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Jacuzzi J - 325 User Manual

Jacuzzi swimming pool vacuum user manual.

 
Standard Troubleshooting Approach
S.T.A. Manual
2004 Jacuzzi Premium
Protech LED Model Hot Tubs
(J-315, J-325, J-335, J-345)
1

Summary of Contents

  • Page 1

    Standard Troubleshooting Approach S.T.A. Manual 2004 Jacuzzi Premium Protech LED Model Hot Tubs (J-315, J-325, J-335, J-345)

  • Page 2

    The following symbol is placed throughout this manual for your protection. Always use extreme caution whenever performing repairs to electrical control system components of any kind! Danger: Electrical Shock Hazard Exists! High Voltage Present On Circuit Board. Use Ex- treme Caution While Servicing Circuit Board.

  • Page 3: Table Of Contents

    Table of Contents Chapter Standard Troubleshooting Approach (S.T.A.) ... Why A Standard Troubleshooting Approach? ... How To Use The STA ... Professional Customer Service ... Responding To An Incoming Service Call ... Preparing Foe A Service Call ... Before Calling Technical Support ... Before Leaving The Customer ...

  • Page 4: Table Of Contents

    Chapter Hot Tub Doesn’t Come On For Filter Cycle ... House Breaker Trips ... Hot Tub Light Will Not Come On ... No Jets ... Weak Or Surging Jets ... Pump Runs And Quits During Jet Mode ... 8.10 Circulation Pump Not Working ... 8.11 Troubleshooting A Thermal Pump Cutout ...

  • Page 5: Standard Troubleshooting Approach (s.t.a.), Why A Standard Troubleshooting Approach, Professional Customer Service

    The Jacuzzi Premium STA Manual has been designed to help you control the overall cost of service by focusing on the three important aspects of your job outlined above. The STA will help you fi x your customer’s hot tub quickly, fi x it well, and use fewer parts.

  • Page 6

    Question the homeowner to determine, if possible, what specifi c component is not functioning. • Use the map of the spa (see below); become familiar with the components and their names. This will also help when speaking to technical service. •...

  • Page 7

    Make Sure there is access to the main breaker and GFCI, and ask the homeowner to disconnect if possible before you arrive at their home. Use the home service visit as an opportunity to sell aftermarket items such as chemicals, towels, etc.

  • Page 8

    1.5 Preparing For A Service Call Know what each call is asking of you; determine whether or not the extent of service can be han- dled with a simple phone call or if it requires a visit. • Determine whether the call is warranty or non warranty. Make sure the customer is aware that the manufacturer will not cover out-of-warranty service.

  • Page 9: Before Calling Technical Support, Before Leaving The Customer

    Make professional repairs. • Putting bondo, underwater epoxy, silicone or any other product to fi x cracked or leaking plumbing will not adequately correct the problem and will most likely result in a return visit. Replace the com- ponent or come back and do it for free! •...

  • Page 10: Satisfying The Customer

    1.8 Satisfying The Customer Most customers do not care what work you have done or what parts you have replaced, but they always care whether or not their problem goes away. When you are done, show them that their problem is gone. If they ask how you did it, take a few minutes to explain.

  • Page 11: Avoiding Esd Damage, What About Wrist Straps And Special Mats

    C) lay the replacement board on the ground, D) place the bad board in the bag from which you removed the re- placement board, E) return bad board(s) to Jacuzzi Premium in undamaged sealed static protective bags.

  • Page 12: Main System Specifi Cations (j-345)

    3.0 Main System Specifi cations J-345 Dimensions ... 84” x 84” x 36” (213cm x 213cm x Dry Weight ... 882 lbs (400kg) Filled Weight ... 3,611 lbs (1,638kg) Water Capacity (Avg. Fill) ... 336 US gallons (1,272 Liters) Electronic Controls ... Solid State Electronic Controls with LED Pump 1 ...

  • Page 13

    Jet Selector / Air Control Operation Diagram Air Control 1: Opens / Closes Air Inlet to Jet Group A Jet Selector 2: Directs Jet Pump 2 Output Between Jet Groups C or D. Air Control 4: Opens / Closes Air Inlet to Jet Group D A = 25.50”...

  • Page 14: Main System Specifi Cations (j-335)

    3.1 Main System Specifi cations J-335 Dimensions ... 84” x 84” x 36” (213cm x 213cm x Dry Weight ... 781 lbs (354kg) Filled Weight ... 3,752 lbs (1,702kg) Water Capacity (Avg. Fill) ... 358 US gallons (1,355 Liters) Electronic Controls ... Solid State Electronic Controls with LED Pump 1 ...

  • Page 15

    Jet Selector / Air Control Operation Diagram Air Control 2: Opens / Closes Air Inlet to All Lounge Jets A A = 26.50” (67.3cm) F = 19.75” (50.2cm) B = 24.00” (60.1cm) G = 27.00” (68.6cm) C = 28.75” (73.0cm) H = 34.00”...

  • Page 16: Main System Specifi Cations (j-325)

    3.2 Main System Specifi cations J-325 Dimensions ... 84” x 76” x 34” (213cm x 193cm x Dry Weight ... 738 lbs (335kg) Filled Weight ... 3,386 lbs (1,536kg) Water Capacity (Avg. Fill) ... 320 US gallons (1,211 Liters) Electronic Controls ... Solid State Electronic Controls with LED Pump 1 ...

  • Page 17

    Jet Selector / Air Control Operation Diagram Jet Selector: Directs Jet Pump Output Between Jet Groups A or B&C Air Control 3: Opens / Closes Air Inlet to Jet Group C A = 27.00” (68.6cm) F = 31.25” (79.4cm) B = 27.25” (69.2cm) C = 25.75”...

  • Page 18: Main System Specifi Cations (j-315)

    3.3 Main System Specifi cations J-315 Dimensions ... 76” x 66” x 32” (193cm x 168cm x Dry Weight ... 640 lbs (290kg) Filled Weight ... 2,283 lbs (1036kg) Water Capacity (Avg. Fill) ... 200 US gallons (757 Liters) Electronic Controls ... Solid State Electronic Controls with LED Pump 1 ...

  • Page 19

    Jet Selector / Air Control Operation Diagram Air Control 2: Opens / Closes Air Inlet to Jet Group B A = 26.50” (67.3cm) B = 28.00” (71.1cm) C = 27.00” (68.6cm) D = 28.00” (71.1cm) E = 27.75” (70.5cm) Dimensions/Specifi cations Subject to Change Without Notice Jet Selector: Directs Jet Pump Output Between...

  • Page 20: Main Control Panel Functions, Setting Filter Cycle Start Time, Programming Filter Cycles

    4.0 Main Control Panel Functions Panel Functions: Heat Indicator: Lit when heater is on. Warmer Button: Increases water tempera- ture setpoint. Cooler Button: Decreases water tempera- ture setpoint. LED Display: Can display current water temperature (default display*), water tem- perature setpoint, selected fi ltration mode, and error messages.

  • Page 21

    Standard Filtration Modes FØ - F3 Heating in either of these modes (FØ - F3) is automatically controlled by the water temperature. If the hot tub water drops 2ºF (1.2ºC) below the temperature setpoint, the heater will turn on with the circula- tion pump.

  • Page 22: Aftermarket Ozone Facts, Additional Control Panel Functions, Selecting Jet Speeds, Underwater Light Operation

    4.3 Aftermarket Ozone Facts An aftermarket ozonator can be installed on all 2002+ models. A mazzei injector is required on all mod- els. Ozone System Specifi cations • Circulation pump runs 24 hours • Ozonator runs 24 hours • The ozonator shuts off when a Jets Button is pressed. The ozonator will resume operation approxi- mately 5 minutes after the jets are turned off intentionally or automatically.

  • Page 23: Lock Out Mode, Summer Logic, Understanding Circuit Board Pin Assignments, Circuit Board Jumpers

    5.5 Lock Out Mode The control panel temperature display fl ashes when the Lock Out Mode is active. Lock Out Mode disables all hot tub functions to permit fi lter cleaning. If the hot tub is heating when lockout mode is selected, the heater will immediately turn off and the circulation pump will cycle water for 30 seconds to cool the heater element, then turn off.

  • Page 24: Troubleshooting Using The Control Panel, Control Panel Displays, Control Panel Default Display

    7.0 Troubleshooting Using The Control Panel 7.1 Control Panel Displays Complete operating instructions for the control panel can be found in the owner’s manual. The hot tub’s self-diagnostic control system constantly monitors the hot tub for proper operation. When anything goes wrong, the control panel displays a message for the user which may result in a service call.

  • Page 25

    FL1 And FL2 Water Flow Problem • FL1: The fl ow switch is not closed when the circulation pump is running. The heater is deactivated. Proper water fl ow is inhibited or the fl ow switch may be obstructed, misaligned or defective.

  • Page 26: Testing Flow Switch

    Plug in a new control panel. If the problem is corrected, replace the control panel. If the problem persists, proceed to step 3. Check the voltage at the transformer secondary. See section A15, page 57, for transformer testing instructions. If the voltage is bad, replace the transformer. If the voltage is good, proceed to step 4. Check the circuit board transformer connections.

  • Page 27: Troubleshooting Without The Control Panel

    8.0 Troubleshooting Without The Control Panel • Diagnostic Tools for Sections 8.1A - 8.1D: Clamp-on ammeter, voltmeter and ohmmeter. • Suggested Spare Parts for Sections 8.1A - 8.1D: Circuit board, control panel, temperature sensor, fl ow switch, heater assembly, hi-limit, circulation pump. Refer to page 59 for additional information. 8.1A No Heat Or Not Enough Heat •...

  • Page 28

    8.1B No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) not turning, panel heat indicator not lit, panel is fl ashing FL2. Standard Troubleshooting Approach Pull wire off flow switch. Does the FL2 error message go away? Turn off power to hot tub.

  • Page 29

    8.1C No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) not turning, panel heat indicator not lit, panel is fl ashing FL1. Standard Troubleshooting Approach Is there correct voltage coming to the hot tub at TB1? 240 VAC, +/-10%, or (120/240 VAC, +/-10% for J315/J325 models).

  • Page 30

    8.1D No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) is turning, panel heat indicator not lit, panel is fl ashing FL1. Standard Troubleshooting Approach Is the circulation pump (Heat Pump) moving water? Verify hot tub is in standard filtration mode (page 21).

  • Page 31

    (page 21). Set temperature high enough to initiate a heat call. Remove power to hot tub then plug in a spare control panel. Turn power on. Does indicator work now? Replace control panel. Call Jacuzzi Premium Technical Support.

  • Page 32: Intermittent Heating

    Explain what you will do if the problem returns. Check back with the customer in a few days if you haven’t been contacted. If the customer calls back, call Jacuzzi Premium Technical Support. Note: All models use a ‘magnetic reed switch” type of fl ow switch that can remain closed or open from debris interference.

  • Page 33: Nothing Works 3, Hot Tub Doesn't Come On For Filter Cycle

    8.3 Nothing Works Things to remember: when a system fails, there is probably one, and only one problem. Verify power to the hot tub by observing the control panel’s LED display. The control panel will usually display some- thing as long as there is proper power to the hot tub. Check for error messages. Displayed error mes- sages usually indicate the problem.

  • Page 34: House Breaker Trips

    8.5 House Breaker Trips The hot tub’s current draw will vary depending on how it’s circuit board is jumpered. Jumper options determine whether multiple functions can operate together. If the house breaker trips, check the hot tub’s current draw. If the jumpers are properly set and the current draw is within expected limits, the house breaker or wiring may be defective and need to be replaced or repaired.

  • Page 35

    (Improper installation is not a warranty call which once cor- rected may involve you coming back to replace a component.) If there is a problem with the elec- trician understanding the correct hook up of the hot tub, have the electrician contact Jacuzzi Premium Technical Support.

  • Page 36

    What is the model and serial number of the hot tub? • This will help determine how the hot tub should be hooked up. Did a licensed electrician hook up the hot tub? • See question number one! What is the voltage at the hot tub? •...

  • Page 37

    • If a component has excessive amperage draw, replace that component. If you should need to contact Jacuzzi Premium Technical Support, these are questions that will be asked of you. It is also a good idea to have the “Troubleshooting Data Collection Form” (see example...

  • Page 38: Hot Tub Light Will Not Come On

    North American 60Hz Installations: As of January 1, 1994, the National Electrical Code (NEC) requires a Ground Fault Circuit In- terrupter (GFCI) on all hot tub installations in the US. A GFCI must be wired correctly or it will trip. Make sure the electrician has wired the GFCI according to the diagrams on page 52. 8.6 Hot Tub Light Will Not Come On Diagnostic Tools: Voltmeter.

  • Page 39

    8.7 No Jets This is a condition of constant zero water pressure. The fi rst step in diagnosing the problem is to determine if the pump is actually turning. Once this determination is made, follow the appropriate portion of this S.T.A. Diagnostic Tools: Voltmeter, spare control panel.

  • Page 40: Weak Or Surging Jets

    Remove debris or loose foreign object. If pump suction line is clear, check for blockage in plumbing on the return side of pump. Call Jacuzzi Premium Technical Support for assistance in performing this verification step.

  • Page 41: Pump Runs And Quits During Jet Mode

    240 VAC the pump drawing –10 % (or 120 VAC too much current. –10% for J315, J325 Contact Jacuzzi models) at test Premium Technical points 1 and 2. Support. Replace pump. Danger: Electrical Shock Hazard Exists! High Voltage Present On Circuit Board.

  • Page 42: Circulation Pump Not Working

    8.10 Circulation Pump Not Working The circulation pump should be on for the programmed duration each day and for a heat call unless “Summer Logic” is activated. Verify the pump should be on before trouble- shooting. Check the circulation pump start time and duration setting. Refer to section 5.6C (page 23).

  • Page 43: Troubleshooting A Thermal Pump Cutout, Pump Hums And Will Not Start

    One is to change the fi lter cycle periods so that they do not coincide with the hottest time of the day and peak power consumption hours. Another is to ventilate the equipment bay. Call Jacuzzi Premium Technical Support for advice on this matter.

  • Page 44

    8.13 Ozone not working Diagnostic Tools: Clamp-on ammeter and voltmeter. Suggested Spare Parts (Page 59): Ozonator, circuit board, control panel. Standard Troubleshooting Approach Turn power to hot tub off and on. Wait approximately two minutes for filter cycle to begin and turn on ozonator and circulation pump.

  • Page 45

    Appendix...

  • Page 46

    A1.0 Checking Voltage To Hot Tub Correct supply voltage wiring to the hot tub is essential for safe/proper operation. The fi rst step in troubleshooting a new installation should be to take voltage readings at the terminal block TB1. Do not trust wire colors.

  • Page 47

    A2.0 Checking Voltages To Devices Device voltages are often measured at the circuit board to determine whether the board or the device is bad. If the circuit board delivers voltage when the device operation is called, the circuit board is prob- ably good and the problem lies with the device or the wiring to the device.

  • Page 48: A4.0 Testing The Flow Switch, A5.0 About Fuses, A6.0 The Watchdog (----)

    A4.0 Testing The Flow Switch When the “FL1” or “FL2” message appears, it means the fl ow switch contacts have failed to close when the circulation pump was on, or failed to open when the circulation pump was off. This could be caused by an obstruction in the fl ow path or by a bad switch. The fi rst thing to look for is an obvious obstruction, remembering (while not likely) that it is possible for a small object to work its way into the plumbing where it will not be obvious.

  • Page 49: A7.0 Understanding Ozone, A8.0 Understanding Ph

    “fresh-as-all-outdoors” smell. Jacuzzi Premium offers a type of ozone system, the corona discharge (CD). The corona dis- charge (CD) uses a highly effi cient low current/high voltage arching chamber to generate ozone. The CD ozone introduces ozone into the hot tub water through a “Mazzei”...

  • Page 50

    A9.0 2004 J-315, J-325 Circuit Board Wiring Diagram (US/Canada 60Hz) US/Canada 60Hz Model • Circuit Board Type: ProTech LED, 6600-086.

  • Page 51

    A10.0 2004 ProTech LED Circuit Board Wiring Diagram (US/Canada 60Hz) J-335, J-345 US/Canada 60Hz Models • Circuit Board Type: ProTech LED, 6600-088.

  • Page 52

    A11.0 Load Box Connection Diagram For J-335, J-345 (240 VAC only, 60Hz) 2-Pole Circuit Breaker with 2-Wire Grounded Load Connection (3 Wires to Hot Tub, 2-Hot, 1-Ground) 240 VAC/120 VAC White Black Main Service Panel with GFCI Ground Main Panel with Secondary GFCI Sub-Panel Using a 2-Pole GFCI Breaker with 2-Wire Grounded Connection (3 Wires to Hot Tub, 2-Hot, 1-Ground) Main Panel*...

  • Page 53

    Load Box Connection Diagram For J-315, J-325 (120/240 VAC, 60Hz) 2-Pole Circuit Breaker with 3-Wire Grounded Load Connection (4 Wires to Hot Tub, 2-Hot, 1-Neutral, 1-Ground) 240 VAC/120 VAC White Black Main Service Panel with GFCI Ground Main Panel with Secondary GFCI Sub-Panel Using a 2-Pole GFCI Breaker with 3-Wire Grounded Connection (4 Wires to Hot Tub, 2-Hot, 1-Neutral, 1-Ground) Main Panel*...

  • Page 54

    Load Box Connection Diagram For J-315, J-325 (120 VAC only, 60Hz) 2-Pole Circuit Breaker with 2-Wire Grounded Load Connection (3 Wires to Hot Tub, 1-Hot, 1-Neutral, 1-Ground) 240 VAC/120 VAC White Black Main Service Panel with GFCI Ground Main Panel with Secondary GFCI Sub-Panel Using a 2-Pole GFCI Breaker with 2-Wire Grounded Connection (3 Wires to Hot Tub, 1-Hot, 1-Neutral, 1-Ground) Main Panel*...

  • Page 55: A12.0 Temperature / Hi-limit Sensor Resistance Chart

    A12.0 Temperature / Hi-Limit Sensor Resistance Chart Fahrenheit (ºF) Celcius (ºC) 59.0 ... 15 ... 60.8 ... 16 ... 62.6 ... 17 ... 64.4 ... 18 ... 66.2 ... 19 ... 68.0 ... 20 ... 69.8 ... 21 ... 71.6 ... 22 ...

  • Page 56: A13.0 Flow Switch Illustration

    A13.0 Flow Switch Illustration Flow Switch #6560-852 Compatibility: All 2004 J-315, J-325 Models Connection: This fl ow switch style has spade connectors at the top for easy cable removal for electronic troubleshooting. Flow Switch #6560-860 Compatibility: All 2004 J-335, J-345 Models Connection: This fl ow switch style has connectors that are potted into the top and cannot be removed at the fl ow switch.

  • Page 57: A15.0 Transformer Test

    A15.0 Transformer Test To Test The Transformer: Leave the transformer connector J4 plugged into the circuit board. Set your voltmeter to the highest VAC range. Place the voltmeter probes directly into the backside (wire side) of the J4 connector and test as follows: US/Canada 60Hz J-315, J-325 (120 VAC or 240 VAC Powered*)

  • Page 58: A16.0 Troubleshooting The Optional Stereo System

    A16.0 Troubleshooting the Optional Stereo System (J-335 and J-345 only) The optional stereo system provides a marine AM/FM/CD stereo receiver with two “pop-up” speaker towers for superior sound quality. If the stereo deck does not turn on, refer to the following test proce- dure.

  • Page 59: A17.0 Suggested Spare Parts

    A17.0 Suggested Spare Parts (ProTech LED) Circuit Boards • 6600-088: J-335, J-345, 50/60Hz • 6600-088: All Export Models • 6600-086: J-315, J-325 Domestic Only Control Panels • 2600-301: One Pump Control Panel, 50/60Hz • 2600-302: Two Pump Control Panel, 50/60Hz Filter Cartridges •...

  • Page 60: A18.0 Glossary Of Terms

    A18.0 Glossary Of Terms Circuit Board: Printed circuit board assembly that distributes voltage to selected components. Control Panel: Component that allows user to access functions provided by the circuit board. Ammeter: Device which measures electrical current conducted through a wire or electrical device.

  • Page 61

    Address Before troubleshooting, collect the following: Model # of Hot Tub Serial Number Operating Voltage Before calling Jacuzzi Premium, collect the following: Low Speed Pump 1 Amps Circ Pump with Heater Amps High Speed Pump 1 Amps Pump 2 Amps...

  • Page 62

    Jacuzzi Premium 14525 Monte Vista Avenue, Chino, CA, 91710, U.S.A.; Phone (909) 606-1416; Fax (909) 393-1583, Website: http://www.jacuzzipremium-dealers.com/ Revision B: 06/04 © 2004 Jacuzzi Premium Created in the U.S.A.

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