with one Replace Rigel epee Pump is board f mingi overheating Wait until Bb ese feonel water during spa
7. 9 25 or 48 amps 5 0 9 6 or 10 5 ohms The math part is kept simple by EIZ using our Handy Dandy Decoder Ring shown at right Let s say you O AN want to figure the amps rating of a heater marked 240 volts amp 5500 watts Use W V that would be 5500 divided TAV WA by 240 and the answer is 22 9 amps The next three are measured with a meter at an operating heater Measured Voltage like Measured Amps like Measured Ohms like 112 227 or 238 volts 11 5 21 24 6 or 44 amps USING THE NUMBERS All that follows applies to all electrical heaters The task is simple to determine if the heater is producing heat watts and then make sure that it is safe these are the facts ma am First measure and compare the voltage at the heater USING TEST terminals with the voltage at the panel board receptacle or other METER power source Don t blame the hater for poor performance if this Measured Voltage is more than 10 below the heater s Rated Voltage Do the math V O to see how quickly the watts drop as the volts drop If the Measured Voltage was much different than the Rated Voltage you ll have to re figure the Calculated Amps using V O You can t use W V because you re not sure what the wattage is anymore Then with power still on put your clamp on ammeter around ONE of the heater wires either one but only one You re now reading Measured Amps which should match the Calculated Amps number within
8. Replace Spa Pack if FLO error on pressure switch condition does not occur If FLO error condition occurs when pump is started adjust pressure switch or replace it Refer to How to Adjust the Pressure Switch section of this manual SSPA Spa Pack Service M anual 22 Prr Flow Chart If Prr error condition occurs potential regulation sensor problem follow Troubleshooting Flow Chart below to identify the problem Make sure to use the right probe MSPA 1probe does not work on an SSPA spa pack Probe wires should be in this order Press any key after each step to reset the system N ote that water temperature must be over 35 F to operate spa Check if regulation probe is properly connected Unplug probe connector and clean pins on the board even a small coating of film may cause a bad connection Reconnect the probe Replace probe with a spare and verify if problem is solved If it is replace probe with spare Replace Spa Pack if problem persists 23 SSPA Spa Pack Service M anual Prr Error Condition The Prr error condition indicates a problem with regulation sensor The system is constantly verifying if temperature probe reading Is within normal limits e Note that water temperature must be over 35 F in order to carry out the following steps Press any key after each step to reset the system Power may remain On Note M ake sure to use th
9. black wire connectors 2 If replacing the fuse is not effective or 240 VAC pump P14 amp P18 if Pump 1 works in only one speed 120 VAC pump P7 amp P14 take voltage reading on the board for both speeds Your reading shoud be 240 VAC for a240 VAC pump 120 VAC for a 120 VAC pump 4e If voltage is as it should be replace Pump 1 5e Ifnot replace Spa Pack Turn Pump 1 to high speed and take voltage reading between white and red wire connectors 240 VAC pump P12 amp P18 120 VAC pump P7 amp P12 Your reading shoud be 240 VAC for a 240 VAC pump 120 VAC for a 120 VAC pump 39 SSPA Spa Pack Service M anual Pump 2 or Blower Flow Chart If Pump 2 or blower does not work follow Troubleshooting Flow Chart below to Identify the problem 0 For SSPA Dual Pump Systems only yes B mv EE Have any error WA messages FLO FLC A 3 flashing a etc Refer to appeared on Verify if Jumper 3 specific section keypad display is Set properly indicated by error message yes Bm mv Does Pump 2 or Blower indicator Replace appear on keypad display keypad when you press Pump 2 or Blower key If still not working replace Spa Pack yes Bm mv Is Pump 2 or blower working yes mv Replace blower fuse 1 __ Pump 2 still not working yes Bm mv Measure voltage on the board Do you get a 240 VAC 1 reading or 20 VAC for
10. cools chould disappear filter cycle down add Peme cold water Lower Do you get a if needed 240 VAC reading n between two pene heater wires on the board 13 SSPA Spa Pack Service M anual Wrong Temperature Flow Chart On SSPA NE packs if system detects that temperature is not within normal limits wrong temperature will be displayed Follow Trouble shooting Flow Chart below to identify the problem Make sure to use the right probe MSPA 1probe does not work on an SSPA spa pack Probe wires should be in this order Press any key after each step to reset the system Check if regulation probe is properly connected Unplug probe connector and clean pins on the board even a small coating of film may cause a bad connection Reconnect the probe Replace probe with a spare and verify if problem is solved If it is replace probe with spare Replace board if problem persists 15 SSPA Spa Pack Service M anual FLO Flow Chart If FLO error condition occurs problem with the pressure switch pump is on but no water pressure detected follow Troubleshooting Flow Chart below to Identify the problem e Make sure circulation pump parameter is set correctly depending on your system configuration There must be adequate water in spa for normal use yes Bm mv a Is pump working when you try to start TA it from keypad l yp Refer to Pump not W
11. tightening or loosening The trick to analyzing this failure is to carefully examine the Cold Seal Signs of severe fracture or chipping are an almost sure bet that the Cold Seal is no longer able to do its job to seal If the heater has been acting strange erratic sometimes working fine and other times tripping the GFCI look at that Cold Seal THE NOISY HEATERS HUMS VIBRATIONS SQUEALS TWITTERS SHREKS SCREAMS RATTLES WHISTLES TWEETS amp CHIRPS Rarely maybe never is the element itself at fault when noise is reported ina heater even though it is the element that is usually making the noise The huge amount of water moving rapidly past the element can set up some wild vibration patterns as it twists and turns through the heater Usually it is simply a matter of re aligning the element by a bit of gentle bending to move it away from the heater housing or tying the noisy part down with a clip or wire made for the purpose Check with us Dry Fire The Ultimate Element Destroyer SETTING THE STAGE In normal operation the heaters that we deal with daily i in pools and spa operate at temperatures only a few degrees above the temperature of the water that is flowing past them If the thermostat in a spa is set to maintain the water at 102 for example the temperature of the Incoloy Outer Sheath will be about 110 The water flowing past the element is SHEATH BURNED carrying the heat away just about
12. 0VAC gt z a LINE2 Fl l ay 00V l l 3 C F2 I F25a7300v1 l SC oO l TME DELAY P AvdAD 4dOUd dL FIBER BOX Pump 1 Ozonator Light Connector Voltage 120v 240v Voltage 120v 240v White Light P23 Green Ground P4 P4 Green Ground P5 P5 Black 12 VAC P22 Black Low Speed P14 P14 Black Line P16 P16 Red H igh Speed P12 P12 White Com P8 P19 White Com P7 P18 Pump 2 Blower Heater Voltage 120v 240v Voltage 120v 240v Black1 P20 Green Ground P6 P6 Green Ground P37 p37 Black2 P21 Black Line P11 P11 Black Line P34 P34 White Com P9 P17 White Com P35 P36 Jumper Settings Fiber Box Pressure Switch Refer to page 10 Voltage 120v Green P24 Green Ground P1 Red P25 Black Line P33 White N eutral P35 Professional Repair it g All you need in one case Gecko s professional repair kit contains all you need to service and repair Gecko s line of power spa packs e Top side controls keypads e Temperature probes e Pressure switch cables e Flow switches e Elements e Heater wires e Transformer e Ground lugs e Grommets e Standoffs e Light cords e Strain reliefs for light cord e Plugs e Fuse kits e Screws GECKO Call 1 800 78 GECKO to order or for more info OPA SERVICE MANUAL COMPLETE SERVICE GUIDE WITh STEP BY STEP INSTRUCTIONS ON GFCI Troubleshooting umper Setup Understanding amp Correcting Er
13. 10 Turn OFF all power then DISCONNECT BOTH WIRES from the heater terminals Set the meter to the OHM s scale and take the following readings at the element terminals Terminal to terminal the Measured Ohms should read within 10 of Calculated Ohms From each terminal one at a time to the element sheath or element mounting plate should read OPEN or INFINITY ANY OTHER READING says the element is internally shorted This is a bad element Look for signs of dry fire damage That s it You now know all there is to Know about the electric stuff in the heater You can now re calculate the wattage using the voltage amps and ohms numbers you have measured confident in your knowledge The Meter Sidebar A good test meter is a must if we are to learn what s going on in the electric heart of that heater Take full advantage of today s technology and check out the latest units that combine the digital volt ohm meter with a clamp on ammeter It s like they knew about electric heaters when they designed these guys Check out B amp K Precision s 330 amp 340 A W Sperry s DSA 2007 and others by Radio Shack Fluke and Scope All are available in the 80 100 range
14. PA MP spa pack TSC 38 TSC or TSC 9 keypad with SSPA 1spa pack Also refer to Jumper Section p 10 to see if outputs are set correctly yes BH mv Is Jumper 3 set properly for lor 2 pumps Set Jumper 3 U nplug spa keypad and replace with properly Spare keypad yes Bm mv Are keys working Replace Replace keypad Spa Pack 49 SSPA Spa Pack Service M anual Keys Don t Work lf any of the keys do not seem to be working carry out the following tests to correct the problem Make sure to use the proper keypad TSC 35 keypad works with a SSPA MP spa pack TSC 3 TSC or TSC 9 keypad works with a SSPA 1spa pack Also refer to Jumper Section p 10 to see if outputs are set correctly Jumpers le Verify that Jumper 3 is set prop 3 Verify if keys respond correctly erly for 1 or 2 pumps refer to page 10 for more info 4e fthey do replace keypad 5e Ifthey do not respond replace Spa Pack 2 Replace spa keypad with a spare keypad SSPA Spa Pack Service M anual 50 How To Replace The Spa Pack W hen replacing an SSPA spa pack it is important to make sure to turn power off before proceeding m pm A Mo L 1 Unplug Pump 1 Pump 2 or blower and ozonator connectors 2 Remove 2 screws from front pack cover a PA 3 Lift the Spa Pack cover SSPA Spa Pack Service M anual How To Replace
15. Pump 2 or blower does not work even when indicator is on replace Pump 2 or blower fuse 2 If replacing the fuse is not effective take voltage reading on the board Turn Pump 2 or blower on and take voltage reading between white and black wire connectors 240 VAC pump or blower P11 amp P17 120 VAC pump or blower P9 amp P11 Your reading shoud be 240 VAC for a240 VAC pump or blower 120 VAC for a 120 VAC pump or blower 43 SSPA Spa Pack Service M anual Spa Light Flow Chart If spa light does not appear to be working follow Troubleshooting Flow Chart below to identify the problem yes Bm mv E bs you tried replacing es lt gt no the spa i light bulb Try replacing light bulb Is light yes no still not lighting Does Light up indicator eod Replace display when keypad you press Light key If still not working replace Spa Pack Do B yes Do you get a Zi P VAC reading _ on light output Replace spa on board Replace spa light socket light fuse Replace Spa Pack if light is still not working 45 SSPA Spa Pack Service M anual Spa Light Does Not Work If soa light is not working carry out the following tests to correct the problem It is important to measure voltage when light is connected to pack Power must remain On le The first step is to replace the spa s light bulb Light indicator
16. SION ON those spas out there were filled with clean pure water PREMERI and no one ever added any chemicals to them the word corrosion would soon leave our vocabulary Unfortunately that s not going to happen and all hose spas are going to continue being filled with water of every type from the Cascade Mountain s rain water to big city sludge A DEADLY SOUP Then to add to the problem we have learned that many many spa owners are notfollowing all of the instructions they ve been given about pH Total Alkalinity Calcium Hardness and Total Dissolved Solids or about how to handle those unique cor rode k rod v 1 to eat or wear away gradually as if ZIPPERED ELEMENT rN water problems that may exist in their spa when it is filled with water from their tap EXTREME CALCIFICATION LOW pH BOO HISS lf we had to pick the worst offender in the corrosion list it would definitely be LOW pH because as we all learned long ago when a test sample of the water shows a LOW pH below 7 0 it indicates the water is ACIDIC Remember now this is not just saying that there is ACID in the water it says that the water has become an ACID It doesn t matter at all what kind of ACID caused this to happen hypochlorous hydrochloric hypobromous muriatic or whatever when the water becomes an ACID it becomes a starving hungry corrosive beast looking for lunch ACIDS will corrode eat away almost any metal in
17. The Spa Pack W hen replacing an SSPA spa pack it is important to make sure to turn power off before proceeding 5 Disconnect light cables keypad 7 Disconnect heater ground and temperature probe con cable nectors 6 Disconnect pressure switch 8 With wrenches free the Cable board blades by removing the 2 heater nuts SSPA Spa Pack Service M anual 52 How To Replace The Spa Pack When replacing an SSPA spa pack it is important to make sure to turn power off before proceeding 9e Slide the pack out of the heater barrel 10 Check if high limit sensor is properly in place in its slot and Slide new pack into position 11 Connect heater to the board blades It is important to hold both nuts when tightening If you bend or twist the end of the element you may damage it 12 Reconnect heater ground cable and pressure switch cables 3 13 Reconnect light cables keypad and temperature probe 14 Plugin Pump 1 Pump 2 or blower and ozonator con nectors 15 Reconnect power input cables 16 Close pack cover SSPA Spa Pack Service M anual How To Adjust The Pressure Switch When a voltmeter Is available e le Set voltmeter to Q while both probes are touching one another voltmeter should beep to show there is continuity 2 Turn pump off 3 Do you have continuity on pres sure switch If you have no c
18. a 20 VAC pump Replace Pump 2 Replace or blower Spa Pack 41 SSPA Spa Pack Service M anual Pump 2 or Blower Does Not Work lf Pump 2 or blower does not work carry out the following tests to correct the problem For SSPA Dual Pump Systems only To increase the life of the relay we use a snubber circuit on the pump relay W ith this type of circuit if no pump is connected to an output and relays are open the voltmeter will continue reading around 60 volts This is normal It is important to measure voltage when pump is connected to pack Power must remain On 1 Check for an error message on keypad display If there is one refer to specific section indicated by error message 4e f Pump 2 or Blower indicator does not appear use a spare key pad to verify if keypad is defective l KRPA l If it is replace keypad 2 Also verify that Jumper 3 is set properly for 2 pumps refer If not replace Spa Pack to page 10 for more info Pump 2 indicator 3 Verify if Pump 2 or Blower indicator appears on keypad display when you press Pump 2 or Blower key SSPA Spa Pack Service M anual 42 Pump 2 or Blower Does Not Work If Pump 2 or blower does not work carry out the following tests to correct the problem Pump 2 or blower fuse 3 If voltage is as it should be replace Pump 2 or blower 4e Ifnot replace Spa Pack le If
19. as fast as the element can OUT peat DRY produce it Everyone is happy WHAT GOES WRONG One of three things can happen A the water flow slows down too much B the water flow stops or C the heater is somehow turned on with either no water in the housing or only partially filled The results will be the same the Incoloy DISCOLORED Outer Sheath temperature will rapidly rise 200 500 HEATER TUBE 1 000 1 500 in a matter of just a minute or two The DUE TO DRY FIRE melting point of the Sheath is 1700 to 1800 F and it will get there quickly unless it isn t turned off by some safety device like a high limit switch The failure can show up in several different ways v The Outer Sheath splits open The Heating Coil wire is hanging out in all directions and the MGO Filler is cracked smashed and blown away The element is totally destroyed and frequently the Stainless Steel Heater Housing may be damaged as well v Just one or two small holes are blown through the Sheath not as dramatic as a complete explosive meltdown but just as costly The element is destroyed Y No holes are visible but the walls of the Sheath are bulged outward in spots the normally smooth surface of the Sheath is now bumpy and has become discolored Inside of the element the Heating Coil may be broken or it might be electrically shorted against the Sheath Or both WHY WHY WHY That s three good questions Lets take a look at a few o
20. ctrical failure that a resistance wire heater ever suffers is when the Heating Coil breaks causing an OPEN in the circuit This is also the only electrical failure ever covered by our warranty It s exactly the same as a light bulb burning out it just gets tired of the tremendous trauma it goes through each time the power is applied Picture it it goes from cold to very very hot in less than 1 10th of a second it opens its door to see who s knocking and a thousand billion billion electrons that s 21 zeros rush in during the first second Because of the careful selection of components in the Heating Coil this sort of failure is actually quite rare You will rarely see a light bulb burn out while it was on Probably never they always burn out just as you turn them on That s turn on trauma However it can be brought on more quickly by switching the heater on and off rapidly this can happen with a defective control such as a chattering contactor or thermostat for example Be very suspicious if a replacement heater burns out quickly Watch for this Another suspect in an OPEN situation is a reduced water flow that causes the element to operate at a much higher temperature than normal but not high enough to cause a dry fire condition There may be no signs of the problem on the outside of the element it just got tired of working too hard A Special Note To Our Manufacturer and Assembler Customers Please remember that bot
21. e problem Y To increase the life of the relay we use a snubber circuit on the ozonator relay W ith this type of circuit if no ozonator is connected to an output and relays are open the voltmeter will still get a reading of around 60 volts This is normal It is important to take voltage reading when ozonator is connected to pack Power must remain On Please take note that ozonator output will be shut down when Pump J Pump 2 or blower have been turned on manually Filter Cycle indicator le Verify if Filter C ycle indicator appears on keypad 3 Measure voltage between 2 Ifnot start up a filter cycle ozonator black and white connectors Press and hold 240 VAC ozonator P16 amp P19 Light key for es STEER 120 VAC ozonator P16 amp P8 5 seconds e E The display i You should read 240 VAC will show a 120 VAC for a 120 VAC value that ozonator represents the filter cycle duration in hours 4e Replace ozonator if you get a Press Light key good voltage reading again The filter IThi cycle will start E immediately i 5e Check if Pump 1 is working If so replace Spa Pack If Pump 1 is not working refer to Pump 1 does not Work section SSPA Spa Pack Service M anual 48 Keys Flow Chart If any of the keys on the keypad do not seem to be working follow Troubleshooting Flow Chart below to identify the problem Make sure to use the proper keypad TSC 35 keypad with SS
22. e right probe M SPA 1 probe does not work on a SSPA spa pack Probe wires should be in this order N e Disconnect probe connector PIN 1 and clean probe connector pins Even a small coating of film may cause a bad connection 3 Reconnect probe p If Prr error condition still persists replace probe with a spare and place probe head directly in spa water If problem is solved replace 1 Verify if regulation probe is probe properly connected 4 Replace Spa Pack if problem persists SSPA Spa Pack Service M anual 24 HL Flow Chart If HL error condition occurs potential hi limit probe problem follow Troubleshooting Flow Chart below to identify the problem Press any key after each step to reset the system yes lt Q mv Take water temperature with a digital thermometer yes gt no Is water temperature 19 F or higher Are you getting correct water temperature reading on the display E Verify if E yes lt temperature probe Is weather is touching water Verify if or if cold air from temperature probe uA very hot back can affect its is properly connected reading If so replace gt m probe Remove es spa cover y even during Lower Set Point tne migati below actual T Start m water temperature purple Wa blower if Spa Pack H eater indicator overheating Replace spa IS 4 on keypad disp
23. eal do or neglecting to do the things that they This will allow moisture to get into the shoulddo inside of the element where it will be absorbed by the MGO Filler and will eventually cause an electrical short circuit between either the electrically hot Cold Pin or Heating Coil and the electrically grounded Outer Sheath of the heater With luck there will be a GFCI on the system that will open the circuit lf you don t Know what caused the GFCI to turn the power off you might start investigating nuisance tripping Without the GFCI there will eventually be arcs sparks flames and anger you can bet on that BROKEN EPOXY SEAL HOW CAN THIS BE PREVENTED Moisture may get inside of the element when tt Is off Part of the cooling off process is to suck in any surrounding air through any crack Then the next time the element is energized the moisture in the element may provide a path for current to flow and the GFCI will trio But a BIG BUT the heater may have been on just long enough to produce enough heat to drive that moisture out of there You come along and reset the GFCI and the heater will come back on again Drive ya nutty as they say Check that Cold Seal carefully TWISTED COLD PIN Never bend push pull or twist the Electrical Terminal 1 Always use two wrenches to tighten or loosen the Terminal Nut 2 One wrench holding the Terminal Hex 4 to keep it from turning and one on the Terminal Nut to do the
24. ee anywhere from a rustlike deposit to crack and fissures in the metal RUST BUILD UP ON At its worst it can result in corrosion fatigue causing ELEMENT the Bulkhead Fitting to breakaway from the Outer Sheath This corrosion ts bad stuff AND THEN THERE S THE IRON EATER A slippery brownish coating on the inside wall of a spa may not be any form of algae but can be the effects of an iron eating bacteria that is gnawing away at the heater This one is easy to correct the water simply needs some BACTERIA RESULT sanitizer chlorine bromine or ozone here a drain and refill if it won t go away WHAT S THE BOTTOM LINE ON CORROSION Corrosion of the metal in a pool or spa heater happens when the water becomes corrosive because somebody makes mistakes with its chemistry There are more than 2 000 000 spas in the USA alone that have never shown any signs of corrosion some more than twenty years old Their owners follow the instructions of the professionals at their local pool spa store and maintain a good sanitizer level along with a non corrosive pH level and monitor their Total Alkalinity Calcium Hardness and Total Dissolved Solids for a good water balance They do not Throw in a little of this or a little of that Thats like signing a Pledge Of Corrosion Electrical Failures DO THEY EVER JUST BURN OUT It s correct to say that the only natural like in died of natural causes ele
25. ent electrocution There are different GFCI models on the market Note that illustrations are generic only For 120 VAC systems Jumper location le Verify if Jumper 1 Is set in the LC position If it is not set Jumper 1 in the LC position Refer to page 10 for more information on jumpers SSPA Spa Pack Service M anual For 240 VAC systems From electrical box To spa le Verify if GFCI is properly connected Important connections e Neutral of GFCI must be connected to neutral bus Neutral from spa must be connected to breaker ii i From electrical box To spa 2 Ifitisnot verify GFCI wiring diagram and reconnect it GFC Trips If GFCI continues to trip even after having replaced the transformer carry out the following tests to correct the problem le IfGFCI is properly connected but 3 If problem is not solved yet still tripping or Jumper 1 is set in disconnect incoming power LC mode for 120 VAC systems lines unplug all outputs including the If GFCI still trips there must be two blades of at a cable problem the heater pgs Grr and light cord 2 Call an electrician 2 IfGFCI still trios replace Spa Pack 4e If GFCI stops tripping replace GFCI If it stops tripping reconnect one component at a time until G FCI starts tripping Replace defective 5e IfGFCI trips again replace component Spa Pack 9 SSPA Spa Pack Service M anual
26. f the things we have learned from a lot of field experience plus a ton of hours in the engineering lab HIGH LIMIT PROTECTION the primary job of the High Limit Switch in the finished product is to prevent scalding water from ever reaching the people using the product Sure the Thermostat should shut the heater off SWITCH needed but Thermostats like everything else fail Will the High Limit do its job It hasn t had to operate for months or years is it ready Is it in the right place to do the job If the High Limit is not sensing the water temperature close to the element and the pump suddenly quits its dry fire time in just a minute or two The element will boil the water in the heater housing and create its own dry condition Following that the service technician arrives and finds the heater assembly full of water again and claims it couldn t have been a dry fire Check that High Limit FLO PRESSURE SWITCHES Various types of devices are used to detect whether there is any water flowing through the heater assembly Unfortunately when these things fail they generally fail in the closed position and there is no indication that they are not doing their job In most cases a spa system will work just fine with a stuck pressure or flow switch until there is a need for it lf a full scale dry fire destroys the flow or pressure switch along with the element it s impossible to determine which went first but one thi
27. h Aquatemp and the original manufacturer of the heater element have run the required Dielectric Voltage Withstand Test Hi Pot Test on every unit we build Both of us are very careful to keep the test time to the absolute minimum allowed to prevent any degradation of the dielectric material within the element everything You always wanted to know about testing of the electric part of electric heaters aes Of any piece of equipment you might find on a spa or tub _ today the electric heater is probably the most simple we re sy not talking here about the controls now just the heater itself What makes it simple is that it is a straight resistive device It doesn t have any coils like motors and transformers giving TYPICAL TEST them inductive charact eristics and it isn t anything at all like METER a solid state printed circuit board mounted micro processor based control system With heaters the electrical is plain Jane THE IMPORTANT NUMBERS You can learn just about all there is to Know about an electric heater by applying a little Knowledge and a smidgen of easy math along with a decent test meter We ll start with the basic numbers These first two numbers are stamped or marked on the heater Rated Voltage like Rated Wattage like 115 120 240 or 230 volts 1500 5500 watts or These next two are calculated using the above numbers Calculated Amperage like Calculated Ohms like 12 5 22
28. iring problem Call an electrician le On the terminal block measure voltage between line 1 and line 2 You should get 240 VAC For 20 VAC systems 2 Measure voltage between le Measure voltage between line 1 and neutral line 1 and neutral You should get 120 VAC You should get 120 VAC 3 Measure voltage between 2 Verify that there is a jumper cable line 2 and neutral es between line 2 and neutral You should get 120 VAC SSPA Spa Pack Service M anual 30 3l Nothing Works If you are getting good voltage readings but nothing seems to work carry out the following tests to correct the problem E i Pm le Verify if keypad is correctly connected to the board 2 f nothing works replace Spa Pack SSPA Spa Pack Service M anual Spa Not Heating Flow Chart If the soa does not seem to be heating the water follow Troubleshooting Flow Chart below to identify the problem _ r Any error messages FLO FLC 3 flashing dots etc m Refer to on keypad display Ensure temp specific section Set Point is referred to higher than error message actual water temp m gt Has Heater indicator appeared on keypad display yes m yes A eS Do you get a 240 VAC Take water temp yes ding bet and compare with te fa pe temp value displayed a terminals on Keypad n orena Is difference works fine grea
29. k SSPA Spa Pack Service M anual 6 OFCI Flow Chart If GFCI trips follow this Troubleshooting Flow Chart to identify the problem yes BB mv Is GFCI properly connected uA es gt no Verify Wiring Diagram a po VAC n and reconnect it yes gt v Is Jumper 1 aa in LC position see page 10 Change Jumper 1 position yes Is GFCI still tripping yes Unplug everything i including the two blades of the heater amp light cord Is GFCI Reconnect still tripping one component at a time until GFCI starts tripping i D gt ue Replace defective component If GFCI is T still tripping a disconnect There is incoming Replace a problem power line GFCl with the cable Is GFCI Call still tripping all an electrician T Replace Spa Pack if GFCI is still tripping 7 SSPA Spa Pack Service M anual GFC Trips If all connections are made but nothing seems to be working you probably have a power supply problem Carry out the following tests to identify and correct the problem Note that for new installations GFCI trippings due to miswiring are common If breaker is wired properly GFCI trippings may occur when total amount of current drawn by spa exceeds breaker rating A current leak to ground will also cause GFCI to trip If any of the components is faulty and a leak of more than 5mA occurs GFCI will trip to prev
30. lay water during Spa Pack if aa should disappear filter cycle HL error One condition stil Wait until 240 Vac reading filter cycle pe Spa cools between the duration down add two heater wires cold water on the board if needed yes No lt a When HL error m condition occurs i does heater Verify if anything Verify if is obstructing water pee ene H i Limit probe is flow closed traps or properly connected dirty filters Try to clean pins p and reconnect probe If HL error condition persists replace Spa Pack 25 SSPA Spa Pack Service M anual HL Error Condition The HL error condition is related to the H I Limit sensor Steady message Means system has shut down heater because water temperature at the heater has reached 1192F Blinking message M eans except for the Smart Winter M ode system has shut down because water temp in the spa has reached 112 F Press any key between each step to reset the system Power may remain On le Take water temperature with digital thermometer 2 If reading is below I9 F a Check if heater barrel feels hot If it s hot verify if anything is obstructing water flow closed valves or dirty filter b IfHL error condition persists replace Spa Pack 3 If reading is 19 F or higher Proceed to following page if keypad display shows correct temperature Proceed to page 22 if keypad doesn t show correct tempera ture
31. ng is certain the heater was doing its job It isn t very smart it just makes heat Attack of the Killer Chemicals CORROSION the Bad Guy It s a mean angry sounding word bringing visions of all sorts of nasty things Even the dictionary makes it sound pretty evil akin to RODENT no less Come to think of it we ve seen a few heaters that looked like rats had been gnawing on em We think it s a safe bet to say that one of the major causes of heater failure has always by gnawing esp by chemical action been corrosion Given any chance at all this ME lt MF lt L corrodere to gnaw akin demon will destroy a heater element or in to RODENT many cases the entire heater The corrosion we come across in our industry particularly in spa equipment comes in many varieties each with it s own name and characteristics we are faced with galvanic corrosion chemical pitting intergranular corrosion stress corrosion cracking corrosion fatigue electrochemical corrosion we even have a strain of bacteria Ferrobacillus in the Siderocapsaceae family also called iron eating bacteria to contend with Gee Whiz WHAT CAUSES ALL THIS Well a full discussion of the chemistry and electrochemistry involved with this pretty complex subject is beyond the intent of this Handy Dandy Guide It s much easier to describe what doesn t cause it than to attempt to explain all the chemistry that does Consider this if all BAD CORRO
32. ontinuity go to step 4 If you do have continuity increase pressure switch setting by turning clockwise until voltmeter stops beeping Then decrease another 1 4 of turn 4e Turn pump on at low speed and wait afew minutes IfFLO does not appear you have adjusted the pressure switch suc cessfully IfFLO appears decrease pressure Switch setting by turning counter clockwise until voltmeter starts beeping there is continuity Then decrease another 1 4 of turn Turn pump off FLC Should not appear restart pro cedure ifFLC appears 5e When adjustment procedure Is completed apply Loctite 425 to the adjustment screw to secure it in place SSPA Spa Pack Service M anual 54 How To Adjust The Pressure Switch W hen a voltmeter is not available le Turn pump on at low speed 2 Increase the pressure switch setting to 4 PS I or until FLO message is displayed 3 Start decreasing pressure switch setting by very slowly turning adjustment screw counter Clockwise until FLO message disappears Then decrease another 1 4 of turn 4e Turn pump on at high speed for 30 seconds there should be no FLO message 5 Turn pump off and wait 30 seconds You should not see an FLC message 6 Turn pump to low speed for 30 seconds You should not see an FLO message 7 If you see an FLO or an FLC message restart the adjustment procedure If you are not able to adjust the pressu
33. orking section yes Bm mv Is anything limiting WA flow of water into pipes Remove a anything obstructing Verify if filter pressure switch Clear any cable is properly air locks connected and verify to pressure water valves switch _ m Lower Set Point at 60 F and Loo turn pump off A Short two pressure switch Adjust or terminals with a jumper cable Replace replace Spa Pack pressure switch Does FLC error condition persist 17 SSPA Spa Pack Service M anual FLO Error Condition An FLO error condition indicates a pressure switch problem If system does not detect any pressure when pump is manually or automatically turned on an FLO error condition will occur En There must be enough water in the spa for normal operations FLO error condition may occur if spa filter is dirty or if something restricts flow of water in piping The heater will automatically shut down when an FLO error condition occurs Power may remain On when the following steps are carried out Make sure circ pump parameter is set correctly depending on your system configuration le Verify if pump is working If pump is not working right refer to Pump does not Work section 2 Clean filter and check for air blockages closed trap valves or anything that could be restricting water flow 3 Verify if pressure switch cable is properly connected to pressure switch SSPA Spa Pack Service M anual 18
34. owing tests Y le Verify if temperature probe is in contact with water and if cold air from the back could be affecting readings Use foam to isolate probe from cold air if that is the problem 2 Make sure temperature probe is properly connected If it is replace probe 3 Replace Spa Pack if HL error condition still persists SSPA Spa Pack Service M anual 28 Nothing Seems to Work Flow Chart If nothing seems to work follow Troubleshooting Flow Chart below to identify the problem yes Bm mv For 240 VAC systems Do you read 240 VAC between line 1 amp line 2 20 VAC between line 1 amp neutral a 20 VAC _ between Verify if line 2 amp neutral There is keypad is on the board an electrical connected wiring correctly For 20 VAC systems problem to board Do you read Call an All eight pins 20 VAC electrician must be plugged in __ between and black wire line 1 amp neutral must be on top of the plug l Is there a jumper cable connected between n line 2 amp neutral Replace Spa Pack if there is still nothing on keypad display 29 SSPA Spa Pack Service M anual Nothing Works If everything is connected but nothing seems to work there is probably a power supply problem Carry out the following tests to identify and correct the problem For 240 VAC systems 4e Ifyou do not get good readings this probably indicates an electrical w
35. package of 25 9 86 13 42 22 430AC0103 P10 Fuses for light package of 10 11 14 155 gt 23 430AE0033 P10 Fuses for pumps package of 10 56 57 76 97 29 430AD0066 P10 Fuses for transformer 11 14 15 15 30 9920 400262 10 foot temperature probe 19 20 262 57 SSPA Spa Pack Service M anual Wiring Diagram 5SPA 1 The wiring diagram below provides a general idea of SSPA 1 wiring but it is important to note that it may not apply to all systems The wiring diagram including on inside power box cover is the one to be used as main reference for the spa you are servicing eel _ rs ia DELAY L UNES p PUMP1 OZONE F2 OO P24 P25 Pump 1 Ozonator Heater Voltage 240v Voltage 120v Black1 Green Ground P4 Green Ground P5 Black 2 Black Low Speed P14 Black Line P16 Red High Speed P12 White N eutral P8 White Com P18 Pump 2 Light Connector Pressure Switch Voltage 240v White 0 VAC P23 Green Green Ground P6 Black 12 VAC P22 Red Black Line P11 White Com P17 Jumper Settings Refer to page 10 JUMPERS a O P27__P28 amp P20 P21 P25 P24 JdO d dINAL Wiring Diagram SSPA MP The wiring diagram below provides a general idea of SSPA M P wiring but it is important to note that it may not apply to all systems The wiring diagram including on inside power box cover is the one to be used as main reference for the spa you are servicing I20VAC BESANI 24
36. r indicator will be on when heater is on It will flash if more heat has been requested but heater has not yet started SSPA Spa Pack Service M anual 34 Spa Not Heating If H eater indicator appears on the display but spa is still not heating carry out the following tests to correct the problem If Heater indicator lights up on the display le Remove plastic cover and measure voltage between the two heater screws on the board 2 If voltage reading is correct verify if heater nuts are Replace board if you are not properly connected to the getting a reading of 240 VAC element If not tighten nuts to the element 3 If problem persists replace the element 35 SSPA Spa Pack Service M anual Pump 1 Flow Chart If Pump 1 is not working follow Troubleshooting Flow Chart below to identify the problem De gt Have any error WA messages FLO FLC aa 3 flashing 2 etc Refer to appeared on Verify if Jumper 3 specific section keypad display is set properly indicated by error message yes B mv Does Pump T as indicator appear on keypad display a when you press l Pump 1key If still not working replace Spa Pack yes BH mv Is Pump lworking in either speed ys lt Q mv a Replace Pump 1 fuse Pump still not working yes Bm mv Measure voltage on the board for both speeds Do you get a 240 VAC 1 reading o
37. r 20 VAC 1 for a 20 VAC pump Replace for both speeds Replace Pump 1 Spa Pack 31 SSPA Spa Pack Service M anual Pump 1 Does Not Work If Pump 1 is not working carry out the following tests to correct the problem To increase the life of the relay we use a snubber circuit on the pump relay W ith this type of circuit if no pump is connected to an output and relays are open the voltmeter will continue reading around 60 volts This is normal It is important to measure voltage when pump is connected to pack Power must remain On 1 Check for an error message on keypad display If there is one refer to specific section indicated by error message 4e f Pump 1 indicator does not appear use a spare keypad to verify if keypad IS defective Jumpers o If it is replace keypad set properly for 1 or 2 pumps refer to page 10 for more info Pump 1 5e If Pump 1 indicator appears when indicator Pump 1key is pressed verify if pump works In either speed HAH ce eT 3 Verify if Pump 1 indicator appears on keypad display when you press Pump Lkey SSPA Spa Pack Service M anual 38 Pump 1 Does Not Work If Pump 1 does not work in either speed carry out the following tests to correct the problem Pump 1 fuse le If Pump 1 does not work in either speed 3 Turn Pump 1 to low speed and take replace Pump 1 fuse voltage reading between white and
38. re switch change it 8 W hen adjustment procedure is completed apply Loctite 425 to the adjustment screw to secure it in place 55 SSPA Spa Pack Service M anual a Parts List We recommend that field service technicians keep the items identified with an in stock Ref Part Number Description Retail U S 1 530AB0061 Tail piece for 2 heater 5 39 7 33 1 530AB0042 P5 Gasket for 2 tail piece package of 5 8 00 10 88 2 282CA0071 N ut for 2 heater 4 90 6 67 4 9920 400178 Light cords option LS 7 57 10 3 6 9920 400200 J amp J mini connector for pump 1 7 26 9 88 6 9920 400199 J amp J mini connector for pump 2 single speed 6 68 9 09 6 9920 400200 J amp J mini connector for pump 2 two speeds 7 26 9 88 6 9920 400204 J amp J mini connector for ozone 5 92 8 06 6 9920 400203 J amp J mini connector for blower 5 92 8 06 6 9920 400205 J amp J mini connector for circulation pump 5 92 8 06 6 9920 400277 AMP connector for pump 1 7 26 9 88 6 9920 400276 AMP connector for pump 2 single speed 6 68 9 09 6 9920 400277 AMP connector for pump 2 two speeds 7 26 9 88 6 9920 400278 AMP connector for ozone 6 68 9 09 6 9920 400278 AMP connector for blower 6 68 9 09 6 9920 400276 AMP connector for circulation pump 6 68 9 09 12 530AA0107 In line 5 5Kw heater 143 17 194 79 12 530AB0087 5 5Kw 240V element for in line heater 88 20 119 99 13 510AD0064 Pressure switch 28 42 38 67 19 282AD0038 P25 Ground screws
39. ror Messages System Malfunctions Part Replacement Procedure amp More C 9919 100298 A Handy Dandy Guide to Heaters with Information on the Causes amp Corrections of the Bad Things That Can Happen Mechanical Failures The term Mechanical Failure covers everything from shipping damage to dog bite but the most common mechanical failures in electric heaters are caused by improper handling destroying the Epoxy End Seal and Brand New Element breaking or twisting the Cold Pin until it breaks are the two leaders in this failure mode Because they are so closely related we ll look at them together WHAT HAPPENS Any form of rough handling can put pressure on the part of the heater that sticks out the most the Electrical Terminal which is welded to the Cold Pin which in turn passes through the Epoxy End Seal to get to the Heating Coil inside d the element If the Electrical Terminal is A Sidebar broken away from the Cold Pin there is When we tak about Mechanical failure we obviously no way to connect electrical i Oe ee ee oe y y parts There is nothing to wear out There wires to the heater and it becomes a are no parts that spin tum jerk or slide and throwaway no gears to mesh or hinges to squeak All of the mechanical failures we can name are More often the rough handling results caused by people doing things they shouldnt in the destruction of the Epoxy End S
40. st equioment and components needed to carry out SSPA power spa pack service calls Required tools 7 Pliers 3 8 open end wrench Phillios amp flat screwdrivers Jumper cable 1132 nut driver Multimeter 1 4 open end wrench GFCl tester amp digital thermometer optional Required pack parts Fuses Pressure Switch Regulation sensor Top side control keypad SSPA complete pack Gecko Electronic Inc sells Professionnal Repair Kits that include everything needed for SSPA power spa pack servicing For more information go to the last page of this manual SSPA single and dual pump systems are available with a selection of keypads All the procedures and instructions described in the next pages are applicable to SSPA systems equipped with one of the following keypads Please note that the TSC 9 model is used througout this manual to illustrate specific actions SSPA MP only gt e fi TSC 35 Keypad 7 3 1 4 SSPA TSC 19 Keypad 7 3 1 Ca TSC 9 Keypad 2 4 1 2 SSPA Spa Pack Service M anual Electrical Wiring Correct wiring of the electrical service box GFCI box and pack terminal bloc is essential OT le Carry out a visual inspection to check for signs of miswiring Refer to supplied wiring diagrams Call an electrician if necessary Yi For 240 VAC systems Electrical Box For 220 VAC systems Pack Terminal Bloc
41. ter than 2 F Is temp probe touching water or WA hot air rear affecting reading Replace Spa Pack Isolate back of probe with foam o yes lt no m Are heater nuts Replace pere temp probe to the with spare element gt yes a If water temp Try tightening nuts still doesn t to element a match temp on keypad display Still not heating replace Spa Pack Replace element 33 SSPA Spa Pack Service M anual Spa Not Heating If the spa does not appear to be heating the water carry out the following tests to correct the problem le Check for an error message on If Heater indicator does not keypad display If there is one light up refer to section indicated by the error message 4e Use a digital thermometer to take water temperature and compare Set Point your reading with the value on K indicator keypad display cekeli If values are different 2 F verify if ae sensor is touching water or if hot air te from rear could be affecting readings A 5 Ifso use foam to isolate behind alr Meee the probe 2 fthere isno message try to increase temperature by raising temperature Set Point Press Up arrow key to increase Set Point H eater indicator 6 Ifnot replace temperature sensor with a spare one 3 Verify if H eater indicator appears 7 If spa is still not heating replace on the display Spa Pack H eate
42. their path in order to satisfy that hunger An element or heater corroded because the water has a LOW pH is easy to spot it has pieces eaten away fom its surface Gone disappeared departed It looks like the craters of the moon And people are putting their bodies in there SCALE CALIFICATION HISS BOO At the other end of the we have SCALE In some ways SCALE can be considered as the opposite of ACID with SCALE the water has too much of something and wants to get rid of it and the nice warm heating element is a good place to deposit it The problem is that it s like asking a Hawaiian to run a marathon in Honolulu dressed in a fur coat wool cap and mukluks He s going to have a rough time getting rid of the heat he s generating and probably won t finish the race MORE UGLINESS Bad chemistry corrosion can show up where the element sheath is brazed to the bulkhead fitting or welded to a mounting plate Even though all of the parts are stainless steel and selected just for this purpose the ingredients mostly iron chromium nickel and molybdenum in the steel must vary the mix has to be different for parts like the Bulkhead Fitting that needs to be machined vursus the thin high temperature Incoloy Outer Sheath that must be bent and formed Very special welding techniques are used at these joints to make sure that no impurities are left behind that might corrode But if the water gets bad enough you may s
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