Balboa VS501Z User manual

Installation P/N 73-200-8501, Rev. B, 12/09/2020 Page 1of 4
Installation Instructions for Licensed Electricians, Plumbers,
and Spa Technicians
All components are intended to be installed and tested by a licensed electrician who is experienced in spas
and hot tubs. A properly installed GFCI and grounding must be installed with any system. Installation
must be permitted and inspected prior to use.
Any sales or technical advice provided on the Spaguts.com website or by Spaguts.com staff shall not be
construed to authorize or suggest anything but professional installation.
Balboa brand VS501Z Spa Controller Kit
Parts Content:
(1) Balboa brand VS501Z Spa Controller w/ M7 5.5KW Flo-Thru Heater, P/N G5152
(1) Topside Panel, VL200 Model w/ 7ft cable and 8-wire phone-type connector (Note that a topside substitution may be provided)
(1) Topside Overlay, P/N 11095 (Overlay may be pre-installed on topside panel)
(1) Topside Adapter Plate, P/N 11718
(2) Heater Split Nuts, 2 inch, P/N 40-350-5421 (installed on each end of heater)
(2) Heater Tailpieces, 2 inch, P/N 25-350-1052 (installed on each end of heater)
(2) Heater O-Ring Gaskets, 2 inch, P/N 25-350-4030 (installed on each end of heater)
(1) System Wiring Diagram, Labeled VS501Z –PN G5152 (attached to inside controller cover)
(1) Double-Sided Operation Guide with Diagnostic Messages, 500Z Series, P/N 40789
(1) Installation Instructions, P/N 73-200-8501
(1) Light Harness, 2-Prong Amp Plug, Light Socket, 8ft Cable
(1) Light Bulb, Clear, 12V 12W
(1) Pump Cord, 4ft, 4-wire, 14 AWG, w/ 4-Prong Amp Plug, P/N 15-150-3060
(2) Pump Cord, 4ft, 3-wire, 14 AWG, w/ 4-Prong Amp Plug, P/N 15-150-0024
Plumbing up the system:
This system will work if the pump draws or discharges water through the heater. Minimum water flow required is 25 GPM. Minimum
plumbing size required is 1.5 inch. This system is equipped with M7 Technology (no pressure switch). There are dual sensors installed
on the heater to measure the water temperature flowing through the heater. No need to mount any sensors or flow switches. The heater has
standard 2.0 inch plumbing fittings. If the spa plumbing is 1.5 inch, use reducers to connect to the heater 2.0 inch heater tailpieces. If re-
plumbing is necessary, use PVC Glue with primer to connect the plumbing. When installing an In-Line Filter System, either install it
before the heat pump and controller or after the heat pump and controller. Never install the filter system in between the heat pump and
controller. Make sure to create a water flow bypass plumbing around the filter for sufficient water flow. For systems installed near or
above the water level, and more than 5 feet from the tub, install the In-Line Filter System after the heat pump and controller with a water
flow bypass plumbing. A water flow bypass plumbing allows half the water to go through the filter and half the water to go around the
filter. This way water flow is not restricted. We recommend NSF rated flexible PVC for simpler connections. Go to this link for more
info: http://www.spaguts.com/Product.aspx?ID=42.
Wiring Instructions:
*110V Power Supply, 60Hz
*Minimum 20A Power Supply is required. Use Copper Conductors Only. See wiring diagram for more information.
Please note that this Installation requires 3 dedicated wire connections to the power terminal block (TB1) on the Circuit Board. These
include Line 1, Neutral and Ground. Connect Hot wire to Line 1 terminal. Connect Neutral wire to Neutral terminal. If a dedicated
Neutral wire is not connected, the heater will never come on and/or the system will not operate properly. For 110V operation, add a
jumper wire from terminal J11 to terminal J32 (SEE WIRING DIAGRAM FOR VERIFICATION). If this jumper wire is not installed,

Installation P/N 73-200-8501, Rev. B, 12/09/2020 Page 2of 4
the heater circuit will not activate. Note that this jumper wire may have already been installed at the factory. Lastly, connect Ground to the
Grounding Bar located on the outside of the controller box. Run the Ground Wire through a hole that is labeled Green Ground located
from the inside of the controller box. Since this system is not equipped with a GFCI, it is REQUIRED by the National Electric Code to
install an external GFCI for safety and protection. Any mis-wiring or improper installation will void the warranty and could cause
personal injury, death, fire or property damage.
Note: For 110V systems, the heater will only operate when the pump is running on low speed. When the pump is on high speed, the heater
will not operate until the high speed turns off.
*220V Power Supply, 60Hz
*Minimum 50A Power Supply is required. Use Copper Conductors Only. See wiring diagram for more information.
Please note that this Installation requires 4 dedicated wire connections to the power terminal block (TB1) on the Circuit Board. These
include Line 1, Line 2, Neutral and Ground. Connect Line 1 wire to Line 1 terminal. Connect Line 2 wire to Line 2 terminal. Connect
Neutral wire to Neutral terminal. If a dedicated Neutral wire is not connected, the heater will never come on and/or the system will not
operate properly. Lastly, connect Ground to the Grounding Bar located on the outside of the controller box. Run the Ground Wire through
a hole that is labeled Green Ground located from the inside of the controller box. If a White Jumper Wire is installed between J11 and J32
on the circuit board, make sure to remove it completely. This White Jumper wire is NOT needed for 220V Power Supply. If the White
Jumper Wire is NOT removed, it will cause the breaker to trip, and may cause other damages including blowing the fuses, which will
affect the warranty. Since this system is not equipped with a GFCI, it is REQUIRED by the National Electric Code to install an external
GFCI for safety and protection.Any mis-wiring or improper installation will void the warranty and could cause personal injury, death, fire
or property damage.
Do Not follow the color of the original power wires, Black, Red, White and Green. DON'T ASSUME THESE WIRES ARE WIRED
ACCORDING TO LOCAL CODES. Some original wirings can have the wires mixed up. Get a voltage meter and verify each wire to
make sure which colored wire is Line 1, Line 2, Neutral, and Ground. Failure to do so will cause major electrical damage to the controller
and/or other equipment, and void the warranty.
DO NOT POWER UP THE SPA UNLESS THE SYSTEM IS COMPLETELY INSTALLED AND THE SPA IS COMPLETELY FILLED
UP WITH WATER. Doing so can cause a dry fire, which can damage the heater and controller, and will void the warranty.
Primary Pump Circuit: The primary pump circuit should have already been configured for the correct voltage output based on your
order for Factory Configuration. If you find out that the pump motor is rated at a different voltage, make sure to configure pump 1 circuit
to the correct voltage for the pump motor by following the wiring diagram that is provided, which is required for Field Configuration.
Pump Motor wiring: The primary pump cord will have 4 wires for two speed operation. This system utilize the RED wire for High-
Speed and the BLACK wire for Low-speed in Two-Speed Pump Circuits. The White wire is for Line/Common connection, and the Green
wire is for Ground. Keep this in mind when connecting a Two-Speed pump that has not been purchased with this system. If using a single
speed pump as the primary pump, cap off the RED wire. Connect the primary pump cord in Pump 1 location (J23) on the circuit board.
The plug will only fit one way. Make sure the clip on the plug latches to ensure tight connection. This pump circuit is rated 12AMax. If a
complete Spa Pack with pump was ordered, the pump cord should have already been connected based on your order for Factory
Configuration.
Blower or Pump 2 Circuit: The blower/pump 2 circuit should have already been configured for the correct voltage output based on your
order for Factory Configuration. If you find out that the blower/pump 2 motor is rated at a different voltage, make sure to configure the
blower/pump 2 circuit to the correct voltage for the blower/pump 2 motor by following the wiring diagram that is provided, which is
required for Field Configuration. This circuit is single speed only.
Blower or Pump 2 wiring: The blower/pump 2 cord will have 3 wires for single speed operation. The Black wire is for High Speed. The
White wire is for Line/Common connection, and the Green wire is for Ground. Connect the blower/pump 2 cord in the blower location
(J17/26) on the circuit board. The plug will only fit one way. Make sure the clip on the plug latches to ensure tight connection. Only
connect the blower/pump 2 cord if it is being used. If a complete Spa Pack with a blower/pump 2 was ordered, the cord should have
already been connected based on your order for Factory Configuration. If this circuit is being used for pump 2, make sure to connect the
Black Jumper Wire from W3 to J62 as shown on the wiring diagram, which allows a maximum of 12A rating.
Ozone Circuit: The ozone circuit should have already been configured for the correct voltage output based on your order for Factory
Configuration. If you find out that the ozone unit is rated at a different voltage, make sure to configure the ozone circuit to the correct
voltage for the ozone unit by following the wiring diagram that is provided, which is required for Field Configuration.
Ozone wiring: The ozone cord will have 3 wires. The Black wire is for Line 1. The White wire is for Common connection, and the Green
wire is for Ground. Connect the ozone cord in the Ozone location (J29) on the circuit board. The plug will only fit one way. Make sure the
clip on the plug latches to ensure tight connection. The ozone circuit is rated 2A Max. Only connect the ozone cord if it is being used.
Circulation Pump Circuit: If a small circulation pump is connected to the system and being used as the heat pump, make sure to follow
the wiring diagram to setup the correct voltage output for the circulation pump. Also setup the dip switches on the circuit board so that the
system works properly with the small circulation pump, which is required for Field Configuration. Minimum water flow is 25 GPM
with minimum 1.5 inch plumbing. This system will NOT work with a Low-Flo Circulation Pump. This circuit is rated 2A MAX.

Installation P/N 73-200-8501, Rev. B, 12/09/2020 Page 3of 4
DO NOT plug a Jet Pump or Higher Rated Circulation Pump into this circuit, otherwise the circuit will overheat and burn up,
which voids the warranty.
Circulation Pump wiring: The circulation pump cord will have 3 wires (cord is not included, sold separately). The Black wire is for Line
1. The White wire is for Common connection, and the Green wire is for Ground. Connect the circulation pump cord in the Circulation
Pump location (J47) on the circuit board. The plug will only fit one way. Make sure the clip on the plug latches to ensure tight connection.
Only connect the circulation pump cord if it is being used. (See notes above regarding the circulation pump circuit and using a
circulation pump with this system)
Dip Switch Settings: The dip switches on the circuit board (as known as Switch Bank A, red in color with white switches) should have
already been configured for the correct setting based on your order for Factory Configuration. If a different setup is made in the field
and/or a circulation pump is added, the dip switches need to be reconfigured. If so, please follow the dip switch settings based on the new
setup by using the wiring diagram as a reference, which is required for Field Configuration.
Topside Panel Installation: A hole cut out of 3.75 inch x 1.0 inch is required for the Balboa VL200 Model Topside Panel. A topside
cover plate (included) may be used if the existing hole cut out is larger than the new topside panel. Clean the surface area before
installation of the new topside panel. Position the topside panel in the direction for operational purpose as desired. Then carefully insert
the topside cable through the hole cut out. Remove the protective label from the sticky gasket on the back of the topside panel. Then apply
the topside panel above the hole cut out or cover plate. Silicone can be used under the lip of the topside panel and/or topside cover plate
for additional water leak protection prior to installation of the topside panel. Connect the topside cable plug into J1 connector on the
circuit board. The clip on the topside cable plug should snap in place to ensure a secure connection. The J2 connector is for a secondary
topside panel, which can be purchased separately. If a longer topside cable is needed, do not splice the cable for it will void the topside
warranty. Available at www.spaguts.com is P/N 30311 for the 10ft extension cable, and P/N 22639 for the 25ft extension cable. Maximum
cable length is 50ft in order for the topside panel to work properly.
Light wiring: The light harness is 8ft long with 2 wires. One end of the light harness has a 2-prong amp plug, and the other end has a
light socket that fits a 12V 12W light bulb or a ColorGlo Led Light (http://www.spaguts.com/Products/colorglo-led-lights-47.aspx).
Connect the 2-prong amp plug in location (J20) on the circuit board. The plug will only fit one way. Make sure the clip on the plug latches
to ensure tight connection. Insert the light bulb into the light socket. Then insert the light socket with light bulb into the existing light
housing on the spa. If a light housing is not installed, it can be purchased by going to this link: http://www.spaguts.com/Products/thru-
shell-light-lense-kit-88.aspx. The light circuit is rated 12V 1A Max. Only connect the light harness if it is being used.
Audio Video wiring (A/V): The A/V circuit is normally setup for 110V (unless it was specified over the phone at the time of order for
220V output). This circuit is a constant voltage output normally used for a stereo, radio, CD or TV systems. The A/V cord will have 3
wires (cord is not included, sold separately). The Black wire is for Line 1. The White wire is for Common connection, and the Green wire
is for Ground. Connect the A/V cord in the A/V location (J50) on the circuit board. The plug will only fit one way. Make sure the clip on
the plug latches to ensure tight connection. The A/V circuit is rated 2A Max. Only connect the A/V cord if it is being used.
DO NOT POWER UP THE SPA UNLESS THE SYSTEM IS COMPLETELY INSTALLED AND THE SPA IS COMPLETELY
FILLED UP WITH WATER. Doing so can cause a dry fire, which can damage the heater and controller, and will void the
warranty.
After installation is complete, completely fill the spa with water to the required level. Refer to the Spa Owners Manual for the required
water level. We recommend using a Spa Pre-Filter for fresh clean water. DO NOT OVERFILL. Overflowing the spa will cause water to
infiltrate the system and other electrical parts. Damages caused by water infiltration will not be covered under warranty. Once the spa is
completely filled to the required level, then power up the spa and purge the water lines to help remove air from the lines. The “Pr”
message will appear on the topside panel which indicates water purging is required or is in progress. If the pump is not running, press on
the Jets key to activate the pump on high speed. You may also bleed air out of the plumbing by loosening the plumbing fittings a bit, and
then run the pump high speed on/off until all the air is removed. Once there is constant strong water pressure from the jets, you can now
proceed with normal operations. Make sure all plumbing fittings are tightened, and to fix any water leak.
System Maintenance: It is recommended to monitor the spa equipment every month. Check for any water leaks, internally and
externally, and for abnormal operations. Get it repaired right away if there is a problem. Don't allow the problem to get worst. It is
recommended to inspect for any loose connections and for any damaged cables every 3-6 months (especially on the power terminal block,
component cord, and sensors). Loose connections will cause improper operation and overheat the wires. Damaged cables may also be
chewed by rodents. Neglect of maintenance and damages are not covered under warranty.
Spa Maintenance: Refer to the Original Spa Owners Guide for proper water maintenance. Use ONLY Spa rated chemicals. We
recommend using ozone, Mineral Cartridges and a small amount of chemical to treat the water (may depend on usage). Ozone and
Mineral Cartridges reduces maintenance and decreases the use of chemicals up to 90%. We also recommend to test the spa water every
single day, and treat the spa water as needed. Your local dealer is familiar with local water conditions and which chemicals are compatible
with the water and are designed specifically for your spa. This is the best person to advise you on proper water quality management.
The one thing you can do to insure years of trouble free equipment operation is to maintain proper water chemistry.
Two basic goals of the chemical water treatment are sanitizing and balancing the water.
Sanitizing simply means keeping water free from living micro-organisims including algae, bacteria, and viruses. The current most popular
chemicals for sanitizing include chlorine, bromine, and ozone.

Installation P/N 73-200-8501, Rev. B, 12/09/2020 Page 4of 4
Balancing water means establishing a balance among pH, total alkalinity and total hardness. Water that is unbalanced can corrode the spa
and its support equipment or leave deposits of minerals. Properly balanced water is essential to allow the sanitizing chemical(s) to work
effectively. There are numerous chemical additives to help you in controlling pH, total hardness and total alkalinity. NEVER use softened
water when filling your spa. Softened water is extremely corrosive to the metal parts of spa equipment and may lead to unforeseen failure.
Sometimes, despite your most diligent efforts, your water chemistry may become too far out of balance to be managed chemically. At this
point it is probably better to drain and clean the spa and start over with fresh water.
Equipment failure caused by improper water chemistry will not be covered under warranty.