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BWG 50Hz BP Troubleshooting Service Manual

1. 1uJnq 1030 AJ Jedoud aay SI 9 MOT JO SSO 54091 p soj 912 sjar X XIX X pabpo SIp 10 pex2oq Eqn 9An UO u91IMS JO JI peo 19Ao X X ON 8814 1039 SIOU SUNY dung 92IAJ9S 10 Uel214129 8 paiijenb 1363002 ON suolun 1 MOJ aunssaid 1978M MO Jou 5 uedoud jou dung 100 dung 12018 100 1010 5 9 asneg 9 sdwing 5 02 13 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 20 Acceptable Ranges for Testing Equipment VOLTAGE CHECKLIST All voltages specified as 120 V or 240 V may show ceptable variance of 10 Voltage Ranges Wire Combo Voltage 10 Range Black amp Red 240V 216V 264V Black amp White 120V 108V 132V Red amp Wh
2. 55 Pre Production Software 58 5 5 57 Press and Hold PRICE 43 MOOD 137 FIIO MIQUE ess dii aes Redes weg Pow we a 44 Priming Mode MBIB 5 Priming 19 55 Primingthe Pumps 44 trie PUMPS cox ue sce aes Swe Pe 3s Program memory failure M022 51 e d pak de bes 72 the connector straight 24 the connector straight out 25 TAMPO S unos oom qo ded ooh ese 33 o 2 23 Ru oor oo a eh 45 FUNC s 46 RCD Line in 19 RCD Line out Wiring Check for 230 V Dedicated System 19 Recommended Parts to have For Service 7 5 02 13 Index of Paragraph Topics cont Release tab 2 llle 24 Reminders Dr Remove both nuts that secure the element in place 40 Removing a System Circuit 41 Removing BP Expander Board an Alternate Way 41 Restricting Operation Locking the Panel 47 RUN PURG AIR 57 safety Trip Pump Suction M033 B SavIH SECUS 5 acu
3. JISVWWVYDONd 03385 1 03385 03385 2 3NON 03345 1 34445 1 03385 2 i s Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 NOLIVTIVISNI TWNI4 NOd 440 OL 135 38 CINOHS 9 HOLIMS OvXV OtXV OcXv OIXV S TANWd WI Q3N9ISSV LON Q3N9ISSV LON Q3NDISSV LON e 3NBISSV LON DONE un 28 RUE ro d 01 187 NOILO3NNOO INIT 3N0Z0 2412 579 NMOT1000 NIN S ZY P 2313 NMOGIOOO I Ov 01 3 YOLVYSNAD 3NOZO 3NOZONOIVH3N39 YOLVYANSINOZO cer MEME See 2 9T vI 4 40135 2412 NOILVINOYID 30 3dWOd 3dW d 4NVISIAW 3704 4 1612345 4 TINY 39vu3dWv 1410345 01 UI T tt lV3H HLIM SdW d SH 00 SdW d SH t L NOQ 03 610 NOILO3NNOO I XAV xx yit I 03345 2 SASSALIA V I 3dWOd NOILVIN3AIIV T 3dWf d MH2S39 2 5714 et 39IA3d NOIIV201 v9IX dT NOES 39IAW3S 33WMHl W2EXT dT AVE 1 35 31915 HLIM SdW d SH c 0 V SdW d SH adv L NOG HLIM dW d SH I 007 zv 1
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5. 2 3 Equipment Overview 7 service Tools and Parts Checklist 0 0 0 0 0 0 0 0 0 7 TP Panel Overview and User Guides 0 0 8 2 2 9 230 Volt 50 Hz Residential Wiring Schematic with 2 Pole RCD Breaker 10 General Troubleshooting amp Servicing of Spa s Electrical Equipment 12 Basic Control System Troubleshooting 2 0 0 0 13 Testing a System with Power 0 0 0 a 0 e eos 15 230 Volt 50 Hz Residual Current Devices 8 17 WON Zu aqoa oe 18 Wiring Check for RCD and Service Disconnect 2 2 19 Troubleshooting Pumps Problem amp Cause aaa a a 20 Acceptable Ranges Testing Equipment 2 2 ee n 21 Troubleshooting Using Resistance 22 Onm S LIW s s ss hw eee eRe Ree eee eee ___ we 22 Testing Fuse Continuity ios oo om ok RRA EG eR o we 23 Troubleshooting Heater Resistance 0 a 24 Troubleshooting Heater Posts Resistance to Heater Housing 25 Troubleshooting with Voltage 26 Verifying Incoming Voltage at the Terminal Block BP2100 amp BP600
6. Waiting time depends on menu item that reverts to original setting and ignores any change to that menu item Indicates a Menu Item that Depends on a Manufacturer Configuration and may or may not appear To FIRST item in Main Menu TEMP Range When the GFCI trips the spa will shut down poe eae ele ee After the breaker is i im IE TRIP may also reset PASS will Only if GFCI One of these screens appear briefly appear in this menu is enabled 1 will appear under certain and the spa will A circumstances operate normally If the GFCI does The GFCI will be tripped NOT trip FAIL will at a random interval appear and Spa will not operate Or Wait to Only appears Revert if a GFCI test 1 NA 3 has been V passed Or Wait to Or Wait to Revert o Revert To next item in Info Menu KkKKKK A B Waiting several seconds inside the GFCI Menu will allow the screen to return to normal operation Forcing the GFCI Trip Test The installer can cause the GFCI Trip Test to occur sooner by initiating it using the above menu The GFCI should trip within several seconds and the spa should shut down If it does not shut down the power and manu ally verify that a GFCI breaker is installed and that the circuit and spa are wired correctly Verify the function of the GFCI with its own test button Restore power to the spa and repeat the GFCI Trip Test
7. 21 Testing Pump Fuses Damage with Voltage BP2100 28 Testing Heater Voltage All BP Systems 29 Safer Way Test Heater Voltages 2 30 Testing Pump Fuses for Damage with Voltage 600 31 Testing Heater Amperage 2 32 Testing Low Speed and High Speed atthe AMP Pump Connector 33 Testing the Sensor Set 2 2 0 0 34 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Table of Contents cont Component Failure and Replacement Testing 36 software Setups and Test Mode 2 2 36 setup Changes with DIP Switch 1 ON Using a 600 TP400 Panel 37 Setup Changes with DIP Switch 1 Using a 900 or TP800 Panel 39 Removing the Heater Assembly froma BP Spa System 40 Remove and Replace System CircuitBoard 41 800 TP900 Panel Operations 43 The Main Screen Navigation 0 0 0 0 0 0
8. TEMPERATURE SENSORS LOCATION WIRES REMOVED Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group lt i Depress tab when removing Re Rem Re dr RS mo 1 nr pn is 3x0 6003 1191314 277 2 TEMPERATURE 73856 che URE J17 SENSOR A J16 SENSOR B 5 02 13 Testing the Sensor Set cont If there is a message indicating an open or faulty sensor Unplug the sensor set but leave the original sensors in the heater and plug in the test sensor set Put both sensors into the same cup of warm water ideally above the set temperature so the spa won t try to heat during this test as there is no heater protection during this test and verify that they read the same temperature within 1 F 0 5 C e 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 fthe problem continues after following the above steps then replace the circuit board M 7 Replacement Sensor M 7 REPLACEMENT SENSOR HEATER METAL TUBE
9. 422178 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 37 Setup Changes with DIP Switch 1 ON Using a TP400 Panel cont Again you will have 1 minute to complete the setup change after you manually exit Priming Mode Immediately after exiting Priming Mode press this sequence of buttons Warm Light Warm Warm Warm Warm Continue to press Warm until the display shows the Setup Number 5 01 5 02 etc you want to switch to When the correct setup number is showing press Light once and the system will reset using the newly selected Setup from that point on Move DIP Switch 1 to the OFF position to take the spa out of Test Mode F or C will replace T Using a permanent marker write the Setup number on the Setup label mounted inside the system lid right This is very important to any service person in the future who may need to replace a circuit board or system and needs to change the Setup on a replacement part while in the field THIS SYSTEM IS CONFIGURED AS SETUP NOTE Changing the Setup may require wiring changes as well refer to the wiring diagram or wiring diagram addendum Key indicates Flashing or Changing Segment indicates Alternating or Progressive Message every 1 2 second temperature button used for Action 0 Light or dedicated Choose button d
10. Warning Shock Hazard No User Serviceable Parts Do not attempt service of this control system Contact your dealer or service organization for assistance Follow all owner s manual power connection instructions Installation must be performed by a licensed electrician and all ground ing connections must be properly installed Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group CSA Compliance Conformit Caution e Test the ground fault circuit interrupter or residual current device before each use of the spa Read the instruction manual Adequate drainage must be provided if the equipment is to be installed in a pit For use only within an enclosure rated CSA Enclosure 3 e Connect only to a circuit protected by a Class A ground fault circuit interrupter or residual current device To ensure continued protection against shock hazard use only identical replacement parts when servicing e Install a suitably rated suction guard to match the maximum flow rate marked Warning e Water temperature in excess of 38 C may be injurious to your health e Disconnect the electrical power before servicing Attention Toujours v
11. 0 3 amp 23 1 DIP Switch 36 1 switch 37 amp 23 6 pin connector J40 69 10 amp 23 30 35 in Ibs torque 40 30 amp 23 30A pump fuses 28 120V Amp Draw 21 120 V Draw 21 120V Watts 21 230V Amp Draw 2 230V Watts 21 240V Amp Draw 1 240 V Draw 21 240V Watts 2 20600 part number 23 21581 part number 23 22117 B 67 68 2221 E 57598 30122 part number 23 30136 part number 23 42012 Document No 70 42013 Document 70 50211 Document No 70 50212 Document No 0 56131 02 67 68 56284 67 68 51 F or C replaced by 36 T 38 T F or C is replaced by 36 A A B Sensor 36 A B Sensor Temperatures 36 A B Temps 49 Acceptable Heater Amperage Draw Ranges 21 Acceptable Heater Ohm 0 Ranges 21 24 Acceptable Ranges for Testing 21 Index Access lest Menu 36 access to the power board 31 address Assigning anew 0 Address Dolphin 70 Addressing your Dolphin 70 Address Spa 70 Adequate drainage 2 amp 0 3 23 amp 3 23 10 23 30 23 33 Amperage Draw Ranges 21 Amperage Heater lest 32 Amperage Heater Test BP2100G1 32 appliance continuous duty 3 Apply Loctite 40 arrow right 51 A sensor 36 49 assembly reinstall the heater 40 Assigning anew address 70 asterisk message with an 44 Auxiliary freeze sensor 45 Avoid damaging the post 40 Avs Bor T vs 34 B background colors 52 ball valves 40 Pump Su
12. 222 58 SW _ Dip Switch Settings 2 aa 56 system Box Wire Gauge Check 18 system nformation 48 system Model 48 We aaa eee 15 18 lemp Display Temperature amp High Limit Sensor Ohm Table 21 Temperature Sensors location Wires removed 34 ED EM 36 Terminal Block amp F6 Fuse a BP600 Power Board 230V Setup13 Terminal Block amp F6 Fuse on a 2100 Board 13 Testing a Fuse Check continuity with the fuse removed 23 Testing low speed and High Speed at the AMP Connector 33 Testing 35 Test Menu Access 51 Switch 1 36 16 Test software installed 51 Test the Amperage Draw 14 Test the 14 14 Test 14 The brown wire should connect to load out the blue wire from neutral out All wires will exit the box via conduit routed to the spa EIU IEEE hoe kh ow Oo ORG ROO RS 19 The clock has failed M020 51 The Control System is in Test Mode if 102 T appears In this case F or C is replaced By T a uaa oko moe os 36 The Dolphin
13. 5 3 pem STANVd NIVW dl WI E gt lisaL oer ete B cet ZULH 9ZC 3 280 E Tet TULH S20 __ 21 02 10 PEPER J LEM 8I ZI ZI 6 G 541135 NI YIC NO 1 OL 10 68 96 Nd 900 10 6898 Hed 1000248 wesberg Ve ae WN 8 dg Jaye eogjeg 63 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 422178 T 0 T0 J LEM BY G ye T TE 9006 40 WOWINIW 6871 NI 0 Z2 JYAIND SUNSLONGNOD 538 119 ALIOVdNV 309 30 SISVG I 0 688994 p 13001 vg 181 X90709 1 INAWANDINN IHL 03715 SYOLONGNOD 351 404 JONVY SYOLINGNOD ISN SNOLLO3NNOO ATddNS 804 aS SSS SS m desir SS Se eee 135 26805 Nd LIJ IWNOILdO NI 914 2 W3ldVOV 14 4 WILSAS 4 1 403 314 43504 TvNOILIGOV 9T SI 4 1 5 vI EL 40135 680 4 LIA 3HIM X2d8
14. Desired Temperature Pump and Heat otatus Set 104 104 F Spa 8 32 ELA Shortcuts Ozone Settings Filter 1 Ready in Rest Mode Heating Messages Lock Indicator 422178 NAVIGATION Navigating the entire menu structure 15 done with the 5 buttons on the control panel When a text item changes to white during navigation that indi cates the item is selected for action Operating or changing a selected item is generally done with the center or select button The only item that can be changed on the left side of the Main ocreen is the Set Temperature Press the Left Arrow button to change the Set Temperature number to white The Set Tem perature can then be adjusted with the up and down buttons Pressing the Select button or the Right Arrow button will save the new set temperature the right side of the screen the menu selections can be selected with the Up and Down Buttons Use the Select Button to choose an item Selecting one of these items will change to a different screen with additional controls PRESS AND HOLD If an Up or Down button is pressed and held when the Set lemperature is selected the temperature will continue to change until the button 15 released or the Temperature Range limits are reached MESSAGES At the bottom of the screen messages may appear at various times Some of these messages must be dismissed by the user Manufactured under one or more of these patents U S
15. Once the GFCI is tripped by the test reset the GFCI and the spa will operate normally from that point You can verify a suc cessful test by navigating to the above menu PASS should appear after a temp button is pressed from the GFCI screen The end user must be trained to expect this one time test to occur and how to properly reset the GFCI Warning If freezing conditions exist a GFCI should be reset immediately or spa damage could result The end user should always trained to test and reset the GFCI on a regular basis Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 00 Simplified vs Standard Panel Operations SIMPLIFIED MENUS Simplified Menus is an option that manufacturers OEM s offer to their end users order to provide an easier to navigate menu A simplified menu structure does not have extended features such as Utilities Restricting Operation Unlocking and SO on yet provides basic spa operations that satisfy the needs of end users Navigating the menu structure is similar for both standard and simplified menus which is done using two or three buttons on the control panel All TP600 and 00 panels a
16. Z 3dW d MH2S39 z 9NnO9uUOSH3AWOMLSZL3N lV3H HLIM SH Veext dW d 03305 2 S3SS3l1IA Z V 3dWOd NOILVIN3AITV 3dW d MH2S39 Z 9NnOUOSHW3AWOMLSZL3N M dt noe 330 TS INNVSHO LIMS 102 18 96 iequiny Wed WOIXE AOE 301 435 33 YZEXT dr 329IAW3S JI NIS Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 66 Wiring Diagram 600 Setup 1 16 as Manufactured Boards Shown Power Board 22117 56284 Logic Board 22121_ 56131 02 Power Requirements Single Service 3 wires line neutral ground 230VAC 50Hz 1 16 Circuit Breaker rating 20 max System Ouputs 16A Service Pump 1 230VAC 2 Speed 7 5 max 30 minute timer for Low Speed 15 Minutes for High Speed This is the heater pump Must deliver a minimum of 20 GPM through heater Low Speed may not exceed 2A max Pump 2 230VAC 1 Speed 7 5A max 15 minute timer Ozone 230VAC 5 max Uses the same relay as Pump 1 Low Spa Light 10VAC On Off 1A max 4 Hour timer Heater 3kW 240VAC Wiring Diagram and Settings ON POSITION 51 SWITCH OFF PO
17. gt Wireless Remotes e Dolphin manual domestic Document No 42012 e Dolphin manual CE is Document No 42013 DOLPHIN REMOTES e Dolphin Ill domestic Document No 50211 e Dolphin Ill CE no RF Document No 50212 5 02 13 Spa Guidelines to Keep in Mind Below are guidelines when designing replacing an older control system or if designing a new spa system This information 15 included in order to offer more insight into spa plumbing and mechanics 1 The heater requires at least 20 Gallons per Minute of flow for proper function 2 Some systems may require at least 25 GPM 3 suction system for the 2 speed pump or for the circ pump must be dedicated There must not be any other pumps connected to this suction system 4 The suction system for the 2 speed pump or for the circ pump must include the following a 2 suction fittings or 1 suction fitting and a skimmer 5 If the suction system for the 2 speed pump or for the circ pump includes a filter it is desirable that the filter incor porate a by pass around the filter cartridge that opens when the cartridge gets dirty Spring tension holding the by pass valve closed must be overcome by the vacuum of the pump This by pass should be capable of flowing a minimum of 20 GPM during the low speed operation of the 2 speed pump or during circ pump operation with the cartridge 100 blocked The inclusion of a suction fitting appropriately plumbed into
18. 30137 Fuse 25a Power Input 21447 Fuse 25a Power Input High Surge 30136 Fuse 30a Power Input RECOMMENDED PARTS TO E Wes m HAVE FOR SERVICE CALLS J M aw e Extra Board s rem 7 d e Extra Panel s M e Fuses UM corr M BP2100 Circuit Board e Jumpers IH TM B nr e Heater Assemblies amm ck e Sensor Wires 30344 sensor wire for example Heater Assembly 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group TP Panel Overview and User Guides System Models BP2000 and other BP Series Systems as required Panel Model TP900 Series TP800 Series Software Version s Software versions vary and are constantly changing See Tech Sheets for latest version and software compatibility BALBGA TP900 User Guide 40985 TP800 System Models BP500 and other BP Series Systems as required Panel Model TP600 Series TP400 Series Software Version s Software versions vary and are constantly changing See Tech Sheets for latest version and uw E E software compatibility TP600 e User Guide 40940 User Interface and Programming Reference Standard Menus e User Guide 42185 Ref Card 40947
19. 5 02 13 Index of Paragraph Topics cont Depress tab when removing 34 DOCS kee 45 35 4 2 Dip Switch SSEHBOS suec ce dem dy UR PEST qe es 48 Disconnect the connector by depressing the tab 24 69 Dolphin Il and Dolphin Applies to RF Dolphin only 52 eee ee e ee s 70 eine af ae ade 70 MANUAL 70 Dolphin Receiver 69 Dolphin 70 Do not measure across 29 DO NOT REMOVE AND REPLACE THE CIRCUIT BOARD UNLESS THE FAULT HAS POSITIVELY BEEN DETERMINED TO BE THE EDOARD dd Edu GS wn 41 DranMode 49 Exiting Priming 44 Exiting 55 F6 and F8 are on the main board F1 is located on the expander 41215 15 28 ween aye 6 onc eps ag ET 13 qup ETT 20 PALELUG a aot xdg ede odo d bep d 36 PALTLUG PP 57 Fault Log Message Codes 59 Fabi MD yee pear aoe ee pt dhs en 49 ik sf IE CP 51 Filter Cycle 2 Optional Filtration 46 FIOM ANG UONE dos xd ee eR
20. ERE MESI Ur uu Du uM e e lt 42 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 900 TP900 Panel Operations The Main Screen Navigation SPA STATUS Important information about spa operation can be seen quickly from the Main Screen The most important features including set Temperature adjustment can be accessed from this screen The actual water temperature can be seen large text and the desired or Set Temperature can be selected and adjusted Time of day Ozone operation and Filter Operation status is avail able along with other messages and alerts High Temperature Range vs Low Temperature Range 15 indicated in the upper right corner The Jets Icon in the center will spin on a TP900 if any pump is running and changes color when the heater is on The icon does not spin on 800 but still indicates pump and heater function Lock icon is visible if the panel or settings are locked The Menu choices on the right can be selected and the screen will change to show more detailed controls or programming functions Water Temperature Temperature Range
21. Heater Wattage as Configured in Software CE Systems Only 48 Heater Wattage as Configured in Software CE Systems Only 56 Heat LED in Heat Waiting Mode 0 15 _ 56 37 46 FALT CALL FOR SRVC 58 MUSD TC 51 How the Dolphin Works 69 htr flow fail 2 bi htr flow loss rne 57 is too Hot OHH 57 MAY BE DRY WAIT 2 2 2 2 5 1 2 b If the problem stays with the same sensor according to topside messages it s a board problem if the problem moves to the other Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 79 Index of Paragraph Topics cont sensor its sensor problem 35 Important Use 18 INFO System Information sub menu 56 Installing a System Circuit 42 3102 1 3 33 ORS 52 Locate the heater conn
22. NUT STAINLESS WASHER ORING SENSOR SENSOR HOUSING MOUNT 422178 TESTING SENSOR PINS ALWAYS TURN THE POWER OFF WHEN PLUGGING AND UNPLUGGING Sensor Pins At times a protective coating may on accident coat the sensor pins during manufacturing Those pins may need to be scraped and the sensors plugged back Tip If one sensor A or B seems to be having problems swap the cables of sensor A with sensor B If the problem stays with the same sensor according to topside messages it s a board problem if the problem moves to the other sensor 5 a sensor problem Sample Board Shown Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 35 Component Failure and Replacement Testing Software Setups and Test Mode All BP systems have the capability for Test Mode Test Mode is used when changing setup configurations through the panel which also means that wiring changes may be necessary See the specific spa control system Tech Sheet for more details Note Although Test Mode allows access to certain utility fea tures most Utilities are available without entering Test Mode A B Sensor Temperatures and Fault Log inform
23. 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 73 continue monitoring temperature 48 continuous duty appliance 3 continuously spa to filter 16 Control System 69 cord AMP 33 Current Setup 36 cycle cleanup 46 Cycle Clean up or purge 72 Cycle Filtration 72 cycle second filter 45 cycles filtration 45 D damaged terminal 40 DEMO Demo Mode 56 Demo Mode 36 49 Depress sensor tab 31 Depress tab 34 Device Residual Current 2 different LCD readouts may look slightly 56 57 DIP Switch 1 36 DIP switch for proper configuration 41 DIP switch positions of 51 56 discolored slow blow fuses are not always 14 Document No 42012 70 Document No 42013 70 Document No 50211 70 Document No 50212 70 Dolphin 69 Dolphin Address 70 Dolphin Addressing your 0 Dolphin 69 Dolphin Ill manual 70 Dolphin receiver 69 DolphinIM Remote 69 Do not pry up 41 do not pull on the wires 41 down spa 15 shut 57 dr 5 drainage Adequate 2 Drain Mode 49 Draw 120 V 21 Draw 120V Amp 21 Index Draw 230V Amp 1 Draw 240 V 21 Draw 240V Amp 21 Dry Heater May be 57 duration 45 E End User Warning 2 error condition 48 event fault 59 exit Priming Mode 37 exit lest Mode 39 expander board 28 41 F failed
24. 57 Displays the Model Number of the System M030 48 57 M031 58 SETP CURRENT SETUP M031 Sensor A 51 Displays the currently selected Configuration Setup Number SIG CONFIGURATION SIGNATURE M033 Displays the checksum for the system configuration file M034 51 58 HEATER VOLTAGE FEATURE NOT USED M035 51 58 RATED SYSTEMS M036 51 58 Displays the operating voltage configured for the heater 46 HEATER WATTAGE AS CONFIGURED IN SOFTWARE CE SYSTEMS ONLY Displays a heater kilowatt rating as programmed into the control system software 1 3 or 3 6 HEATER TYPE Displays a heater type ID number SW _ DIP SWITCH SETTINGS Displays a number that represents the DIP switch positions of S1 the main circuit board PANL PANEL VERSION Displays a number of the software in the topside control panel A B SENSOR TEMPERATURES When this is set to On the temperature display will alternate to display temperature from Sensor A and Sensor B in the heater 56 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 b2 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 00 Messages cont FALT LOG FAULT LOG The Fault Log is a record of the last 24
25. 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group ASSIGNING A NEW ADDRESS TO THE DOLPHIN In some instances you may want to reset the address of your Dolphin You ll need to match that new address in the control system and that of your Dolphin Step 1 Addressing your Colossus through your control panel Main Screen gt Settings scroll to Preferences gt Preferences gt Dolphin gt Dolphin Screen Use the arrow key to change the address to 5 in this example Exit with Arrow Left key Step 2 Addressing your Dolphin 1 Press the SPA Button on the Dolphin once b Press and hold SETUP until the LED blinks once c Hold it until it blinks twice 2 Enter one of the set up codes below set Up Code Spa Address 0000 0 no address 0008 1 0080 2 0088 3 0800 4 0808 5 0880 6 0888 7 3 If the code is entered correctly the LED will blink twice Refer to the Dolphin manuals for more details SAVING YOUR DOLPHIN ADDRESS For future reference make a note of the address for your records Keep mind that you may have to change the address if there are conflicts with your equipment Also the address may have to be reentered after servicing DOLPHIN MANUAL Dolphin IIl manuals can be found on our site www balboawater group com Click on Spa Products
26. BP2100 board screw locations 42 BP2100 board without wires 42 Dre HO Circuit DUG ca ke RE d ee eS 7 sU ss be eGR A 13 Brown to Blue Wires on 230V BP600 System 2 Brown to Blue Wires on a 230V BP2100 System 21 CEPOT Pr 50 Changing Menus Through Configurations 61 Check for Loose Connections or Damaged Wires 18 Checking the System Power Input Fuse 13 Circ Pump or circulation pump 72 Circulation Pump 45 Cleanup 2 Cleanup Cycle optional 46 Clean up or purge 17 FAIL 58 FAIL 58 Background km wee Gece 52 Common Fuses Used spa Systems 7 51 Compatibility on Dual Board Control Systems 42 Configuration Error Spa will not Start 51 Configuration Error Spa will not StartUp 58 Configuration Signature 48 CON PD 27 Curent BUD Lucii ues Ro oe oe ERR a 48 DEMO Demo Mode 36 DEMO Demo Mode 56 Demo 49 Depress sensor tab when removing 31
27. READY RANGE 1 Waiting Several Seconds in the Main Menu will allow the display to revert to the Main Screen Most changes are not saved unless Light 0 is pressed Refer to Key above 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 53 TP400 TP600 Panel Utilities Menu If the system can power up you have access to the Utilities and Fault Log menus Key indicates Flashing or Changing Segment indicates Alternating or Progressive Message every 1 2 second temperature button used for Action Main Screen UIL READY RANGE FLIRI While the Temperature is still flashing press Light repeatedly until UTIL Utilities appears in the LCD Start display of string There is a 2 second delay on each number NA AP V4 01 0 To FIRST item in Main Menu WA ee Start display of string There is a slight delay on each number UL system at startup OR Heater Type DIP Switch 1 Test Mode Off 0 or On 1 pu gt _ gt lt m rain 71 Store Settings 0 M
28. Runs 0 HR 0 Min Ends at 12 00 AM Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7 417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 TP800 TP900 Panel Lock amp Unlock RESTRICTING OPERATION LOCKING THE PANEL Main Screen gt Settings gt Lock e The control can be restricted to prevent unwanted use or temperature adjustments e Locking the Panel prevents the controller from being used but all automatic functions are still active e Locking the Settings allows Jets and other features to be used but the Set Temperature and other programmed set tings cannot be adjusted e Settings Lock allows access to a reduced selection of menu items These include Set Temperature Invert Lock Utili ties Information and Fault Log They can be seen but not changed or edited UNLOCKING THE PANEL Main Screen Unlock Right Select Select Down e Unlocking the panel is accomplished from within the Lock screen The Unlock Sequence is the same for both Panel Lock and Settings Lock However the Panel must be un locked before the Settings is unlocked e NOTE When inside the Lock Screen be sure that Settings or Panel is highlighted and not Back before using the
29. 43 TP800 TP900 Priming Mode Start up Sequence 44 600 9005 45 TP800 TP900 Adjusting Filtration 2 46 800 TP900 Panel Lock amp Unlock 0 0 0 0 47 TP800 TP900 Sensor and System Related Messages 48 TP800 TP900 Utilities 52 TP400 TP600 Standard Panel 5 53 Main Screen Navigation 0 53 TP400 600 Panel Utilities 54 400 TP600 Preparation and Priming a a a a a a a 55 TP400 TP600 Message Codes aa a a a RR 56 TP400 TP600 Utilities Fault Log Menu a 59 TP400 TP600 Utilities Menu Test Feature 60 TP400 TP600 Simplified vs Standard Panel Operations 61 400 TP600 Simplified and Standard Panel Main Menus 62 Balboa Water Group BP Wiring Diagrams 63 Wiring Diagram BP2100G1 Part Number 56389 01 63 Wiring Diagram BP21MSSH Part Number 56381 65 Wiring Diagram BP600 Setup 1 16 as Manufactured 67 Wiring Diagram BP600 Setup 2 32 as Manufactured 68 Supplemental Infor
30. Draw Ranges 21 Amperage Heater lest Amperage Heater Test 210061 32 Apply Loctite when reinstalling 40 A Pump Appears to be Stuck ON 034 58 A Pump Appears to have been Stuck ON when spa was last powered 58 A pump may be stuck on 034 51 A Reset Message May Appear with other Messages 57 Simplified Main Menu Doc 42188 62 Assigning a new address tothe Dolphin 70 A Standard Main Menu Doc No 40940 62 Avoid damaging the post Reinforce the post especially when reinstalling the upper nutonanewheater 40 78 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Be sure that both clamps are not making contact with anything below the insulating material on the terminal arrows 30 Be sure to set the Time of Day 45 BE SURE TO TURN THE POWER OFF BEFORE REPLACING ANY COMPONENT ESPECIALLY A CIRCUIT BOARD 41 VER SION 58 600 board Setup switch ay
31. M035 Pump Appears to have been Stuck ON when spa was last powered POWER DOWN THE SPA DO NOT ENTER THE WATER Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 51 TP800 Utilities Menu THE UTILITIES MENU CONTAINS THE FOLLOWING PREFERENCES The Preferences Menu allows the user to change certain param eters based on personal preference TEMP DISPLAY Change the temperature between Fahrenheit and Celsius TIME DISPLAY Change the clock between 12 hr and 24 hr display REMINDERS Turn the reminder messages like Clean Filter On or Off CLEANUP Cleanup Cycle Duration 15 not always enabled so it may not ap pear When it is available set the length of time Pump 1 will run after each use 0 4 hours are available DOLPHIN 11 AND DOLPHIN 111 APPLIES TO RF DOLPHIN ONLY When set to 0 no addressing is used Use this setting for a Dolphin Il or Dolphin IIl which is factory set for no address by default When set between 1 and 7 the number is the address See Optional Balboa Dolphin Remote within this manual or the Dolphin Ill domestic manual for details Doc No 50211 COLOR OF BACKGROUND Pressing the Select Button when
32. Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 43 TP800 900 Priming Mode Start up Sequence PREPARATION AND FILLING Fill the spa to Its correct operating level Be sure to open all valves and jets in the plumbing system before filling to allow as much air as possible to escape from the plumbing and the control system during the filling process After turning the power on at the main power panel the top side panel will display a splash or startup screen Jets 2 Jets 3 Exit Jets 1 PRIMING MODE After the initial start up sequence the control will enter Priming Mode and display a Priming Mode screen Only pump icons ap pear on the priming mode screen The system will automatically return to normal heating and filtering at the end of the priming mode which lasts 4 5 minutes During the priming mode the heater is disabled to allow the priming process to be completed without the possibility of ener gizing the heater under low flow or no flow conditions Nothing comes on automatically but the pump s can be energized by selecting the Jet buttons If the spa has a Circ Pump it can be turned on and off by press ing the Circ Pump button during Priming Mode In addition if the spa h
33. Recommended Parts 7 Reduced Heater Flow is 57 Ref Card 40947 8 Reference Programming 8 Reinforce the post 40 reinstalling the board 42 reinstalling the upper nut on a new heater 40 reinstall the heater assembly 40 release tab 41 REMOTE 69 Remote DolphinIM 69 Replacement Sensor 35 Required Service Tools 7 reset Messages that can be 51 reset the 50 Residual Current Device 2 Resistance Iroubleshooting 24 25 Restricting Operation 47 RF Receiver 69 right arrow 51 RUN PMPS PURG AIR 57 5 51 36 91 DIP switch positions 56 Safety 57 screen spa 45 scrolling TP400 TP600 Messages 57 scroll messages will 5 second filter cycle 45 sensor A 36 49 sensor A B 36 sensor A Fault 51 sensor A M031 51 sensor Auxiliary freeze 45 sensor B 36 49 sensor Balance is Poor fault 58 sensor B Fault 51 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group sensor M032 51 sensor circuit has failed 51 sensor connector 31 sensor High Limit 21 sensor Location BP500 31 sensor Pins 35 sensor problem 35 sensor Replacement 35 sensor set 16 35 sensor temperatures 16 sensor Wires 7 sequence of
34. Remote 69 PPP 0 The GFCI test failed System Could Not Test the GFCI M036 51 The Ground Fault Circuit Interrupter 50 The heater is M027 48 The heater is too 48 The heater dry MO028 48 The preferred way to check for fuse continuity is with the fuses Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 81 Index of Paragraph Topics cont removed from the circuit 23 Water is too 0 5 29 57 There are three 30A pump fuses in the BP2100G1 spa control Water Temperature is 51 28 Water Temperature is Unknown 57 These readings should taken under peak load conditions 14 7 settings have been reset Persistent Memory M021 What Priming Mode does 2 72 Wiring Check Precautions 18 The Utilities Menu contains the following 52 mE With the pump high speed ON take a voltage reading at the AM
35. SETUPS 15 16 W HEATER 1 SPEED PUMP 2 AND 1 SPEED PUMP 3 IN SETUPS 5 11 12 2 SPEED PUMP 2 IN SETUPS 3 9 1 SPEED PUMP 2 IN SETUP 17 18 UNUSED IN SETUPS 4 10 J14 AUX IS 2 SPEED PUMP 2 IN SETUPS 2 4 7 10 15 16 1 SPEED PUMP 2 IN SETUPS 5 6 11 14 1 SPEED BLOWER IN SETUPS 3 5 9 11 12 17 18 PART A 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 10 230 Volt 50 Hz Residential Wiring Schematic with 2 Pole RCD Breaker Box 230VAC House Breaker Box RCD Breaker Box 230 VAC Live Wire Neutral Ground Outside Ground Rod 1 3 4 7 5 9 10 11 207V 253V 1 2 2 3 4 6 5 8 6 7 8 9 10 12 11 12 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Spa System Box Elf BLUE Neutral Oo GREEN Ground O 9 BROWN Hot 0006006898 Test fo
36. Some UL registered systems do not have the GFCI Test Feature activated e The end user must be trained how to properly test and reset the RCD Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 TP800 900 Sensor and System Related Messages cont MOST MESSAGES AND ALERTS WILL APPEAR AT THE BOTTOM OF THE NORMALLY USED SCREENS several alerts and messages may be displayed in a sequence some messages can be reset from the panel Messages that can be reset will appear with a right arrow at the end of the message 1115 message can be selected by navigating to It at pressing the Select button Clean the filter WATER TEMPERATURE IS UNKNOWN ap After the pump has been running for 1 minute the temperature will be displayed POSSIBLE FREEZING CONDITION A potential freeze condition has been detected or the Aux Freeze switch has closed All water devices are activated In some cases pumps may turn on and off and the heater may operate during Freeze Protection This is an operational message not an error indication THE WATER IS TOO HOT M029 The system has detected a spa water temp of 110 F 43 3 C or more and spa f
37. 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 14 TEST THE AMPERAGE DRAW 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 fthe 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 slow blow fuses are not always discolored when blown Always test continuity of a fuse with an ohmmeter NOTE Miswiring of the spa is the most common reason for this fuse to blow However a lightning strike in the area is a possible though less likely cause of the failure Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pendi
38. User Interface and Programming Reference Simplified Menus See section TP400 TP600 Simplified vs Standard Panel Operations for more information TP400T NOTE TP panels work with all BP Spa Control Systems They all have capabilities for navigation setting functions and modes such as time temperature filter cycles preferences sensor related messages reminder messages diagnostic messages and utilities such as fault logs TP400W 8 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 Product Identification BALBQA weter group 4 963897121 10016 230 50Hz 40 Number 56389 ME referto Spa s rating label UR Model BP21 BP2100G1 AU This device complies with part 15 of the FCC rules Operation is o subject to the following conditions 1 Device may not cause harmful interference 2 Device must accept any Interference received including interference that may cause undesired operations Made in Tustin CA On Every System an Identification Label Is Placed on Top of the Casing g 2x2 Mf W STUD ALTRE Y ih Heater Element Specification
39. dWNd SH 00 1 0 VZEXI 3d0N 1531 IV 330 AGOW 1531 NO TS 5 440 IS 5 102 10 6898 10001248 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 64 V 1 TWNOILVNYALNI NOSWC 40 0343151934 V SI WIISOYJIW 7 TM TEEd X YJ0NYdX4 YACNVdX4 IC d3aNvdx3 11150 21 4 41089 NO 9 c NO IM Vel Adve 045 L 14 NO Pon ww OL Saw SEN 3orraa NOLIYOOT 8V SV 8f WO 1 8 SC LJLM JW 40 J AL D Y YI Get ver STANVd NIVW dl 0 0 18699 Nd 55 du u31V3H 0 8 YOSNAS E V WOSN3S nn dI m ES 7 4 820 9If LIC INO H Creen A5 TE IVA 8 N35 ove Gi eec SIC 94 ul Sm ma Der 9er 11435 cet g 1017 JH Bm Te 0 8010 16 ASTSIT 820 O 1 C isal 0er 695 o 5 5 1 NIVW sec vet 1 92 TULH S2C L cet 12 3 280 e OV
40. foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 V 1 81 ZT ZI 16 9 54 35 NI 1 03345 1 vI IT 39 4 54 135 NI Z 03385 1 9I GT 01 4 54 135 NI Z dWnd 03385 2 SI XAV VICxx OT 54 135 NI GaSANN 8I ZI 40135 NI c dWNd Q33dS T 6 SdNLIS NI c dWNd Q33dS c ZI G 540135 NI dW d 03345 ANY 2 dW d 03345 1 1N3N3 132 13 YALVAH 0 9T 40135 NI WOSN3S E v WOSN3S ISNA 3NIT NI 9 WALLITdS HLIM 3 18 Q33dS I ONY dWhd 03348 1 VL CL 9 SaNL3S NI AINO 03345 1 WZEXT L 541135 NI dWnd 03345 m di SI QuVOS N30NVdX3 MOEZ OOOO O zii 820 15 i fi m loo xnv m eo ae an9 c N35 xS3SS31IA 2 V D uer B 3dWOd NOLLVIN3WITV n En x 2539 Z eee oo tet ser B YNNIYOSYIAWOULSZLIN oett ma oer 9er 5 oo Xv a 101 Fal E u3aNvdXx3 NO ww OL Saw SEA NOLIYOOT M3QNVdX3 IC d3aNvdX3 XVW dWNd 41099 NO 97 41089 NO IM Vcl NOEC x ldS c 8V SV SEC ver yV IV SC SEC vec 4 0 n M 5 SEC WO ver
41. navigate each section Typical use of the Temperature button s allows changing the Set Temperature while the numbers are flashing in the LCD Pressing the LIGHT button while the numbers are flashing will enter the menus MEAE JETS AUX LIGHT HEAT A lt The menus can be exited with certain button presses Simply waiting for several seconds will return the panel operation to normal Key Power up Screens Indicates Flashing or Changing Segment Each time the System powers up a series of numbers is displayed indicates Alternating or Progressive Message every 1 2 second After the startup sequence of numbers the system will enter Priming Mode See Page 3 3 A temperature button used for Action 0 Light dedicated Choose button depending on control panel configuration eeeee Waiting time that keeps the last change to a menu item xx Waiting time depends on menu item that reverts to original setting and ignores any change to that menu item Main Screen AER 101 READY RANGE FLTR1 While the Temperature is still flashing press Light Indicates a Menu Item that Depends on a Manufacturer Configuration and may or may not appear Light Cycle if E T E M LE FU Vine MEI ILI SET READY If Time of Day is not set SET TIME will appear in this menu Main Screen EL OCT
42. restart heater start up See Flow Related Checks below THE HEATER IS TOO HOT M030 One of the water temp sensors has detected 11891 47890 in the heater and the spa is shut down You must clear the message when water is below 108 f 42 2 C See Flow Related Checks below FLOW RELATED CHECKS Check for low water level suction flow restrictions closed valves trapped air too many closed jets and pump prime Note some systems even when spa is shut down by an er ror condition some equipment may occasionally turn on to or if freeze protection is needed 5 02 13 TP800 Sensor and System Related Messages cont 5 Off fete Fault Loo Demo 05 Fault Log gt Fault Log Beet HOE 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group DRAIN MODE Main Screen gt Settings gt Hold gt Drain some spas have a special feature that allows Pump 1 to be employed when draining the water When available this feature a component of Hold mode UTILITIES MENU Main Screen gt Settings gt Utilities The Utilities Menu con
43. sensor circuit has 51 FALT LOG Fault Log 57 fault event 59 fault ground 50 Fault Log 36 47 49 59 Fault Log information 36 Fault Log Menu 59 Fault Log Message Codes 59 Fault Message Code 59 Fault Sensor A 51 Fault Sensor B 51 fault Sensor Balance is Poor 58 faults last 24 36 faults Stray 34 Feature GFCI Test 50 Filter Cycle 2 46 filtration 45 Filtration Cycle 72 filtration cycles 45 Filtration Main 46 Filtration Optional 46 flash Heat LED will 15 Flashing Heat LED 15 flow problem 16 Flow Related Checks 58 Four Pole RCD 17 freeze protection 45 48 Freeze Protection 57 72 freezing conditions 50 fuses 30A pump 28 Fuses installed in the system 23 G generator ozone 45 46 GFCI 72 GFCI breaker 50 GFCI should be reset immediately 50 GFCI should trip within several seconds 50 GFCI Test Feature 50 GFCI Trip Test 50 Glossary 72 GPM 71 ground fault 50 guard VG Compliant suction 2 Guidelines Motor Amperage 21 Guidelines Spa H H AvsBor T vs 34 Heater element retainer nuts 40 Heater Flow is Reduced 57 Heater Matrix 21 Heater May be Dry 5 heater no voltage to the 15 heater reinstalling the upper nut on a new 40 Heater Related Messages 48 Heater terminal nuts 40 Heater 21 Heater Voltage 56 Heater Wattage as Configured in Software 56 heater wires 40 heating assembly sensor wires 40 Heat LED will flash 15 Heat Waiting 15 HFL 16 57 H Heater T
44. speed up reinstallation Other technicians prefer to take the board out with wires intact place both defective and new board side by side on a bench then swap wires recheck the logic jumpers and DIP switch for proper configuration Whatever technique 15 used a wiring diagram should always be used to ensure proper wire placement e Remove the sensor wire connectors at the board and the WS ah vs CCNI REMOVE ELEMEN J44 heater connector on the BP2000 Board located to the ELEMENT OS Ml enearo anoni WARRANTS left of the transformer Be sure to use the release tab on the connectors do not pull on the wires e Some BP spa control systems use an expander board Removing the expander board first simplifies the process To remove it remove the screw and then gently squeeze the locking flange on each standoff with needle nose pliers while lifting the board out Some technicians after removing the screw and if the standoffs allow it gently pry the board up where theres a plastic stand off Do not use excessive force if the standoff will not yield Do not pry up directly into the board as damage to the board may result e Remove the seven screws if BP2000 see illustration e The board should now be free and can be removed from the system box no WO NOVEM x gt B AN B A REMOVE EL ON AK 105 ELEMENT wate f WARRANTY 422178 Manufact
45. tests 14 service Calls 7 service Tools Required 7 SETP Current Setup 56 set sensor 16 35 set Temperature 47 Settings Configuration 36 settings Lock 47 setup Change the 36 oet Up Code 70 set up codes 70 setup configurations 36 Setup Current 36 setup Number 37 Setups Software 36 shimmer 15 SIG 56 Signature Configuration 56 simplified Menus 8 36 61 slice valves 40 slow blow fuses are not always discol ored 14 software compatibility 8 software ID 48 software in the topside control panel 56 software Self Identification 72 software Setups 36 software test 51 58 spa Address 70 Spa Guidelines 71 Spa 15 shut down 57 spa Miswiring of the 14 5 02 13 Spa screen 45 spa to filter continuously 16 spike nuisance 14 SSID 48 72 SSID Software ID 56 standard Menus 8 36 Stray faults 34 suction problem 5 SW _ Dip Switch Settings 56 switch 1 37 Switch 1 ON 36 system code 16 system Control 69 system Fuses installed in the 23 system Information 48 system Information Menu 56 system Panel ID 72 system lest the 14 tab Depress 34 tab Depress sensor 31 Table Ohm 21 tab release 41 TB1 18 Tech Sheets 8 temperature continue monitoring 48 temperature display will alternate 49 Temperatures A B Sensor 36 Temperature Set 47 temperatures sensor 16 Temp Limit 36 Temps A B 49 terminal connector 40 terminal damaged 40 Test Amperage Heater 32 test bu
46. the R C D trips again then unplug the blower and push the reset button If the R C D continues to trip then do the same procedure for the ozone generator If the R C D stops tripping after you unplugged one of the spas components turn off the power to the spa then plug in each component except the one that tripped the R C D Power up the system If the R C D 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 spas components and the R C D still doesnt reset then the problem is most likely a ground fault in the heater Disconnect the heater and test Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 19 sDuueag 00 9 9 10 uong 1291102 p jjezsu 100 X uey 61 19 ur edid X X pe1ees uedouduui peua1uDi 1340 0 3009 uad
47. the suction circuit in conjunc tion with a vacuum filter may also meet this requirement 6 The pressure system for the 2 speed pump or for the circ pump must be dedicated There must not be any other pumps connected to this pressure system 4 The pressure system for the 2 speed pump or for the circ pump must discharge water freely into the spa 8 If the pressure system for the 2 speed pump includes a diverter valve or a diverter jet there must not be an off position that would stop water flow from the pump or any other position that would throttle or reduce water flow from the pump 9 Ifthe pressure system for the 2 speed pump includes flow adjustable jets that can be 100 closed at least 2 non adjustable jets must be included in each possible inlet circuit so that a minimum of 20 GPM can flow during low pump operation with all the jets closed Any other means of by passing flow around the closed jets is acceptable as long as the by pass means is down stream from the heater and allows a minimum of 20 GPM to flow through the heater during low speed operation 10 If the pressure system for the 2 speed pump includes flow adjustable jets that do not close 10096 at least 20 422178 11 12 19 14 15 16 17 18 GPM must flow during low speed operation through each possible inlet circuit with all the jets closed If the pressure system for a 2 speed pump or for a circ pump includes a filter the filter must
48. 1 Sensor A 51 M032 58 M032 Sensor B 51 M033 57 M034 51 58 M035 51 58 M036 51 58 M037 46 Main Filtration 46 manual Dolphin III 70 Matrix Heater 21 Menu Fault Log 59 Menus Simplified 8 36 61 Menus Standard 8 36 Menu System Information 56 Menu lest 59 Menu TEST 36 Menu Utilities 49 Message Code 59 Message Codes 56 Messages 43 messages can be reset from the panel 51 Messages Heater Related 48 Messages scrolling TP400 TP600 57 Messages that can be reset 51 messages will scroll 57 message with an asterisk 44 Miswiring of the spa 14 Mode Demo 36 49 Mode Drain 49 Mode exit Priming 37 Mode exit lest 39 Mode Priming 57 72 Mode Ready 45 mode test 15 16 Mode lest 36 37 38 51 Mode lest 16 MODL System Model 56 Motor Amperage Guidelines 21 N National Electrical Code 3 newer revision board 42 no voltage to the heater 15 nuisance spike 14 Number Setup 37 nuts Heater element retainer 40 nuts Heater terminal 40 0 57 OHH 16 Ohms 21 Ohm s Law 22 Ohm Table 21 OHS 57 ON Switch 1 36 Operation Restricting 47 Optional Filtration 46 Outs Time 36 out Water may splash 40 overlapping filter times 16 ozone generator 45 46 P panel Link the 37 panel messages can be reset from the 51 panel software the topside control 56 panel stops operating 36 panels 8 panels 36 panels TP900 TP800 36 Panel Unloc
49. 135 38015 oo 8 3708 39vuddWv 1612345 v di 9 34 1VIO3dS mifi 1 HLIM SdW d SH 00 vv SH L NOQ lv3H HLIM SH 2 Me wiH M SdWnd SH 2 1 NOd 033451 GdadS 1 03342 3NON lvaH HLIM dW d SH Me dW d SH GAY 1 0 V9TX qds 1 qHds z 09945 2 3NON GOW 1531 IV We 330 3008 1531 de noez 03345 1 13345 2 NO IS 11 440 IS NVaHOLIMS 03345 1 03345 2 03385 2 03385 2 WIS dWIL 311504210 Z dW d dWnd 2812 41135 NOLLVTIVISNI TIWNI4 NOdN 440 OL 135 38 GINOHS 9 HOLIMSx OvXV OEXV OzXV OIXV S T3NVd QNOISSV LON e Q3NOISSV 10N N3A3IOSU WI Q3NDISSV LON Q3NDISSV LON N A Q3NDISSV LON Q3NDISSV LON 9 93 SdNLIS GGC 01 8 NOLLO3NNOO 3NI1 3NOZO QNV 2812 Q3NBISSV LON Q3NDISSV LON NI qas LON SI Z dWnd MOLVH3N39 3NOZO 3NOZONOIVHJN39 YOLVYINIONOZO 1353 xxSONLLLJS 38015 G 3 Z 40135 4 2812 NOILVINOYID 30 3dWOd 3dW d 4 151347 JINY 39vuddWv 1VI23dS JINY 9 4 1VI23dS NI 03386 SI Z lH9I1 9 193 AOT 1V3H HLIM SdW d SH 00 um SdW d SH t 00 L NOG v 9 I 54 135 SC 02 610 NOLLO3NNOO INIT Z lV3H HLIM SdW d SH Z 00 NI q33dS 2 SI Z 2 dW d 03345 2 S3SS31IA Z V Z 3dWOd
50. 343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 17 Index of Paragraph Topics 0 3amp 21581 23 20600 23 10 30122 23 30 35 in Ibs torque when 40 30 part number 30136 23 6 ks ae ee denm 57 102 SNSR 58 13 bea ea end a Sa es 58 VU rmt 21 ENA 5 e 6b OK Ae GR AH Os 21 Sensor 56 PD TES ia iuc pom a AR Hw DE 49 Temps Sensor Temperatures 36 Acceptable Heater Amperage Draw Ranges 21 Acceptable Heater Ohm Q Ranges 21 Acceptable Heater Ohm Q Ranges 24 A common programming mistake is overlapping filter times that may cause the spa to filter continuously 16 A fuse with the meter reading bad 29 A fuse with the meter reading good 23 TP Panels have Molex Type Connectors 9 Always turn the power off when plugging and unplugging 35 message with an asterisk can be reset from the topside d rr 44 Amperage
51. 4 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 Troubleshooting Heater Posts Resistance to Heater Housing A TEST IS WITH POWER OFF TROUBLESHOOTING HEATER POSTS RESISTANCE TO HEATER HOUSING VERIFY THAT THERE IS NO HEATER LEAKAGE gt UB umm mpm Locate the heater connector Pull the connector straight out Disconnect the connector by depressing the tab Measure resistance from a heater post to the Verify there is NO continuity from the heater post to heater housing the ground earth On the resistance scale the a digital Verify there is NO continuity from the heater post meter should read OL indicating infinite resistance to the heater housing or heater current collector connection The meter reading shown is OL indicating infinite resistance 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 25 Troubleshootin
52. 7030343 7417 834 52 422178 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 59 TP400 Utilities Menu Test Feature Not Available on CE Rated Systems A GFCI is an important safety device and is required equipment on a hot tub installation Your spa may be equipped with a GFCI Protection feature UL rated systems only If your spa has this feature enabled by the manufacturer the GFCI Trip Test must occur to allow proper spa function Within 1 to 7 days after startup the spa will trip the GFCI to test it The number of days is factory programmed The GFCI must be reset once it has tripped After passing the GFCI Trip Test any subsequent GFCI trips will indicate a ground fault or other unsafe condition and the power to the spa must be shut off until a service person can correct the problem Key indicates Flashing or Changing Segment Main Screen Indicates Alternating or Progressive Message every 1 2 second w temperature button used for Action fez ps While the Temperature is 0 Light or dedicated Choose button depending on control panel configuration La 0 still flashing press Light REMIS RANGER repeatedly until UTIL Utilities Waiting time that keeps the last change to a menu item appears PRU ECE
53. A0S2 WOT 43 r3 ozr 72 VOT 24 lo J LEM 18698 requiny Hed 4 weiberg 65 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 422178 Luvd el T0 18699 Nd HSSWI dd amp JSIMYSHLO SSFINN T 40135 NI 3 TIIM WALSAS 40135 NI G4YNDIANOD SI WALSAS SIHL HE 40135 40 9 NOILVTIVLSNI TWNI4 NOdN 440 OL 135 38 CINOHS 9 HOLIMS x 91557 LON Q3N9ISSV LON Q3N9ISSV LON Q3N9ISSV LON Q3N9ISSV LON ev Q3N9ISSV LON Q3N9ISSV LON 91557 LON IN V 1 5 02 13 9206 30 WNWINIW 119 ALIOVdNV 9 09 dO 51579 AHL 03215 SYOLONGNOD ASN SNOLLO3NNOO AlddNS 404 J M uo NI 0 2 T91L 90018 TWNIWYSL NIVH FYAIND 30 SYNALINGNOD 53 INAWANDINN H3A0 1dW3 SYOLONGNOD 34400 ASN 9 1189 9 T ADEZ NO IS 1 5 xxliS3H 5941
54. Balboa s BP Troubleshooting amp Service Manual THIS MANUAL COVERS THE FOLLOWING SPA CONTROL SYSTEMS PANELS BP600 900 800 BP2100G1 TP600 TP400 BALBOA woter group 422178 Introduction Intellectual Property Advisement All Intellectual property as defined below owned by or which is otherwise the property of Balboa Water Group or its respective suppliers relating to the Balboa Water Group BP opa Control Systems including but not limited to accessories parts or software relating to the System is proprietary to Balboa Water Group and protected under federal laws state laws and international treaty provisions Intellectual Property includes but is not limited to inventions patentable or unpatentable patents trade secrets copyrights software computer programs and related documentation and other works of authorship You may not infringe or otherwise violate the rights secured by the Intellectual Property Moreover you agree that you will not and will not attempt to modify prepare derivative works of reverse engineer decompile disassemble or otherwise attempt to create source code from the software No title to or ownership in the Intellectual Property is transferred to you All applicable rights of the Intellectual Property shall remain with Balboa Water Group and its suppliers End User Warning This Installation Manual is provided solely to aid qualified spa service technicians in insta
55. Color is highlighted will cycle through 5 background colors available in the control LANGUAGE Change the language displayed on the panel 52 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 TP400 TP600 Standard Panel Operations Main Screen Navigation Note 400 menu structure is similar to the TP600 This section is only for quick reference as it applies to troubleshooting For complete menu operations please refer to BWG user guide document No 40940 or user guide 42185 for simplified menus TP400 TP600 error codes and fault messages are similar to TP800 TP900 Navigation Navigating the entire menu structure is done with 2 or 3 buttons on the control panel Some panels have separate WARM Up and COOL Down buttons while others have a single Temperature button In the navigation diagrams Temperature buttons are indicated by a single button icon Panels that have two Temperature buttons Warm and Cool can BALBOA WARN use both of them to simplify navigation and programming where NC E READY RANGE FLTRI a single Temperature icon is shown The LIGHT Button is also used to choose the various menus and
56. E CONDITION When either sensor reads below 40 F 4 C the system provides freeze protection It automatically activates the pump and the heater if necessary to circulate the water and warm the plumb ing The equipment stays on until the sensors detect that the spa temperature has risen to within 15 F of the set temperature The other pumps and the blower will purge for 30 seconds to 2 minutes at the end of the freeze condition If pump 1 was turned on due to this reason alone this message will appear for up to two minutes right after very cold water is detected NOTE Internal freeze protection only functions when there Is proper power running to the spa and the control system 15 operational Using an optional freeze sensor may be necessary in extreme climates to prevent plumbing damage but will only 16 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group work properly if placed inside the spa skirt in the coldest area All spa models are different in shape and size and have different thermal characteristics therefore Balboa Water Group cannot be held responsible for freeze damage to the spas plumbing Testing is the responsibility of the spa manufacture
57. H SETTINGS Displays a number that represents the DIP switch positions of S1 on the main circuit board PANEL VERSION Displays a number of the software in the topside control panel 48 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group HEATER RELATED MESSAGES THE WATER FLOW IS LOW M016 There may not be enough water flow through the heater to carry the heat away from the heating element Heater start up will begin again after about 1 min See Flow Related Checks below THE WATER FLOW HAS FAILED M017 There is not enough water flow through the heater to carry the heat away from the heating element and the heater has been disabled See Flow Related Checks below After the problem has been resolved you must press any button to reset and begin heater start up THE HEATER MAY BE DRY M028 Possible dry heater or not enough water in the heater to start it The spa is shut down for 15 min Press any button to reset the heater start up See Flow Related Checks below THE HEATER IS DRY M027 here is not enough water in the heater to start it he spa is shut down After the problem has been resolved you must clear the message to
58. HEIZELEMENT SENSOR B SWITCH 6 SHOULD BE SET TO OFF ALL UNUSED SWITCHES SHOULD BE OFF RADIATEUR EIT PON FINAL INSTALLATION 5 0 22117 ADDED JUMPER FOR WHT AC GND CE INSTALLATIONS 357 3 J15 SPA LIGHT 556 BELEUCHTUNG L1 ECLAIRAGE BAIN HYDRO 10 1A N 045 WIR A Ho 8 J28 AUX FRZ HTR B F6 748 T 150mA 250V amp UNFUSED 5 250V 8 Configuration Changes based on Default Feature Orig Setup 1 Changes to IE TE oceans es ee Hot Output Useable DIP Switch Option Orig Setup 1 Changes to Add 1 High Speed Pump with Heat DIP Switch 2 OFF DIP Switch 2 ON 68 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Supplemental Information Optional Balboa Dolphin Remote THE DOLPHIN REMOTE The Dolphin Remote works much the same way as your entertainment remote at home does yet it s designed to control pumps blowers and any option that you have on your pool or spa including entertainment equipment HOW THE DOLPHIN WORKS The Dolphin communicates with a Dolphin RF Receiver or IR Receiver The receiv
59. P The water flow has failed 7 46 receptacle on the 33 The water flow is low M018 2 ee 46 With the pump low speed ON take voltage reading at the The water is too 029 51 J9 This would typically show high speed voltage for Pump one 230V 33 This would typically show low speed voltage for Pump one 230V 33 Time he 52 HIME OUTS ce ab BB eed 36 Tip If one sensor or B seems to be having problems swap the cables of sensor A with sensor B 20 To Determine the Cause of a Blown Power Input Fuse 14 Too Cold Freeze Protection D TP400 TP600 error codes and fault messages are similar to 800 p 53 Troubleshooting Heater Posts Resistance to Heater Housing 25 Troubleshooting heater Resistance 24 Twa Foe RUU ao ook OR eR a GO Ho RH Bed 17 Unlocking 47 Used for verifying a 50 Utilities menu 49 Verifying Incoming Voltage at the Terminal Block 21 Verify that there is no heater leakage 25 Verify there is NO continuity from the heater post to the ground earth On the resi
60. PA CONTROL SYSTEM F6 AND F8 ARE ON THE MAIN BOARD F11S LOCATED ON THE EXPANDER BOARD TEST THE VOLTAGE FROM THE RIGHT SIDE OF THE FUSE TEST THE VOLTAGE FROM THE LEFT SIDE OF THE FUSE 230V on each side indicates a good fuse F6 TB1 BLUE 230V on one side and OV on the other side indicates a bad fuse Then continue measuring the other two fuses F8 F1 F6 F8 F1 28 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Testing Heater Voltage All Systems A CAUTION TEST 15 WITH POWER ON A cic THE HEATER IS ATTACHED TO GROUND Testing at the heater terminal verifies that Many people use probes to test live heater voltages there 15 not a broken line to the heater It from TB1 to a heater post or across both posts may also indicate problems that may not be apparent visually such as corrosion or DON T a damaged heater terminal post There is danger in measuring voltages across However before you do test read on heater posts Some of the common problems in testing spa systems are that 1 The area is often tight and confined 2 The area is often not well lit 3 Spacontrol systems are usually p
61. Programmed events according to personal preferences SSID software Self Identification or System Panel ID PROGRAMMING setting an order and time for planned events such as filter times clean up cycle etc PRIMING MODE Act of water flow through the plumbing to purge air from the spa system Normally priming mode can be bypassed The prim ing mode is necessary only if the spa refilled and if there s the possibility of air being in the system 72 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group WHAT PRIMING MODE DOES Each time the spa is powered up it will enter Priming Mode The purpose of Priming Mode 15 to allow the user to run each pump and manually verify that the pumps are primed air 15 purged and water is flowing This typically requires observing the output of each pump separately and is generally not possible in normal operation Priming Mode lasts 4 minutes but you can exit it earlier by pressing any Temp button The heater is not allowed to run during Priming Mode NOTE If your spa has a Circ Pump it will turn on with Jets 1 Priming Mode The Circ Pump will run by itself when Priming Mode is exited 5 02 13 Symbols
62. Res 45 os bau 4 64 be 4G boa oe 72 Flashing Heat LED on TP600 Heat Waiting 15 Flow Related 48 Flow Related 58 Forcing the Test os sds sw we R 50 For Te hw wd 51 For OV E uu rego oe 58 422178 Four Fole ok we eee Ur Freeze condition 16 Freeze Protection 45 Freeze Protection 72 Fuses Installed the system 23 Py beh GAG ee ke ee 72 GFCI FAIL 58 GFCI Failure System Could Not Test Trip the GFCI M036 58 GFCI Test Feature not available on CE rated systems 49 Ground inSystemEnclosuree 12 Heater Assembly Heater Element Specifications Are Shown on the Heater Tube IL nh eee gt 9 Heater Flow is Reduced HFL 6 57 Heater Flow is Reduced LF 17 5 PCA l 6 6 ee be 21 Heater May be Dry 28 57 Heater Related Messages 48 Heater Start Up Information 15 Heater ype 48 Heater Voltage Feature not used on CE rated systems 48 Heater Voltage Feature not used on CE rated systems 56
63. SITION 9 FOR SUPPLY CONNECTIONS USE COPPER CONDUCTORS ONLY AN USE CONDUCTORS SIZED ON THE EMPLOYER UNIQUEMENT MEMORY RESET 6 P STORE SETTINGS BACB BASIS OF 60 AMPACITY BUT DES CONDUCTEURS DE CUIVRE SPECIAL AMPERAGE RULE ON 5 woter group RATED MINIMUM OF 90 ADD 4 HS PUMPS WITH HEAT 4 DON T ADD 4 HS PUMPS W HTR TORQUE RANGE FOR MAIN TERMINAL BLOCK ADD 2 HS PUMPS WITH HEAT 27 30 IN LBS 31 1 34 5 kg cm ADD 1 HS PUMP WITH HEAT DON T ADD 1 HS PUMP W HTR SENSOR TEST MOUE ON 1 TEST MODE OFF HEIZELEMENT 3 0 kW HEATER 22117 B ADDED JUMPER FOR SWITCH 6 SHOULD BE SET TO OFF ALL UNUSED SWITCHES SHOULD BE OFF RADIATEUR CE INSTALLATIONS UPON FINAL INSTALLATION N A J15 SPA LIGHT J56 BELEUCHTUNG 20 ECLAIRAGE BAIN HYDRO ND N GND 98 J14 2507 722 6 2 F6 4 T 150mA 250V UNFUSED F5 T 30A DIP Switch Option Orig Setup 1 Changes to Special Amperage Rule 0 DIP Switch 5 OFF DIP Switch 5 ON Use this only in cases where there is an overcurrent condition due to pump size This setting will not allow Pump 1 High and Pump 2 to run at the same time 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Austr
64. VICEABLE PARTS ON THE PCB THE PREFERRED WAY TO CHECK FOR FUSE CONTINUITY IS WITH THE FUSES REMOVED FROM THE CIRCUIT A FUSE WITH THE A FUSE WITH THE METER READING BAD METER READING GOOD TESTING A FUSE CHECK CONTINUITY WITH THE FUSE REMOVED FUSES INSTALLED IN THE SYSTEM 0 3amp part number 21581 number 20600 10amp part number 30122 RCM 30amp part number 30136 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 93 422178 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Troubleshooting Heater Resistance A TEST IS WITH POWER OFF TROUBLESHOOTING HEATER RESISTANCE Ww Release tab Locate the heater connector Disconnect the connector by depressing the tab Place the meter probes on the heater terminals om E TER rra 1 3 EJE ES E Se 1 1 E 1 LEE Tr Release tab Pull the connector straight out ACCEPTABLE HEATER OHM RANGES Heater Type Ohms 0 5 5 kW Q 240 V 942 Q 11 52 Q 4 kW Q 240 V 12 96 0 15 84 1 kW 120 V 12 96 Q 15 04 Q Note 1 1000 kQ may vary 10 depending on the accuracy of the meter used 2
65. __ __ Bl cr 17 __ __ _ __ MN D LIILL IL I Sensor Failure Sensor A M031 Sensor M032 A temperature sensor or sensor circuit has failed Conn No Communications The control panel is not receiving communication from the oystem JETA VE ER 510 IN 99786 Pre Production Software e The Control System is operating with test software 02 F or is replaced by T The Control System is in Test Mode MEM FAIL Memory Failure Checksum Error M022 At Power Up the system has failed the Program Checksum Test This indicates a problem with the firmware operation program and requires a service call 58 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group RSET Memory Warning Persistent Memory Reset M021 Appears after any system setup change Contact your dealer Or service organization if this message appears on more than one power up or if it appears after the system has been running normally for a period of time fi rile L LUA Memory Failure Clock Error M020 Not Applicable on the BP1500 FAIL Configur
66. a low enough temperature then the water devices automatically activate to provide freeze protection The water devices will run either continuously or periodically depending on conditions In colder climates an optional additional freeze sensor may be added to protect against freeze conditions that may not be sensed by the standard sensors Auxiliary freeze sensor pro tection acts similarly except with the temperature thresholds determined by the switch See your dealer for details Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 45 TP800 900 Adjusting Filtration CLEANUP CYCLE OPTIONAL When a pump or blower is turned on by a button press a clean up cycle begins 30 minutes after the pump or blower turned off or times out The pump and the ozone generator will run for 30 minutes or more depending on the system On some systems you can change this setting See the Preferences section MAIN FILTRATION Using the same navigation and adjustment as Setting the Time Filter Cycles are set using a start time and a duration Each set ting can be adjusted 15 minute increments The panel calcu lates the end time and displays it automaticall
67. agram inside the system box shows 146 i 53 the main terminal block as TB1 uh BEER IMPORTANT USE OF NON COPPER WIRE Using non copper wire can be dangerous and also can be the cause of a spas malfunction If non copper wire used at any point we recommend servicing the TB1 spa until an electrician replaces it with the proper gauge copper wire 4 5 Total Ampere Rating of Minimum wire size Ampere Rating of Power System Use Copper ONLY RCD Circuit breaker with 90 2 insulation 0 16 12 AWG 20 16 A to 20A 10 AWG 25 20 A to 24 A 10 AWG 30 24 Ato 28 A 8 AWG 28 Ato 32 A 8 AWG 40 18 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Wiring Check for RCD and Service Disconnect A IMPORTANT Remember high voltage 15 still accessible in the house breaker box even though you have turned off the spa breaker Keep in mind that a majority of R C D tripping problems can be attributed to incorrect wiring R C D troubleshooting usually finds the problem RCD LINE IN WIRING CHECK 422178 Locate the proper circuit breaker and turn it off Remove the cover from the house
68. alian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Wiring Diagram BP600 Setup 2 32 as Manufactured Boards Shown Power Board 22117 56284 Logic Board 22121 E 56131 02 Power Requirements Single Service 3 wires line neutral ground 230VAC 50Hz 1b 32A Circuit Breaker rating 40A max System Ouputs 324A Service Pump 1 230VAC 2 Speed 12A max 30 minute timer for Low Speed 15 Minutes for High Speed This is the heater pump Must deliver a minimum of 20 GPM through heater Pump 2 230VAC 1 Speed 12A max 15 minute timer Ozone 230VAC 5 max Uses the same relay as Pump 1 Low Spa Light 10 On Off 1A max 4 Hour timer Heater 3kW 240 Misc 92 amp J32 230VAC 4A max Hot output Stereo Fused equipment or in line fuse required Wiring Diagram and Settings ON POSITION S1 SWITCH OFF POSITION FOR SUPPLY CONNECTIONS USE COPPER CONDUCTORS ONLY E 28 USE CONDUCTORS SIZED ON THE EMPLOYER UNIQUEMENT STORE SETTINGS BASIS OF 60 C AMPACITY BUT DES CONDUCTEURS DE CUIVRE SPECIAL AMPERAGE RULE OFF W o er RATED MINIMUM OF 90 ADD 4 HS PUMPS WITH HEAT DON T ADD 4 HS PUMPS W HTR TORQUE RANGE FOR MAIN TERMINAL BLOCK TB1 ADD 2 HS PUMPS WITH HEAT DON T ADD 2 HS PUMPS W HTR 27 30 IN LBS 31 1 34 5 kg cm ADD 1 HS PUMP WITH HEAT DON T ADD 1 HS PUMP W HTR TEST MODE ON TEST MODE OFF
69. as a Circ Pump it can be activated by pressing the dedi cated Light button during Priming Mode when using a P800 Manually exit Priming Mode by pressing the Exit Button 44 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group PRIMING THE PUMPS As soon as the Priming Mode screen appears on the panel select the Jets 1 button once to start Pump 1 in low speed and then again to switch to high speed Also select the other pumps to turn them on The pumps should be running in high speed to facilitate priming If the pumps have not primed after 2 minutes and water is not flowing from the Jets in the spa do not allow the pumps to continue to run Turn off the pumps and repeat the process Note lurning the power off and back on again will initiate new pump priming session Sometimes momentarily turning the pump off and on will help it to prime Do not do this more than 5 times If the pump s will not prime shut off the power to the spa Important pump should not be allowed to run without prim ing for more than 2 minutes Under NO circumstances should a pump be allowed to run without priming beyond the end of the 4 5 minute priming mode Doing so
70. ation Error Spa will not Start Up BFLI FAIL GFCI Failure System Could Not Test Trip the GFCI M036 NORTH AMERICA ONLY May indicate an unsafe installation STUK PUMP A Pump Appears to be Stuck ON M034 Water may be overheated POWER DOWN THE SPA DO NOT ENTER THE WATER FALI CALL FUR SRE Ss Appears to have been Stuck ON when spa was last powered M035 POWER DOWN THE SPA DO NOT ENTER THE WATER 5 02 13 TP400 Utilities Fault Log Menu THE FAULT LOG The Fault Log stores up to 24 events memory and they can be reviewed under the Fault Log Menu The Fault Log 15 a record of the last 24 faults that can be reviewed by a service tech Each event captures a Fault Message Code how many days have passed since the fault Time of the fault Set Temperature during the fault and Sensor A and B temperatures during the fault The Fault Log is also available from the Test Menu in Test Mode e Pressing TEMP at any fault event reveals a Message Code e Continuing to press TEMP reveals additional information for that specified numbered fault event e Waiting 30 seconds inside the fault log menu allows the screen to return to normal operation Main Screen 1 TET 1 _ READY RANGE FLTR 1 While the Temperature is still flashing press Light repeatedly until UTIL Utilities appears in the LCD 30 20 Press Light To FIRST item in re
71. ation are present ed here since they appear on the Test menu screen see below DANGER HIGH VOLTAGE WILL BE ACCESSIBLE SERVICE TECHNICIAN ONLY TEST MENU ACCESS S1 SWITCH 1 ON SOFTWARE SETUPS Under the TEST Menu the Setup screen will allow changing the setup from 1 to any number established by the manufacturer Changing the Setup may require wiring changes as well 1 While the system is running move DIP Switch 1 on 51 on the Main circuit board to ON 2 The system will enter Test Mode On the home screen below will appear the word TEST 3 Change the setup to the desired setup configuration number depending on DIP switch or wires changes if any Test Mode On Test gt Setup 4 Moving DIP Switch 1 to OFF will exit Test Mode The Control System is in Test Mode if 102 appears In this case F or C is replaced by T 000 Shortcuts Settings C I Test 36 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group OTHER TEST MODE FEATURES A B TEMPS A B SENSOR TEMPERATURES When this is set to On the temperature display will alternate to display temperature from Sensor A and Sensor B in the heat
72. ay will not show the temperature yet as shown below This is because the system requires approximately 1 minute of water flowing through the heater to determine the water temperature and display it NER READY RANGE Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 55 TP400 TP600 Message Codes The following are messages and features that can appear on the 400 and 600 panels NOTE LCD readouts may look slightly different than shown on screen MESSAGE CODES DEMO DEMO MODE Found on the pages listed Demo Mode is not always enabled so it may not appear This MO XX numbers are Message Codes 44 Is designed to operate several devices in a sequence in order M015 51 58 to demonstrate the various features of a particular hot tub on ae INFO SYSTEM INFORMATION SUB MENU M019 57 The System Information Menu displays various settings and M019 44 identification of the particular system As each item in the M020 51 58 menu is highlighted the detail for that item is displayed at the M021 5 rg bottom of the screen Mee okap SSID SOFTWARE ID M026 91 58 Displays the software ID number for the System M027 48 M028 48 57 MODL SYSTEM MODEL M029 51
73. be less obvious from certain angles and more obvious from other angles or in different lighting e dry fire test has passed heating turns back on to heat the spa The heat indicator on the panel returns to solid e During spa heating a difference between the sensors of 2 F 1 0 C or perhaps 3 F 1 5 C at least with 4 6kW 240V heaters is considered normal A significantly higher difference however is usually indicative of a flow problem and will cause a fault which disables the heating for at least a minute and then restarts the whole above process PRELIMINARY PANEL CHECK e problem is not obvious look on the topside control panel for diagnostic messages e fnomessages are seen run through all spa functions and note any inconsistent operation e Most error messages are stored in the fault log To view the fault log the spa must be in test mode and the spa light must be turned on Once you have determined that proper voltage is running through the circuit board and transformer continue to the topside control panel panel that is not functioning properly may include the following symptoms low voltage such as missing or scrambled 422178 segments missing icons on the LCD non functional LED s or nonfunctional buttons If any of these symptoms are present perform the following e the power off and unplug the panel from the circuit board e Then plug in your test panel and restore
74. be equipped with a by pass around the cartridge that opens when the cartridge gets dirty Spring tension holding the by pass valve closed must be overcome by the pressure of the pump This by pass must be capable of flowing a minimum of 20 GPM during low pump operation with the cartridge 10096 blocked If the pressure system for a 2 speed pump or for a circ pump includes branch circulation lines such as circuits intended to operate ozone injection systems these branch circulation lines must be connected downstream from the heater Avoid inter connection of the plumbing circuits for the 2 speed pump or for the circ pump with other pumps in the spa plumbing system for the purpose of freeze protection The Colossus control system will provide freeze protection There is also provision for remote sensing freeze protection If required Position inlets and Jets in the spa so that they do not direct water flow towards suction fittings or skimmers This will avoid a thermal short circuit and prevent excessive heater and pump cycling If service valves are a part of the circulation system for the 2 speed pump or for the circ pump be sure to use valves that incorporate a means of locking in the open position If the 2 speed pump or the circ pump is replaced in the field by service personnel the replacement used must equal or exceed the hydraulic specifications of the original pump To assure adequate performance the spa plumbing must be 1 2 m
75. breaker box Check the main service amperage rating to the breaker box From the circuit breaker locate the brown load wire and the blue neutral wire From the R C D neutral bar locate the blue load neutral and the green ground wire Be sure there are no other appliances on the spa circuit If there are service must be re wired to supply the spa only Make sure all three wires exit the house breaker box via conduit routed to the R C D breaker box The brown should be connected to the R C D line in The blue load neutral con nects to the neutral in RCD LINE OUT WIRING CHECK FOR 230 V DEDICATED SYSTEM The brown wire should connect to load out the blue wire from neutral out All wires will exit the box via conduit routed to the spa control system Once you have found all wiring correctly installed begin to check for proper voltage If Correct Wiring is Verified check to see if the proper RCD is installed Check the label in the system box near TB1 to determine the maximum amperage draw for the system Be sure the R C D is rated for more amperage than the system will draw For a 230 V dedicated system a 2 pole or 4 pole R C D with no load neutral is acceptable For a detailed wiring checklist please review the previous segment of this manual on proper R C D wiring or the R C D manufacturer s instructions If the wiring is correct and the R C D will not reset then unplug the pump and try to reset the R C D If
76. cal codes in effect at the time of installation The selection of electrical materials required to accomplish this installation and the installation of the control system must be made by or be under the direct supervision of a qualified electrician The systems herein are classified as a continuous duty appliance and 15 intended primarily for installation at a single family dwelling The installation recommendations and instructions contained in this manual are directed solely toward these Issues WARNING If there is any doubt whether the system that you are installing into does not have these features contact a licensed qualified electrician Do not attempt to modify the wiring yourself 422178 BP Diagnostic Service Manual This manual is for general servicing of BP Control systems and troubleshooting typical spa control system problems For detailed component settings and wiring configurations service technicians should obtain the latest technical manuals Tech sheets available Contact your Balboa Water Group representative BWG s technical support for technical materials Or visit Balboa Water Group at http www balboawatergroup com Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied f
77. cation WATR TOG HOT mui is too Hot OHS M029 One of the water temp sensors has detected spa water temp TIO F 43 3 C and spa functions are disabled System will auto reset when the spa water temp is below 108 F 42 2 C Check 422178 for extended pump operation or high ambient temp GETH TRIP ee ety Safety Trip Pump Suction Blockage M033 The Safety Trip error message indicates that the vacuum switch has closed This occurs when there has been a suction problem or a possible entrapment situation avoided Note not all spas have this feature JTA I LU 755 one Heater Flowi is Reduced HFL M016 There may not be enough water flow through the heater to carry the heat away from the heating element Heater start up will begin again after about 1 min See Flow Related Checks below HTR FLOW FAIL Heater Flow is Reduced LF M017 There is not enough water flow through the heater to carry the heat away from the heating element and the heater has been disabled See Flow Related Checks below After the problem has been resolved you must press any button to reset and begin heater start up MAD ORY WAIT Heater May be Dry dr M028 Possible dry heater or not enough water in the heater to start it The spa is shut down for 15 min Press any button to reset the heater start up See Flow Related Checks bel
78. city 25 6 10 mm flexible rigid cable 40 60A 16 25 80 100A 35 50 mm Four Pole RCD 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 17 Wiring Checks A WIRING CHECK PRECAUTIONS CHECK FOR LOOSE CONNECTIONS OR DAMAGED WIRES e When working in system box always be aware that it e sure the power is off before you touch any wiring may contain high voltage e Once the power is off carefully examine all wires for e Always keep your fingers and hand tools away from any cuts or defects wiring or circuit board when the power is on Touching anything in these areas can result in serious injury SYSTEM BOX WIRE GAUGE CHECK e All service calls no matter how minor should include a complete wiring check beginning with the house breaker e When inspecting the wiring for any control system note that connections for the incoming wires are clearly labeled at the main terminal block e 30 service minimum ten gauge copper wire e These wires must connect the house breaker box through the local disconnect to the main terminal m block The wiring di
79. ction 57 Blower lest the 14 board access to the power 31 Board Compatibility on Dual 42 board expander 28 41 board isolate the logic 31 board Logic 31 Board Logic 31 67 68 board newer revision 42 Board Power 67 68 board problem 35 board reinstalling the 42 board Torque main 42 BP500 Sensor Location 31 BP2000 board without wires 42 BP2100G1 Amperage Heater Test 32 breaker 50 B Sensor 36 49 button test 50 C Calls Service 7 Canadian Electric Code 3 Cause 20 changes wiring 36 Change the setup 36 Checklist Voltage 21 Checks Flow Related 58 Circ Pump 72 circulation pump 72 Circulation Pump Modes 45 cleanup cycle 46 Clean up or purge Cycle 72 Code Canadian Electric 3 Code Fault Message 59 Code Message 59 Code National Electrical 3 Codes and Compliance 3 Code Set Up 70 Codes Fault Log Message 59 Codes MO XX numbers are Message 44 Codes Message 56 codes set up 0 code system 16 colder climates 45 colors background 52 Compatibility on Dual Board 42 compatibility software 8 Compliance Codes and 3 condition error 48 conditions freezing 50 configuration DIP switch for proper 41 Configuration Settings 36 Configuration Signature 56 configurations setup 36 configuration view the 36 connector receivers 69 connector sensor 31 connector terminal 40 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720
80. d meter used 230V Amp Draw 230V Watts 5oKw 240V 10472 5 2Kw 240V 1 076 10 834 1 3Kw 4Kw 240V 144 8 333 1Kw 3Kw 240V 18 2 6 25 750W 2Kw 240V 28 8 4166 900W 1Kw 120V 144 003 1Kw 11458 1 37Kw 422178 22 916 21 666 5 2Kw 16 666 12 5 3Kw 8 333 2Kw N A N A 5 5 Kw Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 21 Troubleshooting Using Resistance Ohms Law OHM S LAW The direct current flowing in a conductor is directly proportional to the potential difference between its ends It is usually formulated as V IR where V is the potential difference or voltage is the current and R 15 the resistance of the conductor iy Unit of Unit Ampere Amp Voltage Resistans Om a CONTINUITY 29 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7 417 834 b2 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 Testing a Fuse Continuity NOTE THERE ARE NO SER
81. eating assembly sensor wires and replace if e necessary E 8 Remove the heater assembly 9 Reverse the procedure to reinstall the heater assembly Note e Loctite should be applied to heater terminal threads e Heater terminal nuts require 30 35 in Ibs torque e Heater element retainer nuts are also tightened to 30 35 in Ibs torque 40 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 Remove and Replace a System Circuit Board IMPORTANT BE SURE TO TURN THE POWER OFF BEFORE REPLACING ANY COMPONENT ESPECIALLY Removing BP Expander Board an Alternate Way CIRCUIT BOARD DO NOT REMOVE REPLACE THE CIRCUIT BOARD UNLESS THE FAULT HAS POSITIVELY BEEN DETERMINED TO BE THE CIRCUIT BOARD REMOVING 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 damage may result Consider _ L i placing a padlock on the main service disconnect box while working on the spa e Before you begin consider labeling all wires that will be removed from the board This may help
82. ech Sheet applicable MESSAGE CODES Refer to Tech Sheets for each system code a general set of codes for BP systems is found under the section TP400 TP600 Message Codes in this manual Message codes are the same for all TP panels 5 02 13 230 Volt 50 Hz Residual Current Devices A residual current device RCD is the generic term for a device that monitors the current in the line conductor and the neutral conductor of a circuit in an earthed system Two Pole RCD In circuit that s operating properly the vector sum of the live and neutral current values added together will be zero Current flowing to earth due to a line earth fault will return D is SZ ee via the earth conductor and regardless of load conditions will be registered as fault This current flow will give rise to Jus mm a residual current that will be detected by the device If the residual current exceeds the rated sensitivity of the RCD it 25 0 08A i Un 280V will automatically activate a tripping of the faulty circult EE oA 00 2 1 2 3 4 nid In 125A lan 30 1 ZS Un 100090125 P Typical specifications are as follows RCCB Spec Residual Current Devices RCD s range sensitivity from 10 to 500mA Voltage 2 poles 230V 3 4 poles 230 400V Connection capa
83. ector 24 Locate the heaterconnector 25 Locking nuts same location on BP models 40 Logic Board 22121 Ej B613T 0Z oe ae ns 67 Logic Board 22121 E 56131 02 68 Logic Jumper 20618 LOW s 044 Go habe ase OX GRR RS 13 MO XX numbers are Message 44 M 7 Replacement 5 50 90 46 Measure resistance from a heater post to the heater housing 25 MEM FAIL 2 2 58 Memory Failure Checksum Error M022 58 Memory Failure Clock M020 58 Memory Warning Persistent Memory Reset 021 58 RSET 2 2 2 0 58 Message 5 16 Message 5 56 NIBSSRUBS usa d bk Rom X de A RRS s 43 MODL System Model 56 Most messages and alerts will appear at the bottom of the normally used 5 51 Most Probable Overheating Causes Inspect These First 16 Motor Amperage Guidelines 21 pco P 43 IT DOR acus d d pui ee ie md 58 Na Communications a s s aw ok Gad 58 Note Be careful when removing heater assembly from spa plumbing system Water may splash out under pressu
84. emory Reset 1 N A or Special Amperage Rule 1 or 2 iar Only if GFCI 1 Displays GFCI Test Menu is enabled ea 3 When set to ON Panel will display alternate readings from Senor A and Sensor on Main Screen 0 Set KKKKK Waiting Several Seconds Reverts to Original Setting Displays Fault Log 0 C4 ht J LAN d ptt Several Seconds Back to normal operation 54 Manufactured under or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 4 120 or 240 VAC input power d EN _ 3 6 or 1 3 Heater Wattage sensed by a as programmed Displayed by a system at startup DIP Switch 2 3 4 the number of HS pumps with heat 0 Light or dedicated Choose button depending on control panel configurat eeeee Waiting time that keeps the last change to a menu item Waiting time depends on menu item that reverts to original setting and ignores any change to that menu item These strings will display once and return to the beginning Press Temperature again to display the string again EEKEJI Waiting 10 seconds will allow the scree
85. ent Inspect the connections of both sensors on the circuit board The plugs must be clean If the sensors are not totally failing but are showing excessive 2 F 1 0 C or more difference between the two sensors when not heating a possible cause of on SnS SENSOR SYNC HL HFL HTR FLOW LOW and LF LOW FLOW messages do the following Note which sensor 15 reading consistently higher A vs B or T vs Unplug the two sensors from the circuit board and exchange their positions i e plug the one that was the Sen A Jack into the Sen B jack and vice versa Note When removing a sensor wire from the board depress the tab Do not pull on the wire Press a panel button if any stray faults appeared during the process Stray faults are normal when sensors are unplugged then plugged back in while the system Is running Within a minute or so see if the same or other sensor is now reading consistently higher If the same sensor vs B or T vs is reading higher after the sensor interchange the problem is on the circuit board Replace the circuit board If the opposite sensor is now reading higher the problem is with the sensor s Replace the sensor set If you wait more than 2 minutes after plugging the sensors back in heating may start even outside a filter in Economy or Sleep mode due to a stray Cd CLd COLD WATER condition usually detected when sensors are being plugged in while the system Is running
86. epending on control panel configuration eeeee Waiting time varies depending on function Main Screen While the Set Temperature is The System will reset and go into Priming Mode if the Light Button still flashing press Light is pressed while anything other than the current setup is flashing TEST will now appear in If there is no change to the Setup Number S 01 S 02 etc the LCD first the display returns to the SETP screen Several Setups can exist in in this string A dash indicates the current Setup When set to ON Panel will display alternate readings from Senor A and Sensor B on Main Screen Displays Fault Log Approx 5 sec Main Screen READY RANGE FLTRI If the Control Panel does have a Warm Up button but rather a single Temp button use the Temp button in place of the Warm button in the instruction above The flow chart assumes a single Temperature Button 38 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Setup Changes with DIP Switch 1 ON Using a Panel For complete variations of equipment configurations and setups the latest Tech Shee
87. er FALT LOG FAULT LOG The Fault Log is a record of the last 24 faults that can be reviewed by a service tech DEMO DEMO MODE Demo Mode is not always enabled so it may not appear This Is designed to operate several devices in a sequence in order to demonstrate the various features of a particular hot tub TIME OUTS Used only by the manufacturer for specific tests TEMP LIMIT Used only by the manufacturer for specific tests VIEWING CONFIGURATION SETTINGS There are times when a technician may want to view the con figuration settings or config setup before working on a system View the configurations in the following way TP900 TP800 panels System Information Current Setup TP600 TP400 panels 7 1 gt INFO gt SETP Standard Menus TP600 TP400 panels with Simplified Menus can only access the configuration setup when in test mode Note n the event that a panel stops operating a good working panel plugged into the system will reveal the config settings as they are held in memory 5 02 13 Setup Changes with DIP Switch 1 ON Using a or TP400 Panel For complete variations of equipment configurations and setups the latest Tech Sheet should be obtained on the system you re working on The information for setup changes 15 included here in the event you have wiring diagrams available and to facilitate a better understanding of how setup changes are made Note All TP panels can be used with all BP sys
88. er is wired into the Control System 1 Mount the Dolphin receiver module in a vertical position with the molded arrow pointing up 2 Plug the receiver s connector into the 6 pin connector J40 labeled REMOTE located within the Control System box 3 In order for the Dolphin to communicate it must be assigned an address that the Control Center and Dolphin recognize and allows both the Dolphin and specific equipment blower jets or stereo for example to talk to each other The factory default is zero or no address 4 When set to 0 no addressing is used Use this setting for a Dolphin Ill which 15 factory set for no address by default The Dolphin has a total of eight addresses zero and 1 7 Dolphin Receiver Dolphin CONTROL SYSTEM J108 RLY 9 10 J107 RLY 7 8 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 69 Optional Balboa Dolphin Remote cont Dolphin FI Dolphin Address 5 Back Dolphin 50211 Dolphin III CE 50212 70 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815
89. erifier l efficacite du disjoncteur differentiel avant d utiliser differentiel avant d utiliser le bain Lire la notice technique Lorsque l appareillage est installe dans une fosse on doit assurer un drainage adequat e Employer uniquement a l interieur d une cloture CSA Enclosure 3 Connecter uniquement a un circuit protege par un disjoncteur differen tiel de Class A e Afin d assurer une protection permanente contre le danger de shock electrique lors de l entretien employer seulement des pieces de rechange identiques Les prises d aspiration doivent etre equipees de grilles convenant au debit maximal indique Avertissement e Des temperatures de l eau superieures a 38 C peuvent presenter un danger pour la sante e Deconnecter du circuit d alimentation electrique avante l entretien Warning Advertissement e Disconnect the electric power before servicing Keep access door closed e Deconnecter du circuit d alimentation electrique avant l entretien Garder la porte fermer 5 02 13 Table of Contents 2 Intellectual Property 2 End a 2 Bb 254 2 Warnings Danger Risk of Electric Shock 0 0 0 0 2 3 BP Diagnostic Service Manual
90. faults that can be re viewed by a service tech SCROLLING TP400 TP600 MESSAGES The following messages will scroll across the TP400 TP600 pan els NOTE LCD readouts may look slightly different than shown on screen PRIMING MODE M019 Each time the spa is powered up it will enter Priming Mode The purpose of Priming Mode is to allow the user to run each pump and manually verify that the pumps are primed air is purged and water is flowing This typically requires observing the output of each pump separately and is generally not possible in normal operation Priming Mode lasts 4 minutes but you can exit it earlier by pressing any Temp button The heater is not allowed to run during Priming Mode NOTE f your spa has a Circ Pump it will turn on with Jets 1 in Priming Mode The Circ Pump will run by itself when Priming Mode Is exited E EE X Water Temperature is Unknown After the pump has been running for 1 minute the temperature will be displayed 2 TOD COLD Too Cold Freeze Protection n A potential freeze condition has been detected or the Aux Freeze switch has closed and all pumps and blower are activated All pumps and blower are ON for at least 4 minutes after the poten tial freeze condition has ended or when the aux freeze switch opens In some cases pumps may turn on and off and the heater may operate during Freeze Protection This is an operational message not an error indi
91. g with Voltage A IMPORTANT BEFORE TESTING A SPA CONTROL SYSTEM FOR VOLTAGE OR AMPERAGE BE SURE OF THE FOLLOWING DANGERS HIGH AND LOW VOLTAGE CAN KILL QUALIFIED TECHNICIANS SHOULD BE PERFORMING THESE TESTS WHEN TESTING VOLTAGE WHEN TESTING AMPERAGE OBSERVE SAFETY AT ALL TIMES 26 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Verifying Incoming Voltage at Terminal Block BP2100 amp BP600 A CAUTION TEST IS WITH POWER ON VERIFYING INCOMING VOLTAGE AT THE TERMINAL BLOCK Brown to Blue Wires Brown to Blue Wires on a 230V BP2100 System on a 230V BP600 System NOTE THAT BROWN AND BLUE WIRE ORIENTATION IS DIFFERENT ON THE TWO SYSTEMS SHOWN 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 21 Testing Pump Fuses for Damage with Voltage On BP2100 A CAUTION TEST IS WITH POWER ON THERE ARE THREE 30A PUMP FUSES IN THE BP2100G1 S
92. gn and domestic applied for and pending All material copyright of Balboa Water Group 15 Testing a System with Power cont MOST PROBABLE OVERHEATING CAUSES INSPECT THESE FIRST e Check slice or ball valves Make sure that they are open Make sure the correct pump is installed Clean the filter skimmer if there is any blockage Check heater element alignment Check for debris on the heater element In extremely hot weather check for proper cabinet ventila tion e Make sure the temperature sensor Is fully inserted into the sensor fitting on the heater e Check for excessive filter duration e Check the water level Check the water temperature with an accurate temperature thermometer Remove the spa cover and allow the water to cool to below 108 F Adding cool water may be necessary Touch any button to reset the system If the water 15 still hotter than the set temperature press the blower button if applicable to cool the spa e f the Problem Recurs test the Sensor Set NOTE A common programming mistake 15 overlapping filter times that may cause the spa to filter continuously If alternating with temperature it may just be a temporary condition If flashing by Itself spa is shut down If the panel also displays Service Req spa is shut down If the spa shuts down due to this error one or both of the sensors are probably reading several degrees off If the problem recurs test the sensor set FREEZ
93. inimum The use of 2 is highly recommended Either schedule 40 or flexible PVC pipe is acceptable It is recommended that shut off valves be installed in the suction and discharge lines Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 71 Glossary CIRC PUMP OR CIRCULATION PUMP Low horse power pump designated especially for maintenance of filtration and heating It often runs all day CLEAN UP OR PURGE CYCLE An action designed to circulate water to maintain sanitary condi tions Pumps or blowers purge standing water to prevent the water from becoming stagnant FILTRATION CYCLE Period of time designated to filter the system Oftentimes there are two filter cycles 12 hours apart and designated as F1 and F2 FREEZE PROTECTION A safety feature detecting water or air temperature approaching freezing Once set low temperature is reached an action 15 often initiated automatically Oftentimes pumps will start to keep water circulating in all plumbing and the heater may operate GFCI device intended to protect people in the event of an electrical malfunction Spa owners should know how to test the GFCI as routine maintenance PREFERENCES
94. ip Test must occur to allow proper spa function Within 1 to 7 days after startup the spa will trip the GFCI to test it The number of days is factory programmed The GFCI must be reset once it has tripped After passing the GFCI Trip Test any subsequent GFCI trips will indicate a ground fault or other unsafe condition and the power to the spa must be shut off until a service person can correct the problem FORCING THE GFCI TRIP TEST The installer can cause the GFCI Trip Test to occur sooner by initiating It using the above menu The GFCI should trip within several seconds and the spa should shut down If it does not shut down the power and have a quali fied person verify that the GFCI breaker is installed and that the circuit and spa are wired correctly Verify the function of the GFCI with its own test button Restore power to the spa and repeat the GFCI Trip Test Once the GFCI is tripped by the test reset the GFCI and the spa will operate normally from that point You can verify a successful test by navigating to the above menu PASS should appear after a temp button is pressed from the GFCI Screen WARNING e The end user must be told to expect this one time test to occur and how to properly reset the GFCI e ffreezing conditions exist the GFCI should be reset imme diately or spa damage could result CE PRODUCT e registered systems do not have an RCD Test Feature due to the nature of the electrical service e
95. is READY RANGE FITRI ST still flashing press Light fe Indicates a Menu Item that Depends on a Manufacturer Configuration and may or may not appear L x N A with Menu Style 2 T E d Main Screen 50 SSS Cities E y 0 7 READY HU Waiting Several Seconds in the Main Menu 9 will allow the display to revert to the Main Screen NA 1 Ti Most changes ee 10 is pressed SET READY RS Main Screen m ap ons A STANDARD MAIN MENU Mm umen 3 suit ashing press Light DOC NO 409401 N TT MET T EC M EZ LEI SET RANGE NE FN a ru Sa ee SS Both panels can be navigated using 2 or 3 buttons 20 SET READY If Time of Day is not set SET TIME will appear in this menu Waiting Several Seconds in the Main Menu will allow the display to revert to the Main Screen Most changes are not saved unless Light 20 is pressed Refer to Key above Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 62 Canadian Patent 2342614 Australian patent 2373248 other patents both
96. ite 120V 108V 132V Black amp Green 120 108V 132V Red amp Green 120V 108V 132V Green White OV Depending variables such as length of run type of wire and temperature small voltage readings may sometimes occur between ground and neutral MOTOR AMPERAGE GUIDELINES The following ranges represent general parameters for many different motors and applications Check the device label or with the soa manufacturer to get accurate amperage draws AMPERAGE DRAW RANGES DEVICE 120V DRAW 240 V DRAW Pump low 2A 5A 2A 4A Pump high 10A 14A SA 12A Blower 6A 8A HEATER MATRIX Heater Type Ohms 120V Amp Draw 120V Watts 240V Amp Draw 240V Watts ACCEPTABLE HEATER AMPERAGE DRAW RANGES Heater Type 120V Amp Draw 240V Amp Draw 5 5 kW Q 240 V 1042 A 12 74 A 20 83 A 2548 A 4 kW Q 240 V 758 A 9 26 A 15 15 A 18 52 A 1 kW 120 V 758 A 9 26 A ACCEPTABLE HEATER OHM RANGES Heater Type Ohms 5 5 kW 240 V 942 Q 11 52 Q 4 kW 240 V 12 96 Q 15 84 Q 1 kW 120 V 12 96 Q 15 84 Q TEMPERATURE amp HIGH LIMIT SENSOR OHM TABLE Temp Ohms Temp of Ohms of Sensor k 2 sensor k 2 40 F 76 686 kQ2 90 F 22117 45 F 67112 100 F 17636 BUE 58 858 105 F 15 788 60 F 45 550 110 F 14 158 70 F 35 533 12 716 809 21931 1209 1439 Note 1 1000 kQ may vary 10 depending on the accuracy of the thermometer an
97. iven to use Setup 1 or Setup 7 e Below that an option is given to use Setup 2 or Setup 8 e Page 4 An option is given to use Setup 3 or Setup 9 In these three examples out of six possible dual menu options available for this system Setup 1 2 or 3 could be chosen for a simplified menu Of course the option is open to configure a counterpart control system to standard full menus by choosing setup 7 8 or 9 respectively Headings of Setups 1 2 amp 3 in Tech Sheet SR240BP5 12 05 12 Rv A Page 3 Setup 1 Simplified Menu with Flip Setup 7 Full Menu Page 3 Setup 2 Simplified Menu with Flip Setup 8 Full Menu Page 4 Setup 3 Simplified Menu with Flip Setup 9 Full Menu 422178 Manufactured under or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 02 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 61 TP400 TP600 Simplified and Standard Panel Main Menus A SIMPLIFIED MAIN MENU DOC NO 42185B Main Menus Navigation Navigating the entire menu structure is done with 2 or 3 buttons on the control panel Some panels have separate WARM Up and COOL Down buttons while others have a single Temperature button In the navigation diagrams Temperature buttons are indica
98. key sequence below Back Panel 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 4 TP800 900 Sensor and System Related Messages SYSTEM INFORMATION The System Information Menu displays various settings and identification of the particular system As each item in the menu is highlighted the detail for that item displayed at the bottom of the screen SOFTWARE ID SSID Displays the software ID number for the System w System Information Software ID SSID Back System Model Current Setup Configuration Signature Heater Voltage Heater Type Software ID SSID M100_101 V0 6 SYSTEM MODEL Displays the Model Number of the System CURRENT SETUP Displays the currently selected Configuration Setup Number CONFIGURATION SIGNATURE Displays the checksum for the system configuration file HEATER VOLTAGE FEATURE NOT USED ON CE RATED SYSTEMS Displays the operating voltage configured for the heater HEATER WATTAGE AS CONFIGURED IN SOFTWARE CE SYSTEMS ONLY Displays a heater kilowatt rating as programmed into the control system software 1 3 or 3 6 HEATER TYPE Displays a heater type ID number DIP SWITC
99. king the 47 part number 20600 23 part number 21581 23 part number 30122 23 part number 30136 23 Parts Recommended 7 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 15 PASS should appear 50 period time out 45 Pins sensor 35 polling 45 post Avoid damaging the 40 post Reinforce the 40 Power Board 67 68 power connection instructions 2 Preferences 72 pressure Water under 40 prevent unwanted use 4 Priming Mode 5 72 Problem 20 problem board 35 problem flow 16 problem sensor 35 problem suction 5 programmable circ pump 45 Programming 72 Programming Reference 8 properly reset the GFCI 50 protection freeze 45 48 Protection Freeze 5 2 Pump Circ 72 pump circulation 72 pump programmable circ 45 Pumps Troubleshooting 20 Pump Suction Blockage 57 Pump Test the 14 R Range High Temperature 43 Range Low Temperature 43 Ranges Acceptable Heater Amperage Draw 21 Ranges Acceptable Heater Ohm 21 24 Ranges Amperage Draw 21 RCD 2 RCD Four Pole 17 RCD should be tested 2 RCD Iwo Pole 17 Ready Mode 45 76 Index receiver Dolphin 69 Receiver 69 Receiver RF 69 receivers connector 69
100. laced at near ground level which makes measuring with meter probes awkward or difficult The probes may have a tendency to slip or not touch the designated point of test If a probe slips and simultaneously contacts a hot 230V post and ground severe arcing will occur DEATH SEVERE INJURY CAN OCCUR continued on next page WRONG DO NOT MEASURE ACROSS HEATER TERMINALS 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 29 A Safer Way to Test Heater Voltages Equipment needed e Insulated clamps for your voltmeter probes Suggested attire e Safety glasses e Rubber gloves when measuring live electrical wires 1 Turn the power OFF to the spa control system 2 Setvoltmeter for AC high voltage reading Set clamps onto terminals securely Be sure that both insulated boots fully cover the clamps Be sure that both clamps are not touching each other and that they are not making contact with anything below the insulating material on the terminal See photo below 3 Turn on power to the spa Do not disturb the voltmeter or clamps until the power is turned off Be sure that both clamps are not making 4 With the system opera
101. lectrician and all grounding connections must be properly installed No user serviceable parts Water temperature in excess of 38 C may be injurious to your health Disconnect the electrical power before servicing Keep access door closed CAUTION Test the ground fault circuit interrupter before each use of the spa Read the instruction manual Adequate drainage must be provided if the equipment is to be installed in a pit To ensure continued protection against shock hazard use only identical replacement parts when servicing Install a VG Compliant suction guard that is suitably rated to match the maximum flow rate marked WARNING Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Water temperature in excess of 38 C may be injurious to your health Disconnect the electrical power before servicing Keep access door closed 2013 Balboa Water Group All Rights Reserved 5 02 13 Codes and Compliance All of the electrical wiring methods and materials used to complete the electrical installation of the BP control systems must be in accordance with the National Electrical Code or the Canadian Electric Code as well as any local electri
102. lling spas with control systems manufactured by Balboa Water Group Balboa controls have absolutely no end user serviceable parts Balboa Water Group does not authorize attempts by the spa owner user to repair or service any Balboa products Non qualified users should never open or remove covers as this will expose dangerous voltage points and other dangerous risks Please contact your dealer or authorized repair center for service RCD It is strongly advised to install an RCD Residual Current Device in the supply power to a spa Also an RCD should be tested periodically This device will trip the breaker if there is an unsafe electrical condition caused by a malfunctioning component or even the slightest short to ground Note Follow all local electrical codes upon installation diagnosis or testing of the RCD Warnings Danger Risk of Electric Shock All electrical work must be performed by a qualified electri clan and must conform to all national state and local codes Before making any electrical connections make certain that the Main Power breaker from the house breaker box has been turned off Do not attempt service of this control system Contact your dealer or service organization for assistance Do not permit any electric appliance such as a light tele phone radio or television within 5 1 5m of a pool or spa Follow all owner s manual power connection instructions Installation must be performed by a licensed e
103. m a spa plumbing system Water may splash out under pressure Water under pressure the plumbing may splash out and onto the systems electronic board Do not remove the system door until the water has been drained from the heater assembly housed the system 1 Turn off the main power 2 Close off the slice valves or ball valves adjacent to the heater assembly 3 Once the valves are closed slowly crack the heater assembly end tubes until water flows out If the connectors are on too tight it may be necessary to loosen the Phillips screws that hold the connectors together Once the water has been drained continue Locking nuts are in same location on BP models Remove both nuts that secure the element in place 30 35 in Ibs torque when reinstalling 4 Remove the system door cover 5 Remove the nuts securing the heater wires to the heater assembly s terminal connectors Be sure to use a supporting end wrench on the lower nut Upper nut is 3 8 lower nut is 1 4 If a lower end wrench is not used to hold the terminal in a fixed position when removing or installing the upper nut excessive torque will transfer to the terminal connector The result will most likely be a damaged terminal Avoid damaging the post Reinforce the post especially when reinstalling the upper nut on a new heater 6 Remove both 3 8 nuts that secure the element in place wen reinstall 7 Remove the h
104. mation 69 Optional Balboa Dolphin Remote 2 s s RR 69 Spa Guidelines to KeepinMind 71 X o 4 3X 00 X X 0 7b F3 5X4 x 12 UC x3d o x 13 Index of Paragraph Topics 18 6 Manufactured under one or more of these patents U S Patents 5332944 5361215 9990 93 9999 20 9 003 453 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 b2 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 Equipment Overview Service Tools and Parts Checklist SERVICE TOOLS REQUIRED e Ammeter 50A with Insulated Clamps for Probes screwdrivers Assorted Flat and Phillips Digital Multi meter Padlock to lock electrical disconnect during service Precision Thermometer Digital Fever Type Silicone Tube small Wire Cutters 3 8 and 1 4 Open End Wrenches heater Pliers Slip Joint amp Needle Nose wire nut removal Logic Jumper No 20618 COMMON FUSES USED ON SPA SYSTEMS 30074 Fuse 1 Amp Fast Blow Glass 30075 Fuse 5 Amp Fast Blow Glass 30122 Fuse 10a Blower 30595 Fuse 10a Power Input 30076 Fuse 15 Amp Fast Blow Ceramic 30596 Fuse 15a Power Input 30142 Fuse 20a Power Input 30123 Fuse 20a Pump
105. may cause damage to the pump and cause the system to energize the heater and go into an overheat condition EXITING PRIMING MODE You can manually exit Priming Mode by navigating to the Back button on the Priming Mode Screen Note that if you do not manually exit the priming mode as described above the priming mode will be automatically terminated after 4 5 minutes Be sure that the pump s have been primed by this time Once the system has exited Priming Mode the top side panel will display the Main Screen but the display will not show the temperature yet as shown below This is because the system requires approximately 1 minute of water flowing through the heater to determine the water temperature and display it e numbers are Message Codes e A message with an asterisk can be reset from the topside panel 5 02 13 900 Spa Behavior BE SURE TO SET THE TIME OF DAY setting the time of day is important for determining filtration times and other background features Set Time will appear on the display if no time of day is set in the memory On the Settings Screen select the Time of Day line On the Time of Day screen simply navigate right and left to select the Hour Minutes AM PM and 12 24 Hour segments Use the Up and Down Buttons to make changes SAVING SETTINGS The Time of Day screen 15 a simple editable screen that illus trates a feature of the control that applies to all o
106. more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Basic Control System Troubleshooting cont 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 THE CAUSE OF A BLOWN POWER INPUT FUSE Perform the following sequence of tests Test the System e urn 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 fthe fuse blows then re check the internal system wires and connector for burns cracks or cuts in insulation e fthe fuse does not blow turn the power off and plug in the pump NOTE Be sure to test each device individually Test the Pump e Restore the power and activate the pump e fthe fuse blows there is a pump problem e fthe fuse does not blow turn off the power Test the Blower Plug in the blower Power up the system and activate the blower If the fuse blows then there is a blower problem If the fuse does not blow the combined pump and blower amperage may be excessive
107. n the panel push the Jet button once to start Pump 1 in low speed and then again to switch to high speed Also push the Pump 2 or Aux button if you have a 2nd pump to turn it on The pumps will now be running in high speed to facilitate priming If the pumps have not primed after 2 minutes and water is not fl owing from the jets in the spa do not allow the pumps to continue to run Turn off the pumps and repeat the process Note Turning the power off and back on again will initiate a new pump priming session Sometimes momentarily turning the pump off and on will help it to prime Do not do this more than 5 times If the pump s will not prime shut off the power to the spa 422178 Important A pump should not allowed to run without prim ing for more than 2 minutes Under NO circumstances should a pump be allowed to run without priming beyond the end of the 4 5 minute priming mode Doing so may cause damage to the pump and cause the system to energize the heater and go into an overheat condition EXITING PRIMING MODE You can manually exit Priming Mode by pressing Temp button Up or Down Note that if you do not manually exit the priming mode as described above the priming mode will be automati cally terminated after 4 5 minutes Be sure that the have been primed by this time Once the system has exited Priming Mode the top side panel will momentarily display the set temperature but the displ
108. n to return to no rmal operation l l l 7 Indicates a Menu Item that Depends on a Manufacturer Configuration and may or may not appear 5 02 13 TP400 TP600 Preparation and Priming PREPARATION AND FILLING Fill the spa to its correct operating level Be sure to open all valves and jets in the plumbing system before filling to allow as much air as possible to escape from the plumbing and the control system during the filling process After turning the power on at the main power panel the top side panel display will go through specific sequences hese sequenc es are normal and display a variety of information regarding the configuration of the hot tub control PRIMING MODE M019 This mode will last for 4 5 minutes or you can manually exit the priming mode after the pump s have primed Regardless of whether the priming mode ends automatically or you manually exit the priming mode the system will automatically return to normal heating and filtering at the end of the priming mode Dur ing the priming mode the heater is disabled to allow the priming process to be completed without the possibility of energizing the heater under low fl ow or no fl ow conditions Nothing comes on automatically but the pump s can be energized by pushing the Jet buttons If the spa has a Circ Pump it can be activated by pressing the Light button during Priming Mode PRIMING THE PUMPS As soon as the above display appears o
109. ng All material copyright of Balboa Water Group 5 02 13 Testing System with Power See manufacturer s owners manual or reference for general information on operating the spa including programming filters and other settings that are changed from the topside control panel HEATER START UP INFORMATION On M systems the heater goes through a testing phase every time it starts up to assure that there is adequate water flow This provides sophisticated dry fire and low flow protection It can be confusing if you don t know what to expect Step by step here is what happens Note that the timing temperature details may be slightly different on some older M7 systems e Prior to heating the pump is run for at least two minutes and then the temperature difference between the sensors is assessed It must be 2 F 1 0 C or less for heating to proceed otherwise an error 15 issued e The heater turns on for 6 5 to 18 seconds depending on heater voltage and wattage At this point the heat indicator on the panel is solid During this time the panel is not immediately responsive e heater turns off for 90 seconds making sure that the water flow keeps the temperature rise small and short Abnormal water flows or lack of water will produce a large and or long temperature rise and the system faults in that situation At this point the heat indicator on the panel may appear to shimmer or dim on some panels this may
110. or and pending All material copyright of Balboa Water Group Warning Qualified Technician Required for Service and Installation Basic Installation and Configuration Guidelines Use minimum 6AWG copper conductors only Torque field connections between 21 and 23 in lbs Readily accessible disconnecting means to be provided at time of instal lation Permanently connected Connect only to a circuit protected by a Class A Ground Fault Circuit Interrupter GFCI or Residual Current Device RCD mounted at least 5 1 52M from the inside walls of the spa hot tub and in line of sight from the equipment compartment CSA enclosure Type 2 Refer to Wiring Diagram inside the cover of the control enclosure Refer to Installation and Safety Instructions provided by the spa manufac turer Warning People with infectious diseases should not use a spa or hot tub Warning To avoid injury exercise care when entering or exiting the spa or hot tub Warning Do not use a spa or hot tub immediately following strenuous exercise Warning Prolonged immersion in a spa or hot tub may be injurious to your health Warning Maintain water chemistry in accordance with the Manufactur ers instructions Warning The equipment and controls shall be located not less than 1 5 meters horizontally from the spa or hot tub Warning GFCI or RCD Protection The Owner should test and reset the GFCI or RCD on a regular basis to verify its function
111. ow HTR TOG HOT HTR is too Hot OHH M030 One of the water temp sensors has detected 11891 47890 in the heater and the spa is shut down You must press any button to reset when water is below 108 f 42 2 C See Flow Related Checks below PRES RSET A Reset Message May Appear with other Messages some errors may require power to be removed and restored Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 57 00 Messages cont FLOW RELATED CHECKS Check for low water level suction flow restrictions closed valves trapped too many closed jets and pump prime On some systems even when spa 15 shut down some equipment may occasionally turn on to continue monitoring temperature or if freeze protection is needed SNSR BAL ANCE Sensor Balance is Poor M015 The temperature sensors be out of sync by 2 F or 3 F SNSR 5970 CALL FOR SRL Sensor Balance is M026 The temperature sensors ARE out of sync The Sensor Balance 15 Poor fault has been established for at least 1 hour SNSR CALL FOR SRUE SNS mom __ __
112. peatedly until FALT LOG Main Menu appears in the LCD TEMP Range Only if DEMO Mode is enabled The Fault Log is also available from the Test Menu in Test Mode E vU Tah READY RANGE READY 24 Fault messages is the maximum Fewer messages may be displayed FAULT LOG MESSAGE CODES TP400 TP600 Fault Message Code DZZZ How many days have passed since the fault Time of the fault set Temperature during the fault sensor A Temperature during the fault sensor B Temperature during the fault Key Indicates Flashing or Changing Segment Indicates Alternating or Progressive Message every 1 2 second temperature button used for Action 0 Light or dedicated Choose button depending on control panel configuration Waiting time varies depending on function Indicates a Menu Item that Depends on a Manufacturer Configuration and may or may not appear M Message Code N NV po RANGE D Days Ago READY RANGE READY RANGE O 3 Set Temperature 3 Sensor Temp 3 ELEZ Sensor B Temp UE Waiting several seconds inside the Fault Log Menu will allow the screen to return to normal operation Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815
113. power If every thing functions normally replace the topside panel e Disconnect ozone generator if applicable e f you still see symptoms of low voltage such as a sluggish blank or partially blank panel or if the display or the LED S do not function at all turn the power off unplug the ozone generator if equipped then restore power to the system If the problem persists turn off the power and replace the circuit board FLASHING HEAT LED ON TP600 HEAT WAITING When there is a call for heat the system will start the heater for a few seconds and the Heat LED will light After a few seconds of heat the heater will shut off for 90 seconds and the sys tem will look at the sensors to be sure they are within the M7 parameters for flow and a safe environment to run the heater During this 90 second wait time the Heat LED will flash quickly or shimmer until the heater comes on again to heat There is no voltage to the heater during this cycle This is normal for 7 Once the heater comes back on the LED will be on without shim mering On the P800 and TP900 panels the screen will display Waiting JS AU lay am Heat LED in Heat Waiting Mode 600 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both forei
114. pump may be configured to work in one of three different ways 1 The circ pump operates continuously 24 hours with the exception of turning off for 30 minutes at a time when the water temperature reaches 3 F 1 5 C above the set tem perature most likely to happen in very hot climates 2 The circ pump stays on continuously regardless of water temperature 3 programmable circ pump will come on when the system is checking temperature polling during filter cycles during freeze conditions or when another pump Is on e The specific Circulation Mode that is used has been deter mined by the Manufacturer and cannot be changed in the field e Other device options may be available like Blower Light Mist etc FILTRATION AND OZONE On non circ systems Pump 1 low and the ozone generator will run during filtration On circ systems the ozone will generally run with the circ pump but can be limited to filtration cycles The system is factory programmed with one filter cycle that will run in the evening assuming the time of day is properly set when energy rates are often lower The filter time and duration are programmable A second filter cycle can be enabled as needed At the start of each filter cycle the water devices like blower mist device if these exist and other pumps will run briefly to purge the plumbing to maintain good water quality FREEZE PROTECTION If the temperature sensors within the heater detect
115. r Voltages by placing probes on these locations 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 11 General Troubleshooting amp Servicing of Spa s Electrical Equipment HIGH VOLTAGE CAN SERIOUSLY INJURE OR KILL ONLY EXPERIENCED TECHNICIANS SHOULD SERVICE THIS EQUIPMENT DO NOT REMOVE THE PROTECTIVE COVERS FROM ANY ELECTRICAL ENCLOSURE OR ATTEMPT TO SERVICE ANY RELAT ED ELECTRICAL DEVICE UNLESS YOU ARE A QUALIFIED ELECTRICIAN OR SERVICE PROFESSIONAL AX cancer Risk of electric shock Before working with any electrical connections make certain that the Main Power breaker from the house breaker box has been turned off Ww ALL ELECTRICAL WORK MUST BE PERFORMED BY QUALIFIED ELECTRICIAN AND MUST CONFORM ALL LOCAL CODES A IMPORTANT DUE TO THE DANGER OF SEVERE ELECTRICAL SHOCK LOCATE ALL POWER DISCONNECTS BEFORE SERVIC ING A SPA PRECAUTIONS MUST BE TAKEN WHENEVER WORKING WITH BREAKER BOXES G F C L S OR SERVICE DISCONNECTS Always refer to the wiring diagram that included with each system on the inside of the system box cover Use this diagram for voltage measurement points and for proper reconnection of
116. r and must be done to determine the best location for the freeze sensor SOME TROUBLESHOOTING SCENARIOS You find out the system is in This alone doesn t explain a lot What led up to the OHH is much more important If it s a Prestige review the fault log carefully Otherwise see if the user has any additional information for example how long before the OHH was the spa panel last checked and how hot was the water then If the spa has cooled see whether the problem can happen again this time watching carefully to see if there are additional clues leading to the for example other messages that appear shortly before the OHH happens You find out the system keeps showing HFL or is now in LF or is shut down due to a fault Put the spa in test mode with the light on so that you see the two sensor temperatures Are they normal within 1 F 0 5 C when not heating How far apart are they when heating HFL happens when they are 6 F 3 C apart 4 F 2 C on 120V and other low heater wattage systems see how quickly that happens after heating starts If it s getting close to that right away it s probably a consistent flow problem but if it s nowhere close to the HFL causing temperature difference the flow problem may be intermittent or only occur in certain specific situations TEST MODE Test modes vary for different systems and configurations Please refer to the specific T
117. re 40 Note These are typical settings only Voltages may be different depending on the configuration that the system Is set to See the system s Tech Sheet for more information 33 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Observe safety at all times 26 URM SLAW C 22 Once the power input fuse has beenchanged 13 On Every System an Identification Label Is Placed on Top of the EC ODD eas yd Ge ead Ge 9 On Every System a Wiring Diagram Is Placed Inside the Door 9 Pale VERON ak eo ne ae de R9 a 48 Panel 5 Place clamp around one heater wire and then the other wire 32 Place the meter probes on the heater terminals 24 Possible freezing condition 51 Power Board 22117 56284 67 Power Board DOZON 68 Preferences 52 5 12 Preliminary Panel 15 and FIIINO a Gok Go ae 44 Preparation and Filling
118. re compatible with simplified menus and standard menus and can access lest Mode Regardless of menu structure test modes have full functionality The control panel user guides for standard and simplified menus are different Balboa user guide 40940 describes standard menus user guide 42185 describes simplified menus Menu attributes are embedded within the spa control system at the factory Swapping out one panel with another will not change a simplified menu to a standard menu and vice versa For the system to be changed from one menu structure to another is dependent on whether that option was programed into the system at the time of manufacturing CHANGING MENUS THROUGH CONFIGURATIONS If the option of an alternate menu structure is available then it Is possible to change the simplified menu to a standard menu and vice versa A technician must refer to the Tech Sheet of that particular system to see what configuration if any is available For instance if a technician plans to install or modify a Sunrise opas BP 240V system in this example and that system has standard menus that he wishes to change to simplified menus he would refer to Tech Sheet SR240BP5 No 56415 97 Rev A Page two provides information in the System Revision History 240V only version with both Simplified Menus and Full Menus The next giveaway of dual menu options is the section headers on the following pages See below e 3 An option is g
119. s Are Shown on the Heater Tube Label On Every System a Wiring Diagram Is Placed Inside the Door All TP Panels have zw Molex Type Connectors 5 QA J43 TO J13 BLOWER ON J14 BP2 100G1 56389 0 1 woter group J25 HTR1 J26 HTR2 J9 K9 K4 J46 238 E F6 30A a F2 10A 250VAC p 1 F3 0 125 sLo sLou 0 125A SLO BLOW 2 IN SETUPS 3 5 9 11 12 17 18 gom oum um um 01 30 13 24082 E J34 J35 zu zn J108 J107 291 8s x 4 Z 03 5 _ stRIAL IR RECEIVER TP MAIN PANELS OR J34 OR J35 RF RECEIVER WIFI J5 A1 A4 TRANSCEIVER OR J34 OR J35 98 A5 A8 LOCATION DEVICE VOLTS AMPS FROM FROM JL ON RT 2 SPD 230v 12 ON GROUP 2 J6 ON GROUP 3 EXPANDER PUMP 3 MAX EXPANDER 21 EXPANDER J53 NETZSTROMVERSORGUNG 2 GESCHW PUMPE ALIMENTATION POMPE 3 A 2 VITESSES EXPANDER RIGHT X P332 EXPANDER EXPANDER 926 030 BLU BRN C VB J29 240 GRN 9 e Jc a 10 317 J16 A 0000000010 is ON 51 228 P3 FRZ 230V 1 1x32A SENSOR A 3 HEIZELEMENT RADIATEUR ________ EXPANDER BOARD IS mmm 2 SPEED PUMP 3 IN SETUPS 1 7 Pes 1 SPEED PUMP 3 ONLY IN SETUPS 2 6 8 13 14 1 SPEED PUMP 3 AND 1 SPEED BLOWER WITH SPLITTER amp IN LINE FUSE SENSOR B IN
120. s ook Rak RE AG 45 saving Your Dolphin 70 scrolling IPA00 TP600 Messages bi sensor Fault Sensor B Fault Sensor A M031 Sensor B M032 5 Sensor Balance is 15 58 Sensor Balance is Poor 026 58 Sensor Failure Sensor A M031 Sensor M032 58 sensor Location BP500 on Logic Board sensor Pins At times a protective coating may on accident coat the sensor pins during manufacturing Those pins may need to be scraped and the sensors plugged back 35 Sensors are out of sync Call for service M026 51 sensors areoutof sync M015 51 service Tools Required 7 SELPADUBRE 56 Sfty 2 5 SIG Configuration Signature 56 Simplified Menus E 61 SNSR CALL 5 58 B CALL 5 58 SNSR SYNC CALL FOR SRVC 58 Software ID SSID nde od 48 SaL were SELUDS dua RR 36 Software Setups 2100 39 some Troubleshooting Scenarios 16 43 Be oe Bs ee eed 12 SSID Software 56 422178 STUK PUMP
121. scrambled messages on the LCD or only a few features will function If the system is getting the proper voltage at TB1 but still doesn t operate then test for a blown power input fuse J25 HTR1 J26 HTR2 J27 HTR3 J30 TE 931 J HT F6 Feso LO 9 Terminal Block amp F6 Fuse on a BP2100 Board CHECKING THE SYSTEM POWER INPUT FUSE WARNING These procedures are performed while the system is powered up and running under peak loads Be careful Systems that use 230V peripheral devices below Measure between the brown B1 terminal and F6 power input fuse at F6 You should see 230 volts If you determine that there is no voltage at this location then the system power input fuse needs to be replaced Only use a fuse of the same type and amp rating when you replace any of these fuse NOTE ALL SYSTEMS each situation the most likely reason for the system power input fuse to blow is a pump problem cont next page Once the power input fuse has been changed Check the voltage between the black and red wires again Acceptable voltage range 15 between 216V and 264V ADDED JUMPER FOR GND CE INSTALLATIONS N ES 9 22117 B si gt _ 045 ms A GRN HTR B F6 748 Ji UNFUSED F5 30A T F5 304 Terminal Block amp F6 Fuse ona BP600 Power Board 230V Setup 422178 Manufactured under one
122. stance scale the a digital meter should read OL indicating infinite resistance 25 Verify there is NO continuity from the heater post to the heater housing or heater current collector connection The meter reading shown is OL indicating infinite resistance 25 Viewing Configuration 36 Voltage Checklist 21 82 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 5 02 13 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Notes 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 83 BALBGA water grou po Tustin Ca 92780 714 384 0384 2013 Balboa Water Group All rights reserved 42217B May 2 2013
123. stralian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Testing Low Speed and High Speed at the AMP Pump Connector TESTING LOW SPEED AND HIGH SPEED AT THE AMP CONNECTOR A CAUTION TEST IS WITH POWER ON Board Connector Key Ground Neutral Common Typically Line voltage for 2 speed pumps Typically Line voltage tL Note flat sides in connector WITH THE PUMP LOW SPEED ON TAKE A VOLTAGE READING AT THE AMP RECEPTACLE ON THE PCB THIS WOULD TYPICALLY SHOW LOW SPEED VOLTAGE FOR PUMP ONE 230V WITH THE PUMP HIGH SPEED ON TAKE A VOLTAGE READING AT THE AMP RECEPTACLE ON THE PCB THIS WOULD TYPICALLY SHOW HIGH SPEED VOLTAGE FOR PUMP ONE 230V Note These are typical settings only Voltages may be different depending on the configuration that the system Is set to See the system s Tech Sheet for more information PUMP 1 AMP CORD 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 33 Testing the Sensor Set 34 Begin the diagnosis with the power off Check sensor wires for cracks or damage that may indicate the presence of a rod
124. t should be obtained on the system you re working on The information for setup changes is included here in the event you have wiring diagrams available and to facilitate a better understanding of how setup changes are made Note All TP panels can be used with all BP systems The setup change process below uses a BP2100 board for illustration A BP600 board setup is shown on the preceding pages TEST MENU ACCESS 51 SWITCH 1 ON SERVICE TECHNICIAN ONLY DANGER HIGH VOLTAGE WILL BE ACCESSIBLE SERVICE TECHNICIAN ONLY While the system is running move DIP Switch 1 on 51 on the Main circuit board to ON The system will enter Test Mode Moving DIP Switch 1 to OFF will exit Test Mode SOFTWARE SETUPS BP2100 Under the TEST Menu the Setup screen will allow changing the Setup from 1 to any number established by the manufacturer Changing the Setup may require wiring changes as well F4 SLO BLOW Spa Shortcuts Settings Test Y 0000 10 m Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 422178 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 39 Removing the Heater Assembly from BP Spa System Note Be careful when removing a heater assembly fro
125. tains the following A B TEMPS When this is set to On the temperature display will alternate to display temperature from Sensor A and Sensor B in the heater DEMO MODE Main Screen gt Settings gt Utilities gt Demo Mode Demo mode is not always enabled so it may not appear This 15 designed to operate several devices a sequence order to demonstrate the various features of a particular hot tub FAULT LOG TP800 TP900 Main Screen gt Settings gt Utilities gt Fault Log The Fault Log 15 a record of the last 24 faults that can be re viewed by a service tech GFCI TEST FEATURE NOT AVAILABLE ON CE RATED SYSTEMS GFCI Test is not always enabled so it may not appear This screen allows the GFCI to be tested manually from the panel and can be used to reset the automatic test feature If the GFCI Test Feature Is reset the device will trip within 7 days 49 TP800 Sensor and System Related Messages cont 50 Utilities Reset THE GROUND FAULT CIRCUIT INTERRUPTER The Ground Fault Circuit Interrupter GFCI or Residual Current Detector RCD is an important safety device and 15 required equipment on a hot tub installation The GFCI Test Feature is not available on CE rated systems USED FOR VERIFYING A PROPER INSTALLATION Your spa may be equipped with a GFCI Protection feature If your spa has this feature enabled by the manufacturer the GFCI Tr
126. ted by a single button icon Panels that have two Temperature buttons Warm and Cool can use both of them to simplify navigation and programming where a single Temperature icon is shown LL LJ The LIGHT Button is also used to READY RANGE FLTR T choose the various menus and navigate each section FLIP JETS AUX LIGHT HEAT Power up Screens Indicates Flashing or Changing Segment indicates Alternating or Progressive Message every 1 2 second JETS Typical use of the Temperature button s allows changing the Set Temperature while the numbers are flashing in the LCD Pressing the LIGHT button while the numbers are flashing will enter the menus The menus can be exited with certain button presses Simply waiting for several seconds will return the panel operation to normal Each time the System powers up a series of numbers is displayed After the startup sequence of numbers the system will enter Priming Mode See Page 3 temperature button used for Action 0 Light dedicated Choose button depending on control panel configuration Waiting time that keeps the last change to a menu item amp Waiting time depends on menu item that reverts to original setting and ignores any change to that menu item Main Screen amp in _ _ OL UL UG d While the Temperature
127. tems The setup change process below uses a BP600 logic board for illustration A BP2100 board setup is shown on the following pages READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE BEGINNING THIS PROCESS Know the Setup Number you want before you power up the spa and wait to power up the spa until you re ready to change the Setup Number The system must be in Test Mode so move Switch 1 to the ON position The Test Menu will then be available Power up the spa and press any button once to Link the panel Note Switch 1 can be moved to the ON position immediately after power up if preferred Danger High Voltage will be present You will have 1 minute to complete the setup change after you manually exit Priming Mode Once familiar with the process the Setup change should take less than 15 seconds As soon as Switch 1 is placed in Test Mode SETUP SWITCH in the ON position The temperature will show des HUN IRE after it instead of F or C 929 VAC 6 indicating the System is 917 Ex oo BP600 BOARD When the panel displays RUN PMPS PURG AIR press any Temperature button ONCE to exit Priming Mode You should see T where the I indicates the system is in Test Mode READY RANGE Continued on Next Page Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52
128. terial separating the components below Sensor Location BP500 on Logic Board Also if you must move the components around for testing add remove sensors or wires take a few moments to power down the system a Depress sensor tab when removing For safety an antistatic bag a piece of card board as shown here or any other insula tor should be used to separate the chassis ground from the logic board The Logic board must not be in contact with any hot spots chassis ground or floor of the O spa area when the system is powered up for testing Be especially careful if the surround ing floor area 15 wet E 422178 Manufactured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 31 Testing Heater Amperage CAUTION TEST IS WITH POWER PLACE CLAMP AROUND ONE HEATER WIRE AND THEN THE OTHER WIRE rv gt TS rumen wa AMPERAGE HEATER TEST BP600 AMPERAGE HEATER TEST BP2100G1 32 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Au
129. ther editable screens as well When changes are made the icon to go Back changes to Save and new icon for Cancel appears under the Save icon Navigating to the left will highlight the Save icon and navigat ing down from there will allow the user to cancel the pending change Pressing the Select button will save or cancel the changes and go back to the previous screen NOTE f power is interrupted to the system Time of Day will be maintained for several days PUMPS On the Spa Screen select a Jets button once to turn the pump on or off and to shift between low and high speeds if equipped If left running the pump will turn off after a time out period The pump 1 low speed will time out after 30 minutes The high speed will time out after 15 minutes non circ systems the low speed of pump 1 runs when the blower or any other pump is on If the spa is in Ready Mode Pump 1 low may also activate for at least 1 minute every 30 minutes to detect the spa temperature polling and then to heat to the set temperature if needed When the low speed turns on automatically it cannot be deactivated from the panel however the high speed may be started CIRCULATION PUMP MODES some spas may be manufactured with Circ Pump settings that allow programming filtration cycle duration Some circ Modes are pre programmed to operate 24 hours a day and are not programmable 422178 If your system 15 equipped with circ
130. ting and the panel display set contact with anything below the insulating for the need for heat verify the voltage at the heater material on the terminal arrows posts On a 230V system the reading will be near Note Black boot removed below to show 230V Allow for 10 variance detail 5 When finished with testing turn the power off before removing the clamps from the terminal posts xy NET E i E Me oS AU EI 30 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 9 02 13 Testing Pump Fuses for Damage with Voltage On BP600 Due to the design of the BP500 the upper Logic board must be moved out of the way to test most of the power board fuses To gain access to the power board 1 Power down the system 2 Remove the sensor wires from the logic board Be sure to depress the release tab on the sensor connector Do not pull on the wire 3 Remove the four corner retaining screws 4 Place the Logic board out of the way of any metal or points of system voltage or grounding areas once the system is powered up Note One consideration to isolate the logic board from the metal chassis 15 to place a non conductive ma
131. tton 50 tested RCD should be 2 Test GFCI Trip 50 Testing Acceptable Ranges for 21 Test Menu 59 TEST Menu 36 Test Menu Access 36 Index test mode 15 16 Test Mode 36 37 38 51 Test Mode 16 test software 51 58 tests sequence of 14 lest the Blower 14 Test the ground fault circuit interrupter 2 lest the Pump 14 Test the System 14 threads Loctite should be applied to heater terminal 40 time out period 45 Time Quts 36 times overlapping filter 16 torque 30 35 in Ibs 40 lorque main board 42 TP600 TP400 panels 36 900 800 panels 36 TP panels 8 Trip Safety 57 Troubleshooting Pumps 20 Troubleshooting Resistance 24 25 Two Pole RCD 17 Type Heater 21 U Unlocking the Panel 47 User Guide 40940 8 User Guide 40985 8 User Guide 42185 8 User Interface 8 Utilities 47 Utilities Menu 49 V valves ball 40 valves slice 40 version latest 8 VG Compliant suction guard 2 view the configuration 36 Voltage Checklist 21 W Waiting Heat 15 Warning End User 2 Water 15 too Hot 57 Water may splash out 40 Water under pressure 40 Watts 120V 21 Watts 230V 21 Watts 240V 21 wires BP2000 board without 42 wires do not pull on the 41 wires heater 40 wires heating assembly sensor 40 Wires Sensor 7 wiring changes 36 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030
132. unctions are disabled System will auto reset when the spa water temp is below 108 F 42 2 C Check for extended pump operation or high ambient temp SENSORS ARE OUT OF SYNC M015 The temperature sensors MAY be out of sync by 2 F 3 F SENSORS ARE OUT OF SYNC CALL FOR SERVICE M026 The temperature sensors ARE out of sync The fault above has been established for at least 1 hour SENSOR A FAULT SENSOR B FAULT SENSOR M031 SENSOR B M032 A temperature sensor or sensor circuit has failed Call for Service COMMUNICATIONS ERROR The control panel is not receiving communication from the system 422178 TEST SOFTWARE INSTALLED The Control System is operating with test software F OR C IS REPLACED BY T The Control System is in Test Mode PROGRAM MEMORY FAILURE M022 At Power Up the system has failed the Program Checksum Test This indicates a problem with the firmware operation program and requires a service call THE SETTINGS HAVE BEEN RESET PERSISTENT MEMORY ERROR M021 Contact your dealer or service organization If this message ap pears on more than one power up THE CLOCK HAS FAILED M020 CONFIGURATION ERROR SPA WILL NOT START UP THE GFCI TEST FAILED SYSTEM COULD NOT TEST THE M036 North America Only May indicate an unsafe installation A PUMP MAY BE STUCK ON M034 Water may be overheated POWER DOWN THE SPA DO NOT ENTER THE WATER HOT FAULT
133. ured under one more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Remove and Replace a System Circuit Board cont INSTALLING A SYSTEM CIRCUIT BOARD COMPATIBILITY ON DUAL BOARD CONTROL SYSTEMS When reinstalling the board system BP600 has two boards a power board and logic board If e lorque main board hold down screws to 8 10 in Ibs one board is found to be defective and is replaced with a newer Do not over tighten as damage to the board may result revision board it will still be compatible with the other older e Reconnect all wires and slip on connectors system board Restore power to the spa at the main breaker Test to make sure all functions work correctly Po BP2100 board screw locations J39 i3 LOJ ILOILO LO MAIN MAIN F8 30A zic EFO 230V u reer 1 J108J107 J91 95 J23 o j22 200000 SERIAL 9 sJ J26 J30 gt J44 mr 2B J25 J31 LLJ CY 5 m E 15 E an uw E LLJ drenta iti VAS LDI REMOTE 10 J17 J16 GND A 000000000 E F2 10 250VAC F7 10 250VAC UN Sd J28 BP2100 board without wires ATT Wu a
134. wires F A terminal marked GROUND is provided within the System Control Center enclosure To reduce the risk of electrical shock connect this terminal to the grounding terminal of the electric supply panel with a continuous green insulated copper wire equivalent in size to the circuit conductors supplying this equipment but no smaller than 12 AWG A SAFETY TIPS e Keep children and pets away e aware of your surroundings Standing in water while repairing a spa puts you at serious risk e Avoid working in cramped or crowded conditions e Consider placing a padlock on the service panel to lock out anyone who might power up the system Ground in System Enclosure 12 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 Basic Control System Troubleshooting Note Local codes and laws vary Use information below as a guide LOW VOLTAGE 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 operation in a variety of ways The control panel may go blank have
135. y FILTER CYCLE 2 OPTIONAL FILTRATION Filter Cycle 2 is OFF by default Simply navigate to the Filter Cycle 2 line by pressing the Right Navigation Button and when is highlighted press Up or Down to toggle Filter Cycle 2 on and off When Filter Cycle 2 is ON it can be adjusted in the same manner as Filter Cycle 1 by navigating to the right It is possible to overlap Filter Cycle 1 and Filter Cycle 2 which will shorten overall filtration by the overlap amount PURGE CYCLES In order to maintain sanitary conditions as well as protect against freezing secondary water devices will purge water from their respective plumbing by running briefly at the beginning of each filter cycle If the Filter Cycle 1 duration is set for 24 hours enabling Filter Cycle 2 will initiate a purge when Filter Cycle 2 is programmed to begin HOLD MODE M037 Hold Mode is used to disable the pumps during service functions like cleaning or replacing the filter Hold Mode will last for 1 hour unless the mode is exited manually If spa service will require more than an hour it may be best to simply shut down power to the spa 46 Back Filter Cycles Filter Cycle 1 Starts at 12 00 AM Runs 0 HR 0 Min Ends at 12 00 AM Filter Cycle 2 No Starts at 12 00 AM Runs 0 HR 0 Min Ends at 12 00 AM Filter Cycles Filter Cycle 1 Starts at 6 15 AM gt Runs3HRO Min Cancel Ends at 9 15 AM Filter Cycle 2 No Starts at 12 00 AM
136. ype 56 High Limit Sensor 21 High Temperature Range 43 Hot HIR too 57 Hot Water is too 57 74 Manufactured under one or more of these patents U S Patents 5332944 5361215 5550753 5559720 5 883 459 6253227 6282370 6590188 6976052 6965815 7030343 7417 834 52 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 5 02 13 how to 50 is too Hot 57 Identification Software Self 72 ID Software 48 ID System Panel 72 immediately should be reset 50 Information 47 information Fault Log 36 Information System 48 Instructions power connection 2 Interface User 8 Invert 47 IR Receiver 69 isolate the logic board 31 L last 24 faults 36 latest version 8 Law Ohms 22 LCD readouts may look slightly different 55 57 LED Flashing Heat 15 lightning strike 14 Limit Temp 36 Link the panel 37 Lock 47 Locking the Panel 47 Locking the Settings 47 Lock Settings 47 Loctite Apply 40 Loctite should be applied to heater termi nal threads 40 Log Fault 36 47 49 59 Logic board 31 Logic Board 31 67 68 Low Temperature Range 43 M MO XX numbers are Message Codes 44 M015 51 58 M016 48 57 M017 48 57 422178 Index M019 57 MO19 44 M020 51 58 M021 51 58 M022 51 58 M026 51 58 027 48 M028 48 57 M029 51 57 48 57 M031 58 M03

BWG 50Hz BP Troubleshooting Service Manual

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