Balboa Water Group Revolution Installation And Service 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.

INSTALLATION AND SERVICE MANUAL

REVOLUTION

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Summary of Contents for Revolution

Page 1: ...53 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...

Page 2: ...ecrets copyrights software computer programs and related documentation and other works of authorship You may not infringe or otherwise violate the rights secured by the Intellectual Property Moreover...

Page 3: ...nd local codes Before making any electrical connections make certain that the Main Power t breaker from the house breaker box has been turned off Do not attempt service of this control system Contact...

Page 4: ...Compliant suction guard that is suitably rated to match the maximum flow rate marked WARNING Water temperature in excess of 38 C may be injurious to your health Disconnect the electrical power before...

Page 5: ...boa Water Group GFCI It is required by code to install a Ground Fault Circuit Interrupter GFCI in the supply power for a spa This device will trip the breaker if there is an unsafe electrical conditio...

Page 6: ...400 19 Topside Panel Cable Installation 20 Terminal Block Connections 21 FILLING AND PRIMING THE SPA 22 Preparing the Spa 23 Fill the spa 23 Power up the Spa 23 RUN PMPS PURG AIR 24 Priming Mode 25 If...

Page 7: ...60 Configuration Setup 7 8 61 120 Volt Configuration 61 BP1600 230V Conversions 62 The Following Pages Are BP1600 230V Setups 62 IT Electrical System No Neutral 69 TN and TT Electrical Services Line...

Page 8: ...61215 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 p...

Page 9: ...t tub control systems all but eliminate leaks due to corrosion or harsh chemicals Together with a newly designed energy efficient heating coil that reduces element failures due to rattling Balboa is p...

Page 10: ...low ow circ pumps con gurations special low ow adapter to support M7 more options for circ pump tubs design exibility the ease with which the system can be modi ed for use in applications or environm...

Page 11: ...ement 56126 02 With 4kW Titanium Element BP1600 50Hz 56129 02 3kW 800 Incoloy Element 56130 02 3kW Titanium Element Topside Panels TP600 Panel AX10 One button AX20 Two button AX40 Four button Coupling...

Page 12: ...0188 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...

Page 13: ...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...

Page 14: ...tents 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 an...

Page 15: ...it to be used in most any application and can be mounted on the suction side or discharge side of the pump TIP To improve reliability take steps to minimize vibration from the pump s that could be tra...

Page 16: ...FGPSF ESJMMJOH UIF DVUPVU PG UIF QBOFM UFTU UP TFF UIBU UIF PSJFOUBUJPO PG UIF topside panel is correct Also be sure that the cable reaches the control system without stretching or being forced agains...

Page 17: ...the hole A 3 clean smooth surface that is dry and oil free is required for the adhesive on the back of the panel to attain a good bond Remove the paper backing from the adhesive on the rear of the pa...

Page 18: ...F of this template please visit our web site Or copy paste the following link http www balboawatergroup com getdoc cfm id 1341 The link will automatically download Note To print actual size set Page S...

Page 19: ...tents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Cutout Template for TP400 To download a PDF of this template please visit our web site Or copy past...

Page 20: ...1A S1 J45 J46 F4 3A 250V J18 J19 K7 T1 J15 J33 J31 HCE J30 TST J27 H3 J22 J26 H2 J25 H1 J17 J16 J29 VAC J28 AUX FRZ J5 LIGHT ON 22121_E 1 6 TOPSIDE PANEL CONNECTOR TOPSIDE PANEL Topside Panel Cable In...

Page 21: ...ck sticker Connect the ground wire to the Bond Lug ground bar through the hole in 6 the system box and tighten the screw Tighten the screws on the terminal block torque between 21 and 23 in lbs 7 TIP...

Page 22: ...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 domes...

Page 23: ...Preparing the Spa Preparing refers to t Filling the spa Priming the spa t Fill the spa Fill the spa to its correct operating level Follow manufacturer s instructions TIP Be sure to open all valves in...

Page 24: ...u have 3 options If the spa does not need to be primed Priming Mode can be exited by t pressing any TEMP button Do nothing t Priming Mode terminates within 4 5 minutes Manually initiate Priming Mode t...

Page 25: ...to Switch to High Speed Press to Start Pump 2 Priming Mode Press the JETS button once to start Pump 1 in low speed t Press again to switch to high speed t Press the AUX button to turn on Pump 2 if av...

Page 26: ...not Primed TIP t G UIF QVNQT IBWF OPU QSJNFE BGUFS NJOVUFT BOE XBUFS JT OPU GMPXJOH GSPN the jets in the spa do not allow the pumps to continue to run Turn off the pumps and repeat the process Turnin...

Page 27: ...ts both foreign and domestic applied for and pending All material copyright of Balboa Water Group Exiting Priming Mode Once the system has exited Priming Mode it takes approximately 1 minute of water...

Page 28: ...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 domest...

Page 29: ...e Time Set the time before operating the system Filtration times and other features are determined by the panel clock being set JETS TS S J J AUX UX LIG LIGHT IGHT T HEAT T AT JETS AUX LIGHT HEAT JETS...

Page 30: ...ight of Balboa Water Group P JETS TS S J AUX UX A LIGH IGHT T H HEAT AT T JETS AUX LIGHT HEAT Note TIME and the current set time is displayed if the time is being reset Press TEMP t When the screen fl...

Page 31: ...lian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group P JETS TS S J AUX UX A LIG GH GHT T H HEAT AT T JETS AUX LIGHT HEAT Set...

Page 32: ...ts 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 d...

Page 33: ...53 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...

Page 34: ...the temperature will be displayed Water Temperature is Unknown READY RANGE FLTR1 42 F TOO COLD A potential freeze condition has been detected or the Aux Freeze Switch has closed and all pumps and blow...

Page 35: ...pyright of Balboa Water Group READY RANGE FLTR1 BETA VER SION The Control System is operating with test software Call for Service 102 T The Control System is in Test Mode Call for Service Pre Producti...

Page 36: ...is not enough water flow through the heater to carry the heat away from the heating element and the heater has been disabled See Flow Related Checks below After the problem has been resolved you must...

Page 37: ...cted 118 F 47 8 C in the heater and the spa is shut down You must press any button to reset when water is below 108 F 42 2 C See Flow Related Checks below PRES BTTN TO RSET Some errors may require pow...

Page 38: ...f Balboa Water Group Sensor Related Messages READY RANGE FLTR1 102 F SNSR BAL ANCE The temperature sensors MAY be out of sync by 2 F or 3 F Call for Service SNSR SYNC CALL FOR SRVC The temperature sen...

Page 39: ...roup System Related Messages MEM FAIL At Power Up the system has failed the Program Checksum Test This indicates a problem with the firmware operation program and requires a service call This message...

Page 40: ...e organization This fault can be reset by powering up in Test Mode WARNING HOT FALT indicates a serious condition and should not be treated lightly The spa probably had a pump stuck in the ON position...

Page 41: ...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 dom...

Page 42: ...n Utilities provides access to viewing information on hardware panel and software revisions It also permits viewing of reminder and personal settings Main Menu Utilities Information t SSID Software Se...

Page 43: ...ent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Entering the Utilities Menu READY RANGE FLTR1 JETS TS J AUX UX LIG LIGHT HEAT T...

Page 44: ...ied for and pending All material copyright of Balboa Water Group Entering the Utilities Menu cont JETS TS S J AUX UX LIG LIGHT HEAT T T JETS AUX LIGHT HEAT S JETS S S J AUX UX LIG LIGHT T H HEAT AT T...

Page 45: ...17 834 b2 Canadian Patent 2342614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group JETS TS J AUX UX LIG LIGHT H HE...

Page 46: ...42614 Australian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Entering the Sub utilities Menu READY RANGE FLTR1 JETS TS S...

Page 47: ...alian patent 2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Entering the Sub utilities Menu cont JETS TS S J AUX X A LIG IGHT L T...

Page 48: ...foreign and domestic applied for and pending All material copyright of Balboa Water Group JETS TS J AUX UX A LIG IGHT L T H HEAT T AT JETS AUX LIGHT HEAT JETS TS J J AUX UX LIGH LIGHT IG T H HEAT T A...

Page 49: ...248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Entering the Sub utilities Menu cont JETS TS S J J AUX UX A LIG LIGHT T H HEAT T AT JET...

Page 50: ...J AUX UX A LIGH IGHT T H HEAT AT AT JETS AUX LIGHT HEAT JETS S S J AUX X LIG LIGHT H HEAT T AT JETS AUX LIGHT HEAT JETS S S J AUX X LIG LIGHT H HEAT T AT JETS AUX LIGHT HEAT Current VAC input power sh...

Page 51: ...her patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group JETS TS S J J AUX UX A LIG IGHT L T H HEAT AT T JETS AUX LIGHT HEAT JETS TS S J J AUX X A LIG...

Page 52: ...other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Fault Log The Fault Log stores up to 24 events in memory and they can be reviewed under th...

Page 53: ...2373248 other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group READY RANGE FLTR1 JETS S J S AUX UX A LIGH GHT T H HEAT T AT JETS AUX LIGHT HEAT RE...

Page 54: ...t of Balboa Water Group Fault Log cont JETS S S J AUX UX A LIG LIGH IGHT T H HEAT AT T JETS AUX LIGHT HEAT Press LIGHT repeatedly until FALT appears JETS S J AUX UX LIG LIGHT T HEAT AT AT JETS AUX LIG...

Page 55: ...Water Group Fault Log cont READY RANGE READY RANGE READY RANGE READY RANGE P Pressing TEMP at any fault event reveals a Message Code Continuing to press TEMP reveals additional information for that t...

Page 56: ...atents 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...

Page 57: ...n Flexibility in the Revolution allows the manufacturer or installer to choose from eight 8 preconfigured system options Changing the configurations is made via the topside panel and in some options w...

Page 58: ...connected see 1 chart below Make any changes on the power board if needed 2 If changing voltage make a DIP switch change on the logic board 3 Install incoming voltage supply wires 4 If needed configu...

Page 59: ...J12 2 1 SPD 1 SPD NA YES 240V J12 5 2 SPD NA NA NA 240V J12 6 1 SPD NA NA YES 240V J12 Power Board Setup Chart 1 S1 6 ON L2 L1 N F3 10A 250V F2 3A 250V F6 0 1A 250V J44 J48 J1 J2 J24 J45 J49 J15 J16...

Page 60: ...Pump 1 P1 J8 Pump 2 P2 J14 Blower J14 Circ Pump J21 Ozone J22 Jumper 15 Connects To 3 2 SPD NA YES NA 240V J13 4 1 SPD NA YES YES 240V J13 Power Board Setup Chart 1 S1 6 ON L2 L1 N F3 10A 250V F2 3A 2...

Page 61: ...9 K7 T1 J15 J33 S1 S6 J31 HCE J30 TST J27 H3 J22 J26 H2 J25 H1 J17 J16 J29 VAC J28 AUX FRZ J5 LIGHT ON 22112_A L2 L1 N GFCI GND J29 to J33 Jumper Setup No Pump 1 P1 J8 Circ Pump J21 Ozone J22 S1 Switc...

Page 62: ...46 J24 F4 1A 250V J18 J19 K7 T1 J15 J33 J31 HCE J30 TST J27 H3 J22 J26 H2 J25 H1 J17 J16 J29 VAC J28 AUX FRZ J5 LIGHT ON 22121_C CONTROL PANEL TO J33 AUX TO J5 1 6 S1 ALL UNUSED SWITCHES SHOULD BE OFF...

Page 63: ...R HEIZELEMENT RADIATEUR N L1 N A ADDED JUMPER FOR CE INSTALLATIONS BLU BRN Con guration Changes based on Default Feature Orig Setup 1 Changes to J2 J32 Hot Output Useable DIP Switch Option Orig Setup...

Page 64: ...MP W HTR TEST MODE OFF MEMORY RESET SPECIAL AMPERAGE RULE ON ADD 4 HS PUMPS WITH HEAT ADD 2 HS PUMPS WITH HEAT ADD 1 HS PUMP WITH HEAT TEST MODE ON 6 5 4 3 2 1 ON POSITION S1 SWITCH OFF POSITION SWITC...

Page 65: ...TCH OFF POSITION SWITCH 6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION SENSOR A SENSOR B NOT USED 2S PUMP 1 BLOWER GRN 3 0 kW HEATER HEIZELEMENT RADIATEUR N L1 N A ADDED JUMPER FOR CE INSTALLATIONS BL...

Page 66: ...3 2 1 ON POSITION S1 SWITCH OFF POSITION SWITCH 6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION SENSOR A SENSOR B CIRC 1S PUMP 1 BLOWER GRN 3 0 kW HEATER HEIZELEMENT RADIATEUR N L1 N A ADDED JUMPER FOR...

Page 67: ...ITION SWITCH 6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION SENSOR A SENSOR B NOT USED 2S PUMP 1 NOT USED GRN 3 0 kW HEATER HEIZELEMENT RADIATEUR N L1 N A ADDED JUMPER FOR CE INSTALLATIONS BLU BRN Pow...

Page 68: ...6 SHOULD BE SET TO OFF UPON FINAL INSTALLATION SENSOR A SENSOR B CIRC 1S PUMP 1 NOT USED GRN 3 0 kW HEATER HEIZELEMENT RADIATEUR N L1 N A ADDED JUMPER FOR CE INSTALLATIONS BLU BRN Power Requirements...

Page 69: ...round t terminal as marked All equipment pumps blower and heater runs on service line L1 with L2 t acting as the return 230VAC Set the DIP switches according to the wiring diagram so that total system...

Page 70: ...rial copyright of Balboa Water Group 1 S1 6 ON 2 1 Remove Lid 1 Shut off power Remove Lid 2 Place DIP switch No 1 on the logic board to the ON position Software Setup Note Software Setup is changed th...

Page 71: ...282370 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 W...

Page 72: ...ents both foreign and domestic applied for and pending All material copyright of Balboa Water Group Press repeatedly until a setup choice appears S 01 S 08 SET SET SET 6 Press TEMP repeatedly until yo...

Page 73: ...other patents both foreign and domestic applied for and pending All material copyright of Balboa Water Group 8 9 Software configuration is complete Replace Lid 8 Power down Place DIP switch No 1 to t...

Page 74: ...ents 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...

Page 75: ...s Dimensions mounting holes 7 83 lbs 3 552 kg 8 5 H x 15 0 W x 5 8 D 11 45 x 5 30 Enclosure IPx5 Thermoplastic Heater Certifications UL Standard Files UL 1563 5th Edition E90059 UL 1795 3rd Edition E1...

Page 76: ...ets 2 See Aux Button Note Aux Button A3 Unused See Aux Button Note Aux Button A4 Light See Aux Button Note TIP Aux Buttons can be set with the following functions based on Manufacturer Specification T...

Page 77: ...o glue up to 2 PVC pipe 1 5 TAILPIECE KIT PART No 55914 1 5 sockets to glue up to 1 5 PVC pipe with the I D Be sure to orient the fittings so that the insert is at the 12 00 position to prevent trappe...

Page 78: ...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 G...

Page 79: ...550753 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...

Page 80: ...for maintenance of filtration and heating It often runs all day Clean up or purge Cycle An action designed to circulate water to maintain sanitary conditions Pumps or blowers purge standing water to p...

Page 81: ...ight of Balboa Water Group Glossary cont 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 Preferenc...

Page 82: ...ng Mode The purpose of Priming Mode is to allow the user to run each pump and manually verify that the pumps are primed air is purged and water is flowing This typically requires observing the output...

Page 83: ...No 47012 BWG TP600 and TP400 Control Panel Document No 40940 t A t Cutout Template for the BWG TP600 and TP400 Control Panels Supporting Documents for Download Also visit our t technical site for App...

Page 84: ...and Compliance All of the electrical wiring methods and materials used to complete the t electrical installation of the Revolution control system must be in accordance with the National Electrical Co...

Page 85: ...ode to install a Ground Fault Circuit Interrupter GFCI in the supply power for a spa NOTE A GFCI power cord is included with a 120VAC spa This can be used for a cord connected 120V setup only and only...

Page 86: ...R A HTR B J46 J24 F4 1A 250V J18 J19 K7 T1 J15 J33 S1 S6 J31 HCE J30 TST J27 H3 J22 J26 H2 J25 H1 J17 J16 J29 VAC J28 AUX FRZ J5 LIGHT ON 22112_A L2 L1 N Line 1 and Line 2 240VAC 216VAC 264VAC GND F6...

Page 87: ...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 domesti...

Page 88: ...The Revolution supports two basic circulation configurations When installing the Revolution keep in mind the following characteristics that each system has It will help in determining where to place a...

Page 89: ...eed pump or for the circ pump must include 2 the following a 2 suction fittings or b 1 suction fitting and a skimmer If the suction system for the 2 speed pump or for the circ pump includes 3 a filter...

Page 90: ...be 100 closed at least 2 non adjustable jets must be included in each possible inlet circuit so that a minimum of 20 GPM can flow during low pump operation with all the jets closed Any other means of...

Page 91: ...f freeze protection The Revolution control system will provide freeze protection There is also provision for remote sensing freeze protection if required Position inlets and jets in the spa so that th...

Page 92: ...roup Plumbing Schematic Non Circ 2 Speed Filter Pump Vacuum Filter Vacuum Heater Plumbing Schematic Non Circ 2 Speed Filter Pump Vacuum Heater Pressure Filter Diverter Valve Ozone Injector Suction Ski...

Page 93: ...erial copyright of Balboa Water Group Plumbing Schematic Circulation Pump Pressure Heater Pressure Filter Revolution Pressure Filter w Bypass 1 1 2 to 2 Plumbing Suction Ozone Injector Plumbing Schema...

Page 94: ...Pressure and Suction Side Mounting The Revolution can be used in most any application If installing in a newly t built spa system study the diagrams in order to plan the location of the Revolution Al...

Page 95: ...ound To improve reliability take steps to t minimize vibration from the pump s that could be transmitted to the Revolution Use t rubber isolation pads under the pumps and flexible PVC between the filt...

Page 96: ...nting When mounting the system on the suction vacuum side of the pump care t must be taken to mount the system in such a way that it is aligned with the suction port on the pump wet end The suction si...

Page 97: ...Clean up or purge Cycle 80 closed jets 35 closed valves 35 CNFG FAIL 39 Code Canadian Electric 84 Code Fault Message 52 55 Code Message 55 Code National Electrical 84 Codes and Compliance 84 Codes Fa...

Page 98: ...Entering the Utilities 43 Menu Sub utilities 46 Menu Utilities 42 43 Message Code 55 message reset 37 Messages Heater Related 36 Messages Sensor Related 38 Messages System Related 39 minimize vibrati...

Page 99: ...software test 35 spacer block 96 Spa Priming the 25 26 Speci cations 11 Speci cations Certi cations 75 SSID 81 SSID System panel ID 42 STUK PUMP 40 Sub utilities Menu 46 suction ow restrictions 35 suc...

Page 100: ...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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