Jacuzzi Premium J-325, Troubleshooting Manual

Page 1: ...1 Standard Troubleshooting Approach S T A Manual 2004 Jacuzzi Premium Protech LED Model Hot Tubs J 315 J 325 J 335 J 345 ...

Page 2: ...l 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 Ex treme Caution While Servicing Circuit Board ...

Page 3: ...d Main System Specifications J 345 Main System Specifications J 335 Main System Specifications J 325 Main System Specifications J 315 Main Control Panel Functions Setting Filter Cycle Start Time Programming Filter Cycles Aftermarket Ozone Facts Additional Control Panel Functions Setting Water Temperature Selecting Jet Speeds Underwater Light Operation Lock Unlock Control Panel Lock Out Mode Summer...

Page 4: ...Checking Voltage To Components Checking Current Consumption Of Components Testing The Flow Switch About Fuses The Watchdog Understanding Ozone Understanding pH 2004 J 315 J 325 Circuit Board Illustration 120 VAC 3 or 4 Wire Connection 2004 J 335 J345 Circuit Board Illustration 240 VAC 3 Wire Connection Load Box Connection Diagrams A F Temperature Hi Limit Sensor Resistance Chart Flow Switch Illust...

Page 5: ...control the overall cost of service by focusing on the three important aspects of your job outlined above The STA will help you fix your customer s hot tub quickly fix it well and use fewer parts 1 2 How To Use The STA The STA was developed by the Jacuzzi Premium Technical Support Department and is designed to be the communications link between you and your customers If you call for help on any sy...

Page 6: ...result of a safety feature or if a service call needs to be set up Cool and or Ice are generally the result of a spa that has just been filled or refilled and doesn t require any action on the part of the homeowner or the technician Know how the filtration system works what its defaults are when it comes on and if there are any automatic times that it will come on during each day Know the symptoms...

Page 7: ...nly the whole family bromine or chlorine etc Does the customer know how to properly clean the filter and that the spa needs to be disabled when doing so Suggest a second filter to the customer if the original filter needs to be soaked in a cleaning solu tion Have one in your truck Find out what chemicals the customer is using If they have saturated the spa with different kinds of chemicals sometim...

Page 8: ...hat you may need For example if there is a heating problem or the heater doesn t come on think of all the components that include anything to do with a heat call such as the temperature sensor circulation pump main pump flow or pressure switch filter circuit board heater etc Prepare for the worst possible scenario and plan to be able to satisfy the subsequent problems that may arise Dress appropri...

Page 9: ...licone 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 com ponent or come back and do it for free Make repairs look as good as or better then when you started Make sure you leave the customer s home as clean as you found it Most customers don t mind if you are having lunch in their backyard as...

Page 10: ...ou service Compliment customers on the things they are doing right Tell them how their care and attention can stop trouble before it starts Mention if you noticed any adverse conditions especially if the hot tub is under warranty or con tract that could lead to failure Can the customer correct the problem Would they like you to correct it Can you recommend someone Would they like an estimate Think...

Page 11: ...ment board on the ground D place the bad board in the bag from which you removed the re placement board E return bad board s to Jacuzzi Premium in undamaged sealed static protective bags 2 3 What About Wrist Straps And Special Mats The purpose of these devices is to keep the technician the work surface and the circuit board at the same electrical potential and drain into ground any static charges ...

Page 12: ...ting One Underwater with Two Colored Lenses Cabinet Redwood Cedar with No Stain Optional UV Resistant Synthetic Plastic Cabinet with Embossed Red or Gray Wood Grain Acrylic Colors Textured Bluegrass Jade Marine Onyx Sahara or Sand Marbled Emerald Platinum or Sapphire Solid Azure or Silver Headrests 4 Waterfall Includes Flow Rate On Off Adjustment Powered by Pump 1 Electrical Requirements North Ame...

Page 13: ... Closes Air Inlet to Jet Group D Jet Selector 1 Directs Jet Pump 1 Output Between Jet Groups A or B Air Control 3 Opens Closes Air Inlet to Jet Group B D B A C B D A 25 50 64 8cm F 19 75 50 2cm Listed Dimensions B 24 00 60 1cm G 27 00 58 6cm Represent Distance from C 28 50 72 4cm H 25 75 65 4cm Top of Acrylic to Lowest D 23 00 58 4cm I 34 00 86 4cm Point in Seat E 27 50 69 9cm Dimensions Specifica...

Page 14: ...rwater with Two Colored Lenses Cabinet Redwood Cedar with No Stain Optional UV Resistant Synthetic Plastic Cabinet with Embossed Red or Gray Wood Grain Acrylic Colors Textured Bluegrass Jade Marine Onyx Sahara or Sand Marbled Emerald Platinum or Sapphire Solid Azure or Silver Headrests 4 Waterfall Includes Flow Rate On Off Adjustment Powered by Pump 1 Electrical Requirements North American 60Hz Mo...

Page 15: ...4cm Top of Acrylic to Lowest D 23 00 58 4cm Point in Seat E 27 50 69 9cm Dimensions Specifications Subject to Change Without Notice C Air Control 2 Opens Closes Air Inlet to All Lounge Jets A Jet Selector Directs Jet Pump Output Between Jet Groups A B or C Air Control 1 Opens Closes Air Inlet to Jet Group C Air Control 3 Opens Closes Air Inlet to Jet Group B A B B B C A E D C B A H G F ...

Page 16: ...Lighting One Underwater with Two Colored Lenses Cabinet Redwood Cedar with No Stain Optional UV Resistant Synthetic Plastic Cabinet with Embossed Red or Gray Wood Grain Acrylic Colors Textured Bluegrass Jade Marine Onyx Sahara or Sand Marbled Emerald Platinum or Sapphire Solid Azure or Silver Headrests 4 Waterfall Includes Flow Rate On Off Adjustment Powered by Pump 1 Electrical Requirements North...

Page 17: ... Acrylic to Lowest D 21 50 54 6cm Point in Seat E 28 00 71 1cm Dimensions Specifications Subject to Change Without Notice 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 Air Control 1 Opens Closes Air Inlet to Jet Group A Air Control 2 Opens Closes Air Inlet to Jet Group B B A B C B C E F D C B A ...

Page 18: ...hting One Underwater with Two Colored Lenses Cabinet Redwood Cedar with No Stain Optional UV Resistant Synthetic Plastic Cabinet with Embossed Red or Gray Wood Grain Acrylic Colors Textured Bluegrass Jade Marine Onyx Sahara or Sand Marbled Emerald Platinum or Sapphire Solid Azure or Silver Headrests 3 Waterfall Includes Flow Rate On Off Adjustment Powered by Pump 1 Electrical Requirements North Am...

Page 19: ...m C 27 00 68 6cm Top of Acrylic to Lowest D 28 00 71 1cm Point in Seat E 27 75 70 5cm Dimensions Specifications Subject to Change Without Notice B Jet Selector Directs Jet Pump Output Between Jet Groups A or B Air Control 2 Opens Closes Air Inlet to Jet Group B Air Control 1 Opens Closes Air Inlet to Jet Group A A A B E D C B A ...

Page 20: ...1 Setting Filter Cycle Start Time Two methods for setting the filter cycle start time are possible Turn power on to the hot tub two minutes prior to the desired filter cycle start time or Press and hold both the Warmer and Cooler Buttons at the same time then press and hold the Jet 1 Button to reset the control panel and start the power up sequence During the power up sequence the previously set f...

Page 21: ...manually cancel an active filter cycle or to activate the main jet pump between filter cycles Refer to the options below F4 F5 F6 4 hours of filtration a day 2 hour cycle every 12 hours 6 hours of filtration a day 2 hour cycle every 8 hours 8 hours of filtration a day 2 hour cycle every 6 hours 3 53 Revision F4 F5 F6 1 hour of filtration a day 1 2 hour cycle every 12 hours 1 1 2 hours of filtratio...

Page 22: ...ture setting will be maintained 5 0 Additional Control Panel Functions 5 1 Temperature Setting To enable the set temperature display 4 3 Aftermarket Ozone Facts An aftermarket ozonator can be installed on all 2002 models A mazzei injector is required on all mod els Ozone System Specifications Circulation pump runs 24 hours Ozonator runs 24 hours The ozonator shuts off when a Jets Button is pressed...

Page 23: ...t tub s water reaches 95ºF 35ºC or higher N J1 T EMP HI LIMIT FLOW SW 1 2 3 4 5 6 JP1 7 8 J4 N N N N N N N L L L L L L L L L Spa Light Ozone Circ Pump Pump 1 Pump 2 Red Black Heater In Heater Out F1 Rev 3 53 1 2 3 4 5 6 JP1 7 8 6 0 Understanding Circuit Board Pin Assignments 6 1 Circuit Board Jumpers All ProTech LED circuit boards can be configured for either 15 30A or 50A 240 VAC operation J 340 ...

Page 24: ... water temperature is displayed If the water temperature at this time is less than the factory preset temperature setting of 100ºF 38ºC The circulation pump and heater will turn on and run until the temperature rises to the factory preset temperature setting The heater shuts off and the circulation pump remains on for 24 hour opera tion Approximately two minutes after initial start up the first fi...

Page 25: ...112ºF 44ºC and the low speed pump has activated to circulate water through the hot tub to cool it down Refer to test steps 1 4 below 1 2 3 4 Verify the actual water temperature with an accurate thermometer If the actual water temperature is less than 112ºF 44ºC proceed to steps 2 4 Turn off the main breaker to the hot tub Refer to appendix page 55 for expected hi limit temperature sensor resistanc...

Page 26: ...itting as shown fig A Test the system operation If the condition persists proceed to step 2 Remove the switch from the fitting making note of the number of turns revolutions it takes to do so Visually inspect the switch for debris interference or damage If debris is present remove the debris then reinstall the switch with the same number of turns as originally installed Test the sytem If the switc...

Page 27: ...ange Test thermal switch by connecting voltage meter across the terminals with a heat call present see fig C If 120 VAC or 240 VAC exists the switch is open If no voltage exists the switch is closed Is the switch open Convertible J315 and J325 models only Is voltage present at heater element Test points 8 and 9 No No No No Yes Call Technical Support Yes Yes Yes Yes Current draw is proof that heate...

Page 28: ... inspect for debris interference Remove debris if present Test switch for continuity 0 when closed and for infinite when open fig E Does switch operate correctly Make sure wire is not shorted when installed on switch Install switch making sure flow arrow points in direction of flow and switch doesn t bottom in fitting fig F Retest system Is wire shorted No No Yes Yes Yes Yes No Replace flow switch...

Page 29: ...andard filtration mode page 21 Set temperature high enough to initiate a heat call Is voltage ok from circuit board to circulation pump Test points 16 and 17 for circulation pump No No Yes Yes Replace pump Yes No Is connection OK from circuit board to pump Circuit Board Illustrations A 2002 Protech LED Models Page 50 51 Note Refer to the voltage and current charts on appendix page 46 47 for expect...

Page 30: ... No Yes Yes Yes Yes Yes Remove flow switch connector from circuit board at point 11 fig H Place jumper across exposed connector pins Does heat indicator appear and FL1 error message disappear Lightly scrape contact pins at point 11 with a razor blade or sandpaper to remove conformal coating or oxidation from contact surface Replace circuit board Repair or replace flow sensor cable Clean connectors...

Page 31: ...l 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 Replace control panel No Yes Call Jacuzzi Premium Technical Support ...

Page 32: ...eled heater out on the circuit board test points 6 7 Refer to pages 50 51 for your circuit board configuration If possible clean and renew the connections If a relay is physically burned at the connections replace the circuit board Check the flow switch for proper and consistant mechanical operation Observe the mechanical ac tion of the switch Refer to page 26 for the flow switch testing procedure...

Page 33: ...ck for power at the transformer secondary Refer to appendix page 57 If power exists on the transformer secondary plug in a spare control panel Still nothing Replace the circuit board If no power exists at the transformer secondary check for voltage at the transformer primary Refer to appendix page 57 If voltage exists on the primary but is missing on the secondary replace the transformer No power ...

Page 34: ...on the hot tub 90 of a GFCI s tripping problems are the direct result of improper wiring or installation 1 2 3 4 5 6 7 Has the GFCI always tripped or has it just recently started tripping Has the hot tub just been installed Electricians are not as smart as they think they are and the owner s cousin s nephew who s a painter really isn t a licensed electrician New deliveries cause 90 of all GFCI tri...

Page 35: ...disconnect hooked up Be specific There needs to be FOUR wires two hots a neutral and a ground at the disconnect for the GFCI to properly function Is this a 3 wire or a 4 wire hook up The J 335 J 345 are all 240 VAC 3 wire hook ups The J 315 J 325 is a 3 wire when hooked up to 120 VAC and a 4 wire when hooked up to 240 VAC Is there 240 VAC 120 or 240 VAC on J 315 J 325 at the hot tub Refer to the m...

Page 36: ...CI and the hot tub A licensed electrician should be called at this time What is the voltage between one hot lead to ground and the other hot lead to ground This should be 120 VAC What is the voltage between one hot lead and the neutral There should not be a neutral wire Except on J 315 J 325 Are the wires connected to the proper position inside the hot tub load box Verifiy and be specific Wires in...

Page 37: ...ub has one Do you notice any water deposits near any of the motors or any other electrical devices Look at the area around the air controls If water is backing up into the control it will leak out pos sibly onto an electrical component Is the control panel properly sealed as to not allow water to leak down onto the load box Are there any components specifically the pumps heater ozone etc leaking D...

Page 38: ...ight har ness Standard Troubleshooting Approach Press Light Button on control panel Do you hear a relay click on the circuit board Replace control panel Replace circuit board Change light bulb Is there 12 VAC at test points 12 and 13 Is connection between circuit board and light OK Plug in spare control panel then press Light Button Did you hear a relay click on the circuit board No Replace circui...

Page 39: ...nger Electrical Shock Hazard Exists High Voltage Present On Circuit Board Use Ex treme Caution While Servicing Circuit Board Press JETS Button to turn on jets pump Do you hear a relay click on the circuit board Replace control panel Replace circuit board Repair wiring Plug in spare control panel then press JETS Button Do you hear a relay click on the circuit board No Replace circuit board No Yes Y...

Page 40: ...Troubleshooting Approach Remove debris or loose foreign object No No No No Yes Yes No Yes Yes Yes Is water level OK Are filter cartridges clogged or dirty Clean or replace filter cartridges Adjust water level Are the filters installed correctly Remove debris or replace broken impeller Take pump housing apart Is debris present in pump impeller Is the impeller broken Is there debris or a loose forei...

Page 41: ... down See page 43 Call an electrician to fix problem Replace pump Is there sufficient voltage connected to hot tub Check for 240 VAC 10 or 120 VAC 10 for J315 J325 Models at TB1 test points 1 and 2 Check voltage with pump running Is the voltage 240 VAC 10 or 120 VAC 10 for J315 J325 models at test points 1 and 2 Is voltage from circuit board to pump correct after pump quits Check for 240 VAC 120 V...

Page 42: ...umbing debris in the pump or a broken pump impeller Danger Electrical Shock Hazard Exists High Voltage Present On Circuit Board Use Ex treme Caution While Servicing Circuit Board Is 240 VAC 120 VAC for J315 J325 models present at pump output Circuit board test points 16 and 17 Make sure circulation pump should be on If pump should be on and there is no voltage at test points 16 and 17 change circu...

Page 43: ...rheating problem yet the motor keeps cutting out the pump s thermal switch may be bad In this case the pump should be replaced mmm 8 12 Pump Hums And Will Not Start If the pump impeller is not frozen this condition almost always indicates a bad start capacitor This component is inside the motor housing Diagnostic Tools Voltmeter Suggested Spare Parts Page 59 Pump and motor circuit board Standard T...

Page 44: ...trol panel then turn power on Wait approximately 2 minutes for filter cycle to begin Is filter cycle running Replace circuit board Replace control panel CD Ozonator a faint buzzing sound and or current draw is proof that the ozonator is working Read steps outlined above to ensure customer understands ozone logic Is 240 VAC 120 or 240 VAC present at circuit board ozone outputs Test points 14 and 15...

Page 45: ...45 Appendix ...

Page 46: ...components with 120 VAC Verify Power Connections As Follows US Canada J 315 J 325 Model 120 VAC 60Hz fig K Hot to Neutral Measure across test points 1 and 23 with voltmeter for 120 VAC Hot to Ground Measure across test points 1 and 3 for 120 VAC US Canada J 315 J 325 Model 240 VAC 60Hz fig L Hot to Neutral Measure across test points 1 and 23 for 120 VAC then across test points 2 and 23 for 120 VAC...

Page 47: ... 16 and 17 120 VAC Heater 6 and 7 120 VAC or 240 VAC Ozone Generator 14 and 15 120 VAC Depends whether hot tub is connected to 120 VAC or 240 VAC supply 2004 ProTech LED J 335 J 345 US Canada Export 50 60Hz Device Test points Voltage 10 Pump 1 Low Speed 18 and 19 240 VAC Pump 1 High Speed 18 and 20 240 VAC Pump 2 J 340 Only 21 and 22 240 VAC Circulation Pump 16 and 17 240 VAC Heater 6 and 7 240 VA...

Page 48: ...ty infinite ohms Caution Make sure replacement fuses are exactly those listed above Never test a fuse for continuity while it is installed in the fuse holder A6 0 The Watchdog Three horizontal dashes with no other control panel indicators illuminated is a result of the Watchdog circuitry detecting a potential destructive condition within the hot tub Before making the service call have the customer...

Page 49: ...er disinfectant than the resulting chlorine com pounds Therefore ozone and bromine team up better to do the overall job than ozone and chlorine A8 0 Understanding pH Keeping the hot tub water clean and clear involves a very complex set of chemical reactions Most importantly the hot tub must be sanitized Bacteria algae and other single cell life forms that may find their way into the hot tub must b...

Page 50: ...supply Use copper conductors ONLY Wire size must be appropriate per NEC and or local codes 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 HI LO JP1 4 2 3 1 6 5 8 7 Logic Jumper Settings Factory Defaults Shown JP1 1 2 ON 15A Lo...

Page 51: ...es Operation is 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 STEREO optional 20A 250 V SC 20 Temp Sensor HI Limit Freeze Sensor Flow Switch Heater 5 5 kW JP1 4 2 3 1 6 5 8 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Logic Jumper Set...

Page 52: ...ad Neutral Wire Note service disconnect not shown in this diagram B R Red Red Hot Pigtail Neutral Bus Ground TB2 Black Black Hot Green GFCI Sub Panel Main Panel Hot Tub Load Box 2 Pole GFCI Breaker Ground No Load Neutral Wire J 335 J 345 240 VAC Only Main Panel with Secondary GFCI Sub Panel Using a 2 Pole GFCI Breaker with 2 Wire Grounded Connection 3 Wires to Hot Tub 2 Hot 1 Ground B TB1 White Ne...

Page 53: ...AC C Note service disconnect not shown in this diagram B R Red Red Hot Pigtail Neutral Bus Ground TB2 Black Black Hot Green GFCI Sub Panel Main Panel Hot Tub Load Box 2 Pole GFCI Breaker Ground J 315 J 325 240 VAC Main Panel with Secondary GFCI Sub Panel Using a 2 Pole GFCI Breaker with 3 Wire Grounded Connection 4 Wires to Hot Tub 2 Hot 1 Neutral 1 Ground D TB1 White Neutral Green Ground GFCI Sub...

Page 54: ... VAC E Note service disconnect not shown in this diagram B Red Hot Pigtail Neutral Bus Ground TB2 Black Black Hot Green GFCI Sub Panel Main Panel Hot Tub Load Box 2 Pole GFCI Breaker Ground J 315 J 325 120 VAC Main Panel with Secondary GFCI Sub Panel Using a 2 Pole GFCI Breaker with 2 Wire Grounded Connection 3 Wires to Hot Tub 1 Hot 1 Neutral 1 Ground F TB1 White Neutral Green Ground GFCI Sub Pan...

Page 55: ...93 2 95 0 96 8 98 6 100 4 102 2 104 0 105 8 107 6 109 4 111 2 113 0 Celcius ºC 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Ohms Ω 48840 46680 44610 42630 40770 39000 37290 35700 34170 32700 30000 28740 27540 26400 25311 24270 23280 22329 21429 20571 19740 18960 18210 17490 16800 16149 15519 14919 14349 13800 13281 ...

Page 56: ... removed at the flow switch 6560 860 A14 0 ProTech LED Sensor Harness Diagram Temperature Sensor Wires Hi Limit Sensor Wires J2 Connector Cable Side Shown While Plugged Into The Circuit Board J2 Connector Flow Switch Cable Side Shown While Plugged Into The Circuit Board To remove a sensor flow switch wire from ei ther the J2 or J3 connectors insert the end of a paper clip or similar device into th...

Page 57: ...le models include a factory installed 15 foot GFCI cord rated at 15A 120 VAC To use the cord the hot tub must be installed within 10 feet of a dedicated grounded type electrical outlet Do not use an extension cord of any type If the hot tub is more than 10 feet from such an outlet it must be hard wired to a single pole 15A GFCI breaker Refer to pages 50 51 for your specific circuit board configura...

Page 58: ...e stereo power supply and the deck for 12 15 volts DC If voltage is unstable fluctuating or inadequate replace the power supply 4 If the power supply and the fuses all test properly in steps 1 3 and the deck does not turn on replace the deck If the deck does turn on but is malfunctioning replace the deck B Testing the Wireless Remote Control Purchased Separately 1 Power up the spa 2 Point the wire...

Page 59: ...finger Connectors All Mazzei Kit 6472 486 Includes Hose Clamps All Models Light Bulb 6560 246 Underwater Light All Models 6560 247 Light Harness All Models Owner s Manual 6530 225 All Domestic and Export Models Ozone Generator 6472 685 240 VAC 60Hz J 335 J 345 6472 685E Export 230 VAC 50Hz All Models 2472 650 120 VAC 60Hz J 315 J 325 Main Jet Pumps 6500 254 Pump 1 J 335 J 345 6500 263 Pump 2 J 345...

Page 60: ...evice that measures the resistance in ohms Ω of a component or temperature sensitive device e g temperature sensor heater element etc A device that produces ozone gas by passing air by a UV light source or through Corona Discharge high voltage arc methods A 24 hour ozone filtration system added to a hot tub s circulation pump line which introduces Ozone while circulating the water Locations identi...

Page 61: ...1 2 3 4 5 6 7 8 9 Model of Hot Tub Serial Number Operating Voltage 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 Circuit Board Eprom Revision Input Voltage Before calling Jacuzzi Premium collect the following Jacuzzi Premium Technical Support 866 234 7727 ...

Page 62: ...2 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 ...