Important - Nature Spa
Contents
1. GREEN YELLOW Ground 82 9 20 Front View of R C D Square D BROWN Hot BLUE Neutral 2920090996 BROWN Hot BLUE Neutral GREEN YELLOW Ground GREEN YELLOW Ground Spa System Box BLUE Load GREEN YELLOW 001 714 438 3820 Basic Control System Troubleshooting Low Voltage At Balboa it s been our experience that the majority of the problems associated with electronic control systems are due to low voltage Brown outs Brown outs can have an effect on the spa s operation in a variety of ways The control panel may go blank have scrambled messages on the LCD or only a few features will function e If the system is getting the proper voltage at TBI but still does not operate then measure fingers 5 and 6 of the circuit board You should see 230 V Checking the System Power Input Fuse Deluxe or Standard System e Ifyou determine that there is no voltage at fingers 5 and 6 then the system power input fuse needs to be replaced This fuse is located in the large fuse block inside the system box This configuration utilizes a 30A time delay fuse Duplex System e Remember the system power input fuse may snap directly to the circuit board next to finger 6 e To check this fuse probe finger 5 and the side of the system power input fuse farthest away from finger 6 e If there is no voltage2. 7 Hobel 15 R C D Line in Voltage Check Unexplained Error Messages 15 230 V Dedicated 7 Pressure Switch Calibration 15 R C D Load Out Voltage Check Continuous FLO 15 230V Dedicated 7 Flashing FLO cv voe qua ae 16 System Box Check at TB1 230 V Dedicated 7 R CD Troubleshooting Peak Load Check 7 If Correct Wiring is Verified 17 Peak Load Check for 230 V Dedicated 7 To Disconnect the Heater 17 Wiring Schematic santa eens asas alpino 8 Basic Control System Troubleshooting LOW VOOR cal een ee EROR dS ES s 9 Brown Outs nes eve ED cs 9 Checking the System Power Input Fuse 9 Deluxe or Standard Digital System 9 Duplex System ac 9 To Determine if Fuse Replacement is Necessary 9 www balboa instruments com X 1 Table of Contents cont Testing the Circuit Board Output To use the Balboa Quick Check 18 Changing a System Circuit Board How to Remove a System Circuit Board 19 How to Replace a System Circuit Board 19 Filter Settings Filter Setting Information 20 Optional Features 240V System Power When checking for proper voltage in countries where 240V is standard the acceptable range is between 216
3. Precautions In most areas R C D s are required for spa installations In other areas R C D s are recommended for spa installations but are not mandatory If the spa you are servicing was not installed with an R C D strongly urge your customer to improve safety and comply with current standards by installing one Note A suitable R C D may be acquired through your local distributor A Important Remember high voltage is still accessible in the house breaker box even though you have turned off the spa breaker Digital Fever Thermometer R C D Line in Wiring Check Locate the proper circuit breaker and turn it off e Remove the cover from the house breaker box Check the main service amperage rating to the breaker box Note Typically a house circuit will require at least a 100 Amp service when a spa is installed e From the circuit breaker locate the brown load wire and the blue neutral wire e From the R C D neutral bar locate the blue load neutral and the green ground wire e Be sure there are no other appliances on the spa circuit If there are service must be re wired to supply the spa only e Make sure all 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 should be connected to the neutral in R C D Line out Wiring Check for 230 V Dedicated System 3 wire system induding ground wire The b
4. Technical Service Manual Table of Contents Balboa Control Service Checklist Test the System Pump RU 9 Test the Blower di 10 A 3 Test the Amperage Draw 10 Tools Required 3 Test the Soldered in Fuse 10 System Components Required 3 Transformer Installation Requirement 11 Safet DDS Less does Cr m PEE E E 3 System Description Topside Control Panel Preliminary Panel Check 12 Topside Control Panel Che ee MT ELTE E EEEE NN a de rep DD 4 Bulb Replacement Spaeth ie he Sate te st eae ho A end Dan as 12 Circuit Board a A a E E ee ene A VANS E 4 Remote Panel Troubleshooting et a O Y a eh eee 12 Temperature Sensor 4 High limit Sensor sc vidue Da Oe oad ese s 4 Panel Messages Wiring Checks OH orang E Racer ea are a 13 ONA cee ati eye 14 Wiring Check Precautions 5 A ne eee ER oat 14 System Box Wire Gauge Check 5 FLO Continuous and Flashing 14 R C D Wiring Check 5 COONS A ee Dudas et UEM 15 R C D Line in Wiring Check 6 co eins Cita NA AANG e eels 15 R C D Line out Wiring Check oir teehee 15 230 V Dedicated 6 Unc tute devra udi AR en maha qut 15 DEDO AS suede ead aste dau ese IS 15 Voltage Checks tas basta Marios oa 15 Breaker Box Voltage Check
5. Probe the brown and green ground wires This should also read 230 V e Turn on the R C D breaker before continuing to the system box R C D Load Out Voltage Check 230 V Dedicated System e Be sure the house breaker is on e Be sure the R C D breaker is on e Probe the blue and brown wires at the R C D load out and neutral out The voltage should be 230 V e Probe the blue wire and the green ground wire The meter should read 0 V e Probe the brown wire and the green ground wire The voltage should read 230 V Recheck voltage under peak load conditions A Important If the voltage is not within the acceptable range call an electrician or the local electric company to diagnose the problem System Box Check at TB1 230 V Dedicated System Check e Be sure the R C D breaker is on e Probe the blue and brown wires Look for 230 V e Probe the blue and green ground wires for O V Probe the brown and green ground wires also 230 V e Recheck voltage under peak load conditions Peak Load Check It is important to check the voltage again under peak load conditions To reach peak load turn on the blower heater light and all pumps Peak Load Check for 230 V System e Check the voltage between the blue and brown wires The acceptable voltage range is between 207 and 253 V www balboa instruments com Wiring Schematic House Breaker Box
6. the 20A time delay fuse must be replaced Note In each situation the most likely reason for the system power input fuse to blow is a pump problem However on occasion a blower problem may also cause this fuse to blow if a 10A blower fuse is not built in Once the power input fuse has been changed e Check the voltage between the blue and brown wires again Acceptable voltage range is between 207 and 253 V These readings should be taken under peak load conditions A Important If the voltage is not in the acceptable range call an electrician or the local electric company to diagnose the problem To Determine if Fuse Replacement is Necessary To determine if fuse replacement is necessary perform the following sequence of tests Test the System e Turn the power off e Be sure to replace the system power input fuse with the same type e Unplug the blower and all pumps e Restore the power and verify system operation e If the fuse blows then re check the internal system wires and connector for burns cracks or cuts in insulation e Ifthe fuse does not blow turn the power off and plug in the pump Note Be sure to test each device individually Test the Pump e Restore the power and activate the pump e If the fuse blows there is a pump problem e If the fuse does not blow turn off the power www balboa instruments com Troubleshooting cont Test the Blower Plug in the blower Power up t
7. 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 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 spa s 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 spa s components and the R C D still doesn t reset then the problem is most likely a ground fault in the heater To Disconnect the Heater First turn off the main circuit breaker then remove both heater straps or wires from the terminal block not the heater itself After restoring the power try to reset the R C D again If it no longer trips after the system calls for heat then replace the heater If the R C D still trips look for pinched or shorted wires at the transformer Make sure that the screws that attach the transformer to the system box have not pinched or damaged the insulation of the transformer wires If the transformer wires are undamaged check for any other pinched wires Refer to the wiring diagram to verify the corr
8. all wiring connections terminal block connections wire gauge type and check for shorts between the system box and the service disconnect Once you are confident that all wiring is correct replace the fuse Test the Soldered in Fuse For a class 2 transformer circuit a fuse must be permanently installed to protect the circuit board If you have determined that the system is getting proper voltage through the power input fuse then you must check to see if the soldered in fuse has blown First turn off the power Next unplug the transformer from the circuit board then turn the power back on and probe from finger 5 to one side of the fuse The voltage should read 230 V Probe from finger 5 to the other side of the soldered in fuse The voltage should read 230 V If either side has 0 voltage then the fuse is blown If so turn off the power and replace the circuit board See page 19 Make sure that the transformer is properly rated for the system The voltage reading between fingers 5 and 6 on the circuit board will determine the proper transformer input voltage for Deluxe and Standard models A 230 V transformer should have one blue connector If you determine that the soldered in fuse is not blown this means that the transformer is receiving voltage 10 001 714 438 3820 Troubleshooting cont Transformer Installation Requirement Confirm Transformer Connections Intermittent problems may occur when tr
9. off the heater e The blower if installed will go to low speed when the A l pump high is on Feature A Enabled Feature B Enabled 20 X 001 714 438 3820 Millennium TUV Circuit Board Vo BALBOA FN EN pe IAS im 3 5 2 PRE Po CB ds E eL Nee ES ee CHE Qu gt e 4 AN 1 pa 3 O E E 3 d B tis 6 ae 4 amp 109 PONTO AE A 2 uM zl i am ur f 7e a gt 2 UN j RETA v We BS f confiou PA DE ato gem SS h AI I II 4 Som CH E UM N 7339 l fa 71 2 29 e o act lt K Ae D qued dh pe MX 2 TIONS ARE Net ps Oy ENABLE te m ii WE ET 3 2483 yo i 1 0 T3 PRU nr RIES N oz E CES Simita Os GENERATOR us O O o 2 wuispecd blower option Circuit Board Components 1 Blower Triac TRC6 for multi speed 10 Temp High limit Input J2 22 Serial Number Model blowers 11 Light Fuse Number Designations Use Screw For Heat Sink Only 12 Main Processor with software number 23 50Hz 60Hz Jumper J25 Do Not Overtighten 13 Orp Enable Jumper 24 Soldered in Fuse 2 Blower Hookup 14 Ozone Enable J16 25 Spa Light Hookup 3 Position of single speed blower relay 15 Ozone Generator Hookup J39 amp J40 4 Control Panel Input 16 Perimeter Light Hookup J14 26 Transformer Input 5 Finger 5 17 pH Orp Sensor Input J11 27 50A 20A Jumper 6 Finger 6 18 Pump 1 Hookup 28 Battery Backup Enable 7 Filter Select Jumper 19 Pu
10. spa Precautions must be taken whenever working with breaker boxes R C D s or service disconnects Always refer to the wiring diagram which is included with each system on the inside of the system box cover Use this diagram for voltage measurement points and for proper reconnection of wires A Important Be sure to bring the correct circuit board topside control panel components and tools A Safety Tips e Keep children and pets away e Be aware of your surroundings Standing in water while repairing a spa puts you at serious risk e Avoid working in cramped or crowded conditions DANGER SHOCK HAZARD DO NOT PROCEED IF UNQUALIFIED IN WORKING WITH HIGH VOLTAGE www balboa instruments com System Description Highly advanced microprocessor technology has been combined with solid state electronic switches to produce the world s finest high quality state of the art digital control systems Balboa control systems are technologically sophisticated yet easy to understand use and troublesboot Topside Control Panel The control panel activates functions at the touch of a button Each function will echo from the circuit board to the LCD in a corresponding manner The panel will also display diagnostic messages which enable the service technician to easily troubleshoot the system Circuit Board A typical circuit board has the following output capabilities e 230 VAC System e Two speed pump 230 VAC 50 Hz 2 HP
11. the topside control panel A panel that is not functioning properly may include the following symptoms low voltage such as missing or scrambled segments missing icons on the LCD non functional LED s or nonfunctional buttons If any of these symptoms are present perform the following e Turn the power off and unplug the panel from the circuit board e Then plug in your test panel and restore power If everything functions normally replace the topside panel e f you still see symptoms of low voltage such as a blank or partially blank panel or if the display or the LED s do not function turn the power off and replace the circuit board Bulb Replacement Another panel problem found primarily on the Deluxe model may be burned out backlighting bulbs These bulbs can easily be replaced e With the power off gently pry up the topside control panel with a screwdriver Next locate the gray bulb holes in the back of the panel Use a screwdriver to turn the bulb approximately 3 cm to remove and replace the bulb Needlenose pliers may also be useful lt Set E Electronic Spa Controls Duplex Digital System gt nv a O p Remote Panel Troubleshooting Remote panel applications need special consideration where the panels connect to the circuit board If You are Working on a Spa With a Remote Panel e Before replacing the circuit board or any panel remove the gang connec
12. Test to make sure all functions work correctly See the photos on pages 21 22 and 23 for additional information about Balboa circuit boards www balboa instruments com 19 Filter Settings On the Deluxe Model the filter settings are completely programmable from the topside control panel e On the Deluxe Model if the filter settings have just been changed it takes 24 hours for the filter cycle to reflect the changes You may cycle the time clock forward 24 hours to put the new filter cycles immediately into effect e The low speed pump and ozone generator if installed will run during the filter cycles The blower runs for 30 seconds at the start of each filter cycle This will maintain water quality in the air channel Optional Features A Important Please keep in mind the jumper positions indicated Ozone Generator Indicator below are specific to the Balboa generic models For service On the Deluxe model short the wires on J16 with a on a custom unit please look for jumper names on the jumper or unplug the optical sensor if available 03 will circuit board be displayed on the panel whenever the ozone generator is enabled Pump 2 Enable P e Short the post on the Pump 2 Enable with a jumper the system is converted from a 2 pump to a 1 pump system Logic Jumper Feature Off Feature On Heater Disable When 50A 20A Jumper is in 20A position e The pump high or blower will turn
13. V and 264V 10 of recommended voltage Ozone Generator Indicator 20 Pump 2 Enabl au ce eu 20 Heater Disable 20 Millennium TUV Circuit Board Millennium TUV Circuit Board 21 Super Duplex Digital TUV Circuit Board Super Duplex TUV Circuit Board 22 Lite Leader TUV Circuit Board Lite Leader TUV Circuit Board 23 2 001 714 438 3820 Balboa Control Service Checklist Preface This manual is provided to aid the qualified service technician in troubleshooting and correcting problems found in spas with control systems manufactured by Balboa Instruments Inc Tools Required Ammeter 50A Digital Multi meter Balboa Six in one Screwdriver Includes Two Phillips Head and Two Flathead Screwdrivers Along with a 3 cm and 13 cm Nut Driver 13 cm Socket 3 cm Open End Wrench Small Wire Cutters Pliers amp Needlenose Pliers Quick Check Test Kit Logic Jumper on a Quick Check Test Kit Stick LJS Precision Thermometer Digital Fever Type Padlock to lock electrical disconnect during service Plumber s Sealant System Components Required e Fuses 30 and 20A time delay plus 20 10 and 3A e System Transformers 230 V e System Sensor Assembly e System Panel s e System Circuit Board A Important Due to the danger of severe electrical shock locate all power disconnects before servicing a
14. When the display continually shows FL Li this usually indicates that the pressure switch needs adjustment or has malfunctioned When servicing a spa with a solid FLO message e Disconnect the pressure switch wire at the circuit board The FLO message will disappear within five seconds At this point the pressure switch can be calibrated e Set your voltmeter to ohms e Attach the pressure switch wire and your voltmeter probes to the Balboa LJS You should see continuity at this point e Rotate the star wheel on the pressure switch clockwise until no continuity is shown on the meter e Turn on the high speed pumps and run for at least ten seconds You should again see continuity on your meter e Turn off all pumps and within four seconds continuity should no longer exist e If after four seconds you still see continuity on the meter attempt to recalibrate the pressure switch e Ifyou still have problems calibrating then replace the pressure switch Note The main reason for pressure switch failure is poor water chemistry Instruct the owner in proper water maintenance www balboa instruments com 15 Pressure Switch Calibration cont When the display is flashing FL Lj this may indicate a flow restriction such as a dirty filter Another cause of the flashing FLO message could be a faulty or malfunctioned pressure switch When servicing a spa with a flashing FLO message e Set your voltmeter to ohms e Dis
15. ansformer connections are loose Make sure your fingers are away from exposed high voltage connections Wigele the transformer wires near the connector on the circuit board This will determine if there is a loose transformer connection or bad pin on the circuit board e Ifthe system intermittently turns on and off turn the power off e Plug in the test transformer restore the power and wiggle the transformer wires again e If there is no intermittent failure no further analysis is required e Turn off the power and replace the transformer e After installing your test transformer intermittent symptoms may still occur during the test e Tf so replace the circuit board see page 19 and install the original transformer A Important Be sure to turn the power off before replacing any component especially a circuit board www balboa instruments com 11 Topside Control Panel Deluxe Digital System Mu o SETHEAT sese RA m ZO GEGA o ES A j E y p Preliminary Panel Check If the problem is not obvious look on the topside control panel for diagnostic messages If no messages are seen run through all spa functions and note any inconsistent operation e If diagnostic messages appear on the topside control panel see page 13 for troubleshooting tips Once you have determined that proper voltage is running through the circuit board and transformer continue to
16. cks Safety is key when servicing any spa or spa control panel Remember safety comes first for you and your customer Please take all necessary precautions before attempting any repairs Wiring checks are the first step to ensure safety and proper function before beginning service on a unit A Wiring Check Precautions e When working in a system box always be aware that it may contain high voltage e Always keep your fingers and hand tools away from any wiring or circuit board when the power is on Touching anything in these areas can result in serious injury e All service calls no matter how minor should include a complete wiring check beginning with the house breaker e Keep in mind Balboa equipped spas only run on single phase electrical service Three phase power will not supply proper voltage to the system Three phase power may overheat the pumps and cause the Residual Current Device R C D to trip Check for Loose Connections or Damaged Wires e Make sure the power is off before you touch any wiring e Once the power is off carefully examine all wires for cuts or defects 3dd0I ISN Adve lt z m E o gt lt a 8 gt E a r e TB1 in the System Box System Box Wire Gauge Check When inspecting the wiring for any control system note that connections for the incoming wires are clearly labeled at the main terminal block e 30A service minimum ten gauge copper wire e 40A s
17. connect the pressure switch wire from the circuit board and turn on the low speed pump e Connect the pressure switch wire and voltmeter probes to the Balboa LJS At this point the pressure switch can be calibrated e Adjust the pressure switch by rotating the star wheel counter clockwise until continuity appears on the meter e Switch from low speed to high speed if available and run for ten seconds After ten seconds has passed turn off all pumps c gt Clockwise e After four seconds check the voltmeter and verify c lt Counter clockwise that there is no continuity showing e If there is continuity adjust the star wheel clockwise until there is no continuity Re test with the low speed pump as before e Ifthe pressure switch cannot be adjusted adequately replace it 16 gt 001 714 438 3820 R C D Troubleshooting Keep in mind tbat a majority of R C D tribping problems can be attributed to incorrect wiring R C D troubleshooting usually finds the problem If Correct Wiring is Verified Check to see if the proper R C D is installed Check the label in the system box near TBI 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 a 4 pole R C D is acceptable For a detailed wiring checklist please review the previous segment of this manual on proper R C D
18. e Single speed pump 230 VAC 50 Hz 2 HP e Blower 230 VAC 50 Hz 2 HP e Heater 230 VAC 50 Hz 5 5 kW e Light 12 V 12 W 50 Hz 1A or 230 V 100 W In addition to these outputs the board receives input from the spa temperature sensor high limit sensor and flow or pressure switch A Important Do not remove and replace the circuit board unless you have tested all other components and proven that the circuit board is actually causing the problem Temperature Sensor The temperature sensor is normally located in the tub wall or filter bucket but may be installed in the plumbing Its main function is to monitor the spa water temperature If this sensor reads a temperature above 44 5 C all output relays are opened and the spa is shut down The display will flash GH The spa will reset automatically at 43 C High limit Sensor at the heater Temperature Sensor in the spa High limit Sensor The high limit sensor is located on the heater Its main function is to detect both freeze and high limit conditions If the sensor reads a temperature below 4 C the system will automatically turn on all pumps to circulate the water The display will show E E If the sensor reads a temperature above 48 C the high limit relays will open and the spa will shut down The display will flash GH This sensor must cool down to 43 C before the spa can be manually reset by touching a panel button 001 714 438 3820 Wiring Che
19. ect wiring of the control system If everything looks to be in perfect working order then the R C D may be defective www balboa instruments com 17 Testing the Circuit Board Output Testing the Circuit Board Output If your topside control panel is working properly but a pump blower or other device does not activate when its panel button is pressed further diagnosis is easily accomplished with the Balboa Quick Check Quick Check Test Kit J amp J Adapter Set To use the Balboa Quick Check Turn off the power at the house breaker box Unplug the device in question and plug the Quick Check in its place Restore power to the spa and press the appropriate panel button again If the Quick Check s light appears the device in question is receiving voltage An ordinary multi meter can also be used to check for proper output voltage except when working with a variable speed blower or a dimmable spa light In these cases a component on the circuit board called a triac needs to be under a small load to test output voltage Even if the system is not equipped with a blower triac the best way to verify voltage output is with the Balboa Quick Check If the Quick Check light does not appear after pressing the appropriate panel button trace the wires from the corresponding connector in the system box back to the circuit board Probe these connections at the circuit board after activating the function with
20. ervice minimum eight gauge copper wire e 50A service minimum six gauge copper wire These wires must connect the house breaker box through the local disconnect to the main terminal block The wiring diagram inside the system box shows the main terminal block as TB1 A Important Using non copper wire can be dangerous and also can be the cause of a spa s malfunction If non copper wire is used at any point we do not recommend servicing the spa until an electrician replaces it with the proper gauge copper wire A Important This service must be single phase Any abnormal voltage reading requires an electrician Do not attempt to fix these types of problems yourself High voltage can seriously injure or kill R C D Wiring Check If an R C D has recently been installed a majority of tripping problems can be attributed to incorrect wiring of the R C D A clear understanding of the correct configuration is essential Please refer to the figure on page 8 as needed www balboa instruments com Wiring Check for R C D Service Disconnect A Important Most regional codes state u that a service disconnect 1 ia breaker box an R C D 6 e a can be used for this E purpose must be located at least five feet away from the spa and should be conveniently located near the equipment bay If it is not in plain sight keep the disconnect padlocked when in the off position hager mem CD720H 1643586 25A lAn 0 03A
21. he system and activate the blower If the fuse blows then there is a blower problem If the fuse does not blow the combined pump and blower amperage may be excessive To verify this first check with your spa manufacturer for amperage draw limits on each device Since the blower should now be running you can check the amperage draw with an ammeter by measuring around the blue blower wire and compare with manufacturer s specifications Test the Amperage Draw Turn off the power disconnect the blower make sure the pump is plugged in and restore power Start the pump and switch to high speed if available this should draw the most current Ei Make sure all jets and valves are open Check the amperage at the brown pump wire Compare your reading with manufacturer specifications If the other plug in devices exist they should be tested in the same way If the amperage draw for each device is within manufacturer s specifications the problem could be a nuisance spike in the pump or water in the blower Note 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 Note These slow blow fuses are not always discolored when blown Always test continuity of a fuse with an ohmmeter If one or both fuses have blown and you have turned off all power at the house breaker box IMMEDIATELY check
22. heck heater element alignment e Check for debris on the heater element e In extremely hot weather check for proper cabinet ventilation e Make sure the temperature sensor is fully inserted into the sensor mount and that the sensor mount is properly insulated with foam Note Improper insulation is one of the most common causes of spa overheating Aerosol foam insulation is available at most hardware stores e Check for excessive filter duration Note On the Deluxe model a common programming mistake is overlapping filter times that may cause the spa to filter continuously e Check the water level e Check the water temperature with an accurate temperature thermometer Remove the spa cover and allow the water to cool to below 43 C Adding cool water may be necessary Touch any button to reset the system If the water is still hotter than the set temperature press the blower button if applicable to cool the spa If the Problem Recurs Test the Sensor Set e Check sensor wires for cracks or damage that may indicate the presence of a rodent e Inspect the connections of both sensors on the circuit board The plugs must be clean e Unplug the sensor set at the temp high limit jumper and plug in the test sensor set Hang the test sensors over the spa side and into the water Keep in mind there is no high limit sensor protecting the heater during this test e Ifthe problem is solved replace the sensor set If the prob
23. hout shutting off the power Serious injury or damage may result e Remove the screw which mounts the blower triac TRC6 on the Millennium board e Disconnect all slip on connectors from the board relays and transformer Note Labeling these wires may help speed up reinstallation The wiring diagram should always be used to ensure proper wire placement e Remove all the screws which connect the wires to the terminal block e Remove all the screws which mount the board to the terminal block e Remove the board from the 3 plastic stand offs by gently squeezing the locking flange on each one with a pair of pliers The board should now be free and can be removed from the system box How to Replace a System Circuit Board Check all jumpers on the new board Make sure the jumpers are in the same position as the old board Make sure the new board snaps in place on the plastic board stand offs Attach the screw to the blower triac TRC6 on the Millennium board being careful not to overtighten This screw serves as a heat sink only Replace all the screws on the terminal block fingers Reconnect all the wires to the terminal block with the screws Follow the wiring diagram provided inside the cover of the system box Reconnect all slip on connectors to the board relays and transformer Follow the wiring diagram provided inside the cover of the system box Restore power to the spa at the main breaker
24. iefly Off Once a Second This indicates that the water temperature sensor is open or faulty The spa is deactivated e Unplug the sensor set at the temp high limit jumper and plug in the test sensor set Hang the test sensors over the spa side and into the water Keep in mind there is no high limit sensor protecting the heater during this test e If the 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 If the problem continues after following the above steps then replace the circuit board The Display Continually Shows Fi or the Status Heat LED is Flashing Briefly On Once a Second When this is happening the software is detecting pressure at the pressure switch without the pump running e Make sure the slice or ball valves are open If any valves are closed opening them may remove the error message from the display and the spa should operate normally e Ifthe spa does not operate normally disconnect the wire from the pressure switch e Ifthe spa operates normally turn OFF the spa system recalibrate the pressure switch if possible see page 15 If the pressure switch cannot be recalibrated replace the pressure switch Clean the area where the pressure switch is located with a metal brush Use plumber s sealant when installing a new pressure switch e Ifthe problem continues then
25. is a normal spa function no further action is necessary When the high limit sensor or an optional freeze sensor reads below 4 C the system provides freeze protection It automatically activates all of the pumps to circulate water and warm the plumbing Note An optional freeze sensor located at the pumps or other plumbing is often used in colder climates to protect against freeze conditions The Panel Display Shows Pd Power has been cut off to the spa and it is using its battery backup to preserve its settings The control panel will be disabled until power returns to the unit On the Deluxe Model with an ozone sensor this message will appear when the ozone generator is running On the Standard Model with an ozone sensor this message will flash alternately with current spa temperature when the ozone generator is not working The Panel Display flashes PHSU or PHIG On the Deluxe Model with a pH sensor refer to Note 9B in the Balboa Application Manual On the Deluxe Model without a pH sensor the jumper on positions 3 amp 4 of J20 is missing Add a jumper at J20 The Panel Display shows iL GE or Other Unexplained Error Messages This rare message is only seen in older panels without telephone type panel connectors e Usually appears when a certain device is faulty Often the ballast in an ozone generator can cause enough electrical noise in the circuit to cause this problem Pressure Switch Calibration
26. lem is not solved do not replace the sensor set e Plug in the original sensor set to verify that there is not a connection problem e Ifthe problem continues after following the above steps then replace the circuit board Temperature Sensor in the spa High limit Sensor at the heater www balboa instruments com 13 Panel Messages cont The Panel Display Shows Ini or the Status Heat LED is Flashing Briefly Off Once a Second This indicates that the high limit sensor is open or faulty The spa is deactivated e Check sensor wires for cracks or damage that may indicate the presence of a rodent e Inspect the connections of both sensors on the circuit board The plugs must be clean e Unplug the sensor set at the temp high limit jumper and plug in the test sensor set Hang the test sensors over the spa side and into the water Keep in mind there is no high limit sensor protecting the heater during this test e If the problem is solved replace the sensor set If the problem is not solved do not replace the sensor set e Plug in the original sensor set to verify that there is not a connection problem e Ifthe problem continues after following the above steps then replace the circuit board Note In rare cases rapid system overheat causes sensor error messages Be sure to rule out possible situations like no flow or no water The Panel Display Shows 5n 3 or the Status Heat LED is Flasbing Br
27. mp 2 Enable Jumper J10 Jumper 36 Standard Digital Only J7 Flow Switch Input J3 9 Aux Freeze Control Sensor Input J15 20 Pump 2 Hookup 21 Auxiliary Panel Input www balboa instruments com X 21 Super Duplex TUV Circuit Board Circuit Board Components 1 Blower Triac Use Screw For Heat Sink Only 15 Pump Low Hookup J28 Do Not Overtighten 16 Pump 2 Aux Hookup J35 2 Blower Hookup J19 17 60Hz 50Hz Jumper J13 3 Control Panel Input 18 Serial Number Model Number Designations 4 Filter Select Jumper J7 19 Soldered in Fuse gt Finger5 20 Light Fuse 12 Volt Position 6 Finger 6 21 12 Volt Spa Light Hookup J10 amp J27 7 Flow Switch Input 22 Light Fuse Position for 230 Volt 8 Aux Freeze Control Sensor Input J22 Use J27 and Common for 230 V Hookup 9 Heater Relays 23 Transformer Input 10 Temp High limit Input 24 20A 50A Jumper J8 11 Main Processor with Software Number 25 Pump 2 Enable Jumper J26 12 Ozone Hookup 13 Common Terminals J11 J15 J16 J18 14 Pump High Hookup J37 22 X 001 714 438 3820 Lite Digital TUV Circuit Board ETORO VOET RER 326 ly J5 va Z2 ALL UPRIGHT DIODES 678 SQUARE PAD POL UZ 125 SPASLIGHT IN JIS SPA LIORT OUT N ra AAE A s 1 to 100 deg EN F2 d px u 9 we SQ N Dm AN TE v ul comm U A 20 Ave Circuit Board Components 1 Control Panel Input 16 Power Input for Heater Hot J37 2 Flow Switch Input 17 Power Out
28. put to Heater J35 3 Temp High limit Input 18 Common Input to Heater Circuit J40 4 Main Processor with Software Number 19 Common Output to Heater J38 5 Common Terminals J4 J5 J7 J8 J13 J26 20 Triac Position for Variable speed Blower 6 Pump High Hookup J34 Use Screw For Heat Sink Only Do Not Overtighten 7 Pump Low Hookup J36 21 Blower Output if Available J14 8 Serial Number Model Number Designations 9 Soldered in Fuse 10 12 Volt Spa Light Hookup J15 amp J30 11 Transformer Input 12 30A 20A Jumper J8 13 Filter Select Jumper J33 14 Power Input J3 15 Power Input Fuse www balboa instruments com X 23 Notes 24 001 714 438 3820 Copyright 1999 2004 Balboa Instruments Inc 01 22 04
29. replace the circuit board The Display is Flashing Fi O When this is happening the software is detecting no pressure at the pressure switch with the pump running The following is a list of most probable causes of this message Check these first Check the water level e Remove the filter cartridge then run the spa If the message disappears then clean or replace the filter cartridge e Check the slice or ball valves be sure they are open e Make sure the pump motor is functioning properly If not use the Balboa Quick Check or a multi meter to verify system box output to the pump e Check the floor suction grills for obstructions e Check the pump to be sure it is primed and pumping properly e Check the pressure switch wire for cuts e fall of these items are in working order attempt to recalibrate the pressure switch see page 15 If the pressure switch cannot be recalibrated replace the pressure switch Clean out the area where the pressure switch is located with a metal brush Use plumber s sealant when installing a new pressure switch e Ifthe problem continues then replace the circuit board 14 001 714 438 3820 Panel Messages cont The Panel Display Shows COOL This is a normal spa function no further action is necessary The water is more than 10 C cooler than the set temperature The heater will automatically activate to provide freeze protection The Panel Display Sbows iC E This
30. rown 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 001 714 438 3820 Voltage Checks Breaker Box R C D When checking for proper voltage please keep in mind that the acceptable voltage range is 10 of the recommended voltage Acceptable voltage when 230 V is specified as the desired voltage is between 207 and 253 V A Important This service must be single phase Any abnormal voltage reading requires an electrician Do not attempt to fix problems yourself High voltage can seriously injure or kill Breaker Box Voltage Check e Set your multi meter or voltmeter for AC Volts e Make sure the R C D is off e Carefully turn on the spa circuit breaker e At the house breaker box probe the spa circuit breaker between the blue and brown wires Your meter should read 230 V e Probe between the brown and green ground wires You should also see 230 V e The voltage between the blue load neutral and the green ground wire should be approximately 0 V R C D Line in Voltage Check 230 V Dedicated System e Be sure the spa circuit breaker located in the house breaker box is on e Make sure the R C D is off e Probe the blue and brown wires The meter should read 230 V e Probe the blue and green ground wires The meter should read 0 V
31. the topside control panel e f you do not have correct voltage double check the input voltage before you replace the circuit board e If you do have correct voltage at the circuit board turn off the system power and check for a blown in line fuse Blowing the in line fuse or the power input fuse is usually a symptom of a faulty pump blower or a short in the wiring to one of those devices e If the fuse is good then replace the output connector e If the high speed pump comes on when the system calls for heat or when the system goes into a filter cycle the pump is most likely wired backwards Verify that the blue low speed and brown high speed wires are not switched in the amp connector or the pump itself e Always check to make sure all devices are plugged into the proper location Note Tf the spa light output is not detected with the Balboa Quick Check be sure to check continuity of the light fuse on the circuit board 18 001 714 438 3820 Changing a System Circuit Board 2 DE SITUATED BEN AT EE ROS NT PATAS A Important Be sure to turn the power off before replacing any component especially a circuit board A Important Do not remove and replace the circuit board unless the fault has positively been determined to be the circuit board How to Remove a System Circuit Board e Shut OFF line power to the spa at the main circuit breaker panel Do not attempt to service a spa wit
32. tor from the system box and plug in each panel into the circuit board directly and individually Test all functions with each panel separately If a Remote Panel Doesn t Work e Remove the remote panel from its location e Be sure to secure the end of the panel cable e Plug the remote panel directly into the board This removes the extension loom with its one to one connector from the circuit board and will help you determine whether you have one panel with a problem a defective gang connector a bad extension loom a bad one to one connector or a circuit board problem 12 001 714 438 3820 Panel Messages Panel Messages Panel messages are a quick clue toward solving a variety of problems Here are the most common messages and what they mean The Panel Display is Flashing GH or the Status Heat LED is Flashing 1 second on 1 second off This means that the control system is at a high limit condition and the spa is deactivated Note Overheating may occur if the low speed pump is set to operate for extended periods of time or if the incorrect pump is installed In rare cases usually warmer climates the circulation pump may also cause overheating The following is a list of most probable causes of this message Inspect these first e Check slice or ball valves Make sure that they are open e Make sure the correct pump and pressure switch are installed e Clean the filter skimmer if there is any blockage e C
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