Jacuzzi Z Builder Series Mechanics And Repair
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Jacuzzi Z Builder Series Mechanics And Repair

Jacuzzi Z Builder Series Mechanics And Repair

Whirlpool bath hot tub spas made 1995-2001
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The Mechanics and Repair of
®
Jacuzzi
Whirlpool Bath
Hot Tub Spas
For the Following ELECTRONIC Spas Made 1995-2001
Dealer Premium Model Line
(sold through dealers):
Z Builder Series Line
(sold through big box stores):
(does not include Z101)
Published by Clear Creek Spas
©Copyrighted. All Rights Reserved. B.Bouman and Company, LLC

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Summary of Contents for Jacuzzi Z Builder Series

  • Page 1 Hot Tub Spas For the Following ELECTRONIC Spas Made 1995-2001 Dealer Premium Model Line (sold through dealers): Z Builder Series Line (sold through big box stores): (does not include Z101) Published by Clear Creek Spas ©Copyrighted. All Rights Reserved. B.Bouman and Company, LLC...
  • Page 2 Every effort has been made to be accurate and complete but note we cannot guarantee specific accuracy. Throughout this manual reference to part numbers are Jacuzzi Premium Spa numbers. If the part number prefix is “CC” the part is our own number and...

  • Page 3: Table Of Contents

    Table of Contents Introduction Overview Section One: Equipment and Parts Chapter One: Pumps and Motors Chapter Two: Heaters Chapter Three: Control System Chapter Four: Air Blowers Chapter Five: Pressure Switch: Flow Switch Chapter Six: Sensors Chapter Seven: Topside Control Chapter Eight: Ozonators Chapter Nine: Mood Lights...
  • Page 4 Introduction I started servicing Jacuzzi Whirlpool Bath spas in 1995. I first started by working for a friend who was an Authorized Service Center for Jacuzzi Whirlpool Bath. Shortly after that I purchased the spa repair business from him and became the owner.
  • Page 5 “Z” series. SPA SHELL Jacuzzi’s spa finish skin is acrylic. A sheet of acrylic is heated and dropped into a mold and vacuumed to form the shell. Then it’s flipped over and sprayed with a fiberglass solution that gives it strength. Holes are drilled into the spa and jets installed.
  • Page 6 The paneling of spas has changed over the years. Initially redwood or cedar was the common siding. Jacuzzi built spas with slats glued to a plastic sheet and screwed to the spa frame. An attempt to economize cost panels were built of various woods and stained but this has been discontinued.
  • Page 7 The “wetend” is the more common word for the end that moves the water. Jacuzzi’s pump or wetend is patented by Jacuzzi and only sold by them. The motor is made by others.
  • Page 8 It’s easy to compare the Jacuzzi pump as a wide flowing river verses a narrow fast moving river. By design you can sit again a number of jets for a length of time and not feel irritation.
  • Page 9 Removal: Turn main power off. Drain the spa. Most Jacuzzi models do not have valves to close to avoid draining the spa. Once the spa is drained, disconnect the 2 couplings attached to the pump (wet end). Normally you can hand loosen but occasionally you will need to use a large wrench to loosen.
  • Page 10 bracket or body from the motor. It is held by 4 long bolts that run through the motor and bolt to the pump. Disconnect each bolt but DO NOT pull the bolts out. They also hold the motor together and removal will likely cause the motor to disassemble.
  • Page 11 Removal: Turn off main power. Drain the spa. Most Jacuzzi models do not have valves to close to avoid draining the spa but check yours. Once the spa is drained, disconnect the 2 couplings attached to the pump (wet end).
  • Page 12 The motor itself is attached by four nuts at the feet; remove. There likely is a copper bonding wire attached to the back of the motor. Remove. Unplug the pump cord from the control box. Remove pump/motor assembly. Preface: Although pumps can have different fittings, they basically are the same. So the following is basically applicable for all pump/motors.
  • Page 13 There isn’t a shut off valve to replace the circ pump with water still in the spa so you will have to drain it. For the smaller pump, it‘s a 110-115vac Might Mite. Jacuzzi switched over to a larger 220vac Aquaflo circulation pump for a short period. During this time many Pinnacles were retrofitted with the Aquaflo pump.
  • Page 14 pump/motor will come with a cord. It easy to splice the wires together. On the larger circ pump, you will remove the cord connection from the back of the motor and install into the new.
  • Page 15 On Jacuzzi Whirlpool design, the water passes through the heater and then a manifold disperses the water to many jets and thus spreading out the amount of heater water.
  • Page 16 The various generations of Heater Assemblies: First, there are several generations of heater designs that Jacuzzi used. The first generation was a horizontal heater with a pressure switch that screws into the backside and the high limit clips against the heater. It was the most popular designed used throughout their production.
  • Page 17 Then I thought outside the box and now always do it this way: remove the control box. On models built from 1995-2001 Platinum, 1995-1996 ECHO, 1998-2001 SELECT: Turn off main power. Drain spa. Remove cover on control box. You will see the heater’s post coming through the wall of the control box.
  • Page 18 deal with electrical wiring, disconnect the incoming wires that attach to the terminal at the control box, remove the cord from the box, and pull the box up and out then reverse when installing. The key part if you decide to do yourself is the note which wire goes where.
  • Page 19 from the board terminal to the heater posts. Unscrew the two screws holding the straps to the board terminal. Unbolt the two nuts holding the copper straps to the heater posts. When you reattach the new heater you will tighten to snug. You will see that your control box stands on two legs.
  • Page 20 Remove the 2 copper straps. First unbolt where then attach to the board. Second remove nuts connecting the board to the heater posts. Note that the heater posts have a nut on top and a nut built in to the bottom below the copper contact. This is so you can put less pressure on the post when loosening or tightening.
  • Page 21 Chapter THREE Control System WE label the “Control System” the box which the electronic control is located and on some models, the heater. BOARDS: Overview: Circuit boards came into common use in the mid 90’s. They are a major improvement in many ways over the older mechanical spas. They are more accurate in keeping the proper temperature.
  • Page 22 Jacuzzi Model Generation: In 1995 Jacuzzi began their switchover to board with the F106/7 and the F108/9 control systems by Balboa Instruments. The F106/7 system has “Platinium” written on the topside. It’s their premier system.
  • Page 23 During this time, on their dealer line of spas, they added the “Select” series. It included a digital topside but was simpler then the Platinum. Finally Jacuzzi offered the R576 series which give the unit a small digital topside control with 2 buttons; one for the temperature setting and the other for the jets and mood light.
  • Page 24 H136/276 and H756??? a. Turn off main power. b. Remove control box cover c. Unplug transformer cord from board. d. Unplug sensors and pressure switch cords to board. e. Disconnect topside phone type plug. f. Remove the screws holding to the fingers of the board. Save screws. g.
  • Page 25 Reverse to install. Z112 Unplug the phone type jack from the topside. Unplug the sensors. Note which of the incoming power cord terminals attach to the board. Loosen the screws that hold the incoming cord. The hardest thing about the replacing the board is its in a small space. It has 1-2 screws holding the board to the box and 2 nylon posts.
  • Page 26 When the blower turns off the cleaner sanitized water will flow back into the channels and help keep them clean. Jacuzzi: Only the Dealer Line of Jacuzzi electronic spas had an air blower. This would include Lexus Plus, Quantum Plus, Pinnacle, and Triton to name a few.
  • Page 27 Otherwise it does not . Due to the low pressure of Jacuzzi pumps 2 speed pumps should use a 1lb pressure switch. 2 pump, single speed pumps should use a 2 lb pressure switch. Overtime the microswitch can fail, the post is less responsive, or doesn’t withdraw fast enough.
  • Page 28 R574/6 Turn off power. Open metal cover on control box. You will see the pressure switch on the top center of the heater (steel tube). Manufacturer’s Recommended Procedure: Disconnect the 2 copper straps from the board and the heater posts. Take care in removing the heater posts for the post will bend and break.
  • Page 29 The armature will be toward the water flow so when the flow comes, it moves to the post. Jacuzzi. Most of Jacuzzi’s spas use pressure switches. It wasn’t until about 2000 did Jacuzzi introduce the flow switch on it’s electronic spas specifically late editions of the Pinnacle, the Triton, and some Quantum Plus spas.

  • Page 30: Chapter Six: Sensors

    That is how is determines spa temp. Some spas have their temperature sensor inserted into the actual spa. Others in a housing inserted into the spa. Jacuzzi’s most common design is the sensor inserts into the side of the filter box.
  • Page 31 WHAT IT DOES: Typically, when you power up the sensor the board looks at both Over Heat Sensor and the Temperature Sensor and compares them. It should see no significant difference and the range should be within normal range. If it see outside the tolerances, depending on which system you have, it will notify you of the problem and fail to turn the spa on.
  • Page 32 The Platinum Series topsides are a liquid quartz readout with a light backlight. It’s the only topside Jacuzzi used with a liquid quartz. The remainder use a light emitting diode or LED. Some have more function buttons than others. Jacuzzi also used a topside with a Dial temperature control and a single jet button on many of their Z series spas.

  • Page 33: Chapter Eight Ozonators

    As the ozonated bubbles rise to the surface of the spa they sanitize the water. Jacuzzi began using the Hercules brand ozonator with their electronics spas. This was a 110v ozonator with a bulb type ozone source. They then switched to Prozone brand although different in design was basically the same.

  • Page 34: Chapter Nine: Mood Lights

    120vdc bulb and plugging in the color assembly. Jacuzzi used a single lens/light on most of their spas. A few Platinum models they used 2 lights. On the Platinum topside control they also have a 2 level light...

  • Page 35: Chapter Ten: Plumbing

    In the late 90’s soft plastic piping was introduced and has become popular. It’s common to see current spas using all 3 types of piping. Jacuzzi used all 3 types of piping. The key to gluing is care. First, you need clean both inside and outside of couplings and pipes that will come into contact.

  • Page 36: Chapter Eleven: Spa Jets

    Either silicone or a gasket is used to seal the housing. Jacuzzi: In the mid 90’s Jacuzzi spas used their own patented jets. The older have the AMH jet with is a medium size jet with directional nozzle but you can adjust the flow.

  • Page 37: Chapter Twelve: Stereo

    Chapter Twelve: STEREO: Spas with stereos use car stereos. The spa has a transformer that changes the voltage from AC to DC and lowers the voltage to 12 volts. Jacuzzi used major brand car radios to add music and outdoor speakers.

  • Page 38: Section Two: Troubleshooting

    SECTION TWO: TROUBLESHOOTING: Warning: I need to repeat the warning given at the beginning of this manual. If you don’t have a working knowledge of electricity and can safely work with electricity, then you should have a licensed electrician or properly trained service repairman handle electrical problems.
  • Page 39 TROUBLESHOOTING SECTIONS: Trips GFCI or GFI. Doesn’t Heat III. Motor hums Pump Leaks Diagnosing by CLICKS Error Codes on the Topside:...

  • Page 40: Trips Gfci

    I. Trips GFCI First, check the equipment and electrical connections for any water. Water dripping onto equipment will cause the gfci to trip. Most common cause is the heater. If the gfci pops instantly its almost always the heater. To isolate, do the following: Turn off power.

  • Page 41: Doesn't Heat

    II. Doesn’t Heat If the heater light is solid and the spa is not heating, it’s likely the heater. Remember, spas plugged by a cord into an outlet only gain 1-2 degrees per hour. Spas hardwired to 220-240vac will gain 5-6 degrees per hour. Typically you might not be able to feel a different temperature of water coming out of the heater nozzle.
  • Page 42 even with the power off, then it’s likely the board. What can happen is the heater relay although closed and apply voltage to the heater, it’s not allowing enough current to reach the heater element. To determine if that is the problem, you need to test the amperage draw when the heater is on.
  • Page 43 balanced and not using too much or too little chemicals.

  • Page 44: Motor Hums

    III. Motor Hums Why does the motor hum? Because it doesn’t know the words…. Sorry, just had to say that. Humming motors is typical of a failed motor. Can internal parts be replaced? If a tech was trying to save the motor he might start with a new discharge capacitor. But other parts also can be near failure including bearings.

  • Page 45: Pump Leaks

    IV. Pump Leaks Pumps can leak for several reasons. The most likely is the seal on the pump. The seal is a 2 section construction. Basically the seal has ½ of the seal that’s a ceramic ring with a rubber boot to seal in a seat on the main body or bracket of the seal.

  • Page 46: Diagnosing By Clicks

    I have found over the years that many failures can be determined by the CLICKS the board makes. The CLICKS are relays closing on the board. Since all of the boards used by Jacuzzi Whirlpool Bath spas were made by Balboa Instruments, the CLICKS follow the same sequence.
  • Page 47 If you have proper voltage, double check the fuses inside the control box. You do this with power OFF and the meter set to ohms. Finally, with proper power to the spa and the all fuses are OK, the only possible reason for failure is either the transformer or the board.
  • Page 48 When pressure/flow switch, temperature sensor, and the overheat sensor pass testing, the spa goes to #1 and #2 CLICK and then Nothing. You get the SECOND CLICK then nothing: The 2 Click turns on the #1 or LOW speed pump (see Pinnacle models section for exceptions.) If the pump comes ON and you see water movement you know the pump is OK.
  • Page 49 #1 and #2 CLICK and Pumps Come ON but no HEAT. First step to isolate the problem is the pressure switch. To check, turn off power. Identify the heater and the pressure switch screwed into the heater. It has 2 wires coming out of the switch.
  • Page 50 b. Otherwise, replace the pressure switch to gain dependability. IF shorting out the pressure switch does NOT solve the problem, the failure is the board itself. Double check that the pressure switch cord to make sure it’s plugged securely into the board and the cord isn’t cut. IF not, your short is telling the board water movement is happening and it’s ignoring the signal.

  • Page 51: Error Codes On The Topside

    Error Codes on the topside: DIGITAL TOPSIDE ERROR CODES. Solid FLO or FL This means a failure of the pressure switch. To confirm that is the cause of the failure, turn the main power off. ID whether you have a pressure switch or flow switch.
  • Page 52 Sn3. Water Temperature Sensor has failed. Replaced. OH. Overheat protection enacted. Caused by the heater actually getting hot, a failed OH Sensor, or the board. Option is to replace. Pd. Power failure. Unit is on battery backup if available. COOL. Water temperature is below 20 degrees from what the topside is set for. This is normal when spa water is changed with cold water.
  • Page 53 PC Board turned on heater without water flow which requires replacing the PC board, or Not enough water is moving over the element which is a flow problem, many times due to dirty filters, or Failed sensor Flashing More On then Off: Meaning: PC Board sees a sensor failure.

  • Page 54: Section Three: Review Of Specific Models

    SECTION THREE: Review of Specific Models AERO PLUS and SELECT ALEXA and DELFINO CIRRUS LEXUS PLUS, LC, and SELECT LASER PLUS and SELECT PALIO PINNACLE QUANTUM/PLUS SANTINA SOLARIS TIRAGE TRITON Z-100 Z-110 Z-112 Z-120 Z-130 Z-135 Z-140 Z-145 Z-150 Z-235 Z-240 Z-255...
  • Page 55 Aero Plus/Aero Select Dimensions: 84x76x30 Capacity: 225 g Empty Weight: 675 lbs Water Weight: 3299 lbs Voltage: 230v Pumps: One 2hp Pump on Earlier Production; Two 1hp pumps on Select Accessory: Air Blower on Earlier Production; None on Select Series Heater: 5.5kw Pump (Wetend Only)
  • Page 56 Alexa/Delfino Dimensions: 72x60x30 Capacity: 158 g Empty Weight: 349 lbs Water Weight: 1965 lbs Voltage: 110vac Pumps: ONE 2hp Pump Accessory: None Heater: 1.5kw Part Part # Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050 Board...
  • Page 57 Cirrus Dimensions: 84x84x36 Capacity: 375g Shipping Weight:884 lbs Water Weight: 4659 lbs Voltage: 220vac Pumps: TWO 1hp Pumps Accessory: Air Blower Heater: 5.5kw Part Part # Pump (Wetend Only) CC-1jp* Motor Only 2500-200* Pump/Motor Complete 2500-250* Heater 2600-050 Board 2600-017 Topside 2500-150 Air Blower...
  • Page 58 Lexus Plus/Select/LC Laser Plus/Select Dimensions: 84x84x36 Capacity: 375g Empty Weight: 595 lbs Water Weight: 771 lbs Voltage: 220vac Pumps: Two Pump/motor (either 2 X 1hp OR 1 1hp and 1 3hp) Accessory: Air Blower Optional Heater: 5.5kw Part Part # Pump (Wetend Only) CC-1jp* Motor Only...
  • Page 59 Lexus/Laser Continued Part Part # Pump (Wetend Only) CC-1jp* Motor Only 2500-200* Pump/Motor Complete 2500-250* Heater 2600-050 Board 2600-016 Topside 2500-151 Part Part # Pump (Wetend Only) CC-1jp* Motor Only 2500-200* Pump/Motor Complete 2500-250* Heater 2600-050 Board 2600-019 Topside S-51057 *Some Models 3hp #2 Pump.
  • Page 60 Palio Dimensions: 72x66x30 Capacity: 190 g Empty Weight: 409 lbs Water Weight: 2558 lbs Voltage: 115vac Pumps: One 2hp 2 Speed Pump Heater: 1.5/11kw Part Part # Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050 Board...
  • Page 61 Pinnacle Dimensions: 96x96x42 Capacity: 550 g Empty Weight: 950 lbs Water Weight: 6732 lbs Voltage: 230vac Pumps: One Circulation Pump, 2 High Pressure Single Speed Pumps Accessory: Air Blower, Optional AM/FM Radio Heater: 5.5kw Low Flow Part Part # Circ Pump If Small Pump, 110v Tiny Might If Large Pump, 2500-259 High Volume 1 Speed #1 or #2...
  • Page 62 Quantum Plus Dimensions: 94x87x37 Capacity: 400 g Empty Weight: 748 lbs Water Weight: 4980 lbs Voltage: 220vac Pumps: Either One 1hp and One 3hp Pump/Motor or One “Circulation Pump and 2 High Pressure Single Speed Pump Accessory: Air Blower Heater: 5.5kw Low Flow Part Part #...
  • Page 63 Santina Select Dimensions: 84x84x36 Capacity: 375g Empty Weight: 562 lbs Water Weight: 4771 lbs Voltage: 230vac Pumps: Two Single Speed 1hp (some models replaced one 1hp with a 3hp pump) Heater: 5.5kw Part Part # Pump (Wetend Only) CC-1jp Motor Only 2500-200 Pump/Motor Complete 2500-250...
  • Page 64 SOLARIS Dimensions: 78x72x32 Capacity: 249 g Water Weight: 4281 lbs Voltage: 230vac Pumps: 2 x 1hp Heater: 5.5kw Part Part # Pump (Wetend Only) CC-1jp Motor Only 2500-200 Pump/Motor Complete 2500-250 Heater 2600-050 Board 2600-016 Topside 2500-151...
  • Page 65 TIRAGE PLUS Dimensions: 94x87x37 Capacity: 375 g Empty Weight: 749 lbs Water Weight: 4874 lbs Voltage: 230vac Pumps: 2 1hp Pumps or 1 1hp and 1 3hp Pumps or 1 Circulation and 2 High Pressure Pumps Accessory: Air Blower Heater: 5.5kw Part Part #...
  • Page 66 Triton Dimensions: 91x91x38 Capacity: 390 g Empty Weight: 880 lbs Water Weight: 5335 lbs Voltage: 230vac Pumps: 1 Circulation Pump; 2 Single Speed Pumps Accessory: Air Blower; Optional AM/FM Radio Heater: 5.5kw Part Part # Circulation Pump 6500-035 Pump/Motor Complete 6500-763 Heater 6500-301...
  • Page 67 Z-100 Dimensions: 64x70x28 Capacity: 170 g Empty Weight: 350 lbs Water Weight: 2365 lbs Voltage: 110/220vac Pumps: One 2 Speed 110v Pump Accessory: None Heater: 1.5/5.5kw Part Part # Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050...
  • Page 68 Z-110 Dimensions: 72x66x30 OR 75x69x30 Capacity: 220 g Empty Weight: 327 lbs Water Weight: 3641 lbs Voltage: 110/220vac Heater: 1.5/5.5kw Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050 Board 2600-015 Topside 2500-152 Pump (Wetend Only) CC-2jp Motor Only...
  • Page 69 Z-115 Dimensions: 81x81x30 Capacity: 207 g Empty Weight: 353 lbs Water Weight: 3129 lbs Voltage: 110/220 vac Pumps: One 110vac 2hp Pump Accessory: None Heater: 1.5/5.5kw Part Part # Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050...
  • Page 70 Z120 Dimensions: 78x78x30 81x81x31 Capacity: 300 g Empty Weight: 430 lbs Water Weight: 3641 lbs Voltage: 110/220vac Pumps: One 110vac 2hp Pump Accessory: None Part Part # Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050 Board...
  • Page 71 Z130 Dimensions: 90x76x32 Capacity: 325 g Empty Weight: 587 lbs Voltage: 230vac Pumps: TWO 1hp Pumps Accessory: None Heater: 5.5kw Part Part # Pump (Wetend Only) CC-1p Motor Only 2500-200 Pump/Motor Complete 2500-250 Heater 2600-050 Board 2600-019 Topside S-51057...
  • Page 72 Z-135/145 Dimensions: 81x81x30 Capacity: 248 g Empty Weight: 349 lbs Water Weight: 3317 lbs Voltage: 110/220vac Pumps: One 110vac 2hp Pump Heater: 1.5/5.5kw Part Part # Pump (Wetend Only) CC-2jp Motor Only 2500-204 or CC-C180-HD Pump/Motor Complete 2500-255 or CC-F570HD Heater 2600-050 Board...
  • Page 73 Z-140/240 Dimensions: 84x84x36 87x87x37 Capacity: 400 g Empty Weight: 635 lbs Water Weight: 4578 lbs Voltage: 220vac Pumps: Two 1hp Pumps Heater: 5.5kw Part Part # Pump (Wetend Only) CC-1p Motor Only 2500-200 Pump/Motor Complete 2500-250 Heater 2600-050 Board 2600-601 Topside 2500-152 Pump (Wetend Only)
  • Page 74 Z-150/235 Dimensions: 90x78x32 92x82x32 Capacity: 290g Empty Weight: 410 lbs Water Weight: 3728 lbs Voltage: 230vac Pumps: Two 1hp Pumps Heater: 5.5kw Pump (Wetend Only) CC-1p Motor Only 2500-200 Pump/Motor Complete 2500-250 Heater 2600-050 Board 2600-601 Topside 2500-152 Pump (Wetend Only) CC-1p Motor Only 2500-200...
  • Page 75 Z-255 Dimensions: 87x87x36 Capacity: 302g Empty Weight: 619 lbs Water Weight: 3878 lbs Voltage: 220vac Pumps: Two: 1hp and 3hp Accessory: None Heater: 5.5kw Pump (Wetend Only) CC-1h + CC-3hp Motor Only 2500-200 or 2500-203 Pump/Motor Complete 2500-250 or 2500-251 Heater 2000-684 Board...
  • Page 76 ! " " # & & ( * * & + + &...

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