At Your Service. Cal Spas Service Procedures. For spas built in 2010 and See next page to start troubleshooting immediately!

Transcription

1 At Your Service Cal Spas Service Procedures For spas built in 2010 and 2011 Spa Service and Troubleshooting Procedures See next page to start troubleshooting immediately!

2 Start Here! Spa Service and Troubleshooting Procedures This guide is intended for Cal Spas service technicians who have a basic knowledge of spa operation, spa construction, and electrical theory. You must be able to use basic hand tools, small power tools, and a volt meter. For basic spa troubleshooting for beginners to go page 1. To troubleshoot by symptom, go to Chapter 2 (page 3). Use the flowcharts in chapter 2 to troubleshoot symptoms such as low heat, low water pressure, or no power. To troubleshoot by message code, go to Chapter 3 (page 37). You can troubleshoot problems by following procedures according to the message codes shown on the control panel display. To troubleshoot the entertainment system, go to page Chapter 5 (page 61). Use this section if you already have an idea which component is causing the problem. Cal Spas 1462 Ninth Street Pomona, CA CAL-SPAS LTR , Rev. A 8/25/11

3 How this guide is organized Part 1: Spa Troubleshooting and Repair 1 - Basic Spa Troubleshooting Spa Symptom Troubleshooting Message Code Troubleshooting Component Removal and Installation Part 2: Entertainment Troubleshooting and Repair 5 - Entertainment Troubleshooting Spa Service and Troubleshooting Procedures 6 - Entertainment Installation Part 3: Spa Reference 7 - Spa Installation Spa Operation Circuit Diagrams and Schematics Software Configuration Part 4: Service Calls 11 - Effective Service Calls

4 Spa Service and Troubleshooting Table of Contents 1.0 Basic Spa Troubleshooting 1.1 Troubleshooting guidance For additional assistance from Cal Spas Technical Service Spa Symptom Troubleshooting 2.1 Heat symptoms Water gets warm but not hot Water does not heat at all Water is too hot (>110 F) Spa water is cooler than the temperature displayed on the topside panel Pump symptoms Pump will not prime Pump does not run, it just hums Pump makes a loud noise Pump runs but water does not flow Pump won t turn on Pump overheated and shut down Pump turns on and off frequently Pump runs constantly After spa is first delivered, pumps come on but can t be shut off Electrical symptoms Breaker keeps on shutting off Spa uses too much power (very high power bills) Control panel symptoms message or lights on control panel Numbers are missing or blank Can t read control panel at night Readout flickers during operation Ozone symptoms Ozonator does not work Diverter valve symptoms thing happens when diverter valve is turned Diverter valve is stuck Air venturi symptoms thing happens when air venturi is opened Jet symptoms Some of the jets will not turn Some of the jets pop out The jet insert will not spin Some jets are not as powerful as they used to be Acrylic symptoms There are hairline cracks on the lip of the spa There are several bubbles and blisters in the spa Leak symptoms Spa appears to be leaking iv

5 Spa Service and Troubleshooting Table of Contents There is a leak around the equipment area There is water around the pump There is no water in the equipment area, but the spa is still leaking Spa insulating foam is saturated Water quality symptoms Water is cloudy Water is oily Water is very foamy Water is harsh / caustic (causes skin reactions or rash) Spa shell has calcium build-up Spa has debris on spa floor Spa has algae growth High ph and low alkalinity Water quality troubleshooting Testing and adjusting spa water Troubleshooting water clarity problems Message Code Troubleshooting 3.1 Dry, Dr, Dy, dr HFL, LF, HL ICE, IC OHH, OHS, HH, OH SnS, Sn SA, Sb, SnA, SnB SF Pr, --F, --C Component Removal and Installation 4.1 Electro Static Discharge (ESD) Pump / Motor Smart Spa Flow Through Heater Manifold XL Heat Exchanger (Centered) Smart Spa Sensor Topside Control Panel Circuit Board Control Box Jet Inserts Ozonator Acrylic Repair Blisters, Bubbles, Cracks Replacing Light Fixture in In-ground Spas Replacing Lamp in In-ground Spas v

6 Spa Service and Troubleshooting Table of Contents 5.0 Entertainment Troubleshooting 5.1 Stereo troubleshooting symptoms Power does not turn ON The memory is erased when the power is OFF sound, or volume is very low Sound quality is poor or distorted Poor radio reception Remote control troubleshooting Power Supply Troubleshooting Amplifier Troubleshooting Power does not turn on sound is produced sound output when operating the unit with amplifiers audio Sound is bad directly after power is turned on Power LED does not turn on Status LED turns on Amplifier too hot Speaker wires shorted Internal malfunction Subwoofer Troubleshooting There is no sound from the subwoofer I get sound distortion from the subwoofer LED and Light Troubleshooting Only some of the LED lights come on The main spa light does not come on Entertainment Installation 6.1 Sony CDX-GT10M CD Player Sony CDX-HS70MW CD Player Spa Installation Volt 60A Wiring and GFCI Wiring Guidelines Volt 60A Electrical Installation V GFCI 60A and Wiring Requirements High Power Configuration for 5100DV, 6200DV, and 6300DV systems Volt 60A GFCI Wiring Diagram Volt Electrical Installation Volt 50A Electrical Installation Volt 50A RCD Wiring Diagram / 6215 Circuit Board Wiring Circuit Board Wiring Circuit Board Wiring vi

7 Spa Service and Troubleshooting Table of Contents 7.12 External Equipment Pack Plumbing In-Ground Spa Light Installation Instructions Automatic Priming of the Spa Spa Operation DV, 6200DV, 6300DV Display Messages Circuit Diagrams and Schematics 9.1 Voltage and Amp Draw Ranges DV DV DV P P OE VS VS Software Configuration 10.1 Persistent Memory and Powering Up DIP Switches and Jumpers Configuration Setting Effective Service Calls 11.1 Responding to an incoming service call Preparing for a service call vii

8 Spa Service and Troubleshooting Table of Contents viii

9 Troubleshooting guidance Before you start troubleshooting: Collect this information about the spa before you start: Spa model number Spa serial number Operating voltage Input voltage Basic Spa Troubleshooting Read the table of contents to locate the symptom. Follow the troubleshooting flowcharts in this guide. SYMPTOMS Collect these voltage readings: Low speed pump 1 amps Circulation pump with heater amps High speed pump 1 amps Pump 2 amps High speed pump 1, pump 2, and heater amps Before you call Cal Spas Technical Service: Have as much information as possible! The service technicians will want to know all symptoms, and will ask you these questions: Is there an error code on the control panel? Are all the jets open? Are the filters clean? How long has the problem occured? 1

10 SYMPTOMS 1.2. For additional assistance from Cal Spas Technical Service Dealers and service technicians are welcome to call us. We are ready to help you whenever we can. You can also contact us by For technical support: For claims and warranty: For parts assistance: For returned goods authorizations: For all other customer concerns: 2

11 Spa Symptom Troubleshooting Heat symptoms Water gets warm but not hot Possible causes can include: Is the temperature turned up high enough? Raise temperature on topside control. Follow directions in owner s manual Is the cover on? The cover will keep heat in the spa and help keep heat from escaping. Make sure cover is on at all times when spa is not in use. See owner s manual for cover info. Is the heater element or XL Heat Exchanger coated with scale? If scale has deposited on the heater element or on the inside of the XL Heat Exchanger, the heat will not transfer to the water properly. If this is the case, the element or heater will have to be replaced. Is the heater element old and / or deteriorated? If the element is subjected to chemical abuse, it will loose its ability to generate heat. The 240 volt 5.5 kw elements and heat exchangers should test at least 10.5 ohms to heat properly. If they test lower than this, replace the element or XL Heat Exchanger. Is the filtration time adequate with the spa in economy mode? If spa is in Economy mode, spa only heats during filter cycle, increase the filtration time or set the spa to standard mode (see owner s manual) Does the temperature reset when the power goes off? The automatic default for temperature is 100 F even when its set higher. If power goes off then comes back on, the spa will reset to factory default temperature of 100 F. (Some newer models have memory to prevent this from happening.) SYMPTOMS 3

12 SYMPTOMS Water does not heat at all Is this a new delivery? Is this an older spa? Causes can include: Does the spa have enough water? Check water level. t enough water in spa will keep heater from operating. Fill spa to proper level and make sure pump is primed. See Prime Pump / Water Flow troubleshooting flowchart for further information. Is the incoming voltage correct? Check for Incorrect voltage. On 240 Volt or 230 Volt spas, there needs to be correct voltage (±10%). Contact qualified electrician to provide proper electrical supply. See 240 volt wiring diagram for further information. Is the filtration time sufficient to allow for heating of spa? Filtration times or mode of operation is incorrect. See owners manual for proper settings. Reset filtration times or operational mode to allow for time to heat spa. Are any error codes displayed on topside? Follow appropriate error message flowchart. Follow procedures described in flowchart. Causes can include: When was the filter cleaned or changed? Dirty or clogged filter will restrict water flow and shut down heater. Clean or replace filter to re-establish water flow. Is the water level correct? If the water level is low, this can shut down the heater. Fill spa to proper water level. Is there a display message on the topside panel? FL means the pressure switch is defective. This will shut down the heater. Follow Pressure Switch / Water Flow troubleshooting guide to correct the problem. 4

13 Water is too hot (>110 F) Possible causes can include: What is the temperature set at? If someone raised the temperature on the topside panel, the spa will stay at the new temperature. Turn set temperature down to desired temperature. Follow owner s manual for additional information. What is the filtration time set at? If the filtration time is set too long, the equipment area gets hot. During warm months, running the filter cycle for extended lengths of time can cause heat creep where heat transfers to the water from the equipment area heating up. Turn the filtration cycles down during the warm months. Is there adequate cabinet ventilation? Heat buildup from equipment needs to be vented, if there are obstructions to the ventilation or not enough venting, this can also create heat creep. Make sure the cabinet ventilation is unobstructed. If there is debris, remove it and make sure the air flow around the cabinet is open. How long have the high speed pumps been running? If the high speed pumps run too long, they generate heat from the motor and the friction of the impeller churning the water. Given enough time, friction from the pump can overheat water. During warm months, limit pump cycles to 1 or 2 (15 minutes to 30 minutes) to help avoid water and equipment overheating. SYMPTOMS 5

14 SYMPTOMS Spa water is cooler than the temperature displayed on the topside panel Possible causes can include: The water temperature sensor is probably reading heat in the equipment area instead of the water temperature. This will give the controls false information and cause the heater to shut off due to the false information. Add extra insulation on the temperature sensor. This forces the sensor to read the water temperature accurately and the controls will react accordingly. 6

15 Pump will not prime or low water flow. Pump symptoms Pump will not prime Is the motor running? Follow "Pump won t turn on" flowchart Did the pump prime? SYMPTOMS See page 10 Is the spa at the proper water level? Add water, turn "Jets" on. Did the pump prime? Are the gate valves open? Open all gate valves by pulling handles all the way up. Did the pump prime? Is the filter dirty or clogged? Clean or replace filter cartridge(s). Did the pump prime? Are all of the jets open? Turn all jets to the full "open" position. Did the pump prime? Is water flowing through the jets? Pump must be manually primed. Loosen union nut on front of pump to bleed air out. Retighten and turn "Jets" on. Pump will now automatically prime. Did the pump prime? Call Cal Spas service technician Return to normal operation 7

16 SYMPTOMS Pump does not run, it just hums Does the pump shaft turn? If NO, possible causes include: Something could be stuck in the impeller. Take the wet end apart and remove obstruction. Bearings may have locked up. If so, you will need to replace the pump / motor assembly. Ice in the wet end. If the weather is freezing, you need to allow it to thaw then retry pump. If YES, possible causes include: Faulty capacitor. Change out the pump / motor assembly. Faulty motor switch. Change out the pump / motor assembly. Incorrect voltage. Make sure incoming voltage equals name plate voltage Pump makes a loud noise Does the pump make a grinding noise? Does the pump make a squealing or high pitched sound? If YES, then: If pump / motor assembly is older, replace the bearings or replace the pump / motor assembly The impeller could be broken. If there is no water flow into spa, check impeller. If the impeller is broken, replace it with a new one. There may be an obstruction in wet end. Foreign objects will grind against impeller. Open wet end and remove object. If YES, then: Check whether something is rubbing against the shaft. Inspect the shaft by the pump and remove any foreign objects. Check for incorrect voltage. Too high voltage can make motor run too fast. Check voltage and correct. 8

17 Pump runs but water does not flow Is the spa a new delivery? If YES, possible causes can include: Pump is air locked Follow the prime pump / no water flow troubleshooting flowchart. Gate valves are closed. Pull up to open all the way to allow water to flow to pump. Jets are turned off. Rotate jet inserts into the open position. If NO, possible causes can include: Dirty or clogged filter. Clean filter or replace with new cartridge. Impeller may be broken. Change defective impeller with new one. Clogged pump. During fall, leaves can clog the pump. Clean out the pump and impeller. Obstruction in the line. If the drain line gets clogged, the pump cannot get water. Check for obstruction and remove it. SYMPTOMS 9

18 Pump won t turn on SYMPTOMS Pump will not turn on Is there power to the spa? Reset breaker. Does the motor run? Is the pump plugged all the way in? Plug pump completely in. Make sure connection is tight. Does the motor run? Is the topside panel operational? Replace topside panel. Does the motor run? Does the pump fuse have continuity? Replace pump fuse. Does the motor run? Are the pump wires secure on the circuit board? Tighten all wire connections. Does the motor run? Plug in test motor. Does the test motor run? Replace pump / motor assembly. Replace circuit board. Does the motor run? Call Cal Spas service technician Return to normal operation 10

19 Pump overheated and shut down Pump overheated and shut down Has the pump been running more than 30 minutes? Allow the pump to cool and press "Jets button to restart pump. Has the pump been running more than 30 minutes? SYMPTOMS Are the motor vent holes obstructed? Remove obstructions (leaves, grass, debris, etc.) Did the pump restart? Are the gate valves open? Open gate valves to the full open position. Did the pump restart? Is the filter cartridge clean? Clean or replace filter cartridge(s). Did the pump restart? Is the spa receiving proper voltage? Restore proper line voltage. (240 Volts +/- 10%) (120 Volts +/- 10%) Did the pump restart? Is the motor drawing normal amperage? Replace pump assembly. Did the pump restart? Is cabinet ventilation obstructed? When the outside air is extremely hot or humid, additional cabinet ventilation may be necessary to carry heat away from equipment. Increase ventilation if needed. As an alternative, operate pumps at a time of day when heat and humidity are lower. Remove obstructions (leaves, greass, debris, etc.) Did the pump restart? Call Cal Spas service technician Return to normal operation 11

20 SYMPTOMS Pump turns on and off frequently When spa is in standard mode, if the pump turns on and off frequently, the sensor is trying to maintain the spa s temperature. The water temperature sensor is +/- 1 degree accurate. Switch to economy mode or check sensor for proper water sensor placement and insulation Pump runs constantly The circuit board may have been changed out recently. One of the most common mistakes during a circuit board change out is a sensor that is plugged into the wrong place. If another sensor is plugged into the freeze sensor point, the pumps will run constantly until the wrong plug-in is corrected. Check plug placement and change to proper pin. See series schematic for proper pin After spa is first delivered, pumps come on but can t be shut off If there was freezing weather during the delivery, the hi-limit / freeze sensor may have detected a possible freeze condition and activated freeze control. All pumps will continue to run on high speed until the freeze condition passes. During this time, there will be no topside control over the pumps. When the freeze condition passes, the pumps will automatically shut down and topside control will be restored. 12

21 2.3. Electrical symptoms GFCI breaker tripped Breaker keeps on shutting off Is the load neutral wire coming from the spa connected to the GFCI load neutral connection? Connect the load neutral wire from the spa to the GFCI load neutral connection. Reset GFCI. Breaker still tripping? SYMPTOMS Are the incoming neutral wire and the spa ground connected together? Separate incoming neutral and spa ground wires. Reset GFCI. Breaker still tripping? Unplug all components from control box. Reset GFCI. Breaker still tripping? Plug components back into control box in the following order, one at a time until breaker trips. 1. Pump 1 or Circulation pump (Allow time for heater to engage) 2. Pumps 2, 3, 4, and 5 3. Blower 4. Ozone generator 5. Stereo 6. Alternate lighting 7. Misters If breaker trips, replace component that caused breaker to trip when plugged in. Reset GFCI. Disconnect heater wires from control box or circuit board. Reset GFCI. Breaker still tripping? Replace heater. Disconnect transformer from circuit board and carefully check to see if any wires are touching. Reset GFCI. GFCI still tripping? Replace transformer or if transformer is permanently attached to board, replace entire board. Reset GFCI. Problem is in GFCI or incoming wires. Contact a certified electrician to correct problem. Return to normal operation 13

22 SYMPTOMS All GFCI breakers are designed to provide instantaneous protection against stray voltage. If the GFCI breaker detects stray voltage -- regardless of where it comes from -- it will trip. Because of this fact, all GFCI breakers are designed to err on the side of caution. This can lead to nuisance or intermittent tripping. It is critical that all wiring instructions in the owner s manual be followed--with no exceptions. The GFCI breaker uses the load neutral as its source of electrical protection information. It only takes.0005 of an amp neutral load disruption to trip this type of breaker. For example, one molecule of water will trip a GFCI breaker. Common Causes and Recommended Actions GFCI was installed incorrectly The length of run to spa was excessive The wire size is not the same The spa is drawing power from a common breaker The GFCI breaker trips during thunderstorms The GFCI breaker trips after the spa has been used After the GFCI breaker trips, it won t immediately reset. If the breaker sits for a day, it will reset Separate the spa ground wire and the spa neutral wire at the GFCI breaker so the grounding system doesn t crossover to the neutral system giving the GFCI breaker false load information. Follow the information on the GFCI troubleshooting flowchart. Make sure on runs over 80 (or over 20 meters for international spas) that the wire size is increased to handle the loss of current. It is common for electricians, in other applications, to use different size power wires and different size neutral or ground wires. In a spa application, all 4 wires need to be the same size so there is no difference between voltage travel and current loss. It is important to make sure that the spa is the only item on the supply breaker. If other items are attached to the same breaker, they can draw power away from the spa and cause damage to the spa s equipment or trip the GFCI breaker. If lightning or static electricity is present, the GFCI breaker may sense a potential problem and trip. If this happens, simply reset the breaker after the storm has passed. In storm prone areas, it is a good idea to have a whole house surge suppressor added to the incoming lines to protect against this kind of problem. This is usually caused by water getting onto equipment or equipment connections that the GFCI is connected to. Remember it only takes one drop of water in the right place for the GFCI to think there is a problem and shut down. This is normally a water situation. If the GFCI breaker tripped due to water on the equipment or equipment plugs, when the water dries off, the breaker can be reset. 14

23 Spa uses too much power (very high power bills) Is the spa covered when not being used? If the cover is left off the spa, the heater will continue to heat the water but most of the heat will escape. This could result in extremely high electric bills. Provide a good insulated cover that blankets the entire surface area of the spa. (See parts source book for cover specs.) SYMPTOMS Is there any other appliances installed at the same time as the spa? Other appliances can draw a lot of electricity at the same time as the spa. The spa is very energy efficient and should not cause a large rise in electric bills. In most cases, when carefully investigated, there is always another cause for large electric bills What time of the year is it? Sometimes, weather plays a factor in the electric cost. Common sense dictates that it is going to cost more to operate a spa if it s cold outside with the wind blowing versus hot outside with no wind. Keep the insulated cover on the spa and if the spa is located in an extreme climate, switch to a deluxe cover and extra insulation for additional energy savings. (See parts source book for deluxe cover options.) What temperature do you run your spa at? The higher the operating temperature of the spa, the more electricity it will use to stay warm. Try turning the spa down when you are not using it, especially if not using the spa every day. (See owner s manual for helpful hints on energy savings.) How much filtration time do you have on your spa? If you don t need extra filtration time on your spa, there is no reason to pay for the pumps to run. Adjust the filtration time down based on your usage. (See owner s manual for filtration instructions.) 15

24 SYMPTOMS Control panel symptoms message or lights on control panel Possible Causes Can Include: Topside panel not plugged in. Wrong topside control panel. Topside control panel wire is damaged. Topside control has no power. Check connection point to make sure connection is tight. Make sure topside is common to equipment being controlled. Check entire wire for damage. Rodents only need to bite the wire to make the topside defective. Replace topside if necessary. Make sure incoming power is correct to spa. Plug in known good topside. If new topside works, replace topside. If not, check transformer. If transformer is good, replace circuit board Numbers are missing or blank Check to make sure connection is clean, moisture and dirt will create problems with the readout. Clean them carefully and re-plug topside back in Can t read control panel at night If topside has backlights, they may be burned out and need to be replaced Readout flickers during operation Check for voltage problems, especially low voltage. 16

25 Is the spa s filtration cycle on? Is the topside control ozone indicator light on? What if the topside control doesn t have an ozone indicator light? How often should I change the ozone cell cartridge? Is the ozonator light supposed to glow at all times? Ozone symptoms Ozonator does not work The ozone system is tied to the filtration cycle. If the spa isn t filtering, the ozone system will not be on. Check to see if the spa is filtering. If it isn t or you are not sure, shut the power off to the spa. After 10 seconds, power the spa back up. The spa s control will go through a system check then turn the filter pump on. (depending on the model, this can happen quickly or take up to 5 minutes.) When the spa controls call for ozone, the indicator light on the topside panel (if equipped) will illuminate, indicating that power is going to the ozone machine. The topside control on most models will indicate that power is being sent to the ozone machine with an illuminated LED. To check the ozone indicator, shut the power off to the spa. After 10 seconds, power the spa back up. The spa s control will go through a system check then turn the filter pump on. (depending on the model, this can happen quickly or take up to 5 minutes.) When the spa controls call for ozone, the indicator light on the topside panel (if equipped) will illuminate indicating that power is going to the ozone machine. This indicator light does not tell you that the ozone machine is good or bad, only that power is going to the machine. Most topside controls have some sort of indicator. However on some models the topside doesn t have this capability. If there is no indicator light, look at the ozone machine and there will be a purple / blue glow at the cell. This tells you that the ozone machine is receiving power and generating ozone. The ozone machine has a lifetime warranty on the electronics. The ozone cell cartridge should be replaced yearly. This is a replaceable item and is not included in the lifetime warranty., only when the filtration cycle is on. SYMPTOMS 17

26 SYMPTOMS Diverter valve symptoms thing happens when diverter valve is turned How old is the spa? Is there water flow going to the valve? Is the valve leaking when it is turning? Is the pump that supplies water to the valve operating? Is the shaft running from the valve handle to the bottom valve broken? The year model of the spa determines the type of diverter valve that was used. On older spas, the diverter valve was in the equipment area. In some models, the diverter valve was part of the jets. On newer spas, the diverter valves are located at the top of the spa. This information helps to determine the potential problem. If there is no water flow going to the valve, you will feel little or no resistance at the valve. Make sure that water is flowing through the valve before determining there is a problem. If the valve leaks when turned, the internal insert is probably broken and needs to be replaced. The insert presses against the seal to prevent water from coming out. The valve insert will need to be replaced. If the pump that supplies water to the valve is not running, there will be no water for the diverter valve to divert. Listen and check the topside panel for indication that the pump should be running. On older spas, the handle is attached to a U-joint, which is attached to a shaft, which attached to another U-joint, and then attaches to the valve. If any of these attachment points is broken, the valve handle will just spin but the valve won t turn. Locate the broken component and replace it. 18

27 Diverter valve is stuck Does the diverter valve move when the pump is turned ON? Does the diverter valve move when the pump is turned OFF? On newer spas, the diverter valve is designed to move even with the force of the water flowing against it. If the valve is stuck, it is probably calcium buildup, scale or grit lodged between the valve insert and the valve body. Turn the power off. Lift the handle portion of the valve straight up from the valve. Unscrew the cap to expose the insert. Grab the stem of the insert and pull straight up. When the insert comes out, inspect the outer sides. If there are deep scratches or embedded objects, replace the insert. If there is only calcium buildup, scale or minor scratches, use 220 grit wet / dry sandpaper to smooth out the sides of the insert. Also sand the internal area where the insert rubs against the body of the valve. On older spas, the diverter valves were not designed to turn against the force of the water. The pump must be turned off before the valve will turn. If the valve is still stuck, remove the inserts and replace or sand as in the procedures above. Some diverter valves on older model spas are below the water level. It will be necessary to drain the spa first. SYMPTOMS 19

28 SYMPTOMS Air venturi symptoms thing happens when air venturi is opened How old is the spa? Is the air venturi attached to the jets that are flowing? Does the air venturi have water coming out of it? Is there suction from the top of the air venturi? The age of the spa will determine the location and type of the air venturi and attached components. This information is vital to troubleshooting the problem. If the spa has multiple air venturis, make sure that the one that you think is the problem is actually attached to the jets with no venturi. Check by turning off and on all venturis to determine which goes where. On older spas, when there was a blockage at the jet (for instance an acorn) the water flow would hit the blockage and reverse direction. The water would flow out of the air venturi as it was the path of least resistance. Remove the obstruction to re-establish water flow to the jet. This will also create the venturi effect and re-establish the air flow. Another common scenario for older hot tubs was the gaskets used to separate water and air would fail. When this happens, the water would come out of the air venturi. The repair calls for the gaskets to be replaced or new jets need to be installed. Make sure that the air venturi has suction. Unscrew or pop the top off the air venture and feel or listen for air suction. If you can t determine if it is working, blow into the air venturi and watch where the bubbles come out. This will also dislodge any foreign objects that have gotten into the air venturi intake. 20

29 Jet symptoms Some of the jets will not turn Do you hear the pump running? Is the pump that flows to these jets on high speed? Is the jet housing turned all the way on? Is the water flow valve diverting water flow to this group of jets? Listen for the sound of the motor. If the pump isn t running, try pushing the jets button on the topside. If the pump that supplies water to the jets isn t on high speed, there won t be enough water to operate the jets. Press the jets button to activate the pump on high speed. Rotate outer jet insert housing to turn jet on. Diverter valves direct water towards the jets to allow water flow to reach them. Depending on the model, your spa may have one or more of these diverter valves. Experiment by turning the handle on the valves to see where the water goes. SYMPTOMS Some of the jets pop out Are the jets being turned past their attachment point? Are the jet inserts clipped in all the way? Have there been any chemical issues to weaken the jet inserts? Is the correct jet insert used? The jet inserts are designed to come out if you rotate them past a certain point especially with the pumps on high speed. To help prevent this, teach people using the spa not to play with the jets. Turn them to the stopping point only-not past. By pushing in on the jet insert, you should hear a click. This indicates that the insert is installed all the way into position. If there is no click, the jet is in the wrong way and will pop out. If the jets are subjected to extreme chemical conditions or abuse, they will weaken and fail. The jet insert will have to be replaced. This is a non-warranty condition. If the insert is the wrong size or type for the jet body, it will not stay in place. Change the insert to the correct size or type. te: Many inserts look alike and have the same size face. The nozzle in the back is where the clips are located and is what has to match the jet body. 21

30 SYMPTOMS The jet insert will not spin Is the jet insert turned on all the way? Does the jet contain a spinning type jet insert? Is there intermittent spinning action? On many spinner type jets, there is a certain water flow that must be present to make the jet insert spin. If the jet insert is not turned on all the way, or a diverter valve isn t allowing full water flow to that particular jet insert, the spinning action will not be achieved or will be intermittent. Establish water flow at full pressure to the jet insert for optimum performance. Jet inserts come in many different shapes, sizes, and styles. Spinner jets usually have an internal component that spins or causes the water to spin. If the jet insert doesn t have that component, the jet will produce water flow but not the spinning action that is usually associated with spinner jets. Change the jet insert to a spinner type of insert (if applicable) to achieve spinning action. If the spinner insert hangs up or spins slowly, it is probably due to debris in the spinner insert. Remove the jet insert and clean the debris out of the spinning mechanism. Use a spray hose to spray out grit from inside the insert. If it still turns intermittently, the insert will have to be replaced. Long hair or lint can also wind up around the shaft of the spinning insert and cause a slowdown in spinning action. Turn the insert shaft counter-clockwise to unwind hair and long debris. Replace insert if necessary. 22

31 Some jets are not as powerful as they used to be Check to see if the air venturi is opened. On all spas, the mixture of air and water makes the jets powerful. If the air is not added or is taken away, the jets will lose some of their force Make sure the air venturi is turned on. If the jet has an obstruction, remove it to allow full flow. 3. See the air venturi troubleshooting section on page 20. SYMPTOMS 23

32 SYMPTOMS How old is unit? Acrylic symptoms There are hairline cracks on the lip of the spa Is the spa kept covered when not in use? What do the chemicals read? Has there been a history of chemical abuse? Is the spa setting flat and level? Is the base fully supported? The older the spa, the more likely that some type of outside damage initiated the cracks. Sunlight, freezing temperatures, and harsh chemicals are just a few of the common causes. Repair cracks using acrylic repair procedures. This will help prevent some of the causes. Provide a good cover to help prevent further damage and repair cracks using acrylic repair procedures Harsh chemicals and chemical abuse (especially low ph) are one of the biggest causes of cracking of acrylic. Follow the Cal Spas Clear Water Plan to prevent future chemical damage. Repair cracks using acrylic repair procedures. There will always be other evidence of chemical abuse. Check for the bottom of the cover deteriorated or the jets will be bleached or the pillows will be destroyed. Follow the Cal Spas Clear Water Plan to prevent future chemical damage. Repair cracks using acrylic repair procedures If the foundation that the spa is sitting on has a bow or warp in it, the weight of the water will cause the spa to conform to the shape of the foundation. This will cause cracking due to stress. Re-level and re-support the foundation. Repair cracks using acrylic repair procedures. If the base of the spa isn t supported or has rotted away, over time the weight of the water will cause stress cracks. Re-support or re-build the base to eliminate stress and repair cracks with acrylic repair procedures. 24

33 How old is unit? There are several bubbles and blisters in the spa Is the spa kept covered when not in use? What do the chemicals read? Has there been a history of chemical abuse? What chemicals do you use? Do you let chemicals set on the bottom of your tub? The older the spa, the more likely that some type of outside damage created the blisters or bubbles. Sunlight, freezing temps, and harsh chemicals are just a few of the common causes. Repair blisters using acrylic repair procedures. This will help prevent some of the causes. Provide a good cover to help prevent further damage and repair cracks using acrylic repair procedures Harsh chemicals and chemical abuse (especially low ph) are one of the biggest causes of blisters and bubbles in the acrylic. Follow the Cal Spas Clear Water Plan to prevent future chemical damage. Repair blisters using acrylic repair procedures. There will always be other evidence of chemical abuse. Check for the bottom of the cover deteriorated or the jets will be bleached or the pillows will be destroyed. Different types and brands of chemicals will react differently in spa water. If you use pool chemicals in your spa, or chemicals that are not made for warm water, you can create surface conditions on the acrylic leading to blisters. Switch to using only chemicals that are made for your spa and follow the Cal Spas Clear Water Plan. Repair blisters using acrylic repair procedures. When you add chemicals, if you allow the chemicals to set on the bottom of your spa (especially bromine tablets), the chemical reaction can create enough heat to cause a blister or bubble. Never let tablet chemicals set on the bottom of the spa. Use a floater to dispense these types of chemicals into the spa water. SYMPTOMS 25

34 SYMPTOMS Leak symptoms Spa appears to be leaking How much water is the spa losing? Is the water area just a wet spot or puddle? Has it rained in the last 48 hours? Is the lawn sprinkler spraying towards the spa? Is the cover on and tight? Is the water trailing away from the spa? By knowing how much water the spa has lost in a given period, it can help determine if the spa is actually leaking or not. Place a mark (piece of tape or grease pencil) at the water line of the spa. With normal use, observe the water level and make notes of the amount of water loss (if any) in 24hrs, then 7 days. During normal use, the spa can lose as much as ¼ -1/2 per week. If the measurements indicate more than this, there are still other questions that need to be asked before determining the spa is leaking. If the water area is just a wet spot or a puddle, the spa is probably not leaking. Most leaks leave a trail of water running away from the spa. Before determining if spa is leaking, have customer observe the spa for one week to see if the water area shrinks or dries up. Rainwater will collect under the spa and slowly seep out. This is especially true with spas that have full foam insulation or solid bottoms. If it has rained recently and the water is only a puddle or wet spot, the spa is most likely not leaking. Lawn sprinklers (like rain) will add water that collects under the spa. Because most sprinklers are automatic and sometimes operate at night, sprinklers can be a major contributor to water under the spa that is often forgotten. If the sprinklers are directed at the spa or even close to it, they should be re-directed so they don t spray on the spa. If the cover is not on or tight, the spa water s evaporation rate will increase significantly making it appear that water is leaking out. Another situation that occurs if the cover does not fit well is the condensation that forms on the bottom of the cover can drip off the cover and collect beside the spa, appearing as a leak. This condition is usually more noticeable during the cooler months. To correct both conditions, make sure the cover is in good shape, fits well, and is on whenever the spa is not being used. If the water is actually trailing away from the spa on a constant basis, then the spa is probably leaking. If there is moss or algae growing along the water trail, this indicates a fresh flow of water and most likely a leak. Verify that external conditions are not the cause of the trailing water. (rain, sprinklers, or cover condensation) before further leak investigation. 26

35 There is a leak around the equipment area Is there water in the equipment area when the power is off? Is there water in the equipment area when the pumps are running? Turn the power off to the spa. Check the floor of the equipment area with a flashlight. Look for evidence of leaking including moisture, standing water, or white scale buildups (usually close to the pump area). Use a mirror to inspect hard to reach areas. Pay close attention to the unions and pumps. If leaks are found at unions, tighten connections or inspect for pinched gasket / o-ring. Replace if necessary. If other leaks are found, repair as necessary. If there is no leak found with the power off, turn the power on and inspect the equipment area again this time with all pumps on high speed. Pay close attention for any noticeable drips from connections in the equipment area. Some drips are slow and hard to see. If you suspect a leak but cannot visually confirm, take a piece of dry paper towel and wipe around the fitting / connection. If the paper towel wipes dry, there is no leak. If the paper towel shows moisture, then the fitting / connection is probably leaking and needs repair. SYMPTOMS There is water around the pump Does the water leak when the pump is on? Carefully inspect the area between the pump and motor where the shaft seal is. If the water leaks from this area when the pump is running, this is a shaft seal leak. The seal that keeps the water from the pump out of the motor has failed. This type of leak will only appear when the pump is running. If shaft seal leak is found, replace pump or shaft seal. If this area leaks when the pump is turned off, there is probably a crack somewhere on the wet end or the wet end gasket seal has failed. Replace pump or repair as necessary. 27

36 SYMPTOMS There is no water in the equipment area, but the spa is still leaking Has the spa been subjected to temperature extremes? If the spa has been subjected to overheat conditions, the plastic fittings can warp and lose their structural integrity. This will cause leaks as gaskets can t seal or silicone pulls loose. If a fitting is found that has been subjected to overheating, replace the fitting with a new one. If the spa has been subjected to freezing conditions, anywhere that water froze is a potential leak. More common areas of potential freeze damage include: Pump wet ends, heater unions, drain hose connections, and any plastic fitting (manifold, check valve, etc.) near the bottom of the shell. If a part has cracked due to freeze damage, it should be replaced Replace the damaged fitting, don t just repair the fitting as the freeze stress has weakened the entire fitting Spa insulating foam is saturated Does the water appear to come from a specific side of the spa? Will this hurt the spa? Will his cause mildew or algae to grow? Most leaks will travel to the low side of the spa. Pull the cabinet panel from that side. Inspect the internal components for evidence of leaks. Trace the leak to its source. If the leak is traced to underneath the spa, it may be necessary to drain and tip the spa on its side to repair. Confirm that this is needed before proceeding. Make repair as necessary. The insulating foam used at Cal Spas is expanding polyurethane. It will not deteriorate even if it is wet. The wet foam will also not hurt the other structural components of the spa. If the customer wants the foam to dry, leave the cabinet side panel off for a few days to allow for additional drying to take place. Take care to replace the cabinet panel before rain or freezing weather occurs. The saturated foam from a leak in the spa contains sanitizers that were in the spa water at the time of the leak. These sanitizers inhibit mildew growth in the foam, inside the cavity of the spa. On the outside of the spa, sunlight and fresh air will inhibit the growth of mildew. On the outside of the spa, if water is present on a continuous basis where sunlight can reach, there may be algae growth on the wet area. If you take away the water source, the algae will disappear. Because sunlight can t get to the inside of the spa cavity, algae growth is non-existent. 28

37 Possible Causes Water quality symptoms Water is cloudy Cloudy water is a common complaint. The number one cause of cloudy water is the spa user and what they bring into the spa. Spa users often bring contaminants with them into the spa on their clothes and skin where it remains afterwards. It can be prevented, however, by observing a few precautions. SYMPTOMS Prevention and Treatment Never wash the clothes that you wear into the spa in laundry detergent or fabric softener. Laundry detergent and fabric softener stays in your clothes no matter how well you rinse them. This causes cloudy and foamy water that is almost impossible to clean up. The only thing you can do is wait for it to eventually filter out. Adding Spa Brite in this case will only further delay the spas ability to clear-up. Never enter the spa with sunscreen or lotion on your skin. Oil is very difficult to remove from the water and can cause a reaction with other chemicals that you may add to your spa causing a cloudy water condition. It is best to rinse off prior to entering the spa. Use caution when adding any chemicals to correct a problem. Most cloudy water problems are made worse by the spa owner adding chemical after chemical to correct a cloudy water problem that normally would have cleared up with a little Oxidizer Shock and filtration time. Remember that swimming pool chemicals are completely different than spa chemicals. Entering a spa with wet clothes from a swimming pool can cause a possible chemical reaction to either the spa user and / or the spa water. Always rinse thoroughly when transferring between a swimming pool and spa. Clean the spas filters regularly as described in the Cal Spas Clear Water Plan. Filter problems Microscopic particles too small to filter out. High TDS levels High total alkalinity High ph levels High TDS levels Inspect filter cartridge for tearing and cracking. See section on filters. Test and adjust all chemicals and add 2 oz. of Spa Bright and Clear to cause the particles to combine together so they can be filtered out. Test all chemical levels and make the appropriate adjustments. 29

38 SYMPTOMS Water is oily Possible Causes This is caused by body oil, perspiration, lotions and tanning oil accumulating in the spa. Enzyme Oil Gone is the chemical that will help break-down excessive amounts of body and oils in the spa water. Treatment Add ½ oz of Enzyme Oil Gone to a spa running on filter speed. Allow spa to filter until the spa water no longer feels or looks oily. We recommend placing your spa in filter mode FC (24 Hour Filtration Mode) during this time. You may find the need to add this product to your weekly chemical maintenance plan. If so, simply repeat step once a week. (Weekly dosages do not generally require additional filtration time.) Water is very foamy Possible Causes Foamy water is the product of body oils reacting with the natural alkalinity of the water. High bather load and prolonged bathing sessions can add to the magnitude of the problem. Soft water actually increases the foaming problem and high ph increases the soap formation. Do not use soft water in a spa. Very hard water, on the other hand, can result in soap scum formation. Adding anti-foam will temporarily eliminate the foam. Good sanitation requires that all foam be eliminated from time to time. Adding an enzyme treatment periodically can help digest the body oils and reduce the soap formation. The presence of an ozonator can help destroy the body oils over a period of time and it turn can lessen the foaming. It would be a very worthwhile addition, if you don t have one. Having burnt-out chemicals, bacteria, and other organic waste in a spa can cause water to have an odor. This can be prevented by using one ounce of oxidizer shock per week. Prevention and Treatment Spa water will not clean or clear-up overnight. Cloudy water requires proper identification, the correct treatment, and plenty of filtration Identify the water clarity issue first: is it soap, oil, bacterial, or chemical imbalance? Select the proper treatment. Clean the filter cartridge and increase the amount of filtration until the water clears-up. Add 1 oz. of Oxidizer shock at a time, in 30 minute intervals, with the spa cover at least half off with all the jet on high speed. 30

39 Laundry detergent residual in swimwear. Excess organic contaminants Low Total Hardness High Total Hardness Excess bromine Run an extra rinse cycle on the washing machine or re-rinse well by hand. Some organic matter is prone to causing foamy water as it breaks down in the filter (maple leaves especially). Generally using Spa Foam Down to break up the contaminants, then Spa Bright and Clear to help filter them away followed by thoroughly cleaning your filter will clear up the problem. It may however be necessary to drain and refill your spa if the foaming is quite excessive. Test water with a Total Hardness Test Kit and if necessary increase with Calcium Booster. Test water with a Total Hardness Test Kit. If high, change the water. Generally the water will also have a green tint to it. The spa will need to be drained and refilled, and the bromine feeder adjusted correctly. SYMPTOMS Water is harsh / caustic (causes skin reactions or rash) Possible Causes You are not using your Cal Spas Oxidizer Shock enough and/or your sanitizer level is too high. Because the spa and its chemicals will strip some of your bodies oils away we recommend that you use moisturizer after spa use. If you continue to experience skin irritation, please see your doctor. It may be caused by improper ph or total alkalinity levels. Test all chemical levels and make the appropriate adjustments. If eye irritation is a problem, check for low sanitizer levels or excess combined chlorine. Test all chemical levels with an accurate test kit and make the appropriate adjustments. Shock the spa water Spa shell has calcium build-up This is caused by to high calcium level in the water. Hard water contains calcium, which is necessary to prevent foamy water, but too much calcium may tend to build up on the shell. Reduce the calcium level in the water to between 100 and 200 ppm. Use Cal Spas Stain and Scale Prevention Spa has debris on spa floor The debris at the bottom of the spa are oxidized solids that were in the water and are now visible. Spas equipped with the Quest 2000 Ozonator will produce these oxidized contaminants after initial fill up and water additions. Simply vacuum them out as part of your weekly plan. 31

40 SYMPTOMS Spa has algae growth Algae growth may be the result of low sanitizer levels. Shock the spa s water. Brush the spa walls. Run the filter for a 24-hour period to increase distribution of sanitizer and add spa algaecide High ph and low alkalinity Adjust alkalinity first, even if it continues to throw off the ph. Use ph / Alkalinity Up or ph / Alkalinity Down to adjust and stabilize the total alkalinity Level. This will make it easier to adjust the ph levels later and allow them to remain stable longer. 32

41 Water quality troubleshooting Testing and adjusting spa water You have two types of testing methods to choose from: The reagent test kit is a method which provides a high level of accuracy. It is available in either liquid or tablet form. Test strips are a convenient testing method commonly used by spa owners. SYMPTOMS Testing For: Ideal Range (ppm) Chemicals To Use: Minimum Maximum To Raise To Lower Total Alkalinity ph-alkalinity Up ph-alkaliity Down Calcium Hardness Liquid Hardness Increaser Stain and Scale Defense ph ph-alkalinity Up ph-alkaliity Down Balancing the Total Alkalinity Total alkalinity (TA) is the measure of the total levels of carbonates, bicarbonates, hydroxides, and other alkaline substances in the water. TA can be considered a ph buffer. It is the measure of the ability of the water to resist changes in ph level. The recommended total alkalinity is ppm. If the TA is too low, the ph level will fluctuate widely from high to low. Low TA can be corrected by adding Cal Spas ph-alkalinity Up. If the TA is too high, the ph level will tend to be too high and may be difficult to bring down. High TA can be corrected by adding Cal Spas ph-alkalinity Down. When the TA is balanced, it normally remains stable, although adding water with high or low alkalinity will raise or lower the TA level. Balancing the Calcium Hardness Calcium hardness (CH) is a measure of the total amount of dissolved calcium in the water. Calcium helps control the corrosive nature of the spa s water and is why soft water is not recommended. The low calcium content of soft water is very corrosive to the equipment and can cause staining of the spa shell. The recommended calcium hardness is ppm. If the CH is too low, add Cal Spas Liquid Hardness Increaser. If the CH is too high, dilute the spa water with soft water or, if this is not available, add Cal Spas Stain and Scale Defense. When the CH is balanced, it normally remains stable, although adding soft water or very hard water will raise or lower the CH level. 33

42 SYMPTOMS Balancing the ph The ph level is the measure of the balance between acidity and alkalinity. If the ph is too low, it can cause corrosion of metal fixtures and the heating element. Low ph can be corrected by adding ph-alkalinity Up. Too alkaline, causes scaling Ideal balance Need to lower the ph level If the ph is too high, it can cause scaling by allowing metals or minerals to form deposits and stain spa surfaces. High ph can be corrected by adding ph-alkalinity Down. Too acidic, causes corrosion Need to raise the ph level 34

43 Troubleshooting water clarity problems Problem Probable Causes Possible Solutions Cloudy Water Water Odor Chlorine Odor Musty Odor Organic buildup / scum ring around spa Algae Growth Eye Irritation Skin Irritation / Rash Stains Scale Dirty filter Excessive oils / organic matter Improper sanitization Suspended particles / organic matter Overused or old water Excessive organics in water Improper sanitization Low ph Chloramine level too high Low ph Clean filter Shock spa with sanitizer Add sanitizer Adjust ph and/or alkalinity to recommended range Run jet pump and clean filter Drain and refill the spa Shock spa with sanitizer Add sanitizer Adjust ph to recommended range Shock spa with sanitizer Adjust ph to recommended range Bacteria or algae growth Shock spa with sanitizer if problem is visible or persistent, drain, clean and refill the spa Buildup of oils and dirt Wipe off scum with clean rag if severe, drain the spa, use a spa surface and tile cleaner to remove the scum and refill the spa High ph Low sanitizer level Low ph Low sanitizer level Unsanitary water Free chlorine level above 5 ppm Total alkalinity and/or ph too low High iron or copper in source water High calcium content in water total alkalinity and ph too high Shock spa with sanitizer and adjust ph Shock spa with sanitizer and maintain sanitizer level Adjust ph Shock spa with sanitizer and maintain sanitizer level Shock spa with sanitizer and maintain sanitizer level Allow free chlorine level to drop below 5 ppm before spa use Adjust total alkalinity and/or ph Use a stain and scale inhibitor Adjust total alkalinity and ph if scale requires removal, drain the spa, scrub off the scale, refill the spa and balance the water Use a stain and scale inhibitor SYMPTOMS 35

44 36

45 3.0 Message Code Troubleshooting 3.1. Dry, Dr, Dy, dr Sensors indicate not enough water in heater. Topside display shows Dry, Dr, dy or dr Check to make sure pump is primed. Is water flow present? te: On third occurance of message, "Dry" will display and spa will shut down. Follow "Pump will not prime" flowchart See page 7 MESSAGE CODES Does the error message go away? Test sensor set. Unplug both sensors from the circuit board. Leave the original sensors installed on the heater. Get a cup of warm water from spa. Plug two new test sensors into circuit board and place sensor in cup. Do both new sensors read the same temperature within +/- 1 degree F (.5 degree C)? Replace both original sensors. Problem is with the circuit board. Replace and use original sensors. Does the error message go away? Call Cal Spas service technician Return to normal operation 37

46 3.2. HFL, LF, HL Sensors indicate large temperature difference at heater. MESSAGE CODES Topside display shows HFL, LF or HL Does the spa have proper water flow? Press any topside key. Does the error message go away? Follow "Pump will not prime" flowchart See page 7 te: On fifth occurance of message, LF will display and heater will be disabled. Turn off all power to spa. Wait 10 seconds then restore power to spa. Does the error message go away? Test sensor set. Unplug both sensors from circuit board. Leave original sensors mounted on heater. Get a cup of warm water from spa. Place two new test sensors in cup. Do both new sensors read the same temperature within +/- 1 degree F (.5 degree C)? Replace both original sensors. Problem is with the circuit board. Replace and use original sensors. Does the error message re-occur? Call Cal Spas service technician Return to normal operation 38

47 3.3. ICE, IC Sensors indicate possible freeze condition. Topside display shows ICE or IC Is the outside air cold? Is any sensor located where it can be affected by wind chill? During cold weather temperature sensors and / or auxiliary freeze sensors can indicate that a potential freeze condition exists within the spa. Pumps will continue to run until sensors register water temperature above 44 degrees F (6.67 degrees C). Reposition auxiliary freeze sensor or re-insulate temperature sensors. MESSAGE CODES Are the pumps running constantly? Check the auxiliary freeze sensor plug in. Make sure the auxiliary freeze sensor is plugged into the correct freeze sensor location. Is the water temperature above 44 degrees F (6.67degrees C) and pumps still run constantly? Plug in a new auxiliary freeze sensor. Does the Problem go away? Replace circuit board. Does the Problem go away? Call Cal Spas service technician Return to normal operation 39

48 3.4. OHH, OHS, HH, OH Overheat condition is detected. Equipment high limit temperature sensor has detected a temperature above 118 F (47.7 C). MESSAGE CODES Topside display shows OHH, OHS, HH, or OH Remove spa cover and allow water temperature to drop below 107 degrees F (41.6 degrees C). Press any topside button to reset spa. Does the error message go away? Is there proper water flow through the heater? Is the outside air extremely hot or humid? Ensure cabinet has sufficient ventilation to exhaust heat. Does the error message go away? Is the time set for filtration excessive? Decrease filtration time to minimize heat buildup from equipment. Does the error message go away? Are sensors exposed to any external sources of heat? Do not move sensors! position of sensors is critical to normal operation. Add insulation to sensors or isolate external heat source from sensors. Does the error message go away? Turn off power, wait 10 seconds then restore power. Allow system to cycle. Does the error message go away? Follow "Pump will not prime" flowchart Test sensor set. Use Sn SnS display message flowchart. See page 7 See page 41 Does the error message go away? Call Cal Spas service technician Return to normal operation 40

49 3.5. SnS, Sn Indicates sensors are out of balance. Topside display shows Sn or SnS Is spa water level correct? Is there water flow? Fill spa to proper level. Turn off power. Wait 10 seconds and turn power back on. Establish water flow by following "Pump will not prime" flowchart See page 7 Message code goes away? Message code goes away? MESSAGE CODES Do sensor wires have any cracks or rodent damage? Replace sensor. Message code goes away? Are sensor connections clean and tight? Clean connections and make sure they are plugged in tight. Replace if necessary. Test sensor set. te which sensor is reading highest (A or B). Switch sensor A and sensor B at circuit board. Is the opposite sensor now reading higher? Replace sensor set. If the same sensor is reading higher the problem is with the circuit board. Replace circuit board. Message code goes away? Call Cal Spas service technician Return to normal operation 41

50 3.6. SA, Sb, SnA, SnB Indicates a problem with Smart Spa sensors. MESSAGE CODES SA, Sb, SnA or SnB on topside display Is spa water level correct? Is water flowing in spa? Fill spa to proper level. Turn off power. Wait 10 seconds and turn power back on. Establish water flow by following "Prime Pump / Water Flow" trouble shooting flow chart. Message goes away? Message goes away? Do sensor wires have any cracks or rodent damage? Replace sensor. Message goes away? Are sensor connections clean and tight? Clean connections and make sure they are plugged in tight. Replace if necessary. Message goes away? 1. Test sensor set. Unplug both sensors from circuit board. Leave original sensors mounted on / in heater. 2. Get a cup of warm water from spa. Place two new test sensors in cup. Do both new sensors read the same temp. within +/- 1 degree F (.5 degree C)? Replace both original sensors. Problem is with circuit board. Replace circuit board and use original sensors. Message goes away? Call Cal Spas service technician Return to normal operation 42

51 3.7. SF Indicates a problem with the Safety Suction System. Topside display shows SF Turn the power off to the spa. Is the filter clogged or dirty? Are the gate valves open? Clean or replace the filter cartridge(s) then press any button to reset the spa. Open all gate valves and then press any button to reset spa. Turn the power back on. Does SF go away? Does SF go away? MESSAGE CODES Are there any obstructions in the bottom drains or skimmer? Remove all obstructions and then press any button to reset spa. Does SF go away? Unplug safety suction sensor at circuit board. Make sure it was plugged into the correct location. Does SF go away? Replace safety suction sensor. Problem is with circuit board. Replace circuit board and use original safety suction. Does SF go away? Call Cal Spas service technician Return to normal operation 43

52 3.8. Pr, --F, --C Start up messages. Pr, --F or --C on topside display MESSAGE CODES 1. When the spa is first powered up, Pr will show on the topside display. This indicates that the spa is in priming mode. 2. While Pr is showing, the spa will not be running. This is normal and lasts for approximately four minutes. During this time, no action is necessary. 3. After approximately four minutes the pumps will engage and automatically prime. 4. During the priming phase, the topside panel will read --F or --C. The sensors are determining the water temperature. 5. After 2-5 minutes of pump priming, the temperature will be displayed on the topside panel and the heater will engage. 6. Follow the owner's manual procedures for setting spa to the desired temperature. Did pumps prime properly? If pumps fail to automatically prime, follow "Pump will not prime" flowchart. See page 7 Did pumps prime properly? Call Cal Spas service technician Return to normal operation 44

53 Component Removal and Installation Electro Static Discharge (ESD) What is ESD? Static electricity is always being generated around us, even at those times when we no longer get zapped after walking across a rug and touching something. Like all state-of-the-art circuit boards, the hot tub s circuit board can be damaged by unnoticed static electricity. Damaged is the key word. Sometimes a board which has been subjected to ESD will fail immediately upon being put back into service. Usually a board will operate for a few days, or months, then fail. Avoiding ESD damage We can t prevent static charges from building up within us as we go about our jobs, so we must do three things to protect circuit boards from getting zapped: Never transport or ship circuit boards - good boards or bad boards -except in the static protective bags. Never remove the board from the static protective bag unless you are ready to install it in the hot tub. After removing the bad board from the hot tub, A) lay it on the ground, B) remove the replacement board from the static protective bag, C) lay the replacement board on the ground, D) place the bad board in the bag from which you removed the replacement board, E) return bad board(s) to Cal Spas in undamaged sealed static protective bags. What are wrist straps and special mats? These devices keep the technician, the work surface and the circuit board at the same electrical potential and drain into ground any static charges which might build up. Proper use of the wrist strap and special mat guarantees maximum protection against ESD damage. Should you use a wrist strap and a mat when replacing a circuit board?, it is not necessary if you keep the spare board in the protective bag during transport and you observe a few simple techniques during replacement. The possibility of ESD damage to the circuit board during replacement will be minimal because of the hot tub s design and the way you normally work on it. Touching the ground lug will drain all built-up static charges from your body much like a wrist strap would. Laying the bad board on the ground will tend to keep it neutral. Touching a finger to the grounding lug immediately before removing the good board from the bag will drain charges built up by the rustling of your clothes. Laying the good board on the ground after removing it from the bag will tend to keep it neutral. Another quick touch of the grounding lug before picking up the bad board will drain built up charges. Slipping the bad board into the protective bag will allow it to be transported safely. Another quick touch of the grounding lug before picking up the good board will again drain any charges built up. In the process of installing the replacement board, you and the board will be grounded to the load box or grounding lug, draining off charges you may build up during installation. COMPONENT REMOVAL 45

54 4.2. Pump / Motor Method of Removal Applies to: All spas 1. Turn off power to the spa at the breaker. Suction union 2. Drain the spa or close the gate valves (if equipped). Return union 3. Disconnect 3/8 clear tubing from the wet end. COMPONENT REMOVAL Loosen the unions from the suction and return. Disconnect ground wire and unplug the pump. Remove the attachment bolts. Once the bolts are removed, the pump should come out easily. Method of Installation 1. Install pump in the same location as the original. Connect the suction and the return unions on the pump, making sure they are tight to prevent leaks. (te: Take care not to pinch the O-ring gasket.) Bleeder valve Four 7/16 bolts Return union 2. Reattach the 3/8 clear tubing. 3. Refill the spa and prime the pump by the bleeder valve or by the unions to release the air from the lines. 4. Reattach the ground wire and plug the pump back in. 7/16 bolt mounts Bleeder valve Suction union 5. Power up the spa. 46

55 4.3. Smart Spa Flow Through Heater Manifold Method of Removal Turn off power to spa. Open access panel to the equipment area. Drain spa or close the gate valves (if equipped). Open the control box and disconnect the heater power wires. Remove the sensors from the housings. Remove the bolts that secure the manifold to the control box. Loosen the unions and remove heater manifold. Installation Method Place the new heater manifold in the position of the old heater. Re-tighten the unions. Re-tighten the heater bolts that secure the heater manifold to the control box. Reinstall the sensors into the heater manifold. Firmly tighten the heater element power leads to the heater terminals on the circuit board. Refill the spa through the filter and power up. Test all functions. Applies to: 6100DV ELE HEATER FLOW THRU 5.5 KW W/ SMART SPA SENSOR TAPS COMPONENT REMOVAL 47

56 4.4. XL Heat Exchanger (Centered) COMPONENT REMOVAL Removal Method Turn off power to spa. Open access panel to the equipment area. Drain spa or close the gate valves (if equipped). Open the control box and disconnect the heater power wires. Remove the two sensor (see the figure below). Pay attention to the placement of the sensors. You will need to replace them in the same locations. Remove the bolts that secure the manifold. Slide out the high limit sensor. The high limit sensor slides into the sleeve on the heater. Loosen the unions and remove heater. Installation Method Install both temperature sensors on the new heater. Make sure they have the same placement as before. Place the new heater in place of the old heater. Tighten the four heater bolts that secure the heater to the control box. Connect the sensors to the circuit board. Firmly tighten the heater power leads to the heater terminals on the circuit board. Refill spa through the filter and power up. Temperature sensors are located on both sides of heater. Applies to: Spas with 6000, 6100, 6200, 6300, 7000, 8005, and 9800 controls Part #: HEA Heater Unions 48

57 4.5. Smart Spa Sensor The two smart spa sensors are located on each end of the heater and perform a variety of sensing functions. The sensors send information regarding water temperature and water flow to the system s computer. Applies to: Spas with 6000, 6100, 6200, 6300, 8005, and 9800 controls They also monitor for overheat conditions and protect against freeze conditions. When a condition occurs, the spa s computer will react and control the spa s functions based on the information from the sensors. As the computer reacts, it will display a message on the topside control panel. See page 37 for message code troubleshooting. Method for Removal Turn power off. Drain spa or close gate valves (if equipped). Locate sensors on the heater manifold. Identify faulty sensor (A or B). Unscrew sensor housing and remove sensor. Unplug the faulty sensor from the circuit board. Part #: ELE Very important: The new sensor must go back in the original position! COMPONENT REMOVAL Method of Installation 1. Place the new sensor into the sensor housing. 2. Tighten the housing gasket around the sensor. 3. Plug the sensor into the circuit board. 4. Refill the spa and check for leaks. 5. Power up and test functions. 49

58 4.6. Topside Control Panel Applies to: All spas with topside controls COMPONENT REMOVAL 1. Turn the power off. 2. Remove spa access panels. 3. Remove the cover from the control box. 4. Unplug the wire that goes from the topside panel to the circuit board. 5. Gently pry off the topside control. 6. Remove the plastic from the self-stick backing of the topside controller. 7. Place the topside controller in the place of the previous one. 8. Plug in the topside wire to the circuit board. 9. Power the spa back up and test functions. 50

59 4.7. Circuit Board Do not remove and replace circuit board unless the fault has positively been determined to be the board. Removal Shut off power to spa. Open control box door. Confirm new circuit board is compatible with faulty circuit board. (Look at chip numbers for match or compatibility.) If present, remove the screw which mounts the blower triac. Disconnect all wires and connectors as necessary to remove the board. (Labeling these wires may help speed up reinstallation.) Use the wiring diagram to ensure proper wire placement. Remove all screws which connect wires to the terminal block. Remove all screws which mount the board to the terminal block. Remove the board from the plastic stand-offs by gently squeezing the locking flange with needle nose pliers. The board should new be free and can be removed from the box. Use care to be sure the board clears all internal components when removing. Installation Important: Check all jumpers and DIP switches on replacement board. Make sure they are exactly like the old board. (te: One of the biggest causes for callbacks is misplaced jumpers or DIP switches.) COMPONENT REMOVAL Place the new board carefully into the box. Snap the new board into place on the plastic standoffs. (Take care not to push too hard.) Attach screw to Triac (if applicable). Do not overtighten! Reconnect all screws that mount the board and attachment wires. Connect all remaining slip-on connectors. (Verify placement with the wiring diagram.) Power the spa back up and test functions. 51

60 4.8. Control Box Important: On 9800 series control boxes, you must replace the entire control box minus the heater and sensors. (If only partial components are sent back, warranty credit will be denied.) COMPONENT REMOVAL 1. Turn off power. 2. Drain the spa or close the gate valves (if equipped). 3. Open the control box lid. 4. Remove the incoming power wires. 5. Unplug components from circuit board Unplug Smart Spa sensors and topside panel wire(s) from the circuit board. Loosen unions on heater manifold. Remove the heater. Loosen the mounting bolts that attach the control box to the equipment floor. Remove the control box. Method of Reinstallation Confirm that the control box replacement is compatible with the old unit. Re-attach the heater to the control box. Place the control box in the location of the old control box. Attach unions to the heater manifold and tighten. Secure the box to the equipment floor with bolts. Plug components back into their correct positions. Plug Smart Spa sensors and topside panel wire back into circuit board. Rewire the new control box. Refill the tub and power it back up. 52

61 4.9. Jet Inserts Continue to rotate the jet for another quarter turn. You will feel the jet snap out of position. Continue to rotate the jet as you pull it out of the jet well. To replace jets, insert the jet in the jet well and push and rotate it clockwise until you feel it snap into position. When the jet face can be rotated freely one half turn, it is properly seated. Installing Jet Inserts Push in until you hear a click. Turn the jet clockwise and back to confirm operation. 53 COMPONENT REMOVAL Rotate the face of the jet insert counterclockwise until you feel some resistance.

62 4.10. Ozonator Method of Removal 1. Turn the power off to the spa. 2. Unplug the ozone machine. 3. Disconnect the ozone flow tubing from the ozone machine. 4. Unscrew the ozone machine or remove the machine from the mounting clips. 5. Remove the ozone machine from the equipment area. COMPONENT REMOVAL Method of Installation Confirm the new machine has compatible voltage. Reattach the machine to the original location with screws or clips. Reattach the ozone flow tube to the ozone machine. Plug in the new machine. Power the spa back up and confirm all functions. te: The ozone machine will only power up during the filtration cycle. 54

63 Acrylic Repair Blisters, Bubbles, Cracks Grind out the crack using a Dremel tool or a grinder attachment on a drill using 80 grit sandpaper, extending the crack ¼ on each end of the crack. Wipe up the dust and residue. Tape off the repair with masking tape, leaving 1/8 of unsanded acrylic between the tape and the open crack. Mix the resin filler with the catalyst at a ratio of approximately 97% resin filler to 3% catalyst. The more catalyst used, the faster it will dry, so be careful not to mix too much. This will cause the resin to crack. Fill the crack with resin filler, making it as smooth as possible, but about 1/8 higher then the original surface. Slowly pull the masking tape away, wiping any resin filler that may have been smeared on the outside of the tape. Let the resin dry for about 30 minutes to one hour, depending on the temperature outside and your mixture. Grind the repair down to the original surface, with 220 grit sandpaper and water. Wet sand to make it smooth. If the patch cracks, repeat steps 1 through 8. Method for Repairing Blisters Using a Dremel tool, cut out the blister from the surface. You may have to go 1/8 larger than the blister. Water may come out, so dry the area before continuing. Using a grinding wheel with 80 grit sandpaper, sand down the old fiberglass. You only need to grind away 1/8. Wipe up the dust and residue and mask the repair area. Mix the resin filler with the catalyst at a ratio of approximately 97% resin filler to 3% catalyst. The more catalyst used, the faster it will dry, so be careful not to mix too much. This will cause the resin to crack. Fill the blister with the resin filler, making it as smooth as possible. This will make it easier in the next steps. Fill the area 1/8 wider and 1/8 higher than the original surface. Pull the masking tape off and clear away any resin filler that may have smeared on the outside of the tape. Let the resin dry for about 45 minutes to an hour depending on the temperature and mixture. When dry, grind the repair until it is level with the original surface. Clear away the dust. Using 220 grit sandpaper and water, wet sand the repair to make it smooth. te: When wet sending, use your hands and not a grinder! If the patch cracks, repeat steps 1 through 9. COMPONENT REMOVAL 55

64 If the bubble has not cracked 1. Use a heat gun until the bubble becomes soft. 2. Using the vice grips, grip onto the needle and quickly poke a hole in the center of the bubble. 3. Quickly roll the bubble flat with the roller, getting all the air and any substance out of it. 4. After the bubble is completely dry, coat the hole left with some clear acrylic sealant. COMPONENT REMOVAL If the bubble has cracked te Using a heat gun, heat raise a portion of the bubble. Once heated, quickly roll flat with the roller. Fill with the clear acrylic sealant. If you wish to touch up the color of the crack, you will need to find an acrylic-based paint that matches the color of your spa to paint over it. 56

65 Replacing Light Fixture in In-ground Spas Turn off main electrical switch or circuit breaker, as well as the switch which operates the underwater light itself. To remove the light assembly, remove the special pilot screw at top of the face ring, remove the light assembly from the niche, and place the assembly on the deck. Remove Junction Box cover, disconnect the light fixture wires, and pull the cord through the conduit. Feed the new light fixture cord through the conduit from the niche to the Junction Box. NOTE: Depending on the length of the conduit, special tools may be required to pull the cord through the conduit Leave at least four feet of cord to coil around the light fixture. This four feet of cord coiled around the light allows the light to be serviced after the pool is filled with water. Cut the cord at the Junction Box, leaving at least six inches of cord to make connections. Strip six inches of the outer cord jacket from the cord to expose the three insulated wires--be careful not to damage the insulation on the three inner wires. Connect all three wires to the corresponding circuit wires in the Junction Box, black wire to power, white wire to common, and green wire to ground, and secure the Junction Box cover in place. Replace light assembly into niche and tighten special pilot screw. DANGER Risk of Electrical Shock or Electrocution. This underwater light must be installed by a licensed or certified electrician or a qualified pool serviceman in accordance with the National Electrical Code and all applicable local codes and ordinances. Improper installation will create an electrical hazard which could result in death or serious injury to pool users, installers or others due to electrical shock, and may also cause damage to property. Always disconnect the power to the pool light at the circuit breaker before servicing the light. Failure to do so could result in death or serious injury to serviceman, pool users or others due to electrical shock. Fill the pool until the underwater light is completely submerged in water before operating the light for more than10 seconds. Turn on main switch or circuit breaker, as well as the switch which operates the underwater light itself, to check for proper operation. COMPONENT REMOVAL WARNING Never operate this underwater light for more than 10 seconds unless it is totally submerged in water. Without total submersion, the light assembly will get extremely hot, which may result in serious burns or in breakage of the lamp or lens. This may result in serious injury to pool users, installers, or bystanders, or in damage to property. WARNING Be sure to keep the special pilot screw from this underwater light. This screw mounts and electrically grounds the housing securely to the mounting ring and wet niche. Failure to use the screw provided could create an electrical hazard which could result in death or serious injury to pool users, installers or others due to electrical shock. 57

66 COMPONENT REMOVAL 58

67 Replacing Lamp in In-ground Spas Turn off main electrical switch or circuit breaker, as well as the switch which operates the underwater light itself. To remove light assembly, remove the special pilot screw at top of face ring, remove light assembly from niche, and place assembly on deck. Disassemble light fixture and remove bulb. Remove and discard old gasket. Install new gasket during reassembly of light. Replace the bulb as follows. a. b. c. d. Squeeze wire form at rounded ends until the wire comes together and forms a diamond shape opening; see figure at right. While holding wire form in diamond shape, insert bulb through diamond opening and thread bulb into socket. With the light resting on its base, place the gasket on top of the light shell. A NEW LENS GASKET MUST BE USED EACH TIME THE LIGHT IS REASSEMBLED. Locate the word TOP on the lens surface. Align the pilot screw on the face ring with the letter O in the word TOP and the arrow on the label marked, Arrow on this label must line up with the pilot screw on the face ring. The semi-assembled light will now include the face ring and its new gasket properly aligned with the light shell. Place this light upside down on the old gasket, using the old gasket as an assembly fixture. This will keep the lens and gasket assembly from being pushed out of the face ring while you secure it to the light fixture. Secure the face ring to the light fixture. Sealing screws must be tightened in the following manner to ensure a proper seal. a. Continue partly tightening all screws in the above se- quence until all screws are evenly and securely tightened. Recommended 20 inch pounds torque. b. Partly tighten the screw at the 3 o clock position, and then partly tighten the screw at the 9 o clock position. Partly tighten the screw at another opposite position, and then partly tighten the screw directly across from it. DANGER Always disconnect power to the spa light at the circuit breaker before servicing the light. Failure to do so could result in death or serious injury due to electrical shock. WARNING Replace lamp with a similar type and wattage. Failure to replace lamp with the same type of lamp will damage the light assembly and may cause an electrical hazard resulting in death or serious injury to pool users, installers, or others due to electrical shock, and may also cause damage to property. IMPORTANT Be careful not to touch bulb with bare skin, as this will reduce the life of the bulb. Use the plastic wrapping of the new bulb, or a cloth to grasp the bulb. COMPONENT REMOVAL 59

68 COMPONENT REMOVAL Replace the light assembly into the niche and tighten the special pilot screw. Fill pool until the underwater light is completely submerged in water before operating the light for more than 10 seconds. Turn on main switch or circuit breaker, as well as the switch which specifically operates the underwater light, to check for proper operation. WARNING Be sure to keep the special pilot screw from this underwater light. This screw mounts and electrically grounds the housing securely to the mounting ring and wet niche. Failure to use the screw provided could create an electrical hazard which could result in death or serious injury to pool users, installers or others due to electrical shock. WARNING Use only the special pilot screw provided with this underwater light. This screw mounts and electrically grounds the housing securely to the mounting ring and wet niche. Failure to use the screw provided could create an electrical hazard which could result in death or serious injury to pool users, installers or others due to electrical shock. WARNING Never operate the underwater light for more than 10 seconds unless it is totally submerged in water. Without total submersion, the light assembly will get extremely hot and may result in serious burns or in breakage of the lamp or lens. This may result in serious injury to pool users, installers, or bystanders, or in damage to property. 60

69 5.0 Entertainment Troubleshooting Part : Entertainment Stereo troubleshooting Troubleshooting symptoms and Repair For all stereo troubleshooting, refer to product manufacturer s owner s manual packaged in the same bag as the Cal Spas owner s manual Power does not turn ON Check for blown fuse. After checking for short circuit in the wires, replace the fuse with one the same rating The memory is erased when the power is OFF The power wire may be wired incorrectly. Connect the wire correctly sound, or volume is very low The fader or balance setting are set all the way to one side Center the fader and balance setting The input/output wires or wiring harness are connected in correctly. Reconnect the input/output wires or the wiring harness correctly. The values of the volume offset are low. Turn up the volume. Turn off the built-in amp. ENTERTAINMENT Sound quality is poor or distorted One of the speaker wires is pinched. Check speakers wires Poor radio reception The antenna is not extended, Pull the antenna all the way out. The antenna control wire is not connected. Connect the wire correctly 61

70 5.2. Remote control troubleshooting Remote control does not work. Make sure remote has good batteries. Point the remote to the unit with a direct line of sight. Make sure you are within 15 feet from the unit you are trying to operate Power Supply Troubleshooting The stereo is not powering up. Make sure it has proper voltage (120 Volts). Make sure the output is 12 Volts. Make sure the fuse is good if not, replace it. ENTERTAINMENT The green light blinks. May be caused by a bad power supply. Try replacing the power supply. I only get 7 amps or less. Make sure your volt meter has a good battery. Turn the gain slowly and take amp reading Amplifier Troubleshooting Power does not turn on Fuse could be blown. Replace with a fuse of the same amperage. If the fuse blows again, check all wiring to make sure there s no contact with any other wires sound is produced May be incorrectly wired. Make sure the wires are properly connected. Check to ensure the speakers are good by replacing with a known good speaker. Replace AMP sound output when operating the unit with amplifiers Amplifier turn-on leads are shorted to ground or excessive current is required. Turn the unit off and check each wire for a possible short. If the amplifier turn-on lead shorts out, cover it with insulation, such as electrician s tape. 62

71 audio The speaker protection circuit is operating. Check the speaker connection. Turn down the sound volume. Turning the power off and on again can also restore function. If the sound is muted again, replace the unit Sound is bad directly after power is turned on Water droplets may form on the terminals. Let it dry for about one hour with the power on Power LED does not turn on Fuse at power connection blown or not installed. Replace with correct fuse. Typically twice the rating of the fuse that is on the amplifier Status LED turns on Fuse on amplifier blown. Replace with the correct AMP rated fuse Amplifier too hot Move the amplifier into a more ventilated area Speaker wires shorted ENTERTAINMENT Check that there are no speaker wires shorted to any other wire. Check if wire is shorted to the stereo Internal malfunction Disconnect all wires except ground, power and remote Subwoofer Troubleshooting There is no sound from the subwoofer Is the amplifier turned on? Are the wires from the subwoofer is connected? If the problem still persists, replace the subwoofer I get sound distortion from the subwoofer Are the settings from your amp set in the proper frequency? Check to see if the RCA cables are making contact with each other. If so, insulate each one with electrical tape. If the problem still persists, replace the amplifier. 63

72 LED and Light Troubleshooting Only some of the LED lights come on Do the lights start or stop from a certain spot? Are there some colors that won t light up? Do the colors change? If the lights start or stop at a certain spot on the spa, this indicates a faulty LED manifold connection. Check the connections at the manifold and re-tighten or replace the manifold. If a certain color won t light up, this indicates a bad LED of that color. Identify the faulty bulb and replace with another one. If the color doesn t change, this indicates a bad controller. Replace the LED controller. ENTERTAINMENT The main spa light does not come on Is the bulb burned out? Is the topside panel sending information to the control box? Is the wire connected to the bulb? Check the bulb to see if it is burned out. Replace the bulb with an exact match. te: Tail light bulbs have more intensity and can cause damage due to overheating. See if the topside panel indicates that the light is on but actually is not. Check the bulb first. Check the output on the light connection for 12 Volts. Verify that the jumper or DIP switch on the circuit board is in the 12 Volt position. If not, switch it to correct position. If the circuit board still isn t sending 12 Volts to light, then you will need to replace the circuit board. Check the wire from the control box connection to the bulb housing. If the connections are loose, replace them. Rodents can also cause damage to the wire and prevent the voltage from reaching the bulb. Replace the wire if there is any damage found. 64

73 from car antenna à partir de l antenne de la voiture 12 V DC ght in moving gnition off to leads only ground leads with roduct will t where ou install equately w) with other uit s rating onent s fuse. h, connect in the are re mounting Entertainment Installation Sony CDX-GT10M CD Player Cautions This unit is designed for negative ground 12 V DC operation only. Do not get the leads under a screw, or caught in moving parts (e.g. seat railing). Before making connections, turn the car ignition off to avoid short circuits. Connect the yellow and red power input leads only after all other leads have been connected. Run all ground leads to a common ground point. Be sure to in su late any loose un con nect ed leads with electrical tape for safety. The use of optical instruments with this product will increase eye hazard. This unit is not waterproof. Install the unit where sea or rain water cannot enter the unit. If you install the unit in such a place, ensure that it is adequately waterproofed. tes on the power supply lead (yellow) When connecting this unit in combination with other stereo components, the connected car circuit s rating must be higher than the sum of each component s fuse. When no car circuits are rated high enough, connect the unit directly to the battery. Parts Iist * AUDIO The numbers OUT SUB/REAR in the list are keyed to those in the instructions. The bracket and the protection collar are attached to the unit before shipping. Before mounting the unit, use the release keys to remove the bracket and the protection collar from the unit. For details, see Removing the protection collar and the bracket ( ) on the reverse side of the sheet. Keep the release keys for future use as they are also necessary if you remove the unit from your car. Caution Connection Handle the example bracket carefully to avoid injuring your fingers. Be careful not to allow products which are not waterproof to get wets. tes ( -B) Be sure to connect the ground lead before connecting the amplifi er. The alarm will only sound if the built-in amplifi er is used. Connection diagram Catch te Before installing, make sure that the catches on both sides of To a metal the bracket surface are of bent the inwards car 2 mm ( 3 /32 in). If the catches are First connect straight the or black bent outwards, ground lead, the then unit will connect not be the installed yellow securely and red and power may input spring leads. out. To the power antenna control lead or power supply lead of antenna booster amplifier tes It is not necessary to connect this lead if there is no power antenna or antenna booster, or with a manually-operated telescopic antenna. When your car has a built-in FM/AM antenna in the rear/ side glass, see tes on the control and power supply leads. To AMP REMOTE IN of an optional power amplifier This connection is only for amplifi ers. Connecting any other system may damage the unit. To the +12 V power terminal which is energized in the accessory position of the ignition key switch Troubleshooting tes and Service for Spas 2010 & 2011 If there is no accessory position, connect to the +12 V Rev. power A, 8/25/11 (battery) terminal which is energized at all times. Be sure to connect the black ground lead to a metal surface of the car fi rst. When your car has a built-in FM/AM antenna in the rear/ Connection example Be careful not to allow products which are not waterproof to get wets. tes ( -B) Be sure to connect the ground lead before connecting the amplifi er. The alarm will only sound if the built-in amplifi er is used. Left Gauche Connection diagram To a metal surface of the car First connect the black ground lead, then connect the yellow and red power input leads. Right To the power antenna control lead Droit or power supply lead of antenna booster amplifier tes It is not necessary to connect this lead if there is no power antenna or antenna booster, or with a manually-operated telescopic antenna. When your car has a built-in FM/AM antenna in the rear/ side glass, see tes on the control and Left power supply leads. Gauche To AMP REMOTE IN of an optional power amplifier This connection is only for amplifi ers. Connecting any other system may damage the unit. To the +12 V power terminal which is energized in the accessory position Right of the ignition key switch Droit tes If there is no accessory position, connect to the +12 V power (battery) terminal which is energized at all times. Be sure to connect the black ground lead to a metal surface of the car fi rst. When your car has a built-in FM/AM antenna in the rear/ side glass, see tes on the control and power supply leads. To the +12 V power terminal which is energized at all times Be sure to connect the black ground lead to a metal surface of the car fi rst. tes on the control and power supply leads The power antenna control lead (blue) supplies +12 V DC when you turn on the tuner. When your car has built-in FM/AM antenna in the rear/side glass, connect the power antenna control lead (blue) or the accessory power input lead (red) to the power terminal of the existing antenna booster. For details, consult your dealer. A power antenna without a relay box cannot be used with this unit. Memory hold connection When the yellow power input lead is connected, power will always be supplied to the memory circuit even when the ignition switch is turned off. tes on speaker connection Before connecting the speakers, turn the unit off. Use speakers with an impedance of 4 to 8 ohms, and with adequate power handling capacities to avoid its damage. Do not connect the speaker terminals to the car chassis, or connect the terminals of the right speakers with those of the left speaker. Do not connect the ground lead of this unit to the negative ( ) terminal of the speaker. Do not attempt to connect the speakers in parallel. Connect only passive speakers. Connecting active speakers (with built-in amplifi ers) to the speaker terminals may damage the unit. To avoid a malfunction, do not use the built-in speaker leads installed in your car if the unit shares a common negative ( ) lead for the right and left speakers. Do not connect the unit s speaker leads to each other. te on connection If speaker and amplifi er are not connected correctly, FAILURE appears in the display. In this case, make sure the speaker and amplifi er are connected correctly. AMP REM Max. supply current Courant max. fourni ENTERTAINMENT Précautions Cet appareil est exclusive sur une tension de 12 V C Évitez de fixer des vis sur ceux-ci dans des pièces m de siège). Avant d effectuer les racc pour éviter un court-circu Raccordez les câbles d en rouge seulement après av raccordements. Rassemblez tous les c point de masse comm Pour des raisons de sécuri ruban isolant tout câble li L utilisation d instrument augmente les risques pour Cet appareil n est pas étan un endroit protégé contre Si vous installez l apparei d être exposé à l eau, véri Remarques sur le câble Lorsque cet appareil est ra stéréo, la valeur nominale de la voiture doit être sup fusibles de chaque élémen Si aucun circuit de la voit raccordez directement l a 65 Liste des compo Les numéros de la liste co

74 Precautions Choose the installation location carefully so that the unit will not interfere with normal driving operations. Avoid installing the unit in areas subject to dust, dirt, excessive vibration, or high temperatures, such as in direct sunlight or near heater ducts. Use only the supplied mounting hardware for a safe and secure installation. Mounting angle adjustment Adjust the mounting angle to less than 45. Mounting the unit in a Japanese car You may not be able to install this unit in some makes of Japanese cars. In such a case, consult your Sony dealer. te To prevent malfunction, install only with the supplied screws. How to detach and attach the front panel ENTERTAINMENT Removing the protection collar and the bracket Before installing the unit, remove the protection collar and the bracket from the unit. 1 Remove the protection collar. Engage the release keys together with the protection collar. Pull out the release keys to remove the protection collar. 2 Remove the bracket. Insert both release keys together between the unit and the bracket until they click. Pull down the bracket, then pull up the unit to separate. Frequency select switch The AM (FM) tuning interval is factory-set to the 10 k (200 k) position. If the frequency allocation system of your country is based on 9 khz (50 khz) interval, set the switch on the bottom of the unit to the 9 k (50 k) position before making connections. Before installing the unit, detach the front panel. -A To detach Before detaching the front panel, be sure to press. Press, and pull it off towards you. -B To attach Engage part of the front panel with part of the unit, as illustrated, and push the left side into position until it clicks. Warning if your car s ignition has no ACC position After turning the ignition off, be sure to press and hold on the unit until the display disappears. Otherwise, the display does not turn off and this causes battery drain. RESET button When the installation and connections are completed, be sure to press the RESET button with a ball-point pen, etc., after detaching the front panel. Mounting example Installation in the dashboard tes Bend these claws outward for a tight fi t, if necessary ( -2). Make sure that the 4 catches on the protection collar are properly engaged in the slots of the unit ( -3). 66

75 A B * AUDIO OUT SUB/REAR Left Gauche Right Droit Left Gauche Right Droit * 1 from car antenna à partir de l antenne de la voiture BUS AUDIO Fuse (10 A) Fusible (10 A) AMP REM Blue/white striped Rayé bleu/blanc Max. supply current 0.3 A Courant max. fourni 0,3 A White Blanc White/black striped Rayé blanc/noir Gray Gris Gray/black striped Rayé gris/noir Green Vert Green/black striped Rayé vert/noir Purple Mauve Purple/black striped Rayé mauve/noir ENTERTAINMENT Black ir Blue Bleu Red Rouge Yellow Jaune * 1 RCA pin cord (not supplied) * 2 AUDIO OUT can be switched to SUB or REAR. For details, see the supplied Operating Instructions. * 1 Cordon à broche RCA (non fourni) * 2 AUDIO OUT peut être commuté sur SUB ou REAR. Pour obtenir plus de détails, reportezvous au mode d emploi fourni. ANT REM Max. supply current 0.1 A Courant max. fourni 0,1 A IN L R 67

76 ENTERTAINMENT 1 2 Orient the release key correctly. Orientez correctement la clé de déblocage. Face the hook inwards. Tournez le crochet vers l intérieur Dashboard Tableau de bord 182 mm 53 mm Claws Griffes 68

77 6.2. Sony CDX-HS70MW CD Player Front speaker (right) Haut-parleur avant (d Altavoz frontal (dere Frontlautsprecher (r Voorluidspreker (rec Diffusore anteriore ( Rear speaker (left) Haut-parleur arrière Altavoz posterior (izq Hecklautsprecher (li Achterluidspreker (li Diffusore posteriore M Rear speaker (right) Haut-parleur arrière Altavoz posterior (de Hecklautsprecher (re Achterluidspreker (r Diffusore posteriore 6 M M3 NUT 2 Equipment used in illustrations (not supplied) Appareils utilisés dans les illustrations (non fournis) Equipo utilizado en las ilustraciones (no suministrado) In Abbildungen dargestellte Geräte (nicht mitgeliefert) Apparatuur gebruikt in de afbeeldingen (niet bijgeleverd) Apparecchiatura utilizzata nelle illustrazioni (non in dotazione) ENTERTAINMENT Marine speaker Haut-parleur étanche Altavoz acuático Spritzwassergeschützte Lautsprecher Waterdichte luidspreker Diffusore per uso in ambiente marino XS-MP1620W/MP1620B XS-MP1610W/MP1610B Marine subwoofer Caisson de graves étanche Altavoz potenciador de graves acuático Spritzwassergeschützter Tiefsttöner Waterdichte subwoofer Subwoofer per uso in ambiente marino XS-L100P5M Marine power amplifier* Amplificateur de puissance étanche* Amplificador de potencia acuático* Spritzwassergeschützter Endverstärker* Waterdichte eindversterker* Amplificatore di potenza per uso in ambiente marino* XM-604M CD/MD changer* Changeur de CD/MD* Cambiador de CD/MD* CD/MD-Wechsler* CD/MD-wisselaar* Cambia CD/MD* Marine remote commander Télécommande marine Mando a distancia subacuático Bootsfernbedienung Maritieme afstandsbediening Telecomando per uso in ambiente marino RM-X55M Rotary commander* Satellite de commande* Mando rotatorio* Joystick* Bedieningssatelliet* Telecomando a rotazione* RM-X4S * not waterproof non étanche no es resistente al agua nicht wasserdicht niet waterdicht non resistente all acqua 69

78 non étanche no es resistente al agua nicht wasserdicht niet waterdicht non resistente all acqua A AUDIO OUT REAR* AUDIO OUT FRONT ENTERTAINMENT B * AUDIO OUT REAR/SUB BUS CONTROL IN REMOTE IN BUS AUDIO IN BUS CONTROL IN Source selector* Sélecteur de source* Selector de fuente* Signalquellenwähler* Geluidsbronkiezer* Selettore di fonte* XA-C40 BUS AUDIO IN * not supplied non fourni no suministrado nicht mitgeliefert niet bijgeleverd non in dotazione 70

79 Front speaker (left) Haut-parleur avant (gauche) Altavoz frontal (izquierdo) Frontlautsprecher (links) Voorluidspreker (links) Diffusore anteriore (sinistro) Front speaker (right) Haut-parleur avant (droit) Altavoz frontal (derecho) Frontlautsprecher (rechts) Voorluidspreker (rechts) Diffusore anteriore (destro) Rear speaker (left) Haut-parleur arrière (gauche) Altavoz posterior (izquierdo) Hecklautsprecher (links) Achterluidspreker (links) Diffusore posteriore (sinistro) Rear speaker (right) Haut-parleur arrière (droit) Altavoz posterior (derecho) Hecklautsprecher (rechts) Achterluidspreker (rechts) Diffusore posteriore (destro) 3 * 1 * 1 * 5 Supplied with XA-C40 Fourni avec le XA-C40 Suministrado con el XA-C40 Mit dem XA-C40 geliefert Geleverd met de XA-C40 In dotazione con il modello XA-C40 AUX IN BUS AUDIO IN AUDIO OUT FRONT REMOTE IN * 3 from boat antenna (aerial) de l antenne du bateau desde la antena del barco von Bootsantenne van de antenne van de boot dall antenna dell imbarcazione BUS AUDIO AUDIO OUT REAR AUDIO OUT FRONT AUDIO OUT Fuse (10 A) BUS REAR* 2 Fusible (10 A) CONTROL IN Fusible (10 A) Sicherung (10 A) Zekering (10 A) Fusibile (10 A) * 4 * 4 Blue/white striped / Rayé bleu/blanc / Black / ir / Con rayas azules y blancas / Blauweiß gestreift / Negro / Schwarz / AMP REM Blauw/wit gestreept / Rigato blu e bianco Zwart / Nero Max. supply current 0.3 A Courant d alimentation maximum 0,3 A Corriente máx. de alimentación de 0,3 A Blue / Bleu / max. Versorgungsstrom 0,3 A Azul / Blau / Max. voedingsstroom 0,3 A Blauw / Blu ANT REM Alimentazione massima fornita 0,3 A Max. supply current 0.1 A White / Blanc / Courant d alimentation maximum 0,1 A Blanco / Weiß / Corriente máx. de alimentación de 0,1 A Wit / Bianco max. Versorgungsstrom 0,1 A Max. voedingsstroom 0,1 A White/black striped / Rayé blanc/noir / Alimentazione massima fornita 0,1 A Con rayas blancas y negras / Weißschwarz gestreift / Light blue / Bleu ciel / Wit/zwart gestreept / Rigato bianco e nero Azul celeste / Hellblau / Lichtblauw / Azzurro ATT Gray / Gris / Gris / Grau / Grijs / Grigio Orange/white striped / Rayé orange/blanc / Gray/black striped / Rayé gris/noir / Con rayas naranjas y blancas / Orangeweiß gestreift / Con rayas grises y negras / Grauschwarz gestreift / Oranje/wit gestreept / Rigato arancione e bianco ILLUMINATION Grijs/zwart gestreept / Rigato grigio e nero Green / Vert / Verde / Grün / Groen / Verde Red / Rouge / Rojo / Rot / Green/black striped / Rayé vert/noir / Rood / Rosso Con rayas verdes y negras / Grünschwarz gestreift / Groen/zwart gestreept / Rigato verde e nero 5 6 Purple / Mauve / Yellow / Jaune / Morado / Violett / Amarillo / Gelb / Paars / Viola Geel / Giallo Purple/black striped / Rayé mauve/noir / Con rayas moradas y negras / Violettschwarz gestreift / Paars/zwart gestreept / Rigato viola e nero 7 ENTERTAINMENT Source selector (not supplied) Sélecteur de source (non fourni) Selector de fuente Supplied with the CD/MD changer (no suministrado) Fourni avec le changeur de CD/MD Signalquellenwähler Suministrado con el cambiador de CD/MD (nicht mitgeliefert) Mit dem CD/MD-Wechsler geliefert Geluidsbronkiezer Geleverd met de CD/MD-wisselaar (niet bijgeleverd) In dotazione con il cambia CD/MD Selettore di fonte (non in dotazione) XA-C40 * 1 RCA pin cord (not supplied) * 2 AUDIO OUT can be switched REAR or SUB. For details, see the supplied Operating Instructions. * 3 Insert with the cord upwards. * 4 Supplied with RM-X55M * 5 Auxiliary equipment such as portable DVD player (not supplied) * 1 Cordon à broche RCA (non fourni) * 2 AUDIO OUT peut être commuté sur REAR ou SUB. Pour obtenir plus de détails, reportez-vous au mode d emploi. * 3 Insérez avec le câble vers le haut. * 4 Fourni avec le RM-X55M * 5 Equipement auxiliaire comme un lecteur de DVD portable (non fourni) * 1 Cable con terminales RCA (no suministrado) * 2 AUDIO OUT (Salida de audio) puede cambiarse a REAR (Posterior) o SUB (Secundaria). Para obtener información, consulte el manual de instrucciones suministrado. * 3 Insertar con el cable hacia arriba. * 4 Suministrado con el RM-X55M * 5 Equipo opcional auxiliar como un reproductor de DVD portátil (no suministrado) * 1 Cinchkabel (nicht mitgeliefert) * 2 AUDIO OUT kann zwischen REAR und SUB umgeschaltet werden. Näheres hierzu fi nden Sie in der Bedienungsanleitung. * 3 Mit dem Kabel nach oben einsetzen. * 4 Mit dem RM-X55M geliefert * 5 Zusätzliche Geräte wie z. B. der tragbare DVD-Player (nicht mitgeliefert) * 1 Tulpstekkersnoer (niet bijgeleverd) * 2 AUDIO OUT kan worden ingesteld op REAR of SUB. Raadpleeg de gebruiksaanwijzing voor meer informatie. * 3 Plaatsen met het snoer naar boven. * 4 Geleverd met de RM-X55M * 5 Optionele apparatuur zoals de draagbare DVD-speler (niet bijgeleverd) * 1 Cavo a piedini RCA (non in dotazione) * 2 AUDIO OUT può essere impostato su REAR o su SUB. Per ulteriori informazioni, consultare il manuale di istruzioni per l uso. * 3 Inserire con il cavo rivolto verso l alto. * 4 In dotazione con il modello RM-X55M * 5 Apparecchio ausiliario quale un lettore DVD portatile (non in dotazione) IN L R 71

80 pritzwassergeschützter iefsttöner aterdichte subwoofer ubwoofer per uso in ambiente arino S-L100P5M arine power amplifier* mplificateur de puissance tanche* mplificador de potencia cuático* pritzwassergeschützter ndverstärker* aterdichte eindversterker* mplificatore di potenza per so in ambiente marino* M-604M AUDIO OUT REAR* ENTERTAINMENT REAR/SUB Source selector* Sélecteur de source* Selector de fuente* Signalquellenwähler* Geluidsbronkiezer* Selettore di fonte* XA-C40 Cautions * not waterproof This unit is designed for non negative étanche ground (earth) 12 V DC operation only. no es resistente al agua Do not get the leads under nicht a screw, wasserdicht or caught in moving parts (e.g. seat railing). niet waterdicht Before making connections, non turn resistente the boat s all acqua ignition off to avoid short circuits. Connect the yellow and red power supply leads only after all other leads have been connected. Run all ground (earth) leads to a common ground (earth) point. Be sure to insulate any loose unconnected leads with electrical tape for safety. The use of optical instruments with this product will increase eye hazard. tes on the power supply lead (yellow) When connecting this unit in combination with other stereo components, the connected boat circuit s rating must be higher than the sum of each component s fuse. When no boat circuits are rated high enough, connect the unit directly to the battery. AUDIO OUT FRONT Parts Iist RM-X55M The numbers in the list are keyed to those in the instructions. Connection example Rotary commander* Satellite de commande* Mando rotatorio* Joystick* Bedieningssatelliet* Telecomando a rotazione* RM-X4S tes ( -A) Be sure to connect the ground (earth) lead before connecting the amplifi er. The alarm will only sound if the built-in amplifi er is used. Tip ( -B- ) For connecting two or more CD/MD changers, the source selector XA-C40 (not supplied) is necessary. BUS CONTROL IN BUS AUDIO IN BUS CONTROL IN BUS AUDIO IN REMOTE IN * not supplied non fourni no suministrado nicht mitgeliefert niet bijgeleverd non in dotazione tes ( -A) Be sure to connect the ground (earth) lead before connecting the amplifi er. The alarm will only sound if the built-in amplifi er is used. Tip ( -B- ) For connecting two or more CD/MD changers, the source selector XA-C40 (not supplied) is necessary. Connection diagram To a metal surface of the boat First connect the black ground (earth) lead, then connect the yellow and red power supply leads. To the power antenna (aerial) control lead or power supply lead of antenna (aerial) booster te It is not necessary to connect this lead if there is no power antenna (aerial) or antenna (aerial) booster, or with a manually-operated telescopic antenna (aerial). When your boat has a built-in FM/AM antenna (aerial) in the rear/side glass, see tes on the control and power supply leads. To AMP REMOTE IN of an optional power amplifier This connection is only for amplifi ers. Connecting any other system may damage the unit. To the interface cable of a telephone To the illumination signal Be sure to connect the black ground (earth) lead to a metal surface of the boat fi rst. To the +12 V power terminal which is energized in the accessory position of the ignition switch te If there is no accessory position, connect to the +12 V power (battery) terminal which is energized at all times. Be sure to connect the black ground (earth) lead to a metal surface of the boat fi rst. To the +12 V power terminal which is energized at all times Be sure to connect the black ground (earth) lead to a metal surface of the boat fi rst. tes on the control and power suppy leads The power antenna (aerial) control lead (blue) supplies +12 V DC when you turn on the tuner. A power antenna (aerial) without a relay box cannot be used with this unit. Memory hold connection When the yellow power supply lead is connected, power will always be supplied to the memory circuit even when the ignition switch is turned off. tes on speaker connection Before connecting the speakers, turn the unit off. Use speakers with an impedance of 4 to 8 ohms, and with adequate power handling capacities to avoid its damage. Do not connect the speaker terminals to the boat chassis, or connect the terminals of the right speakers with those of the left speaker. Do not connect the ground (earth) lead of this unit to the negative ( ) terminal of the speaker. Do not attempt to connect the speakers in parallel. Connect only passive speakers. Connecting active speakers (with built-in amplifi ers) to the speaker terminals may damage the unit. To avoid a malfunction, do not use the built-in speaker leads installed in your boat if the unit shares a common negative ( ) lead for the right and left speakers. Do not connect the unit s speaker leads to each other. te on connection If speaker and amplifi er are not connected correctly, FAILURE appears in the display. In this case, make sure the speaker and amplifi er are connected correctly. Exemple de rac Remarques ( -A) Raccordez d abord le câble connecter l amplifi cateur. L alarme est émise uniquem est utilisé. Conseil ( -B- ) Dans le cas du raccordement ou plus, le sélecteur de source indispensable. P Schémas de rac Vers un point métal Branchez d abord le câble ensuite, les câbles d alime Vers le câble de com électrique ou le câb l amplificateur d an Remarques Il n est pas nécessaire d d antenne électrique ni une antenne télescopiq Si votre bateau est équi intégrée dans la vitre ar section «Remarques su d alimentation». Vers AMP REMOTE puissance en optio Ce raccordement s appliq Le raccordement de tout a d endommager l appareil. Vers le câble d inter Vers le signal d écla Commencez par raccorde à un point métallique du b Vers la borne +12 V quand la clé de con accessoires Remarque S il n y a pas de position a d alimentation (batterie) + permanence. Commencez par raccorde à un point métallique du b Vers la borne +12 V permanence Commencez par raccorde à un point métallique du b Remarques sur les câbles d Le câble de commande d an alimentation de +12 V CC lo tension. Une antenne électrique san utilisée avec cet appareil. Raccordement pour la conse Lorsque le câble de command circuit de la mémoire est alime de contact est en position d ar Remarques sur le raccordem Avant de raccorder les hauttension. Utilisez des haut-parleurs ay et une capacité adéquate so Ne raccordez pas les borne bateau, et ne raccordez pas celles du haut-parleur gauch Ne raccordez pas le câble d à la borne négative ( ) du h Ne tentez pas de raccorder Raccordez uniquement des raccordement de haut-parle intégrés) aux bornes des ha l appareil. Pour éviter tout problème de câbles des haut-parleurs int si l appareil dispose d un câ haut-parleurs droit et gauch Ne raccordez pas entre eux l appareil. Remarque sur le raccordem Si les enceintes et l amplifi cate correctement, le message «FA assurez-vous que les enceinte correctement. 72

81 7.0 Spa Installation Volt 60A Wiring and GFCI Wiring Guidelines art 3: Spa Reference All 240 Volt Cal Spas require a dedicated electrical service to spa using #6 copper wires (no aluminum voids warranty). Longer runs may require larger wire. Check with a licensed electrician for the proper size. The dedicated 240 Volt electrical service consists of a 4 wire, GFCI protected electrical connection. The four wires are: Wire Color Black Red White Green Function Hot Hot Neutral Ground GFCI Line-In Wiring Check: (from electrical source to GFCI breaker) see Diagram The black wire (line-hot) should be connected to the GFCI line-in 1. The red wire (line-hot) should be connected to the GFCI line-in 2. The white wire (line neutral) connects to the neutral bar. The green wire (ground) connects to the ground bar or lug. te: The white neutral and green ground wires cannot be connected together as GFCI tripping can occur. The use of a separate ground rod may be necessary to separate neutral and ground wires. Check with a licensed electrician for proper connections. GFCI Line-Out Wiring Check: (from GFCI breaker to Spa) see Diagram The black wire (load-hot) should be connected to the GFCI load out 1. The red wire (load-hot) should be connected to the GFCI load out 2. The white pigtail wire (attached to breaker) connects to neutral bar. The white wire (load neutral) connects to the GFCI load neutral. The green wire (ground) connects to the ground bar or lug. SPA INSTALLATION COMMON WIRING MISTAKES: The most common wiring mistake on new spa deliveries is to connect the load neutral from spa to the neutral bar instead of into the breaker. The second most common is not separating the neutral and ground wires. PROPER LOAD NEUTRAL CONNECTION: On all 240 volt Cal Spas, the load neutral must be connected to the GFCI Breaker at the load neutral connection point. Regardless of the type of breaker, all neutral detecting GFCI breakers will have an extra space for the white load neutral from the spa. (normally designated with a white dot) The white pigtail neutral (white curly wire) from the breaker, connects to the neutral bar. SEPARATE GROUND AND NEUTRAL: If the ground from the spa is connected to the neutral bar with the neutral, the GFCI can trip due to excessive ground interference. Separate the ground and the neutral with a ground rod if necessary or connect the ground from the spa directly to the ground from the electrical supply Check with a licensed electrician for proper connections. 73

82 Volt 60A Electrical Installation All 240V spas must be permanently connected (hard wired) to the power supply. See the wiring diagram on page 77. These instructions describe the only acceptable electrical wiring procedure. Spas wired in any other way will void your warranty and may result in serious injury. When installed in the United States, the electrical wiring of this spa must meet the requirements of NEC 70 and any applicable local, state, and federal codes. The electrical circuit must be installed by an electrical contractor and approved by a local building or electrical inspector. Failure to comply with state and local codes may result in fire or personal injury and will be the sole responsibility of the spa owner. SPA INSTALLATION GFCI and Wiring Requirements The power supplied to the spa must be on a dedicated GFCI protected circuit as required by NEC 70 with no other appliances or lights sharing the power. Use copper wire with THHN insulation. Do not use aluminum wire. Use the table on the next page to determine your GFCI and wiring requirements. Wire runs over 85 feet must increase wire gauge to the next lower number. For example: A normal 50 amp GFCI with four #6 AWG Copper wires run over 85 feet would require you to go to four #4 AWG copper wires. Testing the GFCI Breaker Test the GFCI breaker prior to first use and periodically when the spa is powered. To test the GFCI breaker follow these instructions (spa should be operating): Press the TEST button on the GFCI. The GFCI will trip and the spa will shut off. Reset the GFCI breaker by switching the breaker to the full OFF position, wait a moment, then turn the breaker back on. The spa should have power again. Use the table below to determine your GFCI and wiring requirements. 74

83 V GFCI 60A and Wiring Requirements All 5100DV and 6200DV control systems are set at the factory to run on the low power setting for 40 amp operation. This is the default setting. Spa owners can have their installer change this setting so the spa will run on high power for 50 amp operation. See configuration instructions on page 76. Warning: Never set a spa to run on high power without installing a properly rated GFCI. All Portable Spas (except Ultimate Fitness) Ultimate Fitness Spas Control System Power Setting GFCI Required VS300 Standard One 40 amp GFCI 5100DV 6200DV 6300DV 9800 (except Ultimate Fitness spas -- see below) F854 F1255 FP1455 FP1655 FP2400 FP2500 FP4700 Spa Model Service 1 Service 2 Service 1 Service 2 Service 1 (swim side) Service 2 (swim side) Service 3 (spa side) Power saver mode (This is the factory default setting.) High power setting See configuration instructions on page 76. Power saver mode Default high power setting See configuration instructions on page 76. Standard GFCI Required Wires Required Standard configuration (5.5 kw heater) One 50 amp GFCI One 50 amp GFCI One 50 amp GFCI One 50 amp GFCI One 50 amp GFCI N/A One 40 amp GFCI Four #6 AWG copper wires Four #6 AWG copper wires Four #6 AWG copper wires Four #6 AWG copper wires Four #6 AWG copper wires N/A Four #8 AWG copper wires One 40 amp GFCI One 50 amp GFCI One 50 amp GFCI One 60 amp GFCI One 50 amp GFCI Wires Required Four #8 AWG copper wires Four #8 AWG copper wires Four #6 AWG copper wires Four #6 AWG copper wires Four #6 AWG copper wires Four #6 AWG copper wires GFCI Required Wires Required Configuration for Option 499 (11 kw heater) and Option 157 (swim jets with Speck pump) One 60 amp GFCI One 30 amp GFCI One 60 amp GFCI One 30 amp GFCI One 60 amp GFCI One 30 amp GFCI One 40 amp GFCI N/A Four #6 AWG copper wires Three #8 AWG copper wires Four #6 AWG copper wires Three #8 AWG copper wires Four #6 AWG copper wires Three #8 AWG copper wires Four #8 AWG copper wires SPA INSTALLATION 75

84 7.4. High Power Configuration for 5100DV, 6200DV, and 6300DV systems SPA INSTALLATION OFF Position (Down) ON Position (Up) Test Mode OFF A1 Test mode (normally OFF) Standard / Economy / Sleep Mode changes allowed Use Digital Duplex or Light Duplex plane A2 A3 Standard Mode only Use Mini Panel Pump 2 enabled A4 Pump 2 disabled Single voltage heating (240VAC only) Safety Suction (must be OFF) A5 A6 Dual voltage heating enabled See table at right A7 See table at right Temperature displayed in Fahrenheit circ pump; Pump 1 is two-speed A8 A9 Temperature displayed in Celsius Circ pump acts like Pump 1 low speed (filter cycle, polling); Pump 1 is onespeed See table at right A10 See table at right te: Arrow indicates factory default setting. Number of high speed pumps that can be run before heater is disabled (A5 OFF) OR before heater runs at 120VAC (A5 ON). of Pumps A7 A10 0 OFF OFF 1 ON OFF 2 OFF ON 3 ON ON 76

85 Volt 60A GFCI Wiring Diagram SPA INSTALLATION 77

86 Volt Electrical Installation Always follow applicable local, state and federal codes and guidelines. Use only a dedicated electrical line with a 15-amp breaker. Cord-and-plug connections may not use a cord longer than 15 ft (4.6 m) and must be plugged into a dedicated 15-amp GFCI connection. Do not use extension cords! Always use a weatherproof-covered receptacle. Receptacle shall be located not less than 5 ft (1.5 m) from and not exceeding 10 ft (3.0 m) from the inside wall of the spa. Do not bury the power cord. If your cord becomes damaged, replace it before next usage. Part #: ELE Part # ELE All 120V spas must have a GFCI. This can be either a 15-amp GFCI receptacle or a GFCI cord and plug kit as shown at right (CKIT110 - P/N ELE ). SPA INSTALLATION Testing the GFCI Breaker Test the GFCI plug prior to first use and periodically when the spa is powered. To test the GFCI plug version, follow these instructions. (Spa should already be plugged in and operational.) Press the TEST button on the GFCI. The GFCI will trip and the spa will stop operating. Press the RESET button on the GFCI. The GFCI will reset and the spa will turn back on. The spa is now safe to use. If the GFCI trips while the spa is in use, press the RESET button. If the GFCI does not reset, unplug the spa and call your local Cal Spas dealer for service. DO NOT USE THE SPA! 78

87 Volt 50A Electrical Installation All 230V spas must be permanently connected (hardwired) to the power supply. These instructions describe the only acceptable electrical wiring procedure. Spas wired in any other way will void your warranty and may result in serious injury. This is the only acceptable electrical wiring procedure. Spas wired in any other way will void your warranty. See the wiring diagram on page 81. The electrical wiring of this spa must meet the requirements of any applicable local, state, and federal codes. The electrical circuit must be installed by an electrical contractor and approved by a local building / electrical inspector. RCD and Wiring Requirements The power supplied to the spa must be on a dedicated RCD protected circuit with no other appliances or lights sharing the power. Use copper wire with THHN insulation. Do not use aluminum wire. Use the table below to determine your GFCI and wiring requirements. Portable Spas Ultimate Fitness Spas Spa Model GFCI Required Wires Required All 230V spas (except 6205 control boxes requiring high amperage - see below) Spas with the 6300 control box (when high amperage is selected on circuit board) SEE CONFIGURATION INSTRUCTIONS ON NEXT PAGE. Ultimate Fitness spas with one 5.5 kw heater Ultimate Fitness spas with two 5.5 kw heaters One 32 amp RCD or two 16 amp RCDs One 32 amp RCD or two 16 amp RCDs One 32 amp RCD or two 16 amp RCDs Service 1: One 32 amp RCD or two 16 amp RCDs Service 2: One 32 amp RCD or two 16 amp RCDs Four #10 AWG copper wires Four #10 AWG copper wires Four #10 AWG copper wires Service 1: Four #10 AWG copper wires Service 2: Three #10 AWG copper wires SPA INSTALLATION In-Ground Spas Designer in-ground spas with one 3 kw heater Designer in-ground spa with one 3 kw heater and one 5.5 kw heater One 32 amp RCD or two 16 amp RCDs Service 1: One 32 amp RCD or two 16 amp RCDs Service 2: One 32 amp RCD or two 16 amp RCDs Four #10 AWG copper wires Service 1: Four #10 AWG copper wires Service 2: Three #10 AWG copper wires 79

88 When wires larger than #6 AWG are required, install a junction box near the spa and use #6 AWG wire between the junction box and the spa. Wire runs over 85 feet must increase wire gauge to the next lower number. For example: A normal 50 amp RCD with four #8 AWG copper wires run over 85 feet would require you to go to four #6 AWG copper wires. Testing the RCD Breaker Test the RCD breaker prior to first use and periodically when the spa is powered. To test the RCD breaker follow these instructions (spa should be operating): Press the TEST button on the RCD. The RCD will trip and the spa will shut off. Reset the RCD breaker by switching the breaker to the full OFF position, wait a moment, then turn the breaker back on. The spa should have power again. SPA INSTALLATION 80

89 Volt 50A RCD Wiring Diagram GREEN/ YELLOW (Ground) GREEN/ YELLOW (Ground) SPA INSTALLATION CIRCUIT BOARD GREEN/ YELLOW (Ground) 81

90 GS500Z COPYRIGHT 2007 MADE IN U.S.A. P/N 22015_B GS500Z COPYRIGHT 2007 MADE IN U.S.A. P/N 22015_B GS500Z COPYRIGHT 2007 MADE IN U.S.A. P/N 22015_B Pb Pb Pb AV CIRC. PUMP CIRC. PUMP AV CIRC. PUMP OZONE PUMP 1 OZONE PUMP 1 OZONE PUMP 1 F2 F2 S1 F2 S1 S1 SWITCHBANK SWITCHBANK A OPT. BLWR/PUMP 2 OPT. BLWR/PUMP 2 SWITCHBANK A J43 J6 TST OPT. BLWR/PUMP 2 J43 J6 TST J43 J6 TST J60 J60 EXT RLY EXT RLY J J22 EXT RLY J22 AUXF AUXF J7 J J22 AUXF J7 J7 SEN A SEN A SEN A J8 J8 SEN B SEN B SEN B F3 J44 VAC J44 VAC U4 F3 U4 1 J44 VAC 1 J11 F3 U4 1 J11 J11 J12 J J19 J12 J 1 J19 J13 19 J18 J13 1 J18 1 J / 6215 Circuit Board Wiring Single Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) BROWN BLUE J52 (Hot) (Neutral) J51 F6, T30A 480V J25 J J57 Balboa BALBOA INSTRUMENTS, INC. TB1 W1 J50 J47 G G N N F4, T0.2A 250V J28 J26 J29 G N HTR2 J101 HTR1 00 W2 J58 J23 G N K4 K3 K2 K9 T1 J90 K6 E.GND K1 G N J17/26 J46 J1 J2 J10 K8 10VAC J72 F7 F10A 250V C9 J1A J2A K5 J20 F3A 250V J71 G 10VAC N F1 This is the factory default configuration. 1 x 16 Amp or 1 x 32 Amp 3 Wires (1 Line + 1 Neutral + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. O N SWITCHBANK For 1 x 16 Amp Service: DIP Switch A10 must be ON. For 1 x 32 Amp Service: Set DIP Switch A10 such that total system amperage draw never exceeds rated service input. SPA INSTALLATION Dual Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) BROWN BLUE BROWN BLUE J52 (Hot) (Neutral) (Neutral) 2 x 16 Amp 5 Wires (2 Lines + 2 Neutrals + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. (Hot) J51 F6, T30A 480V J25 J J57 Balboa BALBOA INSTRUMENTS, INC. TB1 W1 J50 J47 G G N N F4, T0.2A 250V J28 J26 J29 G N HTR2 J101 HTR1 00 O N W2 J58 J23 G N SWITCHBANK K3 K4 K2 K9 T1 J K6 E.GND K1 G N J17/26 J46 10VAC J72 J1 J2 J10 K8 F10A 250V C9 J1A J2A K5 J20 F3A 250V J71 G 10VAC DIP Switch A10 must be OFF. N Completely remove the white wire from J26 and J32. te: J32 and J25 are electrically identical. The white wire may be attached to either terminal before removal. From RCD Box J52 J51 F6, T30A 480V J50 G N J29 J23 K9 K6 K1 J46 F7 F10A 250V F3A 250V F1 Completely remove the white wire from J26 and J32, or J25. Three Phase Service GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) BROWN BROWN BROWN BLUE (Hot) (Hot) (Hot) (Neutral) J25 J J57 Balboa BALBOA INSTRUMENTS, INC. TB1 W1 J47 G N F4, T0.2A 250V J28 J26 G N HTR2 J101 HTR1 00 W2 J58 G N K3 K4 K2 T1 J90 E.GND G N J17/26 K8 10VAC J72 J1 J2 J10 K5 J20 C9 G N J2A J1A J71 10VAC Completely remove the blue wire from J28 and J59. If an expansion board is installed, black wire must connect to J28 (Line 2) only. 3 x 16 Amp 5 Wires (3 Lines + 1 Neutrals + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. IMPORTANT: Service MUST include a neutral wire with a line to neutral voltage of 230VAC. O N To an optional fuse-protected expansion board SWITCHBANK DIP Switch A10 must be OFF. 82

91 BALBOA INSTRUMENTS, INC. GL2000 TC MACH 3 P/N REV D COPYRIGHT 2006 MADE IN U.S.A. HTR 2 HTR1 BALBOA INSTRUMENTS, INC. GL2000 TC MACH 3 P/N REV D COPYRIGHT 2006 MADE IN U.S.A. HTR 2 HTR1 BALBOA INSTRUMENTS, INC. GL2000 TC MACH 3 P/N REV D COPYRIGHT 2006 MADE IN U.S.A. HTR 2 HTR1 F1 F1 F1 SWITCHBANK A SWITCHBANK A SWITCHBANK A EXT RELAY J6 G EXT RELAY J6 G EXT RELAY J6 G TST J91 J69 J13 J15 J7 J22 J82 TST J91 J69 TST J91 J69 J24 EXT 2S P3 AUX F ALARM SEN A VAC SEN B J13 J15 J7 J22 J82 J13 J15 J7 J22 J82 J24 EXT 2S P3 AUX F ALARM SEN A VAC SEN B J24 EXT 2S P3 AUX F ALARM SEN A VAC SEN B J8 J8 J8 J20 J20 J Circuit Board Wiring Single Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) J57 J98 FUSE T30A 480V F6 Balboa J96 J59 J58 K3 J93 J5 G N K2 J53 J54 W15 J99 TB1 J97 FUSE F10A 250V F5 J27 J95 J3 J94 J26 J23 J28 G N F7 W4 J32 F2 FUSE T0.2A 240V FUSE T30A 480V W3 J68 J4 G N J55 J79 J56 T1 K7 K6 K8 J1 G N K11 K4 J60 J41 J45 J33 J81 K9 J14 K10 J9 J2 G N G N W1 J30 W2 K1 FUSE F3A 250V F4 J39 J10 J70 J71 J72 ADCM 3.0kW MAIN PANEL MAIN PANEL MAIN PANEL AUX PANEL AUX PANEL REMOTE J36 EXT I/O This is the factory default configuration. GREEN/ YELLOW (Ground) J101 J100 J90 1 x 16 Amp or 1 x 32 Amp 3 Wires (1 Line + 1 Neutral + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. O N SWITCHBANK For 1 x 16 Amp Service: DIP Switch A2 must be ON. For 1 x 32 Amp Service: DIP Switch A2 must be OFF. Dual Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) J57 J98 FUSE T30A 480V F6 G N Balboa J93 J96 J59 J58 K3 J5 2 x 16 Amp 5 Wires (2 Lines + 2 Neutrals + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. J101 K2 J53 J54 W15 J99 TB1 O N J97 FUSE F10A 250V J100 F5 J94 J27 J95 J3 J26 J23 J28 G N F7 W4 J32 F2 FUSE T0.2A 240V FUSE T30A 480V W3 J68 J4 G N J55 J79 J56 T1 K7 K6 K8 J1 G N J90 K SWITCHBANK K4 J60 J41 J45 J33 J81 K9 J14 K10 J9 J2 G N G N W1 J30 W2 K1 FUSE F3A 250V F4 J71 J72 J70 J10 J39 ADCM 3.0kW MAIN PANEL MAIN PANEL MAIN PANEL AUX PANEL AUX PANEL REMOTE DIP Switch A2 must be ON. J36 EXT I/O Completely remove the white wire from J26 and J32. te: J32 and J23 are electrically identical. The white wire may be attached to either terminal before removal. SPA INSTALLATION Three Phase Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) J57 J98 FUSE T30A 480V F6 J93 J96 J59 J58 K3 J5 G N Balboa J101 K2 J53 J54 W15 J99 TB1 J97 FUSE F10A 250V J100 F5 J94 J27 J95 J3 J26 J23 J28 G N F7 W4 J32 F2 FUSE T0.2A 240V FUSE T30A 480V J68 J4 G N J55 J79 J56 T1 K7 K6 K8 J1 G N J90 K11 K4 J60 J41 J45 J33 J81 K9 J14 K10 J9 J2 G N G N W1 J30 W2 K1 FUSE F3A 250V F4 J71 J72 J70 J10 J39 ADCM 3.0kW MAIN PANEL MAIN PANEL MAIN PANEL AUX PANEL AUX PANEL REMOTE J36 EXT I/O Completely remove the white wire from J26 and J32. Completely remove the blue wire from J28 and J57. 3 x 16 Amp 5 Wires (3 Lines + 1 Neutrals + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. IMPORTANT: Service MUST include a neutral wire with a line to neutral voltage of 230VAC. O N SWITCHBANK DIP Switch A2 must be ON. 83

92 HTR 2 HTR1 HTR 2 HTR1 HTR 2 HTR1 F1 F1 F1 SWITCHBANK A SWITCHBANK A SWITCHBANK A SWITCHBANK B SWITCHBANK B SWITCHBANK B J83 EXT RELAYJ6 CFG J83 J83 N G EXT RELAYJ6 CFG EXT RELAYJ6 CFG N G N G TST J91 TST J91 TST J91 J17 J69 J17 J69 J17 J69 J10 J13 J15 J17 J22 J82 J70 J10 J13 J15 J17 J22 J82 J70 J10 J13 J15 J17 J22 J82 J24 EXT 2S P3 AUX F ALARM SENA VAC SENB J24 EXT 2S P3 AUX F ALARM SENA VAC SENB J24 EXT 2S P3 AUX F ALARM SENA VAC SENB J8 J8 J8 J20 J20 J Circuit Board Wiring Single Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) BROWN (Hot) BLUE (Neutral) J57 J98 FUSE T30A 480V F6 J96 J59 J58 K3 J93 J5 G N Balboa K2 J53 J54 W15 J99 TB1 J97 FUSE F10A 250V F5 J27 J95 J3 J94 J26 J23 J28 G Blower N F7 W4 J32 F2 FUSE T0.3A 240V FUSE T30A 480V W3 J68 J4 G N A.V. J55 J79 J56 T1 K7 K6 K8 J1 2-Spd P1 G N K11 K4 J60 J41 J45 J33 J81 K9 J14 K10 J9 J2 G N Ozone G N W1 J30 W2 K1 J31 J12 Spa Light J71 J72 FUSE F3A 250V J70 F4 RTC Enabled ADCM J39 3.0kW MAIN PANEL MAIN PANEL MAIN PANEL AUX PANEL AUX PANEL REMOTE J36 EXT I/O This is the factory default configuration. For 1 x 16 Amp Service: DIP Switch A2, A3, and A4 must be OFF. O N GREEN/ YELLOW (Ground) 1 x 16 Amp or 1 x 32 Amp 3 Wires (1 Line + 1 Neutral + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. J101 J kw Heater 230V J8 must be Jumpered J90 Configuration Settings Enabled For both 1 x 16 Amp and 1 x 32 Amp Service: DIP Switch A11 must be ON if using Special Amperage Rule. DIP Switch A11 must be OFF if not using Special Amperage Rule. For 1 x 32 Amp Service: DIP Switch A2, A3, and A4 can be ON. O N SPA INSTALLATION Dual Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) BROWN BLUE BROWN J96 BLUE J57 J98 FUSE T30A 480V F6 J59 J58 K3 (Hot) J93 (Neutral) (Hot) (Neutral) 2 x 16 Amp 5 Wires (2 Lines + 2 Neutrals + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. J5 G N Balboa J101 K2 J53 J54 W15 J99 TB1 J97 FUSE F10A 250V J100 F5 J94 J27 J95 J3 J kw J23 J28 G Blower N F7 W4 J32 F2 FUSE T0.3A 240V FUSE T30A 480V W3 J68 J4 G N A.V. J55 J79 J56 T1 K7 K6 K8 Heater 230V J8 must be Jumpered O N J1 2-Spd P1 G N J90 K11 K4 J60 J41 J45 J33 J81 K9 J14 K10 J9 J2 G N Ozone G N W1 J30 W2 K1 J31 J12 Spa Light Configuration Settings Enabled FUSE F3A 250V F4 J71 J72 J39 RTC Enabled ADCM kW MAIN PANEL MAIN PANEL MAIN PANEL AUX PANEL AUX PANEL REMOTE J36 EXT I/O Completely remove the white wire from J26 and J32. te: J32 and J23 are electrically identical. The white wire may be attached to either terminal before removal. DIP Switch A2, A3, and A4 must be ON. DIP Switch A11 must be ON if using Special Amperage Rule. DIP Switch A11 must be OFF if not using Special Amperage Rule. Three Phase Service From RCD Box GROUND TERMINAL BLOCK (ATTACHED TO OUTSIDE OF SYSTEM BOX) GREEN/ YELLOW (Ground) BROWN (Hot) J93 BROWN (Hot) BROWN J96 (Hot) BLUE (Neutral) 3 x 16 Amp 5 Wires (3 Lines + 1 Neutrals + 1 Protective Earth) Protective Earth wire (Green / Yellow) must be connected to system ground terminal as marked. IMPORTANT: Service MUST include a neutral wire with a line to neutral voltage of 230VAC. J57 J98 FUSE T30A 480V F6 J59 J58 K3 J5 G N Balboa J101 K2 J53 J54 W15 J99 TB1 J97 FUSE F10A 250V J100 F5 J94 J27 J95 J3 J kw J23 J28 G Blower N F7 W4 J32 F2 FUSE T0.3A 240V FUSE T30A 480V W3 J68 J4 G N A.V. J55 J79 J56 T1 K7 K6 K8 Heater 230V J8 must be Jumpered O N J1 2-Spd P1 G N J90 K11 K4 J60 J41 J45 J33 J81 K9 J14 K10 J9 J2 G N Ozone G N DIP Switch A2, A3, and A4 must be ON. DIP Switch A11 must be OFF. W1 J30 W2 K1 J31 J12 Spa Light Configuration Settings Enabled FUSE F3A 250V F4 J71 J72 J39 RTC Enabled ADCM 3.0kW MAIN PANEL MAIN PANEL MAIN PANEL AUX PANEL AUX PANEL REMOTE J36 EXT I/O Completely remove the white wire from J26 and J32. te: J32 and J23 are electrically identical. The white wire may be attached to either terminal before removal. Completely remove the blue wire from J28 and J57. te: J57, J58 and J59 are electrically identical. The blue wire may be attached to either terminal before removal. Move the brown wire from J23 or J32 to J28. 84

93 7.12. External Equipment Pack Plumbing The example shown below is typical for a system with two pumps with external heater and external filter. Designer Spa Specifications DIJ401 DIJ406: Equipment pack weight = 250 lbs. Applies to: Designer in-ground spas Ultimate swim spas with external equipment pack DIJ407: Equipment pack weight = 300 lbs. 2.5 HP heat pump 4 HP swim pump te: Equipment pack cannot exceed 15 feet from spa. SPA INSTALLATION 85

94 Plumbing Connections IMPORTANT! Always check local codes prior to any in-ground spa installation. Once the spa and equipment are properly located, you will want to lay out the plumbing run. Applies to: Designer in-ground spas Ultimate swim spas with external equipment pack Trenches should be deep and wide enough to allow all pipes to be buried below the frost line and should be in as straight a line from the spa to the equipment as possible. Check local code requirements for underground pipes. Always know what is under the ground before you dig anywhere. You will need 2 flex or PVC lines for your suction, intake, and air line. In ground spas have marked intake and suction lines, making it easy find and connect to and from the spa and equipment pack. The plumbing run should not be any longer than 15 feet to maximize water pressure. Another way to maximize water pressure is to limit (or even eliminate) the use of 90 elbows in your plumbing run. A more direct plumbing run using 45 elbows is more efficient, and promotes increased water pressure. SPA INSTALLATION Identifying Plumbing Lines The spa s plumbing lines are clearly marked during water testing at the factory. This is done to assist installers in properly identifying the installation. We still recommend that the installers verify plumbing lines prior to gluing. This can be done by using one of the following techniques. Air Test The air test requires a wet/dry vacuum. Locate the plumbing line you wish to identify and secure the vacuum hose to cut open end. Turn on the vacuum, enter the spa and listen for vacuum suction sound from inside the spa side filter canister. If you hear the suction sound in the canister, the line is properly marked and can be connected to the suction side of the pump on the equipment pack. Water Test The water test requires a garden hose and water source. Locate the plumbing line you wish to identify and secure the outlet side of the garden hose to cut open end. Turn on the water supply to the garden hose, enter the spa and look for water inside the spa side filter canister. If you see water in the canister the line is properly marked and can be connected to the suction side of the pump on the equipment pack. If any plumbing line is not properly marked or not marked at all, follow either the air or water test procedure until all lines are identified prior to gluing. NOTE: Once complete, water test the plumbing run for at least three days prior to covering any plumbing trenches and back-filling spa cavity completely. NOTE: Some local inspectors require pressure testing the plumbing lines. Although the spa is pressure tested at the factory, local inspectors may insist on pressure testing the plumbing run between the spa and equipment pack. 86

95 Gate/Slice Valves The use of gate valves is recommended on all plumbing lines (both suction and return lines). These valves are used to contain the spa s water in either the equipment or the spa. This will assist in the pump priming process and future servicing without needing to drain the spa. NOTE: When draining the spa to perform maintenance, always close the gate valves prior to draining. This will maintain the pumps prime. Connecting Plumbing to Remote Equipment Connecting the plumbing from the spa to the equipment pack must be performed in accordance to local and city codes. NOTE: Most codes require plumbing to be rigid PVC schedule 40 or heavier in both above and below ground installations. In most cases, the use of flexible PVC plumbing is acceptable when properly buried in trenches. Most water plumbing lines are 2 or larger and must be schedule 40 or heavier PVC. When plumbing, minimize the use of 90 elbows as much as possible. The use of 45 elbows will increase the amount of jet pressure you will have over the use of 90 elbows. The plumbing on the spa shell is labeled by the factory in the following manner: Pump 1 Suction: 2 line that connects the spa filter and bottom drain assembly to the front of pump 1. Pump 1 Return: 2 line that connects the top of pump 1, through the equipment filter and heater back to selected jets in the spa. Pump 2 Suction: 2 line that connects the spa filter and bottom drain assembly to the front of pump 2. Pump 2 Return: 2 line that connects the top of pump 2 back to selected jets in the spa. Ozone Line: 1 line that connects to a 1 flexible line extending off the bottom of the equipment pack filter canister through an ozone injector (If ozone equipped) and connected to ozone port on the spa. SPA INSTALLATION Air Blower: 1 1/2 line that is plumbed out of the air blower (located on the equipment pack) and extended up 18 above the spas water level to prevent water flooding the air blower. Air Venturi: 1/2 line that is plumbed 18 above the spa s water level. Topside Control Panel and Temp Sensor: 1 line that connects to the bottom of the control box located on the equipment pack. 87

96 7.13. In-Ground Spa Light Installation Instructions On spas ordered with in-ground lights, the factory installs the light niche for you. The next steps of installation should be performed by a qualified licensed electrician. Always read and follow light manufacturer s safety and installation instructions prior to installation and operation. Incorrect installation may damage the light and void its warranty. The light circuit must be on a GFCI protected service (alone or with a switch). The water resistant junction box (or for 12 volt models, the low voltage transformer) must be located: at least 8 (20 cm) above water level at least 4 (10 cm) above ground level, and at least 48 (121 cm) away from the spa. See figure on next page. Light niche and any metallic items in a 5 (152 cm) radius must be properly bonded with #8 AWG grounding wire. Applies to: Designer in-ground spas WARNING Never operate the underwater light for more than 10 seconds unless it is totally submerged in water. Without total submersion, the light assembly will get extremely hot and may result in serious burns or in breakage of the lamp or lens. This may result in serious injury to pool users, installers, or bystanders, or in damage to property. SPA INSTALLATION Refer to the figure on the next page for wiring instructions Connect rigid conduit to the 3/4 hub located at the back of the light niche and run to a water resistant junction box (or for 12 volt models to a low voltage transformer) no further than 25 (7.6m). Remember this is a water cooled light, so the conduit and all connections must be leakproof. Feed the light cord through the rigid conduit to the junction box, leaving at least 4 feet of cord at the end of the light fixture. This slack in the light cord will allow servicing without draining the spa in the future. Wrap light cord slack around back of light housing and attach light to niche with mounting screw. Cut the cord at the junction box, leaving at least 6 (15 cm) of cord to make connections. Strip 6 (15 cm) of the out cord jacket to expose the three insulated wires. Be careful not to damage the insulation on the three inner wires. Connect the three wires to the corresponding circuit wires in the junction box and secure the junction box cover in place. Replace the light assembly in the niche and tighten the special pilot screw. Fill the spa until the underwater light is completely submerged in water before operating the light for more than 10 seconds. Turn on the main switch or circuit breaker, as well as the spa light control, to check for proper operation Important: Make sure spa light is submerged in at least 18 of water prior to testing. 88

97 Water resistant junction box location SPA INSTALLATION 89

98 7.14. Automatic Priming of the Spa Priming with the Smart Spa Equipment Once the spa is powered up, the Smart Spa equipment will enter into an automatic pump-priming mode. At this time, several diagnostic messages will momentarily appear on the topside panel, which will then display Pr. This process takes approximately four minutes with no equipment function occurring during this time. Applies to: 6000 systems 6100 systems 6200 systems 6300 systems 7000 systems 8005 systems 9800 systems After this four minute delay, the pumps will automatically come on and prime themselves. During this time, the heater will not come on until the system detects water flow from the pumps through the heater. If the system cannot automatically prime the pumps, the topside panel will display error messages of HFL or Dr. These error messages indicate that there is a water flow problem that needs to be corrected before the heater will come on. (See the appropriate troubleshooting flowchart.) Most new delivery water flow problems are caused by the pump(s) failing to automatically prime. To manually prime the pumps or correct other water flow problems, follow the Pump will not prime troubleshooting flowchart on page 7. SPA INSTALLATION 90

99 8.0 Spa Operation DV, 6200DV, 6300DV Initial Startup When first powered up, it will automatically revert to Priming mode. Pr will show on the topside display. Priming mode will be active for less than five minutes, at which time the heater will be activated and the water temperature will be maintained in Standard mode. The spa will heat to 100 F (37.5 C) at start up until the set temperature is changed as described below. Operating instructions for THESE control panels: Temperature Adjustment The control panel displays the actual water temperature. The displayed temperature will only be current after the pump has been running for at least two minutes. To display the temperature that the spa is set to: Press the Temp button. The temperature setting will flash. While the display is flashing, each time you press Temp button, the set temperature will change up or down one degree. If the desired temperature is opposite of the direction each press of the button is making, release button, allow display to stop flashing and then press Temp button to change temperature the other direction. Heating Modes When the spa is powered up, it will automatically start in standard heating mode. Standard heating mode: For all control panels St will light briefly on the main display. In this mode, the heating system will automatically maintain the set spa temperature. NOTE: There is no control panel message displayed while in the standard heating mode. Only the actual water temperature is displayed. Economy heating mode: Ec will display solid if temperature is not current and will alternate with spa temperature if measured temperature is current. Economy mode will heat the water to the set temperature. In the economy heating mode, the heating system will only activate during filtration times. SPA OPERATION 91

100 Sleep mode: Sleep mode, indicated by a SL on the main display, will also only activate the heater during the filtering cycles but will only heat the water to within 20 F (10 C) of the set temperature. Like Economy mode, SL will display solid when temperature is not current and will alternate with actual temperature when it is current. NOTE: Displayed temperature will only be current after the pump has been running for at least two minutes. Switching Modes To switch from the standard heating mode to the economy heating mode: Press the TEMP button followed by the LIGHT button. Press the same sequence to switch back to the standard heating mode. Once in the economy heating mode, Ec will display in the center of the control panel and flash alternately with the water temperature. Jet Controls All control panels One pump equipment: Press the JETS button: SPA OPERATION Once to activate the low speed pump Twice to activate the high speed pump Three times to turn off the high-speed One pump equipment with circulation pump: Press the JETS button: Once to activate the circulation pump Twice to activate the circulation pump and the high-speed pump Three times to turn off both the circulation pump and the high-speed pump Two pump equipment without circulation pump: Press the JETS button: Once to activate the low-speed pump Twice to activate the high speed on pump 1 Three times to activate the high speed on pump 1 and high speed on pump 2 Four times to turn off the high speed on pump 1. The high-speed on pump 2 will remain on. Five times to turn the high speed off on pump 2. Two pump equipment with circulation pump: 92

101 Press the JETS button: Once to activate the circulation pump Twice to activate the circulation pump and the high-speed pump 1 Three times to activate the circulation pump, high-speed pump 1 and highspeed pump 2 Four times to turn off the circulation pump and high speed pump 1. High-speed pump 2 will remain on. Five times to turn off the high-speed on pump 2 All control panels except 6100 and 6200 Optional Turbo Jets Press the Options button to turn turbo jets on and off control panel only Pump 2 and Pump 3 Sequence Press the OPTION button: Once to activate high speed pump 2 Twice to activate high speed pump3 and high speed pump 2 Three times to activate pump 3 high speed only Four times to turn pumps off Setting the Temperature Lock This feature allows you to lock a temperature into the system. When engaged, the set temperature will blink on and off when the TEMP button is pressed. However, you will not be able to change it until you unlock the set temperature: SPA OPERATION Press the TEMP button. Press the OPTION button to unlock the set temperature. Select a temperature with the TEMP button. Press the OPTION button to set and lock the temperature. 93

102 Automatic Time outs These features will automatically turn themselves off during periods of continuous use: Low speed pump High speed pumps Optional circulation pump Optional turbo Spa light After 4 hours After 15 minutes After 15 minutes After 15 minutes After 15 minutes Setting Filtration Cycles The spa will automatically filter itself twice a day. The first cycle will begin 6 minutes after the spa is turned on and the second cycle 12 hours later. The factory has programmed the cycle to last for 2 hours but this can be switched to 4, 6, 8, or 12 hours depending on your requirements. To set filtration time, turn off the power to the spa at the time of day you would like one of the filtration cycles to begin then turn back on after 30 seconds. When power has been restored, press the Temp button then the Jets button. Press Temp button again to change the filtering cycle duration. When desired duration is selected press the Jets button to exit. At the beginning of each filtering cycle the Turbo system will run for approximately 30 seconds. The low speed pump will run for the duration of the filtering cycle and if an Ozone system is installed it will be activated. During filtering, FC will appear on the main display. SPA OPERATION Light Press the Light button to turn on the light. Press it once again to turn the light off. All optional lighting such as the control panel light and cabinet perimeter lighting is controlled by the Light button and will turn on and off with the spa light. 94

103 Initial Start-up When your spa is first powered up, it displays some configuration codes and then goes into priming mode (Pr will appear on the display panel). This mode lasts up to four minutes and then the spa begins to heat to its pre -programmed temperature of 100 F (37.7 C). You can exit the priming mode early by pressing UP or DOWN buttons. Operating instructions for THIS control panel: Temperature Adjustment The electronic control panel displays the actual water temperature. Press the UP or DOWN buttons once to display the set temperature. Each time either button is pressed again, the set temperature will increase or decrease depending on which button is pressed. After three seconds, the control panel will automatically display the last measured spa temperature. Heating Modes Standard Heating Mode: When the spa is powered up, the heating feature will automatically activate. Whenever the water temperature drops more than one degree below the set temperature, the heating system will automatically activate and heat the spa water to the set temperature. This is programmed to maintain the desired temperature. te that the last measured spa temperature displayed is current only when the pump has been running for at least two minutes. The STAND icon will display until the mode is changed. Economy Heating Mode: Economy mode heats the spa to the set temperature only during filter cycles. The ECON icon will display until the mode is changed. Pressing the JETS 1 button while in economy mode puts the spa in standard-in-economy mode, which operates the same as standard mode but reverts back to economy mode automatically after one hour. During this time, pressing the MODE/ PROG button will revert to economy mode immediately. Sleep Mode: SPA OPERATION Sleep mode heats the spa to within 11 C of the set temperature only during filter cycles. The SLEEP icon will display until the mode is changed. Standby Mode: The standby mode is helpful when changing a filter. Pressing Warm or Cool then Jets 2 will turn off all spa functions temporarily. Pressing any button resets the spa. Switching Heating Modes Press the MODE / PROG button to switch between standard, economy, and sleep modes. Press MODE / PROG to enter mode programming. 95

104 Press the COOL or DOWN button to cycle through to the desired mode. Press MODE / PROG to confirm selection. Jet Controls Press the Jets 1 button: Once to activate low speed on pump 1 or to activate Cal Spa filtration pump (if equipped) Twice to activate pump one in high speed Three times to turn pump 1 or Cal Filtration pump off. Press Jets 2 button: Once to activate pump 2 in low speed Twice to activate pump 2 in high speed Three times to turn off pump 2 SPA OPERATION To Set Time and Filtration Cycles Press the time button once. Press the MODE / PROG button once. Press the WARM or COOL buttons to adjust the time. Once the time is adjusted, press the MODE / PROG button to move to next setting. Press WARM or COOL to set first filtration cycle te: FIL 1 will be displayed Press MODE / PROG to move to the second filtration setting. Press WARM or COOL to set the second filtration cycle. Press MODE / PROG to exit the filtration cycle. Preset Filter Cycles There are two filter cycles per day. The start and end times of each cycle are programmable. To program, set the time as instructed above, then press MODE/PROG to advance to the next setting (or to exit after the last setting). The default filter cycles are as follows: The first filter cycle is automatically activated at 8:00 AM and operates the pump until 10:00 AM. The FILTER 1 indicator icon will light when filter 1 is running. The second filter cycle is automatically activated at 8:00 PM and operates the pump until 10:00 PM. The FILTER 2 indicator icon will light when filter 2 is running. The pump and the ozone generator will run during filtration. At the start of each filter cycle, the blower will run on highest speed for 30 seconds to clean out the air channels. The lowest speed of pump 2 and pump 3 will run for five minutes. In the event of power loss or shut down, the time of day will need to be reset for filter cycles to run according to your desired programming. 96

105 Circulation Pump (optional) If your system is equipped with a circulation pump, it may be configured to work in one of two different ways: The circulation pump operates continuously (24 hours) with the exception of turning off for 30 minutes at a time when the water temperature reaches 1.7 C above the set temperature (most likely to happen in very hot climates). The circulation pump will come on when the system is checking temperature, during filter cycles, during freeze conditions, or when another pump is on. Option (Optional Blower) Press the OPTION button to turn the optional equipment on and off. If left on, the equipment will automatically turn off after 15 minutes. Freeze Protection If the temperature sensors detect a drop to 6.7 C within the heater, the pump automatically activates to provide freeze protection. The equipment stays on until four minutes after the sensors detect that the spa temperature has risen to 7.2 C or higher. 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 protection acts similarly except with the temperature thresholds determined by the switch and without a four minute delay in turnoff. Ozone (optional) On most systems, the ozone generator (if installed) runs during filter cycles (except when pump 1 is operating at high speed on a non-circulation system) and during clean-up cycles. On some systems, the ozone generator operates whenever the pump runs. If your system is configured with the optional ozone disable feature, the ozone generator will turn off for one hour any time a function button (JETS 1, JETS 2, OPTION etc.) is pressed. Clean-up Cycle When the pump or blower is turned on by a button press, a clean-up cycle begins 30 minutes after the pump or blower is turned off or times out. The pump and the ozone generator will run for one hour. Setting the Temperature Lock To activate the temperature lock, press the following buttons within three seconds: SPA OPERATION 1. WARM or COOL (UP or DOWN) 2. TIME 3. JETS 1 4. WARM or COOL (UP or DOWN) The panel will display TEMP LOCK when the set temperature is locked. To unlock the set temperature, press the following buttons within three seconds: 1. WARM or COOL (UP or DOWN) 97

106 TIME JETS 1 COOL (DOWN) Time When time hasn t been programmed, the TIME icon flashes. To set the time, press the TIME button and then the MODE/PROG button. Use the UP and DOWN buttons to adjust time. See the next page for more detailed instructions. Locking the Panel To lock the panel: Press TIME, JETS 1, and the UP button within three seconds. When locked, the panel will display LOCK. All buttons are frozen except the TIME button. To unlock the panel: Press TIME, JETS,1 then the DOWN button within three seconds. Light Press light once to activate spa light. Press light to turn off spa light. Invert This enables you to read the display while you are in the spa. SPA OPERATION Press the INVERT button once to change the numbers in the display to read upside down. Pressing INVERT a second time returns the display to the right-side-up position. 98

107 8.3. Display Messages Diagnostic Messages Message What the message indicates Action required BUF Internal problem detected. Repair required. Contact your dealer or service organization. dr dry dy Ec Pr --F --C HFL LF HL OH OHH OHS HH ICE IC Heater LED light Ozone LED light Pr SA Sb Sna Snb Insufficient water flow through the heater has been detected. Spa will be shut down for 15 minutes. Economy mode. Heater will only operate during filtration times. Temperature unknown A difference in readings between temperature sensors has been detected indicating a possible water flow problem. Overheat protection (spa is shutdown) One of the sensors has detected 118 F (48 C) at the heater. Potential freeze condition detected. Heater LED will come on when the heater is on (and goes off when heater is off). Ozone LED will come on when in filtration cycles. When your spa is first actuated, it will go into Priming mode. Spa is shut down. Spa has detected that one of the sensors is not operating properly. One of these may display briefly during overheat then disappear when overheat situation has been resolved. See page 37 for troubleshooting. Check water level and fill spa if water level is low. Make sure pumps are primed (water is flowing) and filter cartridges are clean. Press any button to reset or wait 15 minutes and spa will automatically reset. action required. See page 44 for troubleshooting. After the pump has been running for two minutes, the temperature will be displayed. See page 38 for troubleshooting. Make sure spa is filled to proper level and that pumps are primed (water is flowing). Also check to make sure filter cartridges are clean. See page 40 for troubleshooting. DO NOT ENTER THE WATER! Remove the spa cover and allow spa to cool below 107 F (42 C). Press any button on the topside display to reset spa. If spa will not reset after spa has cooled, turn off power for approximately 30 seconds and then turn power back on. See page 39 for troubleshooting. action required. action required. The Priming mode will last for up to four minutes and then the spa will begin to heat and maintain the water temperature in the Standard mode. See page 42 for troubleshooting. SPA OPERATION 99

108 Message What the message indicates Action required Sf Sn Sns Stby Safety Suction System (Spa is shut down). The display will show SF as soon as the vacuum switch closes. All functions will turn off and the system will be disabled until a panel button is pressed. Sensors are out of balance. If this is alternating with the temperature, it may just be a temporary condition. If the display shows only this message (periodically blinking), the spa is shut down. Pressing a button combination on the user panel has activated standby Mode. See page 43 for troubleshooting. See page 41 for troubleshooting. Press any button to leave Standby Mode and return to normal operation. Periodic Reminders SPA OPERATION rph Every 7 days Test and adjust chemical levels per manufacturer s instructions. rsa Every 7 days Test and adjust chemical levels per manufacturer s instructions. rcl Every 30 days Remove, clean, and reinstall filter per manufacturer s instructions. rtg Every 30 days Test & reset GFCI per manufacturer s instructions. Drain and refill spa per manufacturer s instructions. rdr Every 90 days Drain and refill spa per manufacturer s instructions. RCO RCH Every 180 days Clean and condition spa cover Every 365 days Install New Bio-Clean Filter 100

109 Circuit Diagrams and Schematics Voltage and Amp Draw Ranges Voltage Ranges Wire combo Voltage + -10% Black & Red 240V 216V - 264V Black & White 120V V Red & White 120V 108V - 132V Back & Green 120V V Green & White 0V Amps Draw Ranges Device 120V 240V Pump low 2A - 5A 2A 4A Pump High 10A 14A 8A 12A Blower 6A 8A 3A 4A Acceptable Heater Amp Draw Ranges Heater type 120V 240V 5.5KW-240V 11.42A-12.75A A 4KW -240V 7.58A-9.26A A 1.KW -120V 7.58A-9.26A Acceptable Heater Ohm Ranges Heater type Ohms 5.5kw- 240V kw-240V te: All voltage specifications in video as 120V or 240V, variance ±10%. Depending on variables such as length of run, type of wire and temperature, small voltage readings may sometimes occur between ground and neutral. CIRCUIT DIAGRAMS 101

110 CIRCUIT DIAGRAMS 102

111 CIRCUIT DIAGRAMS 103

112 W W A B C CLASS G FUSE 30A J66 J65 J11 USE ONLY COPPER CONDUCTORS: #6 AWG MIN. 75 C MIN. WHT AC J15 J16 J25 J63 J64 NEUTRAL WHITE HOT BLACK F5 BLK AC J61 J62 K6 J23 G R B W F4 FUSE 0.3A 250V K1 W1 W4 T1 F7 FUSE 20A 250V J50 G W R G W R B B W7 J17/26 K9 K8 J1 J46 J47 G R B W W2 W3 J1A J2A G R B W J29 K5 J20 FUSE 3A 250V F1 J10 A B C D K4 TORQUE RANGE FOR TB1: IN. LBS. HOT RED TB1 K3 K2 J U4 J12 J18 D J32 J33 J34 J35 J43 E Balboa RED AC HTR2 HTR1 F2 E.GND SWITCHBANK A S1 J60 J22 J6 J7 J8 TST EXT RLY AUX.F SEN. A SEN. B J44 VAC BALBOA INSTRUMENTS, INC. 2-SPD VS500Z EXT RLY P/N REV B MADE IN U.S.A COPYRIGHT 2003 J13 E Output Features Quadrant J23 + W1 2-Speed Pump 1 4-A OR 1-Speed Pump 1 with DIP Switch A5 J50 + W4 Audio Visual power output (Hot) 6-A J17/26 + W7 1-Speed Blower 6-B OR Single-Speed Pump 2 J47 + W2 Circ Pump 8-A J29 + W2 Ozone (Same voltage as Circ Pump, if used) 9-A te X-03 option at right for retro fit J20 Spa Light (12V only) 9-A System can be configured for any Duplex Topside Panel or a Serial Standard Panel. CIRCUIT DIAGRAMS Legend Code Format: System Type Expander Board Identifier VS501 S XO3 P Metal (M) or Plastic (P) Enclosure Standard (S) or Duplex (D) Panel Designator X-Mount P PN Used for mounting any Expander Board in a plastic enclosure. Standoffs attach to heater mounting bracket. 104

113 DV K10 J17/26 is a required device. Black Jumper Required. Do not remove. C J66 J65 N/O N/C CLASS G 30A FUSE F5 WHT AC NEUTRAL WHITE J16 J63 J11 J25 J64 J15 J61 K1 J62 BLK AC J74 K6 J23 F4 FUSE.3A 250V 2-Spd P1 G C Black jumper required. Do not remove. W1 J73 W4 G C T1 F7 FUSE 20A 250V J50 W10 1-Spd P2 G C J17/26 W7 K8 K9 Ozone and Circ Pump must be the same voltage. Do not remove Fuse F7 (20A) J46 J47 G C W2 W3 J1 J1A J29 Ozone G C K5 J20 12V Light G C F1 J10 FUSE 3A 250V K4 TORQUE RANGE FOR TB1: IN. LBS. HOT BLACK HOT RED TB1 K3 K2 J2 J2A VS50x mode U4 J12 J18 J100 J32 Balboa J33 J34 J36 J37 RED AC J35 HTR2 J101 HTR1 F2 E.GND SWITCHBANK A J43 J44 VAC J60 J22 J6 J7 J8 S1 TST EXT. RLY AUX. F SEN. A SEN. B BALBOA INSTRUMENTS, INC. VS500Z P/N REV D To Safety Suction Switch MADE IN U.S.A COPYRIGHT SPD EXT RLY J kw Heater 240V (Approx. 120V) Do t Use an Aux Freeze Sensor with this System. WARNING: Main Power to system should be turned OFF BEFORE adjusting DIP switches. WARNING: Persistent Memory (J43) must be RESET to allow new DIP switch settings to take effect. (See Persistent Memory page) SSID # A1, Test Mode OFF A6, Safety Suction A2, Mode changes allowed A7, See Table 1 A3, Mini Panel A4, Pump 2 Enable A9, Circ Pump Off A5, Dual-Voltage Single Heat A10, See Table 1 J12 VS50x Compatible J43 Memory Reset Wiring Color Key 120 Volt Connections 240 Volt Connections Black AC Jumpers 12 Volt Connections Relay Control Wires Board Connector Key 1 Typically Line voltage 2 Typically Line voltage for 2-speed pumps 3 Neutral (Common) 4 Ground te flat sides in connector CIRCUIT DIAGRAMS 105

114 DV K10 J17/26 is a required device. Black Jumper Required. Do not remove. C J66 J65 N/O N/C CLASS G 30A FUSE F5 WHT AC NEUTRAL WHITE J16 J63 J11 J25 J64 J15 J61 K1 J62 BLK AC J74 K6 J23 F4 FUSE.3A 250V 2-Spd P1 G C Black jumper required. Do not remove. W1 J73 W4 T1 F7 FUSE 20A 250V J50 W10 Audio Visual G C 1-Spd P2 G C J17/26 W7 K8 K9 Ozone and Circ Pump must be the same voltage. Do not remove Fuse F7 (20A) J46 J47 G C W2 W3 J1 J1A J29 Ozone G C K5 J20 12V Light G C F1 J10 FUSE 3A 250V K4 TORQUE RANGE FOR TB1: IN. LBS. HOT BLACK HOT RED TB1 K3 K2 J2 J2A VS50x mode U4 J12 J18 J100 J32 Balboa J33 J34 J36 J37 RED AC J35 HTR2 J101 HTR1 F2 E.GND SWITCHBANK A J43 J44 VAC J60 J22 J6 J7 J8 S1 TST EXT. RLY AUX. F SEN. A SEN. B BALBOA INSTRUMENTS, INC. VS500Z P/N REV D To Safety Suction Switch MADE IN U.S.A COPYRIGHT SPD EXT RLY J kw Heater 240V (Approx. 120V) WARNING: Main Power to system should be turned OFF BEFORE adjusting DIP switches. WARNING: Persistent Memory (J43) must be RESET to allow new DIP switch settings to take effect. (See Persistent Memory page) CIRCUIT DIAGRAMS SSID # A1, Test Mode OFF A6, Safety Suction A2, STD/ECN/SLP Modes A7, See Table 1 A3, Mini-dash Panel J43 A9, n-circ Mode A5, Dual-Voltage 60 Hz Heat A10, See Table 1 Panel Button Assignments Panel Button Positions 1=Pump 2 4=Light 1 2=Pump 1 Aux=Exp. Brd =Temp VS51x/VS5xxS/VS5xxD Compatible J Memory Reset A Wiring Color Key 120 Volt Connections 240 Volt Connections Black AC Jumpers 12 Volt Connections Relay Control Wires Board Connector Key 1 Typically Line voltage 2 Typically Line voltage for 2-speed pumps 3 Neutral (Common) 4 Ground te flat sides in connector 106

115 9.7. Wiring Configuration and DIP Settings Setup 1 (As Manufactured) 6300DV Black jumper required. Do not remove. Ozone and Circ Pump must be the same voltage. Do not remove Fuse F7 (20A) K10 C J66 J65 N/O N/C CLASS G 30A FUSE F5 WHT AC NEUTRAL WHITE J16 J63 J25 J15 J64 J11 J61 K1 J62 BLK AC J74 K6 J23 2-Spd P1 G C F4 FUSE.3A 250V W1 J73 W4 T1 J50 Audio Visual G C F7 FUSE 20A 250V W10 1-Spd P3 G C J17/26 W7 K8 K9 J1 J46 J47 G C W2 W3 J1A J29 Ozone G C K5 J20 12V Light G C F1 J10 FUSE 3A 250V K4 TORQUE RANGE FOR TB1: IN. LBS. HOT BLACK HOT RED TB1 K3 K2 J2 J2A VS51x mode U4 J12 J18 J100 J32 Balboa J33 J34 J36 J37 RED AC J35 HTR2 J101 HTR1 F2 E.GND SWITCHBANK A S1 J43 J44 VAC J60 J22 J6 J7 J8 TST EXT. RLY AUX. F SEN. A SEN. B BALBOA INSTRUMENTS, INC. VS500Z P/N REV D To Safety Suction Switch MADE IN U.S.A COPYRIGHT SPD EXT RLY J kw Heater 240V (Approx. 120V) W1 J1 R B W G 1-Spd P2 F30A 480V X-P231 PN P/N REV B J6 J7 WARNING: Main Power to system should be turned OFF BEFORE adjusting DIP switches. WARNING: Persistent Memory (J43) must be RESET to allow new DIP switch settings to take effect. (See Persistent Memory page) SSID # A1, Test Mode OFF A6, Safety Suction A2, STD/ECN/SLP Modes A7, See Table 1 A3, Mini-dash Panel J43 A9, n-circ Mode A5, Dual-Voltage 60 Hz Heat A10, See Table 1 Panel Button Assignments Panel Button Positions 1=Pump 2 4=Light 1 2=Pump 1 Aux=Exp. Brd =Temp VS51x/VS5xxS/VS5xxD Compatible J Memory Reset A Wiring Color Key 120 Volt Connections 240 Volt Connections Black AC Jumpers 12 Volt Connections Relay Control Wires Board Connector Key 1 Typically Line voltage 2 Typically Line voltage for 2-speed pumps 3 Neutral (Common) 4 Ground te flat sides in connector CIRCUIT DIAGRAMS 107

116 P2 CIRCUIT DIAGRAMS 108

117 P3 CIRCUIT DIAGRAMS 109

118 9.10. OE9900 CIRCUIT DIAGRAMS 110

119 9.11. VS300 Black Jumper Required. Do t Remove. Ozone must be same voltage as Pump 1. Ozone runs with Pump 1 low-speed. CLASS G FUSE 30A F5 WHT AC J11 J15 J25 J63 NEUTRAL WHITE K1 K6 J23 2-Spd P1 G C J73 W1 F4 FUSE.3A 250V T1 W10 FUSE 3A 250V J1 W2 J29 Ozone G C K5 J20 12V Light G C F1 FUSE 3A 250V HOT BLACK K4 TORQUE RANGE FOR TB1: IN. LBS. HOT RED TB1 K3 K2 U4 J18 J32 J33 J34 J35 J43 RED AC F2 Balboa HTR2 HTR1 E.GND SWITCHBANK A J6 J7 J8 S1 TST SEN. A SEN. B BALBOA INSTRUMENTS, INC. VS500Z P/N REV D MADE IN U.S.A COPYRIGHT kw Heater 240V (Approx. 120V) WARNING: Main Power to system should be turned OFF BEFORE adjusting DIP switches. WARNING: Persistent Memory (J43) must be RESET to allow new DIP switch settings to take effect. (See Persistent Memory page) SSID # A1, Test Mode OFF A2, Un, P1, LT, P1, TD, TE, TU LT A7, Mode changes allowed A3, Mini Panel A4, N/A (must be OFF) A9, N/A (must be OFF) A5, N/A (must be OFF) A10, High Amp mode Panel Button Assignments Panel Button Positions 1=Pump 1=Unused1 2=Light 2=Pump 1 3=Temp Down 4=Temp 4=Light Up J43 Memory Reset 3 Wiring Color Key 120 Volt Connections 240 Volt Connections Black AC Jumpers 12 Volt Connections Relay Control Wires Board Connector Key 1 Typically Line voltage 2 Typically Line voltage for 2-speed pumps 3 Neutral (Common) 4 Ground te flat sides in connector CIRCUIT DIAGRAMS 111

120 9.12. VS501 CIRCUIT DIAGRAMS 112

121 10.0 Software Configuration Persistent Memory and Powering Up Any time you change DIP Switches or Software Configuration Settings that affect parameters the user can change (any filter settings, set temperature default, Celsius vs Fahrenheit, 12-hour vs 24-hour time, reminders suppression, etc), you must reset Persistent Memory for your DIP Switch or Software Configuration Settings changes to take effect. You should also reset Persistent Memory after loading a new file into a board (using the ESM, purchased separately). Applies to: 9800P2 (Mach 3) 9800P3 (Mach 3) 9800P5 (Mach 2) OE9900 (Mach 3) OE9905 (Mach 3) To Reset Persistent Memory: Power down. Set A12 ON (See illustration below). Power up. Wait until or is displayed on your panel. te: If appears see section below. Set A12 OFF. (This can be done safely with power on if you use a non-conductive tool such as a pencil to push the switch back to the OFF position. Otherwise, power down before setting A12 OFF) Power up again (if you powered down in the previous step). For all other power ups, leave A12 OFF. About Persistent Memory and Time of Day Retention: This system uses memory that doesn t require a battery to store a variety of settings. What we refer to as Persistent Memory stores all the User Preferences, as well as all the filter settings, the set temperature, and the heat mode. Persistent Memory is not used for Time of Day. Time of Day needs to be kept running (not just stored) while the power is off, so a separate Real Time Clock feature (on all models except the EL1000) keeps track of Time of Day while the unit is off. Time of Day Retention, and Time of Day Retention alone, is controlled by the J91 jumper. J91 must be set according to main system panel used. 113 SOFTWARE CONFIGURATION

122 CFE message on power up: If appears before (and instead of) or, you have not configured DIP Switches and/or Software Configuration Settings in a valid manner. This must be corrected before you can reset Persistent Memory. The switch numbers, jumpers, or configuration settings displayed after are ones with which the system has found a configuration problem. For example: would mean that the combination of how you ve set A5 and how you ve set B2 is not supported on this system. would mean that there is a problem with jumper J99. would mean that the combination of how you ve set pump 3 for 1-speed and blower for 1-speed is not supported on this system. would mean that the combination of how you ve set DIP switches which have been assigned to pump 3 and blower is not supported on this system. Power Up Display Sequence Upon power up, you should see the following on the display: SOFTWARE CONFIGURATION Three numbers in a row, which are the SSID (the System Software ID). The third display of these numbers is the Software Version, which should match the version of your system. For example, if these three numbers are, that is a Mach 3 EL8000 at version 26. If there is a Configuration Error, the message (see above) will appear at this point (and none of the messages below will display). Otherwise what comes next is: (indicating the system is configured for a heater between 3 and 6 kw) or (indicating the system is configured for a heater effectively* between 1 and 3 kw). should appear for all EL models running at 240VAC. should appear for all EL models running at 120VAC, as well as all GL models. (*A heater which is rated at 4 kw at 240VAC will function as a 1 kw heater at 120VAC.) If your system is using a special type of heater, a display such as may appear next. If your system is using the generic Balboa heater, no heater type display will appear. or will appear to signal the start of Priming Mode. At this point, the power up sequence is complete. Refer to the User Guide for the ML Series panel on your system for information about how the spa operates from this point on. 114

123 10.2. DIP Switches and Jumpers When the logic jumper is installed on J83 (CFG), configuration settings are enabled. DIP switches will then operate as shown below. A1, Test Mode OFF A7, N/A B1, N/A A2, + 1 Pump w/heat A8, N/A B2, N/A A3 A9/ N/A B3, N/A A4 A10, edit B4, N/A A5, N/A A11, N/A B5, N/A A6, N/A A12, Memory ON B6, N/A DIP Switch Key A1... Test mode (rmally OFF) A2... In ON position, add one high-speed pump (or blower) with heater A3... In ON position, add two high-speed pumps (or 1 HS pump and blower) with heater A4... In ON position, add four high-speed pumps (or 3 HS pumps and blower) with heater A N/A A10... When switched ON when spa is on, system will enter the Edit Menu for Configuration Settings. Do not start spa with A10 turned on or CFE* error will occur. A11... N/A A12... Persistent memory reset. (Used when spa is powering up) A2, A3, and A4 work in combinations, e.g., A2 and A3 in the ON position and A4 in the OFF position will allow 3 high-speed pumps (or two HS pumps and blower) to run with the heater. Switchbank B is totally disabled (N/A). *CFE errors are illegal configurations such as a pump and a blower set to run on the same output. The configuration must be corrected before the spa will operate. J37 Jumper on Pin 1 and 2 will power one leg of J9 (spa light) at 120 volts AC Jumper on Pin 2 and 3 will power one leg of J9 (spa light) at 12 volts AC. te: W9 controls voltage on the other leg of J9 and must be set for the same voltage. SOFTWARE CONFIGURATION 115

124 10.3. Configuration Setting Accessing Configuration Settings When DIP switch A10 is turned ON while spa is powered up and running, the system will enter the Edit Menu for Configuration Settings Press and Temperature button to scroll through the list of settings shown below and on the next pages. Press Jets 1 on the main control panel to select a Feature. The Configuration Setting will flash. Press any Temp button to scroll through the various Configuration Settings for the Feature. Press Jets 1 to select a Configuration and return to the Feature List. The Configuration Setting will stop flashing. Press Temp to continue scrolling the list. Continue until all settings are chosen. Press any Light button to exit the Configuration Settings Menu. Turn DIP Switch A10 to the OFF (down) position. Spa will automatically begin to run with the new settings. Do NOT start up the spa with A10 turned on or the CFE error will occur. CFE errors are illegal configurations such as a pump and a blower set to run on the same output. The configuration must be corrected before the spa will operate. SOFTWARE CONFIGURATION 116