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WELLSYSTEM WAVE Service Manual

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Service manual
Translation of the original service manual
wellsystem
WAVE / WAVE_TOUCH
wellsystem
SPA COMPLETE
1028520-00
/ us-en / 2.2022
0
wellsystem

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Summary of Contents for WELLSYSTEM WAVE

  • Page 1 Service manual Translation of the original service manual wellsystem WAVE / WAVE_TOUCH wellsystem SPA COMPLETE 1028520-00 / us-en / 2.2022 wellsystem...
  • Page 2 WAVE_TOUCH with SPA COMPLETE  Further information on assembling and dismantling the devices can be found in the documents: 1028522-.. Assembly instructions wellsystem WAVE_TOUCH or operating instructions # 1028521- .. 1024427-..Service information for retrofit kit for internal cooling/exhaust air. 2/74...

  • Page 3: Table Of Contents

    Table of contents Table of contents General ....................6 Symbol explanation ................6 1.1.1 Warning signs ..................6 Safety information for assembly and disassembly ......8 Safety information for avoiding damage to the unit ......8 Information for service technicians ..........9 Electrical connection ................
  • Page 4 Table of contents 3.6.3 5.3 Acrylic bed: Intermediate panel ..........46 3.6.4 5.4 Acrylic bed: Shoulder tanning unit ..........46 3.6.5 5.5 Headrest/neck support ............... 46 Electronic ballasts, ignition units ............47 3.7.1 6.1 Conventional ballast ..............47 3.7.2 6.2 Electrical ballast ................47 3.7.3 6.3 Ignition unit ..................
  • Page 5 Table of contents 3.14.2 Plastic panels ..................61 3.14.3 12.3 Contact guard ................61 3.14.4 12.4 Nozzle trolley................61 3.15 Tank ....................66 3.15.1 13.1 Seals ..................66 3.15.2 13.2 Cooling coil ................67 3.16 14.1 MAN card .................. 68 3.17 Warning sticker..................

  • Page 6: General

    General General Symbol explanation The following types of safety notices are employed in these operating instruc- tions: Authorized, trained and qualified staff Qualified staff from an external company who have been trained and authorized by the manufacturer for assembly and maintenance work with spe- cific devices.
  • Page 7 General Caution notices, nonobservance can lead to less than serious injury or damage of property. CAUTION! Heavy parts! Risk of injury! The word 'Caution' together with the warning sign points out that less than serious injury can be expected here. Countermeasures: –...

  • Page 8: Safety Information For Assembly And Disassembly

    General Safety information for assembly and disassembly WARNING – when installing this massage device, basic precautions should always be followed, including the following: Read and follow all instructions. DANGER! You can be killed or injured by an electric shock! Electricity throughout entire device! Assembly and electrical connection must comply with national and local regulations.

  • Page 9: Information For Service Technicians

    Information for service technicians Information for service technicians Electrical connection DANGER! You can be killed or injured by an electric shock or in- jured by overexposure! Skin damage and sunburn possible. Danger of overheating by obstruction of the air routing. –...

  • Page 10: Disconnecting The Unit From The Power Supply And Secure It Against Re-Connection

    Information for service technicians Disconnecting the unit from the power supply and secure it against re-con- nection DANGER! The device must be powered off before any work is per- formed. – Switching off the device alone is insufficient, as certain points may remain energized.

  • Page 11: Maintenance

    Information for service technicians Maintenance DANGER! Risk of electric shock, which may lead to death or se- vere injury! – Disconnect the unit from the power supply when per- forming maintenance work that requires the unit to be opened. See page 10. Once the maintenance work is complete, all safety equipment must be re- turned to their original operating status.

  • Page 12: Electrostatic Discharge (Esd)

    Information for service technicians Electrostatic discharge (ESD) CAUTION! ESD-sensitive parts! Power connection boards and electrical, electronic or optoe- lectronic components are sensitive to electrostatic discharge and can be terminally damaged on contact. – Wear special ESD shoes. – Always wear a grounding wrist strap when working in close proximity to electrical, electronic or opto-electronic components.

  • Page 13: Technical Data

    Information for service technicians Technical data 2.5.1 Power, connection rating and noise level The technical data can be found in the instructions for use: 1028521-..wellsystem Wave Touch (with SPA COMPLETE) 02/2022 1028520-00 Service manual – 13/74...

  • Page 14: Checking And Replacing Components

    Checking and replacing components Checking and replacing components WARNING! Risk of hand injuries! – Wear safety gloves during maintenance work. Preparation Covers can be opened or closed when checking and replacing components. Further information is available in the assembly instructions # 1028522-.. or operating instructions # 1028521- ..
  • Page 15 Checking and replacing components WAVE: 1. Tank with rubber cover 2. Side frame panels 3. Frame panels at the head and foot ends 4. Front panel/rear panel 5. Control box 6. Cladding at the head and foot ends 7. Frame 8.
  • Page 16 Checking and replacing components WAVE Touch: 1. Tank with rubber cover 2. Side frame panels 3. Frame panels at the head and foot ends 4. Front panel/rear panel 5. Control box 6. Cladding at the head and foot ends 7. Frame 8.
  • Page 17 Checking and replacing components SPA COMPLETE: 1. Hood with rear panel 2. Front panel with loudspeakers NOTE! Additional documents for assembling and removing spare parts: see page 2. 02/2022 1028520-00 Service manual – 17/74...

  • Page 18: Electrical Connections

    Checking and replacing components Electrical connections The electrical connections and cables are located throughout the entire unit: in the control box, on the pump, in the front panels, on the motors and on the nozzle trolley. 3.2.1 Plug connectors 3.2.2 Connectors 3.2.3 Connection terminals...

  • Page 19: Plug Connectors

    These connections only fit in a particular direction. – Circuit board edge connectors in a variety of sizes. RJ 45 connector: – Connector for control panel WAVE. – Connector for data connection SPA COMPLETE. – Connector for LED effect lighting.
  • Page 20 Checking and replacing components – Connector for heating. – Connector for fan and pump. – Crossover connector (SPA COMPLETE: only for RJ45 wire). – Connector SPA COMPLETE: Bus connection. 20/74...

  • Page 21: Connectors

    – Lock the fuse box with a padlock. Only the wellsystem WAVE / WAVE_TOUCH is connected with a fixed con- nection. – Securely wire the mains cable. Further information can be found in the 'Electrical connection' chapter of the operating instructions.

  • Page 22: Connection Terminals

    Checking and replacing components 3.2.3 1.3 Connection terminals Does not apply to this unit. 3.2.4 1.4 Internal terminals (spring-loaded) Optional connection (for external control) 3.2.5 1.6 Cable bushings – Check or replace components in accordance with the checklist # 1016789-... 22/74...
  • Page 23 Checking and replacing components Cable bushings in the middle station – only in WAVE_TOUCH – If present, check for wear and damage. 02/2022 1028520-00 Service manual – 23/74...

  • Page 24: Electrical Wires/Cables

    Checking and replacing components 3.2.6 1.7 Electrical wires/cables – Check or replace components in accordance with the checklist # 1016789-... Designation Information BU21 JK coin device / external coin device connection SD card SD card insertion slot (software update) LAN connection Frequency converter fan ST11 Cooling heat exchanger...
  • Page 25 Checking and replacing components Designation Information X019-1 Frequency converter controller X020-1 Safety chain and relay control X021-1 JK coin device and external coin device connection X024-1 Drive motor (1) voltage supply X025-1 Drive motor (2) voltage supply Not shown: 2-pin BU13 Drive motor (1) voltage supply 4-pin BU23 Drive motor (1) controller...
  • Page 26 Checking and replacing components Middle station for units with an operating unit with touch function Designation Information 24 V voltage supply LED lighting, front X600 Data cable for operating unit Power E4 RJ45 Data transfer BUS PCB power supply Data bus 26/74...

  • Page 27: Electrical Components

    Checking and replacing components Electrical components – Check or replace components in accordance with the checklist # 1018814-... 3.3.1 Electrolytic capacitors Does not apply to this unit. 3.3.2 Interference suppressor filter 3.3.3 Circuit boards (boards, display) 3.3.4 Relays/contactors 3.3.5 Skin sensor Does not apply to this unit.

  • Page 28: Electrolytic Capacitors

    Checking and replacing components 3.3.11 Solenoid switches 2.11 3.3.12 Heating element 2.12 3.3.13 Audio 2.13 Does not apply to this unit. 3.3.14 Control system 2.14 3.3.1 2.1 Electrolytic capacitors Does not apply to this unit. 3.3.2 2.2 Interference suppressor filter Replacing the interference suppressor filter –...

  • Page 29: Power Connection Boards

    Put on the wrist strap as per the manufacturer's instructions. NOTE! The number of power connection boards depends on the unit's functions. Please refer to the technical documentation for the PCB order numbers. Overview of circuit boards WAVE Circuit boards WAVE_TOUCH 02/2022 1028520-00 Service manual – 29/74...
  • Page 30 Checking and replacing components Circuit boards SPA COMPLETE CAUTION! – Always use compressed air to clean dusty circuit boards! NOTE SOFTWARE UPDATE! All circuit boards must be updated at the same time using the same latest version of the software. 30/74...
  • Page 31 Checking and replacing components Replacing the main circuit board in the control box Main circuit board in the control box. – Undo the two top cross-headed screws on the cover. – Remove the cover. – Undo the screws on the main circuit board. –...
  • Page 32 Checking and replacing components – Loosen the screws. – Remove the circuit board. – Open the operating unit. The assembly is the same process in reverse order. Replacing the circuit board for the operating unit with touch function: The operating unit's circuit board and display are glued together. For this rea- son, the entire operating unit must be replaced.
  • Page 33 Checking and replacing components – Undo the grub screw. If the loosely fitted spring washers fall out during assembly/dismantling work, please note: NOTE ON SPRING WASHERS! Place the spring washers on top of one another in opposite directions, i.e. one washer with the curved side pointing up and the following washer with the curve pointing down so that the hinge effect is achieved.
  • Page 34 Checking and replacing components Mounting the operating unit on the opposite side If you need to change the side of the operating unit: 1. The arm must be released from the frame. 2. The rear panel to the operating unit must be opened. 3.
  • Page 35 Checking and replacing components The following steps apply for both variants when dismantling and mounting the arm for the operating unit with touch function. – Loosen the screws. – Attach the operating unit and secure with 2 screws. NOTE POSITIONING THE CABLES! The position of the cables for the WAVE_TOUCH and the position of the cables for the WAVE_TOUCH is described in the assembly instructions 1028522-..
  • Page 36 Checking and replacing components – Loosen the screws. – Replace the circuit board The assembly is the same process in reverse order. Removing the circuit boards in the SPA COMPLETE Preparation: To replace the circuit boards and other components, the SPA COMPLETE's front panel and hood cover must be removed.
  • Page 37 Checking and replacing components Audio circuit board with Bluetooth circuit board: – Undo the screws. – Unplug the plugs. One circuit board is located in the hood to the SPA COMPLETE. Removing the hood cover: – Loosen the screws. – Loosen the screws.
  • Page 38 Checking and replacing components Replacing the NFC circuit board The NFC circuit board is located on the fan box in the WAVE_TOUCH. – Undo the screws. – Pull out the plug. – Remove the old circuit board and insert a new one. The assembly is the same process in reverse order.

  • Page 39: Relays/Contactors

    Checking and replacing components 3.3.4 2.4 Relays/contactors The following components are located in the bottom of the control box, in the fan box and, optionally, in the internal air/water cooling. Replacing the relay on the top-hat rail – Remove the cable. –...

  • Page 40: Power Supply Units And Switching Power Supplies

    Checking and replacing components 3.3.6 2.6 Power supply units and switching power supplies – Unplug the connectors. – Loosen the screws. – Replace the power supply unit The assembly is the same process in reverse order. – Unplug the connectors. –...

  • Page 41: Drive Motors

    Checking and replacing components 3.3.7 2.7 Drive motors – Unplug the connectors. – Undo the cable ties – Unscrew the nuts The assembly is the same process in reverse order. Check the play and security of the drive motors on the mounting plate. 3.3.8 2.8 Solenoid valve Only in units without internal air/water cooling!

  • Page 42: Pump/Frequency Converter Unit

    Checking and replacing components – Unscrew the hose clip – Remove the hose – Unplug the connectors. – Undo the screws on the mounting plate – Replace the solenoid valve The assembly is the same process in reverse order. 3.3.9 2.9 Pump/frequency converter unit The steps for removing and assembling the unit are described in the assem- bly instructions in chapters 5.4 and 6.3.

  • Page 43: Solenoid Switches

    Checking and replacing components 3.3.11 2.11 Solenoid switches The solenoid switches are located under the tank and head end. – Loosen the screws. – Insert new solenoid switches and screw firmly in place (only in units with- out internal air/water cooling). –...

  • Page 44: Audio

    Checking and replacing components 3.3.13 2.13 Audio After the front panel to the SPA COMPLETE has been removed: – Undo the screws for the respective speaker on the back of the front panel. – Replace the speaker. The assembly is the same process in reverse order. Replacing the SD cards –...

  • Page 45: Aqua Fresh

    Checking and replacing components Aqua Fresh 3.4.1 AF compressor Does not apply to this unit. 3.4.2 AF valves / Aroma Does not apply to this unit. AF pumps 3.4.3 Does not apply to this unit. AF aroma hoses 3.4.4 Does not apply to this unit. 3.4.5 Aqua Fresh liquid Does not apply to this unit.

  • Page 46: Acrylic

    Checking and replacing components Acrylic 3.6.1 Acrylic bed Does not apply to this unit. 3.6.2 Acrylic panel canopy/side/front doors Does not apply to this unit. 3.6.3 Acrylic panel intermediate panel Does not apply to this unit. 3.6.4 Acrylic panel shoulder tanning unit Does not apply to this unit.

  • Page 47: Electronic Ballasts, Ignition Units

    Checking and replacing components Electronic ballasts, ignition units 3.7.1 Conventional ballast Does not apply to this unit. 3.7.2 Electrical ballast 3.7.3 Ignition unit Does not apply to this unit. Does not apply to this unit. 3.7.1 6.1 Conventional ballast Does not apply to this unit. 3.7.2 6.2 Electrical ballast Does not apply to this unit.

  • Page 48: Exhaust Flap Spring

    Checking and replacing components 3.8.1 7.1 Exhaust flap spring Does not apply to this unit. 3.8.2 7.2 Exhaust air hose The exhaust air hose is located in the internal air/water cooling unit. Removing the front and rear panel: see assembly instructions: 1028522-.. –...

  • Page 49: Fan

    Checking and replacing components 3.8.7 7.7 Fan The fan is located on the frequency converter. – Check or replace components in accordance with the checklist # 1018814-... Further information is available in the assembly instructions # 1028522- .. NOTE! THE FAN'S DIRECTION OF OPERATION! Mount the fan in such a way that it is set up to rotate anti- clockwise so that the air flows inwards towards the pump.
  • Page 50 Checking and replacing components Internal air/water cooling unit – Removing the cover – Undo the screw on the hose clip. – Remove the hoses. – Undo the screws on the brackets. – Loosen the screws. – Remove the cover. – Clean with a vacuum cleaner, compressed air or comb.

  • Page 51: Servo Motors

    Checking and replacing components Fan in front panel of SPA COMPLETE: – Remove the screws. – Remove the wire on the terminal. – Remove the fan. The assembly is the same process in reverse order. NOTE THE FAN'S DIRECTION OF OPERATION! Mount the fan in such a way that it is set up to rotate clock- wise so that the air flows outwards.
  • Page 52 Checking and replacing components Replacing the air hose The air hose connects the pump and fan box. – Undo one screw on the hose clip. – Replace the air hose. The assembly is the same process in reverse order. 52/74...

  • Page 53: Bearings, Springs, Shock Absorbers

    Checking and replacing components Bearings, springs, shock absorbers 3.9.1 Springs Does not apply to this unit. 3.9.2 Bearings/slide bearings 3.9.3 Rubber-metal buffer (lifting mechanism and fan) Does not apply to this unit. 3.9.4 Cables and guide rollers Does not apply to this unit. 3.9.5 Fall protection Does not apply to this unit.

  • Page 54: Bearings/Slide Bearings

    Checking and replacing components 3.9.2 8.2 Bearings/slide bearings – If present, check for wear and damage. – Disassembling the nozzle trolley, see chapter 3.14.4. – Replace the gear. – Remove the axles. – Replace the ball bearing. – Remove the ball bearing. Exchange guide bearing –...

  • Page 55: Rubber-Metal Buffer (Lifting Mechanism)

    Checking and replacing components – Remove the bearing bracket at the foot end. – Remove the bearing bracket at the head end. 3.9.3 8.3 Rubber-metal buffer (lifting mechanism) Does not apply to this unit. 3.9.4 8.4 Cables and guide rollers Does not apply to this unit.

  • Page 56: Gas Pressure Absorbers/Oil Dampers

    Checking and replacing components 3.9.7 8.7 Gas pressure absorbers/oil dampers Both gas pressure absorbers are located in the hood to the SPA COMPLETE. – If present, check for wear and damage. – Use a screwdriver to lift the safety ball head. –...

  • Page 57: Uv Components

    Checking and replacing components 3.10 UV components 3.10.1 Lamps / LP / HP Does not apply to this unit. 3.10.2 Filter panels Does not apply to this unit. 3.10.3 Reflectors Does not apply to this unit. 3.10.4 Starter Does not apply to this unit. 3.10.5 Chip cards Does not apply to this unit.

  • Page 58: Led Light Show

    Checking and replacing components 3.10.7 9.7 LED Light Show LED panels are located in the hood to the SPA COMPLETE. There are four panels, which can be replaced separately. – Pull out the plug. – Undo the screws. – Remove the panel. Insert the new panel: Install in reverse order.

  • Page 59: Safety Switch/Locks

    Checking and replacing components 3.11 Safety switch/locks 3.11.1 Sensors (temperature, pressure, UV, etc.) 10.1. 3.11.2 Temperature limiter 10.2 3.11.3 Switches/sliding switches/safety switches 10.3 3.11.4 Open/close mechanism 10.4 Does not apply to this unit. 3.11.1 10.1. Sensors (temperature, pressure, UV, etc.) Check the temperature sensor for damage.

  • Page 60: Switches/Sliding Switches/Safety Switches

    Checking and replacing components 3.11.3 3.10 Switches/sliding switches/safety switches Safety switch There are two safety switches in the unit; one behind the front panel and one behind the rear panel – If present, check for wear and damage. 3.11.4 10.4 Open/close mechanism Does not apply to this unit.

  • Page 61: Mechanical Components

    Checking and replacing components 3.14 Mechanical components 3.14.1 Seats 12.1 Does not apply to this unit. 3.14.2 Plastic panels 12.2 3.14.3 Contact guard 12.3 Does not apply to this unit. 3.14.4 Nozzle trolley 12.4 3.14.1 12.1 Seats Does not apply to this unit. 3.14.2 Plastic panels The steps for removing and assembling the panels are described in the as-...
  • Page 62 Checking and replacing components – Detach the magnetic arms. – Undo the screws in the elongated holes on the metal plate in the mount- ing plate. – Release the tension rollers. – Unscrew the tension rollers on the guide track. –...
  • Page 63 Checking and replacing components Toothed belt – Place the toothed belt into the belt tensioner. – Tighten the screws. – Insert the toothed belt with the belt tensioner into the unit. – Tighten the toothed belt in the belt tensioner. NOTE! The tension of the toothed belt must be checked with a spring balance;...
  • Page 64 Checking and replacing components – Securing the magnetic arms NOTE! The magnet holders must not be below the magnetic switches. After installing the nozzle trolley, the magnetic arm must be readjusted using the MAN card. The nozzles are not installed until after this has taken place. Position of the nozzle trolley The nozzle trolley must be equidistant from the two longer sides.
  • Page 65 Checking and replacing components – Secure the hose with the hose clip and screw. Replacing the hoses on the nozzles – Unscrew the hose clips on the hoses. – Remove and dispose of the old hoses. – Apply lubricant to the new hose and thread. –...

  • Page 66: Tank

    Checking and replacing components 3.15 Tank 3.15.1 Seals 13.1 3.15.2 Cooling coil 13.2 The water must be drained before conducting any work on the tank. 3.15.1 13.1 Seals – If present, check for wear and damage. Seals of various sizes. 66/74...

  • Page 67: Cooling Coil

    Checking and replacing components 3.15.2 13.2 Cooling coil – If present, check for wear and damage. – Undo the union nuts. – Remove the connection. – Remove the cooling coil from the holders. 02/2022 1028520-00 Service manual – 67/74...

  • Page 68: Man Card

    Checking and replacing components 3.16 14.1 MAN card 3.16 MAN card 14.1 After installing the nozzle trolley, the magnetic arm must be readjusted using the MAN card. – Remove the pump – Fold the rubber cover halfway back – Start the unit –...

  • Page 69: Warning Sticker

    Checking and replacing components 3.17 Warning sticker Further information is available in the operating instructions WAVE_TOUCH # 1028521-.. Serial no. plate Type plate ESD-sensitive component sticker (a) and 'Voltage present' warning sticker (b)(1020191-..) Warning label (1020230-..) Warning label pump 1020231-.. Not applicable for this device.
  • Page 70 Checking and replacing components Further information is available in the operating instructions SPA COMPLETE # 1028521-.. Serial no. plate Type plate ESD-sensitive components (85662-..) This sticker is mounted in several places in the unit. 70/74...

  • Page 71: Acceptance Test

    Acceptance test Acceptance test After installing the device, an acceptance test must be carried out before handover and start-up. The result of the individual tests must be noted in the test report #1014113-...The report #1014113-.. is attached in the Documenta- tion folder.

  • Page 72: Storing The Device

    Acceptance test Storing the device 4.1.1 Decommissioning The device must be disconnected from the power supply in order to temporar- ily or permanently decommission it. You must abide by the legal disposal requirements when permanently decom- missioning the device. 4.1.2 Storage Store the devices in a dry location with a stable temperature.

  • Page 73: Index

    Index Index Air filters/air hose ....................51 Audio........................44 Base plate Permitted load ....................13 Bearings/slide bearings ..................54 Cable bushings ....................22 Connection terminals ..................22 Connectors ......................21 Control films/switching mat ................60 Cooling coil ......................67 Customer Service ..................2, 71 Decommissioning ....................
  • Page 74 Index Interference suppressor filter ................28 Internal terminals (spring-loaded) ..............22 Lamp sockets ...................... 57 Lamps ........................57 Limit switches for the front and rear panel ............42 Maintenance ....................... 11 MAN card ......................68 Noise level......................13 Nozzle trolley ...................... 61 Packaging ......................

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