Table of Contents
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Balboa's BP Troubleshooting & Service Manual
THIS MANUAL COVERS THE FOLLOWING:
SPA CONTROL SYSTEMS
PANELS
50 Hz
BP600
TP900, TP800,
BP2100G1
TP600, TP400
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,
1
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
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Table of Contents
Troubleshooting
Related Manuals for Balboa Water Group BP2100G1
Summarization of Contents
Introduction
Intellectual Property Advisement
Legal notice regarding proprietary rights of Balboa Water Group and its suppliers.
End User Warning
Warning for non-qualified users regarding servicing and potential hazards from high voltage.
Electric Shock Safety Warnings
Critical safety instructions regarding electrical work, hazards, and qualified personnel.
Cautions and Warnings
Important cautions and warnings for safe spa operation, including temperature limits.
Codes and Compliance
BP Diagnostic Service Manual Information
Information on obtaining service manuals for troubleshooting and configuration details.
Technician Qualification and Safety
Basic Installation and Configuration Guidelines
Essential guidelines for proper spa system installation, wiring, and setup.
CSA Compliance and Safety
Compliance requirements and safety considerations related to CSA standards for spa equipment.
GFCI/RCD and Shock Hazard Warnings
Warnings about GFCI/RCD protection and the risks of electric shock during operation.
Equipment Overview
Service Tools and Parts Checklist
List of essential service tools and recommended parts to have for service calls.
TP Panel Overview and User Guides
TP Panel Navigation and Features
Overview of TP panel controls, navigation methods, and general capabilities.
Product Identification
System and Component Identification
Details on identifying system components, labels, and wiring diagrams.
230V/50Hz Wiring Schematic
Residential Wiring Schematic with RCD Breaker Box
Electrical wiring diagram for a 230V/50Hz system featuring an RCD breaker box.
Spa System Box Wiring
System Box Component Connections
Diagram illustrating the internal wiring connections within the spa system control box.
General Electrical Servicing
High Voltage and Technician Safety
Critical safety warnings and requirements for servicing high-voltage spa equipment.
General Safety Tips
Safety tips to ensure a secure environment and prevent hazards during spa maintenance.
Basic Control System Troubleshooting
Low Voltage and Brown Out Issues
Troubleshooting steps for low voltage and brown out conditions affecting the control system.
Checking System Power Input Fuse
Procedure for checking and testing the system's main power input fuse.
Control System Troubleshooting
Testing Amperage Draw
Procedure for measuring the amperage draw of spa components under load.
Determining Blown Power Fuse Causes
Steps to identify the cause of a blown power input fuse by testing components.
Testing Pump and Blower
Procedures for testing pump and blower functionality related to fuse issues.
Testing System Operation
Heater Start-Up Sequence
Explanation of the heater's startup phase and its integrated protection features.
Preliminary Panel Check
Steps for initial troubleshooting of the control panel for operational issues.
Flashing Heat LED Indicator
Understanding the flashing heat LED on TP600 panels, indicating 'Heat Waiting'.
System Power Testing and Troubleshooting
Probable Overheating Causes
Checklist of common causes for spa overheating and inspection points.
Freeze Protection and Conditions
Information on freeze conditions and automatic system activation for protection.
Troubleshooting Scenarios
Guidance on diagnosing common spa system issues and interpreting message codes.
Test Mode Usage
Instructions on how to use the system's test mode for diagnostic purposes.
Residual Current Devices (RCDs)
Understanding RCD Functionality
Explanation of how Residual Current Devices monitor and protect circuits from electrical faults.
Typical RCD Specifications
Details on RCD types, sensitivity, voltage, and connection capacities.
Wiring Checks and Precautions
Wiring Check Precautions
Safety and procedural guidelines for performing wiring checks on spa systems.
Loose Connections and Wire Gauge
Instructions for checking connections, wire gauge, and identifying potential wiring issues.
Importance of Copper Wire
Critical warning about using only copper wire for spa wiring due to safety and malfunction risks.
RCD Wiring Checks
RCD Line-In Wiring Verification
Procedure to check the wiring connections to the RCD for proper installation.
RCD Line-Out Wiring Verification
Procedure to check the wiring connections from the RCD for 230V dedicated systems.
Troubleshooting Pumps
Pump Problem and Cause Identification
Table correlating pump problems with their potential causes for diagnosis.
Testing Equipment Ranges
Voltage and Amperage Specifications
Acceptable voltage and amperage ranges for testing spa components.
Sensor Ohm Ranges
Ohm resistance values for temperature and high-limit sensors at various temperatures.
Heater Specifications
Matrix of heater types, ohms, amperage, and wattage for testing.
Fuse Identification and Values
Fuse Locations and Protected Devices
Table detailing fuse locations, current ratings, and the devices they protect.
Fuse Part Numbers
List of Balboa Water Group part numbers for various fuses.
Resistance Troubleshooting
Ohm's Law Principles
Explanation of Ohm's Law and its application in electrical troubleshooting.
Continuity Testing
Method for testing electrical continuity using a multimeter.
Fuse Continuity Testing
Preferred Fuse Continuity Test Method
Recommended procedure for checking fuse continuity by removing them from the circuit.
Heater Resistance Troubleshooting
Heater Resistance Testing Procedure
Steps to test heater resistance with the power off.
Acceptable Heater Ohm Ranges
Specifications for acceptable resistance values of heater elements.
Heater Post Resistance Testing
Testing Heater Posts for Leakage
Procedure to check for continuity between heater posts and housing/ground.
Voltage Troubleshooting
Voltage and Amperage Testing Safety
Critical safety warnings before testing voltage or amperage in spa systems.
General Safety Observation
Emphasizes observing safety precautions at all times during testing procedures.
Verifying Incoming Voltage
Terminal Block Voltage Check (BP2100/BP600)
Procedure to verify incoming voltage at the terminal blocks of BP2100 and BP600 systems.
Testing Pump Fuses (BP2100)
Pump Fuse Voltage Testing Procedure
Steps to test pump fuses for damage while the system is powered on.
Testing Heater Voltage
Heater Assembly Safety Precautions
Crucial safety warnings when working near the heater assembly due to attached ground.
Incorrect Heater Voltage Testing Methods
Warnings against improper methods for measuring heater voltage to avoid injury.
Safer Heater Voltage Testing
Method for Safe Heater Voltage Testing
Recommended safe procedure for testing heater voltages using insulated clamps.
Testing Pump Fuses (BP600)
Procedure for Testing BP600 Pump Fuses
Steps to access and test pump fuses on the BP600 power board.
Testing Heater Amperage
Heater Amperage Measurement
Procedure for measuring heater amperage using a clamp meter.
Testing Pump Speeds
AMP Pump Connector Speed Testing
How to test low and high speed voltages at the AMP pump connector.
Testing the Sensor Set
Sensor Set Diagnosis Procedure
Steps for diagnosing issues with the spa sensor set and connections.
Sensor Set Testing Procedures
Sensor Pin Preparation and Swapping
Instructions for preparing sensor pins and swapping sensor cables for diagnosis.
Component Testing and Configuration
Safety for Component Testing
Critical safety warning about high voltage during component testing and setup.
Test Menu Access and Software Setups
How to access the test menu for changing software setups and configurations.
Test Mode Features Overview
Description of features available within the system's test mode.
Setup Changes via DIP Switch
Instructions for Setup Changes
Guidelines for making setup changes using DIP switch 1 on TP600/TP400 panels.
Setup Changes via DIP Switch (cont.)
Procedure for Changing Setup Numbers
Step-by-step instructions for changing the spa's setup number via the panel.
Setup Changes via DIP Switch (TP900/TP800)
Test Menu Access and Software Setups (BP2100)
Accessing the test menu and performing software setups for BP2100 systems.
High Voltage Warning for Technicians
Critical safety warning about high voltage when accessing the test menu.
Heater Assembly Removal
Heater Assembly Removal Safety
Safety precautions and procedures for removing the heater assembly from the spa.
Heater Connector Identification
Information on identifying and disconnecting the heater connector.
Heater Assembly Removal (cont.)
Heater Wire Connections
Details on heater wire connections and accessing them on the power board.
Circuit Board Removal and Replacement
System Circuit Board Installation
Steps for correctly installing a spa system circuit board.
Dual Board System Compatibility
Information on compatibility between different revisions of dual board control systems.
Circuit Board Replacement Procedures
Critical Safety for Circuit Board Replacement
Essential safety warnings before replacing any component, especially a circuit board.
System Circuit Board Removal
Detailed steps for removing the spa system circuit board.
Expander Board Removal Method
Procedure for removing an expander board as an alternate method.
TP800/TP900 Panel Navigation
Main Screen Overview
Description of the main screen layout and available information.
Panel Navigation Controls
How to navigate through the panel menus using the control buttons.
Panel Button Functions
Explanation of specific button functions like Press-and-Hold and Message display.
TP800/TP900 Priming Mode
Preparation and Filling Procedure
Steps for preparing and filling the spa before system startup.
Priming Mode Operation
How the system enters and operates in priming mode to purge air.
Priming the Pumps
Procedure for starting and priming the spa pumps.
Exiting Priming Mode
Methods for manually exiting the spa's priming mode.
TP800/TP900 Spa Behavior
Setting Time-of-Day
Importance and procedure for setting the spa's time-of-day for proper operation.
Pump Operation Modes
Description of how pumps function, including timeouts and circulation modes.
Circulation Pump Modes Explained
Details on different modes for circulation pumps and their programmed functions.
Filtration and Ozone Operation
Information on filtration cycles, ozone generation, and programmable settings.
Freeze Protection System
How the system provides freeze protection and optional sensor usage.
TP800/TP900 Filtration Settings
Filtration Adjustments: Cleanup & Main
How to adjust cleanup and main filtration cycles and durations.
Filter Cycle 2 Configuration
Steps for enabling and configuring a second filter cycle.
Purge Cycles and Hold Mode
Explanation of purge cycles and the use of hold mode for service.
TP800/TP900 Panel Lock and Unlock
Restricting Panel Operation (Locking)
How to lock the panel or settings to prevent unwanted adjustments.
Unlocking the Control Panel
Procedure for unlocking the control panel after it has been locked.
TP800/TP900 System Messages
System Information Menu
How to access and view system identification and configuration details.
Heater Related Messages
Common messages related to heater operation and flow issues.
Flow-Related Troubleshooting Checks
Guidance for diagnosing issues related to water flow and restrictions.
TP800/TP900 System Messages (cont.)
Drain Mode and Utilities Menu
Accessing drain mode and the system's utilities menu.
Utilities Menu Features
Overview of features within the utilities menu, including A/B Temps, Demo Mode, and Fault Log.
GFCI Test Feature Availability
Information on the GFCI test feature and its availability on different systems.
TP800/TP900 System Messages (cont.)
Ground Fault Circuit Interrupter (GFCI)
Explanation of the GFCI's role as a safety device and its importance.
Verifying Proper GFCI Installation
How the GFCI test feature helps verify correct installation.
Forcing GFCI Trip Test
Procedure for manually initiating the GFCI trip test.
GFCI Test Warnings and CE Product Notes
Warnings regarding GFCI testing and specific notes for CE-rated products.
TP800/TP900 System Messages (cont.)
Common System Message Codes
Listing and explanation of various system status and error messages.
TP800/TP900 Utilities Menu
Utilities Menu Features Overview
Description of available settings in the utilities menu like Preferences, Cleanup, and Dolphin.
TP400/TP600 Standard Panel Navigation
Panel Main Screen Navigation
How to navigate the main screen and select menus on TP400/TP600 panels.
Panel Startup and Button Functions
Information on panel startup sequences and button operations.
TP400/TP600 Utilities and Fault Log
Accessing Utilities and Fault Log Menu
Navigating the panel to access the utilities and fault log menus.
TP400/TP600 Preparation and Priming
Spa Preparation and Filling
Steps for preparing and filling the spa before system startup.
Priming Mode Operation
Explanation of the priming mode and its purpose for pumps and water flow.
Exiting Priming Mode
Methods for exiting the priming mode after pump initialization.
TP400/TP600 Message Codes and Features
Message Code Reference
List of common messages and their corresponding codes and page references.
Utilities Menu Feature Details
Descriptions of features available in the panel's utilities menu.
TP400/TP600 Messages (cont.)
Flow-Related Diagnostic Checks
Checks to perform for low water flow and related error messages.
Common Heater and Sensor Messages
Explanations for common messages related to heater and sensor issues.
TP400/TP600 Messages (cont.)
System Error Message Categories
Descriptions of various system error messages like memory, clock, config, GFCI, and pump errors.
TP400/TP600 Fault Log Menu
Understanding the Fault Log
How the fault log stores and displays system events and error codes.
Fault Log Message Code Structure
Format and components of fault log message codes for TP400/TP600 panels.
TP400/TP600 GFCI Test Feature
GFCI Test Feature Overview
Explanation of the GFCI test feature and its purpose for system verification.
Forcing the GFCI Trip Test
Procedure to manually initiate the GFCI test cycle.
GFCI Test Warnings and User Training
Warnings regarding GFCI testing and the importance of user training.
Panel Operation Modes
Simplified vs. Standard Menu Structures
Comparison of simplified and standard panel menu structures.
Changing Menu Structure via Configuration
How to change between simplified and standard menus through system configuration.
TP400/TP600 Panel Main Menus
Simplified Main Menu Navigation
Navigation overview for the simplified main menu interface.
Standard Main Menu Navigation
Navigation overview for the standard main menu interface.
BP Wiring Diagrams
BP2100G1 Wiring Diagram
Detailed wiring diagram for the BP2100G1 control system.
BP Wiring Diagrams (cont.)
BP2100G1 Wiring Diagram Details
Continuation of the BP2100G1 wiring diagram, including setup and connection details.
BP21MSSH Wiring Diagram
BP21MSSH Wiring Diagram Details
Detailed wiring diagram for the BP21MSSH control system.
BP21MSSH Wiring Diagram (cont.)
BP21MSSH Wiring Diagram Setup Details
Continuation of the BP21MSSH wiring diagram, showing switch settings and connections.
BP600/BP1600 Wiring Diagram
Setup 1-16 Wiring Diagram
Wiring diagram for BP600/BP1600 systems configured with setups 1 through 16.
BP600/BP1600 Wiring Diagram (cont.)
Setup 2-32 Wiring Diagram
Wiring diagram for BP600/BP1600 systems configured with setups 2 through 32.
Optional Balboa Dolphin Remote
Dolphin Remote Functionality
Explanation of how the Dolphin remote communicates with the spa system via a receiver.
Optional Balboa Dolphin Remote (cont.)
Assigning Dolphin Remote Address
Procedure for setting or resetting the Dolphin remote's address for communication.
Dolphin Remote Documentation
Information on accessing manuals for Dolphin III remotes and receivers.
Spa Plumbing and Design Guidelines
Heater Flow and Pump Requirements
Guidelines for heater flow rates and pump suction/pressure systems.
Jet and Plumbing Configuration Guidelines
Recommendations for jet placement, plumbing, and freeze protection.
Service Valve and Pipe Sizing Guidelines
Guidelines for service valves, pipe sizing, and shut-off valve installation.
Glossary of Spa Terms
Priming Mode Definition and Function
Definition and purpose of the spa's priming mode for water circulation.
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