Standard Troubleshooting Approach S.T.A.
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 Voltage Present On Circuit Board. Use Extreme Caution While Servicing Circuit Board.
Table of Contents Chapter Page 1.0 Standard Troubleshooting Approach (S.T.A.) ............................................................... 5 1.1 Why A Standard Troubleshooting Approach? .................................................................... 5 1.2 How To Use The STA ......................................................................................................... 5 1.3 Professional Customer Service .......................................................................................
Chapter 8.4 Hot Tub Doesn’t Come On For Filter Cycle ....................................................................... 8.5 House Breaker Trips .......................................................................................................... 8.6 Hot Tub Light Will Not Come On ........................................................................................ 8.7 No Jets ........................................................................................................................
1.0 Standard Troubleshooting Approach (S.T.A.) 1.1 Why A Standard Troubleshooting Approach? Service prices are basically set by local industry and geographic region. Stiff competition in the service industry has made it difficult to raise the price of a service contract; or charge more for time and materials than the competetive shop down the street. If your business is to be profitable, you must control the overall cost of service.
4. Question the homeowner to determine, if possible, what specific 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 the difference between the spa’s components and how they perform when utilized in the spa.
8. 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. 9. Use the home service visit as an opportunity to sell aftermarket items such as chemicals, towels, etc. 10. Educate your staff regarding chemicals that are important for optimal use and longevity of the spa components. • Chemical misuse is not covered under the terms of the warranty. 11.
1.5 Preparing For A Service Call 1. Know what each call is asking of you; determine whether or not the extent of service can be handled 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 cover out-of-warranty service. • If you plan to charge the customer for travel expenses, make sure that they are aware of the costs before you show up. 2.
. Make professional repairs. • Putting bondo, underwater epoxy, silicone or any other product to fix cracked or leaking plumbing will not adequately correct the problem and will most likely result in a return visit. Replace the component or come back and do it for free! • Make repairs look as good as or better then when you started. 10. Make sure you leave the customer’s home as clean as you found it.
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 bad. • • • Develop the habit of examining the hot tub’s you service. Compliment customers on the things they are doing right.
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 something. Like all state-of-the-art circuit boards, the hot tub’s circuit board can be damaged by unnoticed static electricity. Damaged is the key word. Sometimes a board which has been subjected to ESD will fail immediately upon being put back into service.
3.0 Main System Specifications J-345 Dimensions ............................... 84” x 84” x 36” (213cm x 213cm x 92cm) Dry Weight ................................ 882 lbs (400kg) Filled Weight ............................. 3,611 lbs (1,638kg) Water Capacity (Avg. Fill) ........ 336 US gallons (1,272 Liters) Electronic Controls .................. Solid State Electronic Controls with LED Readout, Programmable Temperature, Filtration, and Heat Cycles Pump 1 ...................................... 2-Speed, 4.
Jet Selector / Air Control Operation Diagram Air Control 1: Opens / Closes Air Inlet to Jet Group A A C Jet Selector 2: Directs Jet Pump 2 Output Between Jet Groups C or D. Air Control 4: Opens / Closes Air Inlet to Jet Group D Air Control 2: Opens / Closes Air Inlet to Jet Group C D Air Control 3: Opens / Closes Air Inlet to Jet Group B B A C B D D Jet Selector 1: Directs Jet Pump 1 Output Between Jet Groups A or B. Seat Depths A = 25.50” (64.8cm) B = 24.00” (60.1cm) C = 28.50” (72.
3.1 Main System Specifications 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 .................. Solid State Electronic Controls with LED Readout, Programmable Temperature, Filtration, and Heat Cycles Pump 1 ...................................... 2-Speed, 4.
Jet Selector / Air Control Operation Diagram Air Control 1: Opens / Closes Air Inlet to Jet Group C Jet Selector: Directs Jet Pump Output Between Jet Groups A&B or C. C A A B Air Control 2: Opens / Closes Air Inlet to All Lounge Jets A C B B Air Control 3: Opens / Closes Air Inlet to Jet Group B Seat Depths A = 26.50” (67.3cm) B = 24.00” (60.1cm) C = 28.75” (73.0cm) D = 23.00” (58.4cm) E = 27.50” (69.9cm) F = 19.75” (50.2cm) G = 27.00” (68.6cm) H = 34.00” (86.
3.2 Main System Specifications 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 (1,211 Liters) Electronic Controls .................. Solid State Electronic Controls with LED Readout, Programmable Temperature, Filtration, and Heat Cycles Pump 1 ...................................... 2-Speed, 2.
Jet Selector / Air Control Operation Diagram Air Control 1: Opens / Closes Air Inlet to Jet Group A A Jet Selector: Directs Jet Pump Output Between Jet Groups A or B&C Air Control 3: Opens / Closes Air Inlet to Jet Group C A BC B B C Air Control 2: Opens / Closes Air Inlet to Jet Group B Seat Depths A = 27.00” (68.6cm) B = 27.25” (69.2cm) C = 25.75” (65.4cm) D = 21.50” (54.6cm) E = 28.00” (71.1cm) F = 31.25” (79.4cm) Listed Dimensions Represent Distance from Top of Acrylic to Lowest Point in Seat.
3.3 Main System Specifications 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 .................. Solid State Electronic Controls with LED Readout, Programmable Temperature, Filtration, and Heat Cycles Pump 1 ...................................... 2-Speed, 2.
Jet Selector / Air Control Operation Diagram Jet Selector: Directs Jet Pump Output Between Jet Groups A or B A Air Control 1: Opens / Closes Air Inlet to Jet Group A B A B Air Control 2: Opens / Closes Air Inlet to Jet Group B Seat Depths A = 26.50” (67.3cm) B = 28.00” (71.1cm) C = 27.00” (68.6cm) D = 28.00” (71.1cm) E = 27.75” (70.5cm) Listed Dimensions Represent Distance from Top of Acrylic to Lowest Point in Seat.
4.0 Main Control Panel Functions Panel Functions: A. Heat Indicator: Lit when heater is on. B. Warmer Button: Increases water temperaD A ture setpoint. C. Cooler Button: Decreases water temperature setpoint. C 104 D. LED Display: Can display current water G B temperature (default display*), water temF perature setpoint, selected filtration mode, E and error messages. E. Light Button: Turns underwater light on *Disply shown for example purposes only, actual water temperature display will vary.. and off. F.
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 circulation pump. Both remain on until the water temperature rises to the temperature setpoint, then the heater will turn off. Refer to the options below: 3.53 Revision FØ F1 F2 F3 No filter cycles.
4.3 Aftermarket Ozone Facts An aftermarket ozonator can be installed on all 2002+ models. A mazzei injector is required on all models. Ozone System Specifications • Circulation pump runs 24 hours • Ozonator runs 24 hours • The ozonator shuts off when a Jets Button is pressed. The ozonator will resume operation approximately 5 minutes after the jets are turned off intentionally or automatically. The ozonator also shuts off if the hot tub goes into “Summer Logic.” See section 5.6 (page 23).
5.5 Lock Out Mode The control panel temperature display flashes when the Lock Out Mode is active. Lock Out Mode disables all hot tub functions to permit filter 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 element, then turn off. See section 4.2 (page 20). 5.6 Summer Logic When the water temperature in the hot tub rises 2ºF (1ºC) above the set temperature setpoint.
7.0 Troubleshooting Using The Control Panel 7.1 Control Panel Displays Complete operating instructions for the control panel can be found in the owner’s manual. The hot tub’s self-diagnostic control system constantly monitors the hot tub for proper operation. When anything goes wrong, the control panel displays a message for the user which may result in a service call. Refer to section 7.3 below for a listing of error messages and probable causes. 7.
FL1 And FL2 Water Flow Problem • FL1: The flow switch is not closed when the circulation pump is running. The heater is deactivated. Proper water flow is inhibited or the flow switch may be obstructed, misaligned or defective. Refer to troubleshooting steps 1-4 below: 1. Remove the filter and allow the air to bleed out of the cartridge. Check the filter for trapped air. 2. Check for the proper water level. 3. Check for a clogged filter cartridge. 4. If the problem persists, refer to section 7.
2. Plug in a new control panel. If the problem is corrected, replace the control panel. If the problem persists, proceed to step 3. 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. 4. Check the circuit board transformer connections. If the connections are loose or oxidized, repair the connections and retest the system.
8.0 Troubleshooting Without The Control Panel • Diagnostic Tools 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, flow switch, heater assembly, hi-limit, circulation pump. Refer to page 59 for additional information. 8.1A No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) is moving water, panel heat indicator is lit. water is not getting hot.
8.1B No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) not turning, panel heat indicator not lit, panel is flashing FL2. Standard Troubleshooting Approach Pull wire off flow switch. Does the FL2 error message go away? No Is wire shorted? No Replace circuit board. Yes Replace wire. Yes Turn off power to hot tub. Test flow switch with ohmmeter for continuity across switch terminals (fig. D-E). Does meter read continuity (0)? Fig.
8.1C No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) not turning, panel heat indicator not lit, panel is flashing FL1. Standard Troubleshooting Approach Is there correct voltage coming to the hot tub at TB1? No Call an electrician. 240 VAC, +/-10%, or (120/240 VAC, +/-10% for J315/J325 models). Yes Put hot tub in standard filtration mode (page 21). Set temperature high enough to initiate a heat call.
8.1D No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) is turning, panel heat indicator not lit, panel is flashing FL1. Standard Troubleshooting Approach Is the circulation pump (Heat Pump) moving water? No Yes Verify 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 wires together (see fig. G). Does heat indicator appear and FL1 error message disappear? 1.
8.1E No Heat Or Not Enough Heat • Symptoms: Circulation pump (heating pump) is turning, panel heat indicator not lit, panel is not flashing FL1. Standard Troubleshooting 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. Turn power on. Does indicator work now? No Call Jacuzzi Premium Technical Support. Yes Replace control panel.
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 difficult intermittent problems are to locate. You will be doing a series of things to eliminate the problem. Ask the customer to be patient and please cooperate by calling you back to inform you of the hot tub’s status until the problem is corrected.
8.3 Nothing Works Things to remember: when a system fails, there is probably one, and only one problem. Verify power to the hot tub by observing the control panel’s LED display. The control panel will usually display something as long as there is proper power to the hot tub. Check for error messages. Displayed error messages usually indicate the problem. Diagnostic Tools: Voltmeter. Suggested Spare Parts (Page 59): Fuses (see appendix page 48), control panel, circuit board.
8.5 House Breaker Trips 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 breaker or wiring may be defective and need to be replaced or repaired. The hot tub’s current draw at the breaker represents the sum of all enabled components.
8. Is the GFCI utilized at the main panel? • Verify 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 corrected may involve you coming back to replace a component.) If there is a problem with the electrician understanding the correct hook up of the hot tub, have the electrician contact Jacuzzi Premium Technical Support. 9.
20. What is the model and serial number of the hot tub? • This will help determine how the hot tub should be hooked up. 21. Did a licensed electrician hook up the hot tub? • See question number one! 22. What is the voltage at the hot tub? • Always have your meter with you! 23. What is voltage between the neutral wire and the ground? • There should not be a neutral wire! (Except on J-315, J-325 models.) 24.
31. Are there any sprinklers that will hit the equipment bay of the hot tub? Eliminate The Components 32. 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. 33. Does the hot tub have a blower in it? (2001 and previous models only.) • Disconnect the blower and see if the GFCI will hold. 2002+ models do not have blowers. 34. Check the heater first before you check any of the pumps.
North American 60Hz Installations: As of January 1, 1994, the National Electrical Code (NEC) requires a Ground Fault Circuit Interrupter (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 Tub Light Will Not Come On Diagnostic Tools: Voltmeter. Suggested Spare Parts (Page 59): Control panel, circuit board, light bulb, light harness.
8.7 No Jets This is a condition of constant zero water pressure. The first 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 Tools: Voltmeter, spare control panel. Suggested Spare Parts (Page 59): Control panel, circuit board, pump. Pump Is Turning - Checking For A Flow Problem 1. Is the filter clogged? 2. Is there an obstruction in the plumbing line? 3.
8.8 Weak Or Surging Jets Weak or surging jets are usually caused by an insufficient 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 flow path to the pump or in the pump’s impeller. Before making a service call, ask the customer to verify that all jets are open and that there is sufficient water in the hot tub. Suggested Spare Parts (Page 59): Filter, pump.
8.9 Pump Runs And Quits During Jet Mode This is usually a problem of the pump overheating. The pump motor incorporates a thermal 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. Diagnostic Tools: Clamp-on ammeter, voltmeter. Suggested Spare Parts (Page 59): Circuit board, pump. Standard Troubleshooting Approach Press JETS 1 button.
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. Verify the pump should be on before troubleshooting. Check the circulation pump start time and duration setting. Refer to section 5.6C (page 23). Diagnostic Tools: Clamp-on ammeter, voltmeter. Suggested Spare Parts (Page 59): Circuit board, circulation pump.
8.11 Troubleshooting A Thermal Pump Cutout 1. Verify that the voltage to the hot tub is 240 VAC (120 or 240 VAC for J-315, J-325) ±10%. An insufficient voltage supply can cause the motor to pull too much current and to overheat. This situation must be corrected. 2. Check the voltage to the hot tub. Remember, the power company is required by law to provide the correct voltage to the customer. They will come out and check suspected problems (in most cases, free of charge). 3.
8.13 Ozone not working Diagnostic Tools: Clamp-on ammeter and voltmeter. Suggested Spare Parts (Page 59): Ozonator, circuit board, control panel. Standard Troubleshooting Approach Turn power to hot tub off and on. Wait approximately two minutes for filter cycle to begin and turn on ozonator and circulation pump. No DO NOT press either JETS button at this time or ozonator will shut off! Turn power off, plug in spare control panel, then turn power No on.
Appendix 45
A1.0 Checking Voltage To Hot Tub Correct supply voltage wiring to the hot tub is essential for safe/proper operation. The first 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 incorrectly wired hot tub will result in either of the following symptoms: A) Strange or intermitent symptoms, B) Displays with indications that simply cannot be correct.
A2.0 Checking Voltages To 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 probably good and the problem lies with the device or the wiring to the device. The following voltage chart shows operating voltages for all major hot tub components. Voltage is considered good if it is within ±10% of the listed value.
A4.0 Testing The Flow Switch When the “FL1” or “FL2” message appears, it means the flow 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 flow path or by a bad switch. The first thing to look for is an obvious obstruction, remembering (while not likely) that it is possible for a small object to work its way into the plumbing where it will not be obvious.
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 O2 to speak of “oxygen molecules” rather than oxygen atoms. In the presence of an electric discharge like lightning or a strong source of ultraviolet light, three molecules of O2 can combine to form two molecules of O3 known as Ozone. While oxygen has no smell, ozone has a very pronounced smell in large concentrations.
2 3 TB1 GRN WHT BLK RED 1 RED* BLK 4. If hot tub is to be operated on 30A service, make sure the jumper provided at location JP1 #1&2 on the circuit board is installed. If hot tub is to be operated on 40A service, remove the jumper JP1 #1&2 on the circuit board. 3. Permanently connect to the power supply. Use copper conductors ONLY. Wire size must be appropriate per NEC and/or local codes. 2. Move RED* wire from TB1 position #1 to TB1 position #3 as shown below. 1.
Circ. Pump 51 HI HI LO PUMP 2 PUMP 1 optional CD Ozone O3 SPA LIGHT 1 L1 GRN N 3 22 L 20 19 18 21 17 16 12 13 14 15 N L L N N L N L N L 2 L2 L * L STEREO (optional) N 4 5 N 6 L 11 10 TRANSFORMER 7 5 3 1 JP1 8 6 4 2 7 9 8 subject to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any inteference received including interference that may cause undesired operation.
A11.0 Load Box Connection Diagram For J-335, J-345 (240 VAC only, 60Hz) J-335, J-345 (240 VAC Only) 2-Pole Circuit Breaker with 2-Wire Grounded Load Connection (3 Wires to Hot Tub, 2-Hot, 1-Ground) A Hot Tub Load Box 240 VAC/120 VAC Red White Black 2-Pole GFCI Breaker TB1 R B TB2 Red Black Main Service Panel with GFCI Ground Green No Load Neutral Wire Pigtail Neutral Bus Ground B Note: service disconnect not shown in this diagram.
Load Box Connection Diagram For J-315, J-325 (120/240 VAC, 60Hz) J-315, J-325 (240 VAC) 2-Pole Circuit Breaker with 3-Wire Grounded Load Connection (4 Wires to Hot Tub, 2-Hot, 1-Neutral, 1-Ground) C Hot Tub Load Box 240 VAC/120 VAC Red White Black 2-Pole GFCI Breaker R TB1 B TB2 Red Black White Green Main Service Panel with GFCI W Ground Pigtail Neutral Bus Ground D Note: service disconnect not shown in this diagram.
Load Box Connection Diagram For J-315, J-325 (120 VAC only, 60Hz) J-315, J-325 (120 VAC) 2-Pole Circuit Breaker with 2-Wire Grounded Load Connection (3 Wires to Hot Tub, 1-Hot, 1-Neutral, 1-Ground) E Hot Tub Load Box 240 VAC/120 VAC Red White Black 2-Pole GFCI Breaker TB1 B W TB2 Main Service Panel with GFCI Black White Green Ground Pigtail Neutral Bus Ground F Note: service disconnect not shown in this diagram.
A12.0 Temperature / Hi-Limit Sensor Resistance Chart Fahrenheit (ºF) Celcius (ºC) Ohms (Ω) 59.0 ........................ 15 ........................... ............................................................................... 48840 60.8 ........................ 16 ........................... ............................................................................... 46680 62.6 ........................ 17 ........................... ..........................................................
A13.0 Flow Switch Illustration Flow Switch #6560-852 Compatibility: All 2004 J-315, J-325 Models Connection: This flow switch style has spade connectors at the top for easy cable removal for electronic troubleshooting. Flow Switch #6560-860 Compatibility: All 2004 J-335, J-345 Models Connection: This flow switch style has connectors that are potted into the top and cannot be removed at the flow switch. 6560-852 6560-860 W FLO A14.
A15.0 Transformer Test To Test The Transformer: 1. Leave the transformer connector J4 plugged into the circuit board. 2. Set your voltmeter to the highest VAC range. 3.
A16.0 Troubleshooting 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 procedure. IR SENSORS A. Testing the Power Supply SPEAKERS 1. Check for 240 VAC from the TB1 terminal block to the stereo power supply by measuring across test points 18 and 19 as shown. 2.
A17.
A18.0 Glossary Of Terms Circuit Board: Printed circuit board assembly that distributes voltage to selected components. Control Panel: Component that allows user to access functions provided by the circuit board. Ammeter: Device which measures electrical current conducted through a wire or electrical device. Eprom: Chip on the circuit board that stores hot tub software. Flow Switch: Switch that informs circuit board there is sufficient water movement to activate heater.
Troubleshooting Data Collection Form Protech LED Models Customer Name Address Phone ( ) Before troubleshooting, collect the following: 1. Model # of Hot Tub 2. Serial Number 3. Operating Voltage Input Voltage Before calling Jacuzzi Premium, collect the following: 4. Low Speed Pump 1 Amps 5. Circ Pump with Heater Amps 6. High Speed Pump 1 Amps 7. Pump 2 Amps 8. High Speed Pump 1, Pump 2, and Heater Amps 9.
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 62 Created in the U.S.A.
