Balboa Water Group BP500 Troubleshooting Manual Download | Manualshive

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Manufactured under one or more of these patents. U.S. Patents: 5332944, 5361215, 5550753, 5559720, 5,883,459, 6253227, 6282370, 6590188, 6976052, 6965815, 7030343, 7,417, 834 b2,

Canadian Patent: 2342614, Australian patent: 2373248 other patents both foreign and domestic applied for and pending. All material copyright of Balboa Water Group.

42211 C

Balboa's BP Troubleshooting & Service Manual

60 Hz

SPA CONTROL SYSTEMS

PANELS

BP500

BP2000G1

TP900, TP800,

TP600, TP400

THIS MANUAL COVERS THE FOLLOWING:

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Summary of Contents for BP500

Page 1: ...5815 7030343 7 417 834 b2 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 42211 C Balboa...

Page 2: ...as this will expose dangerous voltage points and other dangerous risks Please contact your dealer or authorized repair center for service GFCI It is required by code to install a Ground Fault Circuit...

Page 3: ...Canadian Electric Code as well as any local electrical codes in effect at the time of installation The selection of electrical materials required to accomplish this installation and the installation...

Page 4: ...iance Conformit Caution K 2 A A52 4 B 1 3 B9A 06 0B6A 6 A2 B A2 2 idual current device before each use of the spa K 2 1 A52 6 A B0A6 B 9 K 12 B A2 1 6 42 B A 2 C6121 63 A52 2 B6 2 A 6 A 2 6 A 9921 in...

Page 5: ...ox G F C I System Box 16 Wiring Checks 17 Testing a System with Power 18 Troubleshooting Pumps Problem Cause 22 Acceptable Ranges for Testing Equipment 23 Fuses Devices Locations and Values 24 BP 60Hz...

Page 6: ...a BP Spa System 52 TP800 TP900 Panel Operations 54 The Main Screen Navigation 54 TP800 TP900 Priming Mode Start up Sequence 55 TP800 TP900 Spa Behavior 56 TP800 TP900 Adjusting Filtration 57 TP800 TP9...

Page 7: ...ers assorted flat and Phillips U Digital Multi meter U Padlock to lock electrical disconnect during service U Pliers Slip Joint Needle nose U RECOMMENDED PARTS TO HAVE FOR SERVICE CALLS Extra Board s...

Page 8: ...5 System Models BP500 and other BP Series Systems as re quired Panel Model TP600 Series TP400 Series Software Version s Software versions vary and are constantly changing See Tech Sheets for latest ve...

Page 9: ...53 J58 J11 J41 J48 J6 J7 J49 J19 J50 J13 J12 J88 J62 F6 30A F8 30A J56 J57 J55 J59 J51 J52 J98 J10 J81 J20 J18 J43 CIRC PUMP OZONE A V HOT PUMP 1 J14 K9 J5 AUX J8 AUX J40 REMOTE J35 MAIN J34 MAIN J109...

Page 10: ...diagram that is included with each system on the inside of the system box cover Use this diagram for voltage measurement points and for proper reconnection of wires HIGH VOLTAGE CAN SERIOUSLY INJURE O...

Page 11: ...the G F C I stops tripping after you unplugged one of the U spa s components turn off the power to the spa then plug in each component except the one that tripped the G F C I Power up the system If t...

Page 12: ...lboa Water Group 6 22 13 120 Volt Residential Wiring Schematic with G F C I 120 VAC 120 VAC Neutral Outside Ground Rod ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF O...

Page 13: ...L F7 10A 250VAC F2 10A 250VAC J44 3 TB1 J15 ON 10 S1 K5 K1 K3 T1 K2 K8 LIGHT GND J33 J32 J9 2 K6 4 3 2 1 J45 J110 J79 J54 J72 J42 J3 J37 J4 J1 J61 J47 J77 J75 J78 J36 J60 J46 J38 J39 J111 J53 J58 J11...

Page 14: ...sidential Wiring Schematic with G F C I Correct Voltage When Probes Are Placed Across 108V 132V 1 3 5 6 5 10 12 14 13 14 2 3 5 7 5 11 12 15 13 15 0v 3 4 5 8 5 9 12 13 108V 132V 1 3 5 6 5 10 12 14 13 1...

Page 15: ...CE HTR SEL F7 10A 250VAC F2 10A 250VAC J44 3 TB1 J15 ON 10 S1 K5 K1 K3 T1 K2 K8 LIGHT GND J33 J32 J9 2 K6 4 3 2 1 J45 J110 J79 J54 J72 J42 J3 J37 J4 J1 J61 J47 J77 J75 J78 J36 J60 J46 J38 J39 J111 J53...

Page 16: ...k To Topside Relay Opens or Closes LED or Icon Is Turned On or Off Hear Or See Relay Open Or Close In Most Cases If This Happens There Is No Problem With The Topside Panel or System Board U 8 7 9 t 1...

Page 17: ...control system note that connections for the incoming wires are clearly labeled at the main terminal block 30A service minimum ten gauge copper wire U 40A service minimum eight gauge copper wire U 50...

Page 18: ...but still doesn t operate then test for a blown power input fuse See section Testing Pump Fuses for Damage F6 Fuse Terminal Block 1 F6 Fuse on a BP2000 Board Terminal Block 1 F5 Fuse on a BP500 Power...

Page 19: ...rst check with your spa manufacturer for amperage draw limits on each device Since the blower should now be running you can check U the amperage draw with an ammeter by measuring around the black blow...

Page 20: ...e heater for a few seconds and the Heat LED will light After a few seconds of heat the heater will shut off for 90 seconds and the sys tem will look at the sensors to be sure they are within the M7 pa...

Page 21: ...1 was turned on due to this reason alone this message will appear for up to two minutes right after very cold water is detected NOTE Internal freeze protection only functions when there is proper pow...

Page 22: ...ater leakage f unions No air mixed into water Contact qualified electrician for service Pump hums noisy GFCI Fuse No incoming power X X Thermal overload tripped X X Air button or switch on pump defec...

Page 23: ...120V DRAW 240V DRAW Pump low 2 A 5 A 2 A 4 A Pump high 10 A 14 A 8 A 12 A Blower 6 A 8 A 3 A 4 A Acceptable Ranges for Testing Equipment ACCEPTABLE HEATER AMPERAGE DRAW RANGES Heater Type 120V Amp Dra...

Page 24: ...All Except Heater Input power Line 1 F6 0 3A Slo Blo BP500 UL 120VAC Transformer Input F6 0 15A Slo Blo BP600 CE 230VAC Transformer Input Fuses BP2000 series UL BP2100 series CE Fuse Fuse Current Rati...

Page 25: ...ight 12VAC On Off 1A max 4 Hour timer Heater 4kW 240VAC Misc J23 J32 120VAC 4A max Hot output Stereo Fused equipment or in line fuse required Wiring Diagram and Settings WS01 L2 L1 N F3 10A 250V F2 3A...

Page 26: ...40 REMOTE J35 MAIN J34 MAIN J109 J27 J91 J22 J23 SERIAL J29 VAC J28 AUX FRZ J17 J16 24082_D J101 J108 J24 J107 K12 K7 TP MAIN PANELS J34 OR J35 10 23 12 BP2000G1 PN 56377 PART A AUX J5 A1 A4 OR J8 A5...

Page 27: ...ION POLLING 2 SPEED 1 SPEED 1 SPEED 1 SPEED F 12 PROGRAMMABLE FILTRATION POLLING 1 SPEED 1 SPEED 1 SPEED 1 SPEED F 13 PROGRAMMABLE FILTRATION POLLING 2 SPEED 1 SPEED 1 SPEED NONE F 14 PROGRAMMABLE FIL...

Page 28: ...4 K9 J5 AUX J8 AUX J40 REMOTE J35 MAIN J34 MAIN J109 J27 J91 J22 J23 SERIAL J29 VAC J28 AUX FRZ J17 J16 24082_D J101 J108 J24 J107 K12 K7 TP MAIN PANELS J34 OR J35 01 29 13 BP2000G1 PN 56377 01 PART A...

Page 29: ...ROGRAMMABLE FILTRATION POLLING 1 SPEED 1 SPEED 1 SPEED 1 SPEED F 13 PROGRAMMABLE FILTRATION POLLING 2 SPEED 1 SPEED 1 SPEED NONE F 14 PROGRAMMABLE FILTRATION POLLING 1 SPEED 1 SPEED 1 SPEED NONE F 15...

Page 30: ...GND J33 J21 J32 J9 1 2 3 4 2 K6 4 3 2 1 J45 J110 J79 J54 J72 J42 J3 J37 J4 J1 J61 J47 J77 J75 J78 J36 J60 J46 J38 J39 J111 J53 J58 J11 J41 J48 J6 J7 J49 J19 J50 J13 J12 J88 J62 F6 30A F8 30A J56 J57...

Page 31: ...D F 3 PROGRAMMABLE FILTRATION POLLING 2 SPEED NONE 1 SPEED F 4 NONE 2 SPEED 2 SPEED 1 SPEED F 5 NONE 2 SPEED 1 SPEED 1 SPEED F 6 NONE 2 SPEED NONE 1 SPEED F SETUP CIRC PUMP PUMP 1 PUMP 2 MICROSILK TEM...

Page 32: ...patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 6 22 13 OHM S LAW The direct current owing in a conductor is directly proportional to the potenti...

Page 33: ...material copyright of Balboa Water Group 42211 C Testing a Fuse Continuity TESTING A FUSE CHECK CONTINUITY WITH THE FUSE REMOVED A FUSE WITH THE METER READING GOOD A FUSE WITH THE METER READING BAD F...

Page 34: ...f Balboa Water Group 6 22 13 Troubleshooting Heater Resistance TROUBLESHOOTING HEATER RESISTANCE Locate the heater connector Disconnect the connector by depressing the tab Pull the connector straight...

Page 35: ...IFY THAT THERE IS NO HEATER LEAKAGE Measure resistance from a heater post to the heater housing Verify there is NO continuity from the heater post to the heater housing or heater current collector con...

Page 36: ...248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 6 22 13 Troubleshooting with Voltage WHEN TESTING VOLTAGE WHEN TESTING AMPERAGE IMPORTA...

Page 37: ...n patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 42211 C Verifying Incoming Voltage at the Terminal Block BP500 BP2000G1 VE...

Page 38: ...Water Group 6 22 13 Testing Pump Fuses for Damage with Voltage On BP2000G1 TEST THE VOLTAGE FROM THE RIGHT SIDE OF THE FUSE TEST THE VOLTAGE FROM THE LEFT SIDE OF THE FUSE THERE ARE THREE 30A PUMP FU...

Page 39: ...re you do test read on AVOID TOUCHING THE HEATER ASSEMBLY WHILE PERFORMING THIS TEST THE HEATER IS ATTACHED TO GROUND Many people use probes to test live heater voltages from TB1 to a heater post or a...

Page 40: ...rely Be sure that both insulated boots fully cover the clamps Be sure that both clamps are not touching each other and that they are not making contact with anything below the insulating material on t...

Page 41: ...n the wire Remove the four corner retaining screws 3 Place the Logic board out of the way of any metal or points 4 of system voltage or grounding areas once the system is powered up Note One considera...

Page 42: ...domestic applied for and pending All material copyright of Balboa Water Group 6 22 13 AMPERAGE HEATER TEST BP2000G1 AMPERAGE HEATER TEST BP500 CAUTION TEST IS WITH POWER ON Testing Heater Amperage AC...

Page 43: ...HE AMP RECEPTACLE ON THE PCB THIS WOULD TYPICALLY SHOW LOW SPEED VOLTAGE FOR PUMP ONE 240V WITH THE PUMP HIGH SPEED ON TAKE A VOLTAGE READING AT THE AMP RECEPTACLE ON THE PCB THIS WOULD TYPICALLY SHOW...

Page 44: ...switch or wires changes if any Test Mode On Test Setup Moving DIP Switch 1 to OFF will exit Test Mode 4 The Control System is in Test Mode if 102 T appears In this case F or C is replaced by T Set 10...

Page 45: ...system must be in Test Mode so move Switch 1 to the ON position The Test Menu will then be available Power up the spa and press any button once to Link the panel Note Switch 1 can be moved to the ON p...

Page 46: ...e Setup on a replacement part while in the field NOTE Changing the Setup may require wiring changes as well refer to the wiring diagram or wiring diagram addendum If the Control Panel does not have a...

Page 47: ...N The system will enter Test Mode Moving DIP Switch 1 to OFF will exit Test Mode SOFTWARE SETUPS BP2500 Under the TEST Menu the Setup screen will allow changing the Setup from 1 to any number establis...

Page 48: ...from the circuit board and exchange their positions i e plug the one that was in the Sen A jack into the Sen B jack and vice versa Note When removing a sensor wire from the board depress the tab Do no...

Page 49: ...f the problem is solved replace the sensor set If the U problem is not solved do not replace the sensor set Plug in the original sensor set to verify that there is not a U connection problem If the pr...

Page 50: ...he board This may help speed up reinstallation Other technicians prefer to take the board out with wires intact place both defective and new board side by side on a bench then swap wires recheck the l...

Page 51: ...J37 J4 J1 J61 J47 J77 J75 J78 J36 J60 J46 J38 J39 J111 J53 J58 J11 J41 J48 J6 J7 J49 J19 J50 J13 J12 J88 J62 F6 30A F8 30A J56 J57 J55 J59 J51 J52 J98 J10 J81 J20 J18 J43 CIRC PUMP OZONE A V HOT PUMP...

Page 52: ...nectors are on too tight it may be necessary to loosen the Phillips screws that hold the connectors together Once the water has been drained continue Remove the system door cover 4 If you received the...

Page 53: ...g nuts are in the same location on other BP models Avoid damaging the post Use an end wrench on the lower nut to reinforce the post when removing the upper nut Heater Wires on a BP500 BP600 Series sys...

Page 54: ...F 8 32 PM Ozone Filter 1 Spa Shortcuts Settings High Range 102 F Ready in Rest Mode Heating Water Temperature Messages Desired Temperature Temperature Range Pump and Heat Menus Lock Indicator Status N...

Page 55: ...it Button PRIMING THE PUMPS As soon as the Priming Mode screen appears on the panel select the Jets 1 button once to start Pump 1 in low speed and then again to switch to high speed Also select the ot...

Page 56: ...high speed may be started CIRCULATION PUMP MODES Some spas may be manufactured with Circ Pump settings that allow programming filtration cycle duration Some circ Modes are pre programmed to operate 2...

Page 57: ...lighted press Up or Down to toggle Filter Cycle 2 on and off When Filter Cycle 2 is ON it can be adjusted in the same manner as Filter Cycle 1 by navigating to the right It is possible to overlap Filt...

Page 58: ...Jets and other features to be used but the Set Temperature and other programmed set tings cannot be adjusted U Settings Lock allows access to a reduced selection of menu items These include Set Temper...

Page 59: ...may not be enough water flow through the heater to carry the heat away from the heating element Heater start up will begin again after about 1 min See Flow Related Checks below THE WATER FLOW HAS FAI...

Page 60: ...n the heater DEMO MODE Main Screen Settings Utilities Demo Mode Demo mode is not always enabled so it may not appear This is designed to operate several devices in a sequence in order to demonstrate t...

Page 61: ...ny subsequent GFCI trips will indicate a ground fault or other unsafe condition and the power to the spa must be shut off until a service person can correct the problem FORCING THE GFCI TRIP TEST The...

Page 62: ...p is below 108 F 42 2 C Check for extended pump operation or high ambient temp SENSORS ARE OUT OF SYNC M015 The temperature sensors MAY be out of sync by 2 F or 3 F SENSORS ARE OUT OF SYNC CALL FOR SE...

Page 63: ...tween 12 hr and 24 hr display REMINDERS Turn the reminder messages like Clean Filter On or Off CLEANUP Cleanup Cycle Duration is not always enabled so it may not ap pear When it is available set the l...

Page 64: ...78 5 5 5 F 8 H 4A 5 5 7 6 7A 5 7 7 B 7 B E 5 3 7 8 9 8 8 7 A 3 7 5 5 A 8 B 7 7 5 7 E 8 7 8 A Navigation Navigating the entire menu structure is done with 2 or 3 buttons on the control panel Some pane...

Page 65: ...system can power up you have access to the Utilities and Fault Log menus 5 E 6 7 18 5 5 E 8 A 4 5 E 6 7 18 5 5 E 8 A 4 5 E 6 7 18 78 5 E 8 A 4 18 7 C 5 E 5 A 8 4 7 7 1 A 7 5 E 8 7 7 3 7 5 C C 8 A E 6...

Page 66: ...THE PUMPS As soon as the above display appears on the panel push the Jet button once to start Pump 1 in low speed and then again to switch to high speed Also push the Pump 2 or Aux button if you have...

Page 67: ...URE NOT USED ON CE RATED SYSTEMS Displays the operating voltage configured for the heater HEATER WATTAGE AS CONFIGURED IN SOFTWARE CE SYSTEMS ONLY Displays a heater kilowatt rating as programmed into...

Page 68: ...pumps and blower are activated All pumps and blower are ON for at least 4 minutes after the poten tial freeze condition has ended or when the aux freeze switch opens In some cases pumps may turn on a...

Page 69: ...Sensor A M031 Sensor B M032 A temperature sensor or sensor circuit has failed NO COMM No Communications The control panel is not receiving communication from the System BETA VER SION Pre Production S...

Page 70: ...FAULT LOG MESSAGE CODES TP400 TP600 MXXX U Fault Message Code DZZZ How many days have passed since the fault U Time of the fault U Set Temperature during the fault U Sensor A Temperature during the fa...

Page 71: ...ccur sooner by initiating it using the above menu The GFCI should trip within several seconds and the spa should shut down If it does not shut down the power and manu ally verify that a GFCI breaker i...

Page 72: ...For the system to be changed from one menu structure to another is dependent on whether that option was programed into the system at the time of manufacturing CHANGING MENUS THROUGH CONFIGURATIONS If...

Page 73: ...ature button In the navigation diagrams Temperature buttons are indicated by a single button icon Panels that have two Temperature buttons Warm and Cool can use both of them to simplify navigation and...

Page 74: ...ol or spa including entertainment equipment HOW THE DOLPHIN WORKS The Dolphin communicates with a Dolphin RF Receiver or IR Receiver The receiver is wired into the Control System Mount the 1 Dolphin r...

Page 75: ...o change the address to 5 in this example Exit with Arrow Left key Step 2 Addressing your Dolphin a Press the SPA Button on the Dolphin once 1 b Press and hold SETUP until the LED blinks once c Hold i...

Page 76: ...flow around the closed jets is acceptable as long as the by pass means is down stream from the heater and allows a minimum of 20 GPM to flow through the heater during low speed operation If the pressu...

Page 77: ...may operate GFCI A device intended to protect people in the event of an electrical malfunction Spa owners should know how to test the GFCI as routine maintenance PREFERENCES Programmed events accordi...

Page 78: ...risk message with an 55 Auxiliary freeze sensor 56 A vs B or T vs H 48 B background colors 63 ball valves 52 black blower wire 19 Blockage Pump Suction 68 blower problem 19 board access to the power 4...

Page 79: ...Warning 2 error condition 59 event fault 70 exit Priming Mode 45 exit Test Mode 47 expander board 38 50 Expander Board 24 F failed sensor circuit has 62 FALT LOG Fault Log 68 fault event 70 fault gro...

Page 80: ...Message Codes 55 M015 62 69 M016 59 68 M017 59 68 M019 68 M019 55 M020 62 69 M021 62 69 M022 62 69 M026 62 69 M027 59 M028 59 68 M029 62 68 M030 59 68 M031 69 M031 Sensor A 62 M032 69 M032 Sensor B 62...

Page 81: ...ed TB1 terminal 18 Reduced Heater Flow is 68 Ref Card 40947 8 Reference Programming 8 reinstalling the board 51 release tab 50 REMOTE 74 Remote DolphinTM 74 removing a heater 52 Replacment Sensor 49 R...

Page 82: ...anges for 23 Test Menu 70 TEST Menu 44 Test Menu Access 44 test mode 20 21 Test Mode 44 45 46 62 Test Mode 21 test software 62 69 Test the Amperage Draw 19 Test the ground fault circuit interrupter 2...

Page 83: ...ors 9 All voltages speci ed as 120 V or 240 V may show an acceptable variance of 10 23 A message with an asterisk can be reset from the topside panel 55 Amperage Draw Ranges 23 Amperage Heater Test BP...

Page 84: ...he main board F1 is located on the expander board 38 F6 Fuse 18 F6 to TB1 Red 38 FALT LOG Fault Log 44 FALT LOG Fault Log 68 Fault Log Message Codes TP400 TP600 70 Fault Log tp800 tp900 60 F C 62 Filt...

Page 85: ...ssages and alerts will appear at the bottom of the normally used screens 62 Most Probable Overheating Causes Inspect These First 21 Motor Amperage Guidelines 23 Navigation 54 No Communications 69 Note...

Page 86: ...tus 54 SSID 77 SSID Software ID 67 SW _ Dip Switch Settings 67 System Box Wire Gauge Check 17 System Information 59 System Model 59 TB1 17 TB1 Marking on Board 18 Temp Display 63 Temperature High Limi...

Page 87: ...ting heater Resistance 34 Unlocking the Panel 58 Used for verifying a proper installation 61 Verifying Incoming Voltage at the Terminal Block 240V system BP2000 shown BP500 system is similar 37 Verify...

Page 88: ...6282370 6590188 6976052 6965815 7030343 7 417 834 b2 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa...

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