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Balboa Water Group BP600, Troubleshooting & Service Manual

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Balboa Water Group BP600 Troubleshooting & Service Manual Download Page 24

24

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.

2013-06-22

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”

FUSES USED ON BP SPA SYSTEMS

Fuse

BWG Part Number

30A

30136

10A 30122

3A Slo-Blo

20600

0.3A Slo-Blo

21581

0.15A Slo-Blo

26281

0.125A Slo-Blo

26397

THE PREFERRED WAY TO CHECK FOR FUSE CONTINUITY IS WITH  

THE FUSES REMOVED FROM THE CIRCUIT.

NOTE: THERE ARE NO SERVICEABLE PARTS ON THE PCB. 

Summary of Contents for BP600

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 42217 C Balboa...

Page 2: ...boa products Non qualified users should never open or remove covers as this will expose dangerous voltage points and other dangerous risks Please contact your dealer or authorized repair center for se...

Page 3: ...boawatergroup com Codes and Compliance All of the electrical wiring methods and materials used to complete the electrical installation of the BP control systems must be in accordance with the National...

Page 4: ...pliance 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 i...

Page 5: ...ting Servicing of Spa s Electrical Equipment 12 Basic Control System Troubleshooting 13 Testing a System with Power 15 230 Volt 50 Hz Residual Current Devices RCD s 17 Wiring Checks 18 Wiring Check fo...

Page 6: ...TP900 Spa Behavior 47 TP800 TP900 Adjusting Filtration 48 TP800 TP900 Panel Lock Unlock 49 TP800 TP900 Sensor and System Related Messages 50 TP800 TP900 Utilities Menu 54 TP400 TP600 Standard Panel Op...

Page 7: ...ed 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 U Extra Pa...

Page 8: ...TP800 TP400 TP600 JETS TS S AUX LIGHT HEA HEAT JETS AUX LIGHT HEAT System Models BP500 and other BP Series Systems as required Panel Model TP600 Series TP400 Series Software Version s Software versio...

Page 9: ...9 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 J27 J91 J22 J23 SERIAL J29 VAC J28 AUX FRZ J17 J16 24082_E J101 J108 J24 J107 K1...

Page 10: ...copyright of Balboa Water Group 2013 06 22 230 Volt 50 Hz Residential Wiring Schematic with 2 Pole RCD Breaker Box Correct Voltage When Probes Are Placed Across 0v 1 3 4 7 5 9 10 11 207V 253V 1 2 2 3...

Page 11: ...VAC 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 J41 J48 J6 J7 J49 J19 J50...

Page 12: ...g 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...

Page 13: ...determine that there is no voltage at this location U then the system power input fuse needs to be replaced Only use a fuse of the same type and amp rating when you replace any of these fuse NOTE FOR...

Page 14: ...U Test the Blower Plug in the blower U Power up the system and activate the blower U If the fuse blows then there is a blower problem U If the fuse does not blow the combined pump and blower U amperag...

Page 15: ...slightly different on some older M7 systems Prior to heating the pump is run for at least two minutes U and then the temperature difference between the sensors is assessed It must be 2 F 1 0 C or less...

Page 16: ...mp 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 p...

Page 17: ...at s operating properly the vector sum of the live and neutral current values added together will be zero Current owing to earth due to a line earth fault will return via the earth conductor and regar...

Page 18: ...fore you touch any wiring U Once the power is off carefully examine all wires for U cuts or defects SYSTEM BOX WIRE GAUGE CHECK When inspecting the wiring for any control system U note that connection...

Page 19: ...t routed to the spa control system Once you have found all wiring correctly installed begin to check for proper voltage If Correct Wiring is Verified check to see if the proper RCD is installed Check...

Page 20: ...Water 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 21: ...DRAW 240 V 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 Draw 2...

Page 22: ...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 Rat...

Page 23: ...patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 42217 C OHM S LAW The direct current owing in a conductor is directly proportional to the potenti...

Page 24: ...material copyright of Balboa Water Group 2013 06 22 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...

Page 25: ...f Balboa Water Group 42217 C Troubleshooting Heater Resistance TROUBLESHOOTING HEATER RESISTANCE Locate the heater connector Disconnect the connector by depressing the tab Pull the connector straight...

Page 26: ...ERIFY 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 c...

Page 27: ...248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 42217 C Troubleshooting with Voltage WHEN TESTING VOLTAGE WHEN TESTING AMPERAGE IMPORTA...

Page 28: ...patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 2013 06 22 Verifying Incoming Voltage at the Terminal Block BP2100 BP600 VERIFYING INCOMING VOLTA...

Page 29: ...Water Group 42217 C Testing Pump Fuses for Damage with Voltage On BP2100 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 FUSE...

Page 30: ...fore 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...

Page 31: ...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 32: ...on 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 conside...

Page 33: ...3 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 42217 C AMPERAGE HEATER TE...

Page 34: ...AT THE AMP RECEPTACLE ON THE PCB THIS WOULD TYPICALLY SHOW LOW SPEED VOLTAGE FOR PUMP ONE 230V WITH THE PUMP HIGH SPEED ON TAKE A VOLTAGE READING AT THE AMP RECEPTACLE ON THE PCB THIS WOULD TYPICALLY...

Page 35: ...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 36: ...If 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 p...

Page 37: ...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 38: ...k the panel Note Switch 1 can be moved to the ON position immediately after power up if preferred Danger High Voltage will be present You will have 1 minute to complete the setup change after you manu...

Page 39: ...nging 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 Warm Up button but rather a single Temp button use the Te...

Page 40: ...nging the Setup from 1 to any number established by the manufacturer Changing the Setup may require wiring changes as well Set 104 F 8 32 PM Ozone Filter 1 Spa Shortcuts Settings Test High Range 102 F...

Page 41: ...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 42: ...ng 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 sy...

Page 43: ...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 44: ...tion Other technicians prefer to take the board out with wires intact place both defective and new board side by side on a bench then swap wires recheck the logic jumpers and DIP switch for proper con...

Page 45: ...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 46: ...Exit 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...

Page 47: ...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 48: ...hlighted 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 Fil...

Page 49: ...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 50: ...e 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 FA...

Page 51: ...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 52: ...any subsequent GFCI trips will indicate a ground fault or other unsafe condition and the power to the spa must be shut off until a service person can correct the problem FORCING THE GFCI TRIP TEST The...

Page 53: ...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 54: ...between 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...

Page 55: ...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 56: ...e 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...

Page 57: ...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 58: ...plays the checksum for the system configuration file HEATER VOLTAGE FEATURE NOT USED ON CE RATED SYSTEMS Displays the operating voltage configured for the heater HEATER WATTAGE AS CONFIGURED IN SOFTWA...

Page 59: ...the aux freeze switch opens In some cases pumps may turn on and off and the heater may operate during Freeze Protection This is an operational message not an error indication WATR TOO HOT Water is to...

Page 60: ...sor or sensor circuit has failed NO COMM No Communications The control panel is not receiving communication from the System BETA VER SION Pre Production Software The Control System is operating with t...

Page 61: ...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 62: ...occur sooner by initiating it using the above menu The GFCI should trip within several seconds and the spa should shut down If it does not shut down the power and manu ally verify that a GFCI breaker...

Page 63: ...r 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 th...

Page 64: ...others have a single Temperature button In the navigation diagrams Temperature buttons are indicated by a single button icon Panels that have two Temperature buttons Warm and Cool can use both of the...

Page 65: ...J40 REMOTE J35 MAIN J34 MAIN J109 J27 J91 J22 J23 SERIAL J29 VAC J28 AUX FRZ J17 J16 24082_E J101 J108 J24 J107 K12 K7 TP MAIN PANELS J34 OR J35 01 30 13 BP2100G1 PN 56389 01 PART A AUX J5 A1 A4 OR J8...

Page 66: ...1 SPEED C SETUPS 15 AND 16 REQUIRE ADDITIONAL FUSED ADAPTER FOR BLOWER OUTPUT SETUP CIRC PUMP PUMP 1 PUMP 2 PUMP 3 BLOWER TEMP SCALE INSTEAD OF SETUP 1 THIS SYSTEM IS CONFIGURED IN SETUP PUMP 1 LOW TI...

Page 67: ...33 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 J55 J5...

Page 68: ...A3 A4 A5 A6 A7 A8 A9 A10 230V 3 3x16A 230V 3 3x16A GRN BLU 1 BRN 2 BRN 3 BRN PUMP 2 IS 2 SPEED IN SETUPS 1 4 PUMP 2 IS 1 SPEED IN SETUPS 2 5 PUMP 2 IS NOT USED IN SETUPS 3 6 SINGLE SERVICE 230V 1 1x3...

Page 69: ...URS DE CUIVRE L2 L1 N F3 10A 250V F2 3A 250V T 150mA 250V F6 J44 J48 J1 J2 J24 J45 J49 J15 J16 J47 J13 J27 J25 J26 J23 J33 J28 J30 J31 J32 J29 J12 J46 J20 J57 J8 J14 J22 J21 J56 F5 T 30A GND K3 K5 K6...

Page 70: ...PPER CONDUCTORS ONLY EMPLOYER UNIQUEMENT DES CONDUCTEURS DE CUIVRE L2 L1 N F3 10A 250V F2 3A 250V T 150mA 250V F6 J44 J48 J1 J2 J24 J45 J49 J15 J16 J47 J13 J27 J25 J26 J23 J33 J28 J30 J31 J32 J29 J12...

Page 71: ...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 72: ...to 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...

Page 73: ...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 74: ...r 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 accord...

Page 75: ...Pump Suction 59 Blower Test the 14 board access to the power 32 Board Compatibility on Dual 43 board expander 29 44 Board Expander 22 board isolate the logic 32 board Logic 32 Board Logic 32 69 70 bo...

Page 76: ...des 61 Fault Message Code 61 Fault Sensor A 53 Fault Sensor B 53 fault Sensor Balance is Poor 60 faults last 24 37 faults Stray 35 Feature GFCI Test 52 Filter Cycle 2 48 ltration 47 Filtration Cycle 7...

Page 77: ...ages can be reset from the panel 53 Messages Heater Related 50 Messages Scrolling TP400 TP600 59 Messages that can be reset 53 messages will scroll 59 message with an asterisk 46 Miswiring of the spa...

Page 78: ...B 37 Sensor A Fault 53 Sensor A M031 53 sensor Auxiliary freeze 47 Sensor B 37 51 Sensor Balance is Poor fault 60 Sensor B Fault 53 Sensor B M032 53 sensor circuit has failed 53 sensor connector 32 Se...

Page 79: ...ground fault circuit interrupter 2 Test the Pump 14 Test the System 14 time out period 47 Time Outs 37 times overlapping lter 16 torque 30 35 in lbs 41 Torque main board 43 TP600 TP400 panels 37 TP900...

Page 80: ...rs 9 Always turn the power off when plugging and unplugging 36 A message with an asterisk can be reset from the topside panel 46 Amperage Draw Ranges 21 Amperage Heater Test BP600 33 Amperage Heater T...

Page 81: ...lphin Receiver 71 Dolphin Remotes 72 Do not measure across heater terminals 30 DO NOT REMOVE AND REPLACE THE CIRCUIT BOARD UNLESS THE FAULT HAS POSITIVELY BEEN DETERMINED TO BE THE CIRCUIT BOARD 44 Dr...

Page 82: ...25 Locate the heater connector 26 Locking nuts are in the same location on other BP models 42 Logic Board 22121_E 56131 02 69 Logic Board 22121_E 56131 02 70 Logic Jumper No 20618 7 Low Voltage 13 M0...

Page 83: ...ternate Way 44 Restricting Operation Locking the Panel 49 RUN PMPS PURG AIR 59 Safety Trip Pump Suction Blockage M033 59 Saving Settings 47 Saving Your Dolphin Address 72 Scrolling TP400 TP600 Message...

Page 84: ...should be taken under peak load conditions 14 The settings have been reset Persistent Memory Error M021 53 The Utilities Menu contains the following 54 The water ow has failed M017 50 The water ow is...

Page 85: ...4 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 a...

Page 86: ...82370 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 Wa...

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