HydroQuip BALBOA CS6000B Series User manual

Series by BALBOATMTMCS6000B SERIESDuplex Models Operation Manual

This manual covers electrical and installation details on the following product series. Some photos and instructions may not apply to the product you have purchased.-U Series"Fixed" Heater configuration: This series is designed to fit the most common heater position. Depending upon the actual control being replaced, you may still need to modify the plumbing to achieve proper alignment.-US Series"Slide" Heater configuration: This series is designed to allow the heater to be positioned within 20" of the control to provide an installation with a minimum of plumbing modifications. Depending upon the actual control being replaced, you may still need to modify the plumbing to achieve proper alignment.-VH Series"Versi-Heat" Heater configuration: This series is designed to allow the heater to be positioned within 60" of the control to provide an installation where there may not be enough room in the immediate equipment area and to minimize plumbing modifications. Depending upon the actual control being replaced, you may still need to modify the plumbing to achieve proper alignment.-LH Series"Less Heater" configuration: This series allows the use of customer supplied custom heater configurations which may not have been available from Hydro-Quip. Please refer to the "LH" wiring diagram enclosed with the "LH" wiring harness for specific wiring connections and details NOT covered within this manual.Introduction

ContentsImportant Safety Instructions..............................3-4Electrical Installation...........................................5-7GFCI Wiring Detail.................................................8Heater Installation..................................................9Sensor Connections............................................12Cord Connections................................................13Circuit Board Configurations...........................14-19System Start-Up................................Filtration Programming.........................................21Modes /Behaviors................................................21Operational Considerations..................................24Spa Side Messages........................................25-26TroubleShooting..............................................26-27Testing Sensors....................................................28System Plug Pinouts............................................28System Data Label...............................................29Warranty Information............................................29Versi-Heat / Optional Heaters..............................10Universal Sensor Fitting Kit..................................10Power Connection................................................11.............19-20Heater Start-Up Sequence...................................20Spa Side Control Operation.................................22Optional Equipment..............................................23

IMPORTANT SAFETY INSTRUCTIONSDANGER To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.WARNING - RISK OF CHILD DROWNING. Extreme caution must be exercised to prevent unauthorized access by children. To avoid accidents, ensure that children cannot use a spa or hot tub unless they are supervised at all times.DANGER To reduce the risk of injury to persons, do not remove suction fittings.Spa location must accommodate sufficient drainage of water around the base of the structure, as well as the power source compartment.Prolonged immersion in water that is warmer than normal body temperature can result in a dangerous condition known as HYPERTHERMIA. The causes, symptoms, and effects of hyperthermia may be described as follows: Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above the normal body temperature of 98.6BF. The symptoms of hyperthermia include dizziness, fainting, drowsiness, lethargy, and an increase in the internal temperature of the body. The effects of hyperthermia include (1) unawareness of impending hazard, (2) failure to perceive heat, (3) failure to recognize the need to exit spa, (4) physical inability to exit spa, (5) fetal damage in pregnant women, (6) unconsciousness resulting in danger of drowning. WARNING The use of alcohol, drugs or medication can greatly increase the risk of fatal hyperthermia in hot tubs and spas.DANGER - RISK OF ELECTRICAL SHOCK. A spa may be installed within 5 feet of metal surfaces if each metal surface is permanently connected by a solid copper conductor attached to the wire connector on the terminal box . Refer to NEC and local codes A bonding lug is provided on the control box to permit connection of a solid copper bonding conductor between this point and any equipment, metal enclosures of electrical equipment, metal water pipe, or conduit within 5 feet (1.5m) of the unit as needed to comply with local requirements.Bond accessible metal to the dedicated connector on the equipment grounding bus, bond the equipment ground bus to the local common bonding grid as part of the installation in the form of (1) a reinforced concrete slab for support, (2) a ground plate provided beneath the hot tub or spa, or (3) a permanent ground connection that is acceptable to the local inspection authority. DANGER RISK OF ELECTRICAL SHOCK. Do not permit any electrical appliance, such as a light, telephone, radio, or television, within 5 feet (1.5m) of a spa or hot tub.To reduce the risk of injury:The water in a spa or hot tub should never exceed 104BF (40BC). Water temperatures between 100BF (38BC) and 104BF (40BC) are considered safe for a healthy adult. Lower water temperatures are recommended for extended use (exceeding 10-15 minutes) and for young children.Excessive water temperatures have a high potential for causing fetal damage during the early months of pregnancy, pregnant or possibly pregnant women should limit spa or hot tub water temperatures to 100BF(38BC).!!!!!Before entering the spa or hot tub, the user should measure the water temperature with an accurate thermometer.The use of alcohol, drugs, or medication before or during spa or hot tub use may lead to unconsciousness with the possibility of drowning.Persons suffering from obesity or with a medical history of heart disease, low or high blood pressure, circulatory system problems, or diabetes should consult a physician before using a spa or hot tub.3in effect at the time of installation.)

Persons using medication should consult a physician before using a spa or hot tub since some medication may affect heart rate, blood pressure, and circulation.Must be connected to a grounded, grounding type receptacle only. NEVER connect the spa to an extension cord.Do not bury the cord.WARNING -To reduce the risk of electrical shock, replace damaged cord immediately.A terminal marked “G” or “ground” is provided in the wiring box located inside the equipment compartment. To reduce the risk of electric shock, connect the terminal or connector to the grounding terminal of your electrical service or supply panel with a continuous green insulated copper wire in accordance with National Electric Code Table 250-95 and any other local codes in effect at the time of the installation. The electrical supply for this product must include a suitably rated switch or circuit breaker to open all ungrounded supply conductors to comply with Section 422-30 of the National Electric Code, ANSI/NFPA 70 1987. The disconnecting means must be readily accessible to the tub occupant but installed at least 5 feet (1.5m) from the tub water.WARNING - Do not install indoors. This unit uses a gas heater that requires proper ventilation and is intended for outdoor use only.For Cord and Plug Connected UnitsFor Permanently Installed UnitsFor Permanently Installed Units not Provided with an Internal Disconnecting MethodFor Units with Gas HeatersHIGH VOLTAGE CAN SERIOUSLY INJURE OR KILL!ONLY EXPERIENCED TECHNICIANS SHOULD SERVICE THIS EQUIPMENT.DO NOT remove the protective covers from any electrical enclosure, or attempt to service any related electrical device, unless you are a qualified electrician or service professional.DANGERWARNINGIMPORTANTRisk of electric shock. Before working with any electrical connections, make certain that the Main Power breaker from the house breaker box has been turned off.All electrical work must be performed by a qualified electrician and must conform to all local codes.Due to the danger of severe electrical shock, locate all power disconnects before servicing a spa. Precautions must be taken whenever working with breaker boxes, G.F.C.I.’s, or service disconnects.High Voltage Warning4

Electrical Installation15A20A30A40A50A60A12A
16A24A 32A40A48A141210864Circuit & Breaker RatingMaximum AmpsMinimum WireSize5A licensed electrician must accomplish the electrical installation in accordance with the National Electric Code(NEC) Article 680, and any local codes in effect at the time of installation.Refer to the System Data Label for equipment voltage and maximum amperage draws.The GFCI (Ground Fault Circuit Interrupter) is a mandatory electrical safety device required for all portable spas and hot tubs as specified in the National Electrical Code Article 680-42. The GFCI in your particular installation may be installed at the electrical service panel or a separate sub-panel. Use copper conductors ONLY. The ground must be sized following the National Electric Code, Table 250-122. For Power conductor size, refer to the National Electric Code Table 310-16.A bonding lug has been provided on the control box to allow connection to local ground points. To reduce the risk of electrical shock, a solid copper bonding wire should be connected from this lug to any metal objects within 5 feet of the spa.The NEC and most local codes require that a “disconnect” be installed within “line-of-site” of the spa.IMPORTANT- If your electrician is not absolutely sure how to connect your system correctly, call your local dealer. Any mistake may be costly and void your equipment warranty.The above table is a wiring chart representation.

ELECTRICAL CONNECTIONSIf your system was configured to include a 120VAC power cord, ensure that the proper receptacle has been installed (a dedicated circuit is required). DO NOT under any circumstances modify a 20 Amp plug to fit into a 15 Amp receptacle or use an extension cord. Doing so will create hazardous conditions and/or invalidate the warranty.DO NOTUSE ANEXTENSIONCORD15 AMPRECEPTACLE20 AMPRECEPTACLEOPTION 115/20AMP CORD END GFCI15A / 120V OUTLETPORTABLE SPAMAIN BREAKER PANELDEDICATEDThis illustration depicts a typical 15 AMP, cord-end GFCI installation. (The spa must be installed on a dedicated circuit.)Units with 15A / 20A GFCI Plug ConnectionElectrical Installation6

ELECTRICAL CONNECTIONSElectrical InstallationMAIN BREAKER PANELLINE 1NLINE 2OPTION 2MAIN BREAKER PANELOPTION 320-60AMP HARDWIREDOption 2 shows the power from GFCI breaker installed into main service panel to a service disconnect within line-of-site of the spa. If the manufacturer of your homes main breaker panel makes a GFCI breaker, you may be able to add it to an open slot in the panel.Option 3 shows the power from main service panel to a GFCI subpanel within line-of-site of the spa. (Note: Most local codes will allow a GFCI subpanel to be a disconnect. If this is not the case in your installation, a disconnect must be provided.)REFER TO GFCI WIRING DETAIL ON PAGE 8GFCI Installed in Main Service PanelSubpanel GFCI InstalledPORTABLE SPA7INLINE SPA DISCONNECT20-60AMP HARDWIREDGFCI DISCONNECT
LINE 1NLINE 2
INLINE SPA DISCONNECT
INLINE SPA DISCONNECT
TO PORTABLE SPAREFER TO GFCI WIRING DETAIL ON PAGE 8

It is important that the GFCI circuit breaker is installed correctly. Often this component has been improperly installed causing the breaker to instantly trip when the system is turned on. Below is an illustration of a typical GFCI breaker installation.WARNING: Refer to the circuit breaker manufacturers installation instructions. This illustration is meant to be a guide for Field Technicians and is not intended to override or substitute the instructions supplied with the circuit breaker.GFCITEST(Ground Fault Circuit Interrupter)CIRCUIT BREAKER
NEUTRAL PIGTAIL
NEUTRAL BUS BAR
LINE 1NEUTRALLINE 2GROUNDGROUND BUS BARLINE LUG #1LINE LUG #2LINE 1LINE 2INCOMINGSERVICECONDUCTORSFROMMAINPANELNEUTRALGROUNDTO SPA CONTROL SYSTEM
LOAD
LOAD NEUTRAL MUST BE CONNECTEDDIRECTLY TO GFCI AS SHOWNGFCI Wiring Detail8

Align the other studded clamp and attach to the other slide bracket. Now determine the proper alignment for the heater and tighten the nuts and clampsPosition 2Position 1The adjustable clamp on the right will be in position 1. Remove the clamp and relocate it to position 2. Step 4Step 5Step 6Step 7 Heater InstallationStep 1Step 2Step 3Remove the control system from the carton and verify contents for completeness. If the application is a bottom mount install then you are ready to go directly to step 7.If you need to utilize the slide brackets simply remove the (2) 3/8” outer nuts securing the heater to the foot brackets and remove from under the box.The mounting studs are attached to adjustable clamps on the heater. Loosen the clamps to adjust the stud locations to align with the slide brackets on one end. Do not tighten the nuts yet.Ground/Bond the heater directly to the control box using the included #8 solid bonding wire.Connect the power control cords from the heater to the matching receptacles on the control box.The "U" Series Fixed Heater and "US" Series Slide Heater systems will arrive from the factory with the heater mounted in the bottom location as pictured in Step 1. The "US" Series Slide Heater can be installed and used in this configuration or you can move the Slide Heater to the back of the control as shown below to align easily with your particular plumbing arrangement.9

10Versi-Heat / Optional HeatersThe series heaters are supplied with a 60” cord which allows for versatile installations and locations. BE SURE HEATER IS INSTALLED HORIZONTALLY. The Heater can be installed on either the pressure or vacuum side of the pump. Versi-Heat IMPORTANT - Heater pump must provide a minimum flow of 23 GPM through the heater.SENSOR BODYSENSORO’RINGSPACER*(03-0003)CAPThe SPACER (HQ PT# 03-0003*) is always required when using this assy to assure a leak-free seal. Note the orientation of the SPACER, the flat side goes against the O’RING, concave side towards the CAP. It is not necessary to replace the existing SENSOR BODY unless leaking, cracked or damaged.Thread sealer is not required when screwing the CAP to the SENSOR BODY. (hand tighten only)A thread sealer such as teflon tape will be required if replacing the SENSOR BODY. SENSOR not included in fitting kit. (HQ PT#: 39-0021-K.)When replacing sensors, please keep in mind that the heater assembly will contain water pressure even with the spa’s power off. Close available slice valves and proceed with caution not to allow water on the surrounding electronics.
HEATER TUBE
Universal Sensor Fitting KitPart Numbers12” Temperature Sensor (HQ PT#. 48-0202-K)24” Temperature Sensor (HQ PT#. 48-0202A-K)46 ” Temperature Sensor (HQ PT#. 48-0202B-K)82” Temperature Sensor (HQ PT#. 48-0202C-K)M7 Sensor Fitting Kit (HQ PT#. 39-0021-K)15 pcs Kit, O’ring & Spacer, M7 (HQ PT#. 48-0002)All Sensors include PT# 39-0021-K

11120-VOLT ELECTRICAL SERVICE REQUIREMENTS Connect the white jumper wire included in the configuration kit to an available RED AC and WHT AC terminal.Move Dipswitch A10 to the on or up position to place the system in low amp mode. Low amp mode turns the heater off when a high speed pump(s) or blower is turned on. Jumper wire240-VOLT ELECTRICAL SERVICE REQUIREMENTS Move Dipswitch A10 to the off or down position to place the system in high amp mode. High amp mode allows the heater to stay on when high speed pump(s) or blower is turned on.IMPORTANT: Always refer to the product data label (located on top of the control box) for specific electrical information. Use copper conductors only as required by the NEC. Secure wires as defined by the NEC and in compliance with any local codes in effect at the time of installation.ŸŸIMPORTANT- All equipment must be rated for 120VAC.Heater wattage is rated at 240V. When running 120V to heater, output is approximately 25%.Ground Lug
J64J16
J34J35J36J37
J64J16
J34J35J36J37
Power ConnectionGround Lug
Connect the white jumper wire included in the configuration kit to an available RED AC and WHT AC terminal.
J34J35J36J37
J64J16

12The control system contains the temperature sensors inside the heater tube. If your spa has a pre-existing temperature sensor, do not connect it to the control system. It may be required to leave the old temperature sensor installed in the wall of the spa to prevent leaking. As shown below, the control systems are shipped with the sensors secured to the heater assembly. Remove the securing ties and route sensors through the access hole located above the heater connector on the left side of the system. See figure 1. With the sensors routed through the system, plug the sensors in to “SEN A” and “SEN B” See figure 2. The two temperature sensors are the same value and completely interchangeable. Figure 1Figure 2Sensor ASensor BSensor Connections

13
Black = Low SpeedRed = High SpeedWhite = CommonGreen = Ground
2-SPEED PUMP CORD CONFIGURATIONThe following wiring configuration is for two-speed pump circuits. SINGLE SPEED PUMP / ACCESSORY CORD CONFIGURATIONThe following wiring configuration is for single-speed pump circuits, circulation pumps, ozones, blowers and accessories. Black = Hot/LineWhite = CommonGreen = GroundBlack = Hot/LineWhite = CommonGreen = GroundCord ConnectionsSpaside connects to J1IR Receiver Module or AUX panel connects to J2PumpSingle Speed Device /AccessoriesSystemSystem

Circuit Board ConfigurationsIMPORTANT- Circulation pump and ozone must be same voltage rating.J29J23J20EXT. RLYJ47J50Expander BoardVoltage Selection Chart for 240V ConversionFigure 2240VConnects to:WHT / 120V or Red / 240V-J37 depending on equipment rating. ( Pre-configured for WHT / 120V )Connects to J65 or J66Connects to Ext. RLYjack on circuit boardAll Device outputs are preset for 120V outputs (as seen above in figure 1). If 240V output is required, please utilize the chart below to configure the appropriate outputs for 240V. For example, to convert pump 1 to 240V, move the red coded wire to J32 (as shown in Figure 2).
DevicePlug LocationVoltsAmpsWire Color CodeMove To2 SPD P1J23240V12ARedRED AC / J32Circ PumpJ47240V4ABrownRED AC / J33Blower / P2J17/26240V12AViolet / BlueRED AC / J34AVJ50240V2AWhiteRED AC / J35OzoneJ29240V1AYellowRED AC / J36LightJ20240V1ANANABlower / P2Expander Board240V12AViolet / BlueRED AC / J37
Figure 1J17/2614
J34J35J36J37
J64J16

Dip Switch Chart for CS610*B
A1 Test Mode (normally OFF) A2 “ON” position: Button layout will be: Pump 1, Light, Temp Down, Temp Up * “OFF” position: Button layout will be: Unused, Pump 1, Temp, Light A3 “ON” position: use Mini Panel * “OFF” position: use Lite Duplex or Digital Duplex panel A4 Aux Freeze (must be OFF) A5+A9 Pump 1 speeds and Circ Modes: A6 “ON” position: 50Hz operation “OFF” position: 60Hz operation A7 “ON” position: Standard mode only “OFF” position: Std/Ecn/Sleep mode changes allowed A8 “ON” position: temperature is displayed in degrees Celsius “OFF” position: temperature is displayed in degrees Fahrenheit A10“ON” position: heater is disabled while any high-speed pump is running
“OFF” position: heater can run while any/all high-speed pumps are running
A1, Test Mode OFFA2, Un, P1, TE, LTA7, Mode changes allowedA10, High Amp modeA9, Non-Circ ModeA5, 2-speed P1A3: OFFPanel Button PositionsPanel Button AssignmentsA3:ONA2: OFF112342341=Unused3=TempA2:ON2=Pump 14=Light1=Pump 12=Light3=Temp Down4=Temp UpIMPORTANT: Power off spa when making any dip switch changes.Hot tubs equipped with pump 1 as a single speed pump must utilize a circulation pump as the heater pump. Circuit Board Configurations
A5A9Circ ModePump 1 Speed
OFFOFFNon-circ 2-speedONOFF Thermostatically Controlled 1-speedOFFON 24 hours with 3°F shut-off1-speedONON 24 hours with 3°F shut-off2-speed
(low amperage mode)(high amperage mode)15( * = 0,7,8,9 )

Dip Switch Chart for CS620*B
A1 Test Mode (normally OFF) A2 “ON” position: Standard mode only “OFF” position: Std/Ecn/Sleep mode changes allowed A3 “ON” position: use Mini Panel * “OFF” position: use Digital Duplex or Light Duplex panel A4 Aux Freeze (must be OFF) A5+A9 Pump 1 speeds and Circ Modes: A6 “ON” position: 50Hz operation “OFF” position: 60Hz operation A7 N/A (must remain OFF) A8 “ON” position: temperature is displayed in degrees Celsius “OFF” position: temperature is displayed in degrees Fahrenheit A10“ON” position: heater is disabled while any high-speed pump or blower is running
“OFF” position: heater can run while any/all high-speed pumps or blowers are running Note: Aux is required. For no Aux, use CS6100 series system.
Panel Button PositionsPanel Button Assignments112342341=Pump 2 or Blower3=Temp2=Pump 14=LightA1, Test Mode OFFA7, N/AA2,
Mode changes allowed
A10, High Amp modeA5, 2-speed P1A9, Non-Circ ModeIMPORTANT: Power off spa when making any dip switch changes.
A3: OFFA3:ONCircuit Board ConfigurationsHot tubs equipped with pump 1 as a single speed pump must utilize a circulation pump as the heater pump.
A5A9Circ ModePump 1 Speed
OFFOFFNon-circ 2-speedONOFF 1-speedThermostatically ControlledOFFON24 hours with 3°F shut-off1-speedONON24 hours with 3°F shut-off2-speed
(low amperage mode)(high amperage mode)16( * = 0,7,8,9 )

A3: OFFPanel Button PositionsPanel Button AssignmentsA3:ON112342341=Pump 22=Pump 13=Temp4=Light
A1 Test Mode (normally OFF)
Control amp draw requirements (See Table 1)
A3 “ON” position: use Mini Panel “OFF” position: use Digital Duplex or Light Duplex panel A4 Aux Freeze (must be OFF) A5+A9Pump 1 speeds and Circ Modes: A6 “ON” position: 50Hz operation “OFF” position: 60Hz operation A7 “ON” position: Standard mode only “OFF” position: Std/Ecn/Sleep mode changes allowed A8 “ON” position: temperature is displayed in degrees Celsius “OFF” position: temperature is displayed in degrees Fahrenheit
Note: Panel layout is always Pump 2, Pump 1, Temp, Light
Table 1 # of Pumps/Blower Before Heat Disabled A2 A10 OFF OFF 0 ON OFF 1 OFF ON 2 ON ON 3A1, Test Mode OFFA7,
Mode changes allowed
A2, See Table 1A10, See Table 1A9, Non-Circ ModeA5, 2-speed P1
A 2+A10
Hi-Speed Circuit Board ConfigurationsDip Switch Chart for CS622*BIMPORTANT: Power off spa when making any dip switch changes.Hot tubs equipped with pump 1 as a single speed pump must utilize a circulation pump as the heater pump.
A5A9Circ ModePump 1 SpeedOFFOFFNon-circ2-speedONOFF 1-speedThermostatically ControlledOFFON24 hours with 3°F shut-off1-speedONON24 hours with 3°F shut-off2-speed
17( * = 0,7,8,9 )

A1 Test Mode (normally OFF) A2 “ON” position: Standard mode only “OFF” position: Std/Ecn/Sleep mode changes allowed A3 “ON” position: use Mini Panel “OFF” position: use Digital Duplex or Light Duplex panel A4 Aux Freeze (must be OFF) A5+A9Pump 1 speeds and Circ Modes: A6 “ON” position: 50Hz operation “OFF” position: 60Hz operation
A7 Control amp draw requirements (See Table 1)
A8 “ON” position: temperature is displayed in degrees Celsius “OFF” position: temperature is displayed in degrees Fahrenheit
Note: Panel layout is always Pump 2+Blower, Pump 1, Temp, Light
Panel Button Positions1234Panel Button AssignmentsA1, Test Mode OFFA2,
Mode changes allowed
A7, See Table 1A10, See Table 1A9, Non-Circ ModeA5, 2-speed P1 A3: OFFA3:ON12341=Pump 2+Blower2=Pump 13=Temp4=LightCircuit Board ConfigurationsIMPORTANT: Power off spa when making any dip switch changes.Dip Switch Chart for CS623*B
Alert:Pump 2 is required,expander board.Blower is also required connect to J17/26. connect to
A5A9Circ ModePump 1 Speed
OFFOFFNon-circ 2-speedONOFF 1-speedThermostatically ControlledOFFON24 hours with 3°F shut-off1-speedONON24 hours with 3°F shut-off2-speed
Table 1 # of Hi-Speed Pumps/Blower Before Heat Disabled A7 A10 OFF OFF 0 ON OFF 1 OFFON 2 ON ON 3Hot tubs equipped with pump 1 as a single speed pump must utilize a circulation pump as the heater pump. 18( * = 0,7,8,9 )

ECO200 Series PanelECO401 Series Panel Dipswitch A3 must be in the on / up position for the ECO200 series spaside to operate correctly.Prior to connecting the optional ECO401 series spaside. Move dipswitch A3 to the off / down position.Circuit Board Configurations1) Unplug the power cord (120-volt system only) or turn the electrical power “OFF” at the service or breaker panel (120 or 240 volt permanently connected units.)2) Open all WATER shut-off valves.3) For spas equipped with a hose bib or drain valve, make sure that it has been closed.4) For spas equipped with in-line or pressure water filters, make sure that the filter nut, housing drain plug, and air relief valve are closed and tight.5) Using a standard water hose, fill the spa with fresh tap water to the level recommended by the spa manufacturer.6) Inspect all plumbing connections and lines for any sign of water leaks.7) Close all AIR control valves. WARNING: Do not confuse with WATER shut-off valves.8) Plug the unit into the proper outlet (120-volt system) or turn on the breaker at the electrical service panel (240-volt system).9) When the system is first started (or any time power is reset) it will go through a series of diagnostic checks, displaying various information on the display, and finally ending with the spaside panel reading “PR” meaning Priming Mode. System Start-Up19