Jacuzzi J-345 manual

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

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 V oltage Present On Circuit Board. Use Ex- treme Caution While Servicing Circuit Board.[...]

3 T able of Contents Chapter 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 5.5 5.6 6.0 6.1 7.0 7.1 7.2 7.3 7.4 8.0 8.1 8.2 8.3 Standard T roubleshooting Approach (S.T .A.) ............................................................... Why A Standard T roubleshooting Approach? ..........[...]

4 Chapter 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.1 1 8.12 8.13 A. A1.0 A2.0 A3.0 A4.0 A5.0 A6.0 A7.0 A8.0 A9.0 A10.0 A1 1.0 A12.0 A13.0 A14.0 A15.0 A16.0 A17.0 A18.0 A19.0 Hot T ub Doesn’t Come On For Filter Cycle ....................................................................... House Breaker T rips .................................................[...]

5 1.3 Professional Customer Service Doing your job in a way that keeps cost of service low and pro t margin high also creates customer satisfaction. That’ s being a professional! 1.4 Responding T o An Incoming Service Call 1.0 Standard T roubleshooting Approach (S.T .A.) 1.1 Why A Standard T roubleshooting Approach? Service prices are basicall[...]

6 4. • • • 5. • 6. • • 7. • • • Question the homeowner to determine, if possible, what speci 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. Keep the Owner ’s manuals in an accessible place. Know th[...]

7 8. 9. 10. • 1 1. • 12. • 13. 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. Educate your staf f regarding chemicals that are important for optimal us[...]

8 1. • • 2. • 3. • 4. • • 5. • • 6. • 7. • 8. • • 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 co[...]

9 1.6 Before Calling T echnical Support Make sure you have followed the ST A and  lled out a “T roubleshooting Data Col- lection Form” (see example on page 61). Have the ST A manual and the T rouble- shooting Data W orksheet near the telephone. T echnical Support can help you best if these things become the communications tools for the phone[...]

10 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. Show them the bad part(s) and explain or show why it is b[...]

11 2.0 Electro Static Discharge 2.1 ESD - What Is It? What Does It Do? Static electricity is always being generated around us, even at those times when we no longer get zapped after walking across a rug and touching some- thing. Like all state-of-the-art circuit boards, the hot tub’s circuit board can be dam- aged by unnoticed static electricity [...]

12 3.0 Main System Speci cations J-345 Dimensions ............................... 84” x 84” x 36” (213cm x 213cm x 92cm) Dry Weight ................................ 882 lbs (400kg) Filled Weight ............................. 3,61 1 lbs (1,638kg) Water Capacity (Avg. Fill) ........ 336 US gallons (1,272 Liters) Electronic Controls .........[...]

13 Jet Selector / Air Control Operation Diagram Seat Depths C D A Jet Selector 2: Directs Jet Pump 2 Output Between Jet Groups C or D . Air Contr ol 1: Opens / Closes Air Inlet to Jet Group A Air Contr ol 2: Opens / Closes Air Inlet to Jet Group C Air Contr ol 4: Opens / Closes Air Inlet to Jet Group D Jet Selector 1: Directs Jet Pump 1 Output Betw[...]

14 3.1 Main System Speci cations J-335 Dimensions ............................... 84” x 84” x 36” (213cm x 213cm x 91cm) Dry Weight ................................ 781 lbs (354kg) Filled Weight ............................. 3,752 lbs (1,702kg) Water Capacity (Avg. Fill) ........ 358 US gallons (1,355 Liters) Electronic Controls ..........[...]

15 Jet Selector / Air Control Operation Diagram Seat Depths A = 26.50” (67.3cm) F = 19.75” (50.2cm) Listed Dimensions B = 24.00” (60.1cm) G = 27.00” (68.6cm) Represent Distance from C = 28.75” (73.0cm) H = 34.00” (86.4cm) T op of Acrylic to Lowest D = 23.00” (58.4cm) Point in Seat. E = 27.50” (69.9cm) Dimensions/Speci cations Sub[...]

16 3.2 Main System Speci cations J-325 Dimensions ............................... 84” x 76” x 34” (213cm x 193cm x 86cm) Dry Weight ................................ 738 lbs (335kg) Filled Weight ............................. 3,386 lbs (1,536kg) Water Capacity (Avg. Fill) ........ 320 US gallons (1,21 1 Liters) Electronic Controls .........[...]

17 Jet Selector / Air Control Operation Diagram Seat Depths A = 27.00” (68.6cm) F = 31.25” (79.4cm) Listed Dimensions B = 27.25” (69.2cm) Represent Distance from C = 25.75” (65.4cm) T op of Acrylic to Lowest D = 21.50” (54.6cm) Point in Seat. E = 28.00” (71.1cm) Dimensions/Speci cations Subject to Change Without Notice A Jet Selector[...]

18 3.3 Main System Speci cations J-315 Dimensions ............................... 76” x 66” x 32” (193cm x 168cm x 81cm) Dry Weight ................................ 640 lbs (290kg) Filled Weight ............................. 2,283 lbs (1036kg) Water Capacity (Avg. Fill) ........ 200 US gallons (757 Liters) Electronic Controls .............[...]

19 Jet Selector / Air Control Operation Diagram Seat Depths A = 26.50” (67.3cm) Listed Dimensions B = 28.00” (71.1cm) Represent Distance from C = 27.00” (68.6cm) T op of Acrylic to Lowest D = 28.00” (71.1cm) Point in Seat. E = 27.75” (70.5cm) Dimensions/Speci cations Subject to Change Without Notice B Jet Selector: Directs Jet Pump Out[...]

20 Heat Indicator: Lit when heater is on. W armer 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  ltration mode, and error messages. Light Button: T urns underwater light on and off[...]

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. Both remain on until the water temperature rises to the temperature setpoint, then the h[...]

22 5.4 Lock/Unlock Control Panel The control panel temperature display  ashes when Lock Mode is active. Lock Mode disables the jets and underwater light to prevent unauthorized use of the hot tub. This mode is selected in the  lter cycle selection menu. When selected, both  lter cycles and heater will operate as programmed. See sections 4.[...]

23 5.5 Lock Out Mode The control panel temperature display  ashes when the Lock Out Mode is active. Lock Out Mode disables all hot tub functions to permit  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 ele[...]

24 T urn of f the main breaker to the hot tub. Refer to appendix page 55 for expected hi-limit sensor resistance/water temperature values. Remove the hi-limit sensor connector from the circuit board test point 10. Refer to pages 50-51 for your circuit board con guration. Set your ohmmeter to 100-200k range, then measure resistance across the hi-[...]

25 Remove the  lter and allow the air to bleed out of the cartridge. Check the  lter for trapped air . Check for the proper water level. Check for a clogged  lter cartridge. If the problem persists, refer to section 7.4 (page 26) for  ow switch testing instructions. FL1 And FL2 W ater Flow Problem • FL1: The  ow switch is not close[...]

26 2. 3. 4. 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. Chec[...]

27 8.0 T roubleshooting W ithout The Control Panel • Diagnostic T ools 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 ,  ow switch, heater assembly , hi-limit, circulation pump. Refer to page 59 for additional information[...]

28 8.1B No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) not turning, panel heat indicator not lit, panel is  ashing FL2. Standard T roubleshooting Approach Pull wire off flow switch. Does the FL2 error message go away? Replace wire. T urn off power to hot tub. T est flow switch with ohmmeter for continuity across switch [...]

29 8.1C No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) not turning, panel heat indicator not lit, panel is  ashing FL1. Standard T roubleshooting Approach Is there correct voltage coming to the hot tub at TB1? 240 V AC, +/-10%, or (120/240 V AC, +/-10% for J315/J325 models). Replace circuit board. Repair connection. Cal[...]

30 8.1D No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) is turning, panel heat indicator not lit, panel is  ashing FL1. Standard T roubleshooting Approach No V erify hot tub is in standard filtration mode (page 21). Remove flow wires from switch. Increase set temperature to Initiate a heat call, then jumper flow switch w[...]

31 8.1E No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) is turning, panel heat indicator not lit, panel is not  ashing FL1. Standard T roubleshooting Approach Put hot tub in standard filtration mode (page 21). Set temperature high enough to initiate a heat call. Remove power to hot tub then plug in a spare control panel.[...]

32 8.2 Intermittent Heating As with all intermittent problems, routine measurements and display panel error messages are not trustworthy . The following procedure will eliminate the most probable causes. It is important to explain to the customer how dif cult intermittent problems are to locate. Y ou will be do- ing a series of things to elimina[...]

33 8.3 Nothing Works Things to remember: when a system fails, there is probably one, and only one problem. V erify 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 indi[...]

34 8.5 House Breaker T rips 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 br[...]

35 8. 9. 10. 1 1. 12. 13. 14. 15. 16. 17. 18. 19. Is the GFCI utilized at the main panel? • V erify how it is hooked up. • If you are not licensed to properly change the wiring, show the customer how it should be hooked up and have them call the electrician. (Improper installation is not a warranty call which once cor- rected may involve you co[...]

36 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 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? • Always have your meter with you! What is voltage between the neutral[...]

37 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. Are there any sprinklers that will hit the equipment bay of the hot tub? Eliminate The Components Does the hot tub have an ozone unit attached to it or any type of sanitizing device? • Unplug or disconnect the unit and see if the GFCI will hold. Does the hot tub have a blower in it? (2001 and pre[...]

38 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 T ub Light Will Not Co[...]

39 8.7 No Jets This is a condition of constant zero water pressure. The  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 T ools: V oltmeter , spare control panel. Suggested Spare Parts (Page 59): Control panel, circuit b[...]

40 8.8 Weak Or Surging Jets Weak or surging jets are usually caused by an insuf cient water supply to the pump or a clogged or broken impeller . The water level may simply be too low , or there may be an obstruction in the water  ow path to the pump or in the pump’s impeller . Before making a service call, ask the customer to verify that al[...]

41 8.9 Pump Runs And Quits During Jet Mode This is usually a problem of the pump overheating. The pump motor incorporates a ther- mal cutout that triggers when the motor gets too hot. There is no reset for this condition. When the motor cools, the thermal switch resets automatically . In some cases, a faulty circuit can also cause this problem. Dia[...]

42 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. V erify the pump should be on before trouble- shooting. Check the circulation pump start time and duration setting. Refer to section 5.6C (page 23). Diagnostic T ools: Clamp-on ammet[...]

43 8.1 1 T roubleshooting A Thermal Pump Cutout 1. 2. 3. 4. V erify that the voltage to the hot tub is 240 V AC (120 or 240 V AC for J-315, J-325) ±10%. An insuf cient voltage supply can cause the motor to pull too much current and to overheat. This situation must be corrected. Check the voltage to the hot tub. Remember , the power company is r[...]

44 O 3 8.13 Ozone not working Diagnostic T ools: Clamp-on ammeter and voltmeter . Suggested Spare Parts (Page 59): Ozonator , circuit board, control panel. Standard T roubleshooting Approach Danger: Electrical Shock Hazard Exists! High V oltage Present On Circuit Board. Use Ex- treme Caution While Servicing Circuit Board. T urn power to hot tub off[...]

45 Appendix[...]

46 A1.0 Checking V oltage T o Hot T ub Correct supply voltage wiring to the hot tub is essential for safe/proper operation. The  rst step in troubleshooting a new installation should be to take voltage readings at the terminal block TB1. Do not trust wire colors. Electricians make mistakes and electrons are colorblind. A low line voltage or inco[...]

47 A2.0 Checking V oltages T o 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. The following voltage ch[...]

48 A4.0 T esting The Flow Switch When the “FL1” or “FL2” message appears, it means the  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  ow path or by a bad switch. The  rst thing to look for is an obvious ob[...]

49 A7.0 Understanding Ozone Oxygen is an element, and like other gaseous elements, normally exists as a pair of atoms bonded together to make a whole molecule. Chemists therefore use the symbol O 2 to speak of “oxygen mol- ecules” rather than oxygen atoms. In the presence of an electric discharge like lightning or a strong source of ultraviolet[...]

50 A9.0 2004 J-315, J-325 Circuit Board Wiring Diagram (US/Canada 60Hz) US/Canada 60Hz Model • Circuit Board T ype: ProT ech LED, 6600-086. Oz on ato r O 3 GRN TB1 Standar d 120 V A C 3-Wire Connection (60 Hz, 1 Phase , 15 A Service) Use copper conductors ONL Y . Wire size must be appropriate per NEC and/or local codes . WHT WHT WHT WH T WHT BLK [...]

51 A10.0 2004 ProT ech LED Circuit Board Wiring Diagram (US/Canada 60Hz) J-335, J-345 US/Canada 60Hz Models • Circuit Board T ype: ProT ech LED, 6600-088. TRANSFORMER SP A LIGHT O 3 optional CD Ozone Circ. Pump N L N L N N N N L L1 L2 N L N L L L L L PUMP 1 PUMP 2 LO HI HI GRN US / Canada 60 Hz Power Connections 240 V AC 60 Hz, 1-Phase; USE COPPE[...]

52 A1 1.0 Load Box Connection Diagram For J-335, J-345 (240 V AC only , 60Hz) Red Pigtail Neutral Bus Ground TB2 TB1 Black Green Main Service Panel with GFCI Hot T ub Load Box 2-Pole GFCI Breaker Ground J-335, J-345 (240 V AC Only) 2-Pole Circuit Breaker with 2-Wire Grounded Load Connection (3 Wires to Hot T ub, 2-Hot, 1-Ground) White Black Red 240[...]

53 Load Box Connection Diagram For J-315, J-325 (120/240 V AC, 60Hz) Red Pigtail Neutral Bus Ground TB2 TB1 Black Green Main Service Panel with GFCI Hot T ub Load Box 2-Pole GFCI Breaker Ground J-315, J-325 (240 V AC) 2-Pole Circuit Breaker with 3-Wire Grounded Load Connection (4 Wires to Hot T ub, 2-Hot, 1-Neutral, 1-Ground) White Black Red 240 V [...]

54 Load Box Connection Diagram For J-315, J-325 (120 V AC only , 60Hz) Pigtail Neutral Bus Ground TB2 TB1 Black Green Main Service Panel with GFCI Hot T ub Load Box 2-Pole GFCI Breaker Ground J-315, J-325 (120 V AC) 2-Pole Circuit Breaker with 2-Wire Grounded Load Connection (3 Wires to Hot T ub, 1-Hot, 1-Neutral, 1-Ground) White Black Red 240 V AC[...]

55 A12.0 T emperature / Hi-Limit Sensor Resistance Chart Fahrenheit (ºF) 59.0 ........................ 60.8 ........................ 62.6 ........................ 64.4 ........................ 66.2 ........................ 68.0 ........................ 69.8 ........................ 71.6 ........................ 73.4 ........................ 75.2 .[...]

56 PIN TINE P APER CLIP Connector (Side View) Hi-limit Sensor , T emperature Sensor , And Flow Switch Wires FLOW A13.0 Flow Switch Illustration Flow Switch #6560-852 Compatibility: Connection: All 2004 J-315, J-325 Models This  ow switch style has spade connectors at the top for easy cable removal for electronic troubleshooting. 6560-852 Flow Sw[...]

57 A15.0 T ransformer T est T o T est The T ransformer: 1. 2. 3. Leave the transformer connector J4 plugged into the circuit board. Set your voltmeter to the highest V AC 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 V AC or 240 V AC Powered*) Conne[...]

58 A16.0 T roubleshooting 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. A. T esting the Power Supply 1. Check for 240 V AC from the [...]

59 A17.0 Suggested Spare Parts (ProT ech 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: T wo Pump Control Panel, 50/60Hz Filter Cartridges • 6540-476: 60 sq. ft., All Models Flow Switch • 2[...]

60 A18.0 Glossary Of T erms Circuit Board: Control Panel: Ammeter: Eprom: Flow Switch: Hi-Limit Sensor: Jumper: Ohmmeter: Ozonator: ProClear: Pin Assignments: Sensor Harness: Summer Logic: T emp. Sensor: T ransformer: V oltage Meter: Printed circuit board assembly that distributes voltage to selected components. Component that allows user to access[...]

61 T roubleshooting Data Collection Form Protech LED Models Before troubleshooting, collect the following: Customer Name Address Phone ( ) 1. 2. 3. 4. 5. 6. 7. 8. 9. Model # of Hot T ub Serial Number Operating V oltage Low Speed Pump 1 Amps Circ Pump with Heater Amps High Speed Pump 1 Amps Pump 2 Amps High Speed Pump 1, Pump 2, and Heater Amps Circ[...]

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.[...]