Intex 28442, Repair Manual

Page 1: ... Tub shape Round Octagon type Production date Start form 2020 6 15 Introduction The purpose of this guide is to help you understand how to repair the most common issues with the main heating and filtration unit This includes problems with the various internal sensors the internal computer printed circuit board water and air pumps IMPORTANT Unplug the power cord before replacing spare parts ...

Page 2: ...Page 2 28442 Internal Part ...

Page 3: ...LET O RING 27 11746D 1 AIR INLET CONNECTOR NUT FOR 28453 54 55 56 BLACK 28 10836 1 RUBBER CAP FOR 03R 638 638R 638G 637R MOTOR 29 10840 1 RESISTANCE TO RUB WASHER FOR 03R 638 638R 638G 637R MOTOR 30 12077 1 CERAMIC BAR FOR 28401MW 28403 04 21 22 23 24 43 44 53 54 28402 MADE ON AFTER 2013 12 10 31 12084 1 MAGNETIC ROTOR AND IMPELLER FOR 28404 28422 28444 28454 28402 MADE ON AFTER 2013 12 10 32 1277...

Page 4: ... Initial Setup 11 Control base repair 12 Wiring Schematic 12 Opening the Control Base 13 Accessing the PCB 14 Internal Parts 15 PCB 17 Main circuit Board 17 Display Errors 19 Error Code E81 19 Error Code E90 21 Error Code E90 Flow Sensor 22 Error Code E90 Water Pump 23 Error Code E90 Transformer 24 Error Code E90 PCB 25 Error Code E90 Heating Element Heater Set 26 Error Code E94 26 ...

Page 5: ...E99 100 000 30 END Heating problems 31 Blank panel 32 Random Display or 888 33 Functional Error 34 Air Blower Problems 34 How to Replace RCD 36 How to replace PCB 37 How to replace the broken base of spa control 38 How to replace switch controller board 39 ...

Page 6: ...Page 6 PCB Schematic New version Wi Fi spa main circuit board has a QR code New version Wi Fi spa has a Wi Fi chip with red color New Old ...

Page 7: ...er thermometers check the temperature of the spa s water and to verify readings provided by the system s internal thermometers Screwdrivers and wrenches will help you disassemble and reassemble the unit Tools required for spa control base repair NAME SPEC PHOTO 1 digital multimeter 0 1mVac 1000Vac 0 1mVdc 1000Vdc 0 1uAac 10Aac 0 1uAdc 10Adc 2 clip on ammeter 20A 3 psophometer 30 130dB 4 water ther...

Page 8: ...r AC or DC voltage based on this guide and adjust the meter to a range above the expected reading For example if we are looking for a DC voltage between 12 14 the knob should be set to 20V in the DC range The position of the black and red probes ports makes little difference A negative number will be displayed if the cables are swapped Ignore this and the number displayed is the current reading ...

Page 9: ...nformation when there are problems with the Control Base Spa Tub Holds the water The tub is different depending on spa s features The inner structure features Dura Beam construction for strength Spa Cover An inflatable safety cover Important for insulating spa water Ground Cloth A cloth that goes underneath the spa tub and provides protection from the ground Control Base Control Panel Spa Tub ...

Page 10: ...Page 10 Model Code SB HWF20 SB n1 H n2 WF n3 20 n4 n 1 SB Spa Bubble n 2 H With Hard Water features n 3 WF Wi Fi n 4 20 220 240V working wattage ...

Page 11: ...epeat the pairing process Flashing rapidly WiFi router internet network problem OFF WiFi router signal is disconnected with product or first time use waiting to be paired up with a mobile device Please follow manual to do some troubleshooting if the problem persists replace the panel 2 Transmission signal failure between control base and the control panel E81 If the LED display shows E81 please re...

Page 12: ...Page 12 Control base repairs Wiring Schematic Main circuit Board ...

Page 13: ... Removing 4 vertical screws around the cover that hold enclosure and then remove 2 horizontal screws Removing 2 screws near on side remove the panel from control base The switch controller board connector is attached to the main circuit board lift the cover vertically carefully to ensure the cable is not pulled and connection between main circuit board and cover is not damaged ...

Page 14: ... the 2 screws that secure the white PCB cover to reveal the PCB Unscrew the 2 screws on the holder to remove the PCB set from the Control Base Loosen all the screws on the PCB to remove the wires take the PCB out from the control base ...

Page 15: ...Page 15 Internal Parts B C G D H F A I E ...

Page 16: ...ransformer 12919 B Air Blower 12848 C PCB Main Circuit Board 10066 D Base 12917 E 20 40 Temperature Sensor 12025 F Heating Element 12846 G Flow sensor 12310 H 84 Temperature Sensor 12029 I 50 Temperature Sensor 12026 N M J K L ...

Page 17: ...l Cord with RCD 11998 N Water Pump Filter 12778 PCB Main circuit Board Black 50C 黑 Water Temperature Sensor White 20 40C 白 Water Temperature Green FLOW 绿 Flow Sensor one E90 Yellow 84 C 黄 Dry Fire Protection E97 1 2 Main power supply 5 6 Transformer power input 7 8 Air blower power 9 to 12 Heating element power ...

Page 18: ...Page 18 Letters and numbers are clearly marked on the main circuit board A B Filter pump power input C D Transformer output for Filter Pump E F Input for control Output of rectifier G H Hard water coil ...

Page 19: ...ace the panel Verify the main circuit board switch controller board problem and replace it No Display E81 Yes 1 Press TEST button to turn off the spa 2 Press Rest button to turn on the spa Check the socket power and replace the RCD RCD working 1 Press and hold Power button for 5 seconds to turn off this step can t be on the control base 2 Put the panel back on the top of control base to charge and...

Page 20: ...still E81 please replace the panel 5 If the issue doesn t disappear please verify the main circuit board switch controller board problem and replace it Please refer to Page 37 39 on how to replace the main circuit board switch controller board for more details Remark Refer to the section replacing the PCB and replace the switch controller board for more details If you replace the panel to verify p...

Page 21: ... and the unit is circulating water without issue no further troubleshooting is necessary Remove the unit for further testing if Error Code 90 continues to appear on the panel If the display indicates Code E90 please follow the logic diagram and instructions as below E90 has two cases Yes Yes No Replace Filter Motor or Rotor Ceramic Bar run system Power on and run filter Water flow Remove cartridge...

Page 22: ... FLOW 2 Proceed to testing the unit if the connection was bad to verify Go to the next step if problem is not fixed 3 Check the flow sensors Short the terminal to simulate an inactivated flow sensor after turning on the system and run the filter function Flow center is located near the air blower Replace the defective flow sensor if the system does not display Code 90 and turn off a Start by unscr...

Page 23: ...rts inside a Refer to the control base open procedure to open the enclosure and base opening procedure to open base b Disconnect water pump power cable Unscrew brown nuts by loosening Release the screw Disconnect the black power cord c Unscrew 5 screws on the pump to reveal the impeller and ceramic shaft The impeller is magnetic so pull it out carefully and make sure it doesn t come in contact wit...

Page 24: ...ulti meter a Check terminals 1 2 5 6 C D and Q R Set the multi meter for AC current with a range that will measure 12 14 Vac Turn on the system and run the filtering function Touch each of the terminals with a multi meter in pairs and see if the reading on the multi meter is between 12 14 Vac Terminals 1 2 and 5 6 is equal to the socket output which depends on the local power supply b The test sho...

Page 25: ...ow all parts taken from the jet spa are laid out for reference v Once the transformer has been exposed it can be taken out and replaced Error Code E90 PCB 1 Test the voltage of the PCB a Check terminals A B Set the multi meter for AC current with a range that will measure 12 14 Vac Touch one of the multimeter s leads to A and the other to B Turn on the system and run the filtering function See if ...

Page 26: ...a problem with the 20 40 C water temperature sensors Please follow the logic diagram and instructions as below Begin the test by installing the spa control base and panel to a tub filled with water to the recommended level Make sure that the water inside the tub is not colder than 4 Turn on the spa control base Run the filtering function for 1 minute If the spa display does not indicate an error c...

Page 27: ...crews that hold the heating element on the support base Remove screw of equipotential bonding system c Pull the pile out and use wrench to disconnect 20 40 water temperature sensor d After exposing the heater remove the 20 40 temperature sensor It should be the lower temperature sensor 2 If the problem still persists after changing the 20 40 sensor the PCB must be replaced Reference the chapter on...

Page 28: ...if Error Code 95 is confirmed 1 Begin by swapping out the 50 water temperature sensor Disconnect the wire connector for the sensor and clip on a new replacement If E95 have been solved reference E94 for more details on testing and changing the upper temperature sensor a Disconnect the flow sensor 50 on the PCB Remove screws that hold the heating element on the support base Remove screw of equipote...

Page 29: ... 84 thermal fuse Disconnect the wire connector for the fuse Test the 84 temp fuse on the heating element next Adjust the multimeter to test for resistance using the Ω function It should near 0 resistance Replace the temp fuse if the reading is 0 MΩ or no reading Ensure that the plastic covering over the fuse is intact Run the control base on a spa Change the PCB if the problem is not resolved Refe...

Page 30: ... if Error Code 99 is confirmed Before beginning the test ensure that the temperature sensor connectors are not loose 1 Begin by swapping out the 20 40 water temperature sensor Disconnect the wire connector for the sensor and clip on a new replacement 2 Run the control base on a spa Change the PCB if the problem is not resolved Follow the instructions on page 33 to do this No Display E99 100 000 21...

Page 31: ...o right the number of the terminal should be 10 9 11 12 If the number is missing you can also test by measuring the AC voltage on the PCB with a multimeter Set the multimeter turn the power on and run the heater function for 20 seconds Test terminals 9 10 then 11 12 and look for voltage reading equal the wall voltage Please refer to page 8 or consult a professional electrician for how to use the m...

Page 32: ... wall output 2 Reset RCD and reactive the panel 3 Replace a control panel and power on the system again 4 If blank panel still persists replace a new PCB or RCD refer to the section replacing the PCB or RCD page 36 37 for more details 1 Replace PCB or 2 Replace RCD or 3 Replace Power Cord Replace a control panel run system END Plug in and Reset RCD Reactive the panel Panel Blank Panel Blank No Yes...

Page 33: ...on restart the control base and panel If restart the Control Panel doesn t work try replacing the Control Panel with a new one If the above steps do not solve the issue proceed with replacing the PCB Refer to the section replacing the PCB page 37 for more details No END Random Display Code 888 Yes 1 Replace Control Panel 2 Replace PCB Go Back to Next Step Random Code ...

Page 34: ...on the PCB next Terminals 7 8 should be tested with a voltmeter for voltage reading equal the wall voltage Do this by putting probes to the two terminals and run the air blower function on the spa If the reading on the terminals is ok change the air blower If the reading is on the terminals is not ok change the PCB To change the air blower first access the inside of the Control Base Release termin...

Page 35: ... the spa tub from the control base and running it on a different tub Vertical air blower tube that heads to the Control Panel Pull out the old air blower and install a new one 4 Lastly the problem could be due to a bad air pump OR an air pump that is beyond its lifetime Air pumps have a life time of about 500 hours Air pumps in this condition will make a very painful high pitched squeal sound or a...

Page 36: ...terproof Reinstall it by reversing the steps above Be careful to match power terminals to their corresponding wires on the RCD 4 Change the Control Panel with a new one Check terminals 1 2 for wall voltage If there is no voltage check the electrical outlet and RCD If the voltage output is ok proceed to replacing the PCB Reference the chapter on replacing the PCB for more details If the RCD is fail...

Page 37: ... white PCB cover to reveal the PCB Once PCB internal layout is appearing There are two screws to hold the entire PCB parts 3 Disconnect all the sensors input terminals and all the around the PCB Cut off the nylon belt which secures the internal wiring to the board Rotate the brown cover to detach the black cord Replace a new main circuit board and put it back ...

Page 38: ...e of spa control unit 1 Refer to the instruction of opening the Control Base to remove the screws 2 Turn over the whole control unit and remove the base 3 Replace a new base and install it back turn it back to the front and lock the screws ...

Page 39: ...h controller board 1 Refer to the instruction of Opening the Control Base to remove the screws Pig 1 Pig 2 Pig 3 Pig 4 Pig 5 2 Loosen the buckle showing on pig 2 and then remove the 4 screws to replace the switch controller board ...