Generic install manual4

2000LE

M-2/M-3

M-1

Lite Leader

Instructions

InstrumentsBalboaIncorporated

Balboa Control Systems

Installation

Models:

2000 Value

2

Important Safety Instructions ..............................................2-3

Introduction (System Configurations) ...............................4-9

Installation Considerations ............................................10-11

Primary Pump Installation ..................................................12

2nd Pump Installation ..........................................................13

Air Blower Installation ........................................................14

Spa Light Installation ...........................................................15

Ozone Generator Installation...............................................16

Top-side Panel Installation..............................................17-19

Sensor/Sensor Mount Instructions ....................................20

Auxiliary Freeze Sensor......................................................21

pH Sensor..............................................................................22

Printed Circuit Board Jumper Settings..............................23

Lite Leader Jumper Settings and Electrical Schematics .......24-25

M-1 Jumper Settings and Electrical Schematics ..........26-27



2000 Value Jumper Settings and Electrical Schematics .......32-33

2000LE Jumper Settings and Electrical Schematics ....34-35

Electrical Connections ...................................................36-39

Table of Contents

Technical Support

WarrantyProducts manufactured by Balboa Instruments, Inc. are warrantedto be free from defects in materials and workmanship for a periodof two years from date of manufacture. Specifically excluded aremisuse, abuse, and damage from improper installation. Repaired,used, and reconditioned boards are also excluded from the two-year warranty. Labor reimbursement is specifically excludedfrom this warranty.

Circuit BoardsNew circuit boards: 2 years from date of manufacture Repaired circuit boards: 90 daysUsed and reconditioned circuit boards: 90 days

Control PanelsNew control panels: 2 years from date of manufacture

Return PolicyA 25% restocking fee will apply to any product returned within 30 days. No refunds after 30 days. No refunds on any used product.No reimbursement for return shipments.

Phone: 1-800-645-3201Fax: 1-714-435-6862

world wide web: Balboa-Instruments.com

2

33

1. A bonding wire connector needs to be supplied by the customeron retrofit systems; however, a bonding wire connector isprovided on purchases of complete Balboa Control Systems toaccommodate the connection of a minimum No. 8 AWG(8.4mm≈) solid copper conductor between this unit and anymetal equipment, metal enclosure of electrical equipment, metalwater pipe, or conduit within 5’ (1.5 m) of the unit.

2. DANGER - Risk of Electric Shock. Do not permit any electricappliance, such as a light, telephone, radio, or television within 5’ (1.5 m) of a spa.

3. WARNING - This Control System is not intended for outdoor useunless protected by the surrounding structure of a portable spa.

4. The electrical supply circuit connected to the Control System mustbe equipped with a suitably rated disconnect device - a circuitbreaker, switch or other device capable of opening allungrounded conductors in the supply circuit. This disconnectmust be installed at least 5’ (1.5 m) from the spa, but be withinsight of and readily accessible to a spa user.

5. A suitably rated Ground Fault Circuit Interrupter (GFCI) must beinstalled in the electrical supply circuit connected to BalboaControl Systems. This GFCI may also provide the disconnectfunction referenced in item 4 above if it meets the within-sight andaccessibility criteria.

6. All GFCI’s require periodic testing to assure their safety featuresare functioning properly. Follow the GFCI manufacturer’sinstructions to perform the test. In the event that the GFCI fails any test or does not operate as described in the manufacturer’sinstructions, immediately turn all electricity to the Control SystemOFF and discontinue use of the spa until a qualified electrician has corrected the problem.

Important Electrical Safety InstructionsWhen installing and using Balboa Power Systems, basic safety precautions should always be followed, including those listed below:

Read And Follow All Instructions

SAVE THESE INSTRUCTIONS • SAVE THESE INSTRUCTIONS • SAVE THESE INSTRUCTIONS

4

Section Title

4

1. WARNING - Risk of Accidental Drowning. Extreme caution mustbe exercised to prevent unauthorized access by children. Toavoid accidents, ensure that children cannot use the spa or hottub to which this Control System is connected unless they areclosely supervised at all times.

2. DANGER - To reduce the risk of drowning from hair or bodyentrapment, assure that the suction fittings in the spa to whichthe Control System is connected are approved for the applicationand are marked with a flow rate that equals or exceeds the flowrate of the pumps.

3. DANGER - To reduce the risk of injury, do not remove thesuction fittings covers. Never operate the spa if the suctionfittings covers are broken or missing. Never replace a suctionfitting with one rated less than the flow rate marked on theoriginal suction fitting.

4. WARNING - To reduce the risk of injury:

a) The water in a spa to which the Control System is connectedshould never exceed 104°F (40°C). Water temperaturesbetween 100°F (38°C) and 104°F (40°C) are consideredsafe for a healthy adult. Lower water temperatures arerecommended for young children and when spa use exceeds10 minutes.

b) Since excessive water temperatures have a high potential forcausing fetal damage during the early months of pregnancy,pregnant or possibly pregnant women should limit spa watertemperatures to 100°F (38°C).

c) Before entering a spa, the user should measure the watertemperature with an accurate thermometer since thetolerance of water temperature-regulating devices vary.

d) Prolonged immersion in water hotter than 104°F (40°C) maycause hyperthermia. Hyperthermia occurs when the internaltemperature of the body reaches a level several degreesabove the normal body temperature of 98.6°F (37°C). Thesymptoms of hyperthermia include dizziness, fainting,drowsiness, lethargy, and an increase in the internaltemperature 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 the spa, (4) physical inability to exit the spa, (5) fetaldamage in pregnant women, and (6) unconsciousnessresulting in a danger of drowning. WARNING - The use ofalcohol, drugs, or medication can greatly increase the risk offatal hyperthermia.

e) Leave the spa immediately if nausea, dizziness or headachesoccur. Immediately cool the body by taking a cool shower orby applying cold towels or ice packs. If the symptoms persist,seek medical attention.

f) The use of alcohol, drugs, or medication before or during spa use may lead to unconsciousness with the possibility of drowning.

g) Obese persons and persons with a history of heart disease,low or high blood pressure, circulatory system problems, ordiabetes should consult a physician before using a spa.

h) Persons using medication should consult a physician beforeusing a spa since some medication may induce drowsiness ormay affect heart rate, blood pressure, and circulation.

5. Occasional users of the spa should be made aware of theseImportant Safety Instructions.

Important Water Safety InstructionsWhen installing and using Balboa Power Systems, basic safety precautions should always be followed, including those listed below:

Read And Follow All Instructions

SAVE THESE INSTRUCTIONS • SAVE THESE INSTRUCTIONS • SAVE THESE INSTRUCTIONS

55

Balboa Control Systems are designed for installation into a portable spa assembly. These state-of-the-artunits will provide years of trouble free operation by combining the latest technology with the finestcomponents available.

Please take a few minutes to read the Installation Instructions in order to become familiar with theelements of a properly installed system.

Introduction

Lite Leader Control System Configurations

Basic Lite Leader Control System

Installation Manual & Operations Card

Top-Side Control Panels

Spa Light 12V

Pump 1Two-Speed120V/240V

Pump 1Shut-Off Valves

Ground-Fault CircuitInterrupter/CircuitBreaker (GFCI)

Ozone Generator 120V/240V

(must be same voltage as pump)

Rated Suction Fittings

Recommended InstallationAccessories(Not Provided)

Optional System Components(Available from Balboa)

Basic System Components

6 6

Introduction

M-1 Control System Configurations

Basic M-1 Control System

Installation Manual & Operations Card Top-Side Control Panels

or



Air BlowerCheck Valve

Ground-Fault CircuitInterrupter/CircuitBreaker (GFCI)Rated Suction Fittings




Air Blower 120V/240V

Spa Light 12V

Pump 2One-Speed

240V



77

Introduction




or

or


Spa Light 12V











Pump 2One-Speed

240V

8

Introduction




or

or


Spa Light 12V

Pump 2One- or Two-Speed

240V

Pump 1Two-Speed

240V










*2-speed 2nd pump available only with Deluxe panel.

9

Introduction

Value Control System Configurations

Basic Value Control System

Installation Manual & Operations Card

Top-Side Control Panels


Spa Light 12V










or

10

Introduction

2000LE Control System Configurations

Basic 2000LE Control System


or


Spa Light 12V

Pump 2One- or Two-Speed

240V











11

Installation Considerations

4VentilationOpenings

6AMP “Mate-N-Lok”Series Plug (4 Pin shown)

5Pump InstalledBelow Water Level

Normal Water Level

Balboa Control Systems are designed exclusively for installation into the equipment compartment of a portable spa. The skirting

of the portable spa, with suitable equipment compartment doorssecurely fastened, serves as a barrier to prevent a spa user from comingin contact with any part of the Control System. Additionally, the skirtingprovides weather protection for the Control System.

The following requirements apply to all installations. Specificinformation pertaining to plumbing, electrical and installation ofaccessory items is provided in other sections of this manual dedicatedto those subjects.

1. The Control System must be installed on a firm, level surfaceprovided by the cabinet of the spa.

2. The area in which the Control System is mounted must haveadequate drainage to prevent flooding of the equipment under all circumstances. A minimum of 4" measured from the spasupporting surface (concrete slab or deck) to the lowest electricalpart of the Control System or to any of the Control System accessories must be provided.

3. If the spa in which the Control System is to be installed is indoors,precautions must be taken to assure that floors, walls, carpetingand nearby furnishings are protected. Water splash during normal spa use, as well as the possibility of water drip andflooding that might occur due to a defect in the spa’s plumbing,must be considered.

4. The equipment compartment in which the Control System isinstalled must have adequate ventilation. A minimum of 64 square inches of ventilation openings should be provided with all Control System configurations. (Mandatory on all spaswith two pumps). Ideally, this is accomplished by having two 32 square inch openings located as shown. The ventilationopenings must be rain proof. This configuration will assureproper cooling of the Control System.

5. All devices such as the pumps, air blowers, ozone generators, andlights that are controlled by the Control System are connected tothe unit via electrical receptacles mounted in the wall of theControl System. The plugs that mate with these receptacles are

Red = High SpeedBlack = Low Speed

INSTALLATION NOTE:

12

Installation Considerations

Parameters forequipment side of spa 7

3’ minimum

BalboaSystem

Shut-offValve

Bonding lugs

Heater

Suction from Spa

Draining the Spa 9

Drain Plug

NOTE: If conditions exist in the spa circulation system that are not represented by the sensors connected to theControl System, an optional air temperature sensing auxiliary freeze sensor is available. This sensor can beremotely mounted to protect isolated pumps or plumbing. Call Balboa to see if this applies to your system.

commonly referred to by their manufacturer’s designation - AMP“Mate-N-Lok.” If existing components are to be connected tothese Control Systems, their electrical plugs must be of this style.

6. The portable spa should be installed with a minimum of 3’ (1 meter) of free, unobstructed space between the opening of the equipment compartment and any wall, fence or other

permanent structure.

This will allow for ease of installation of the Control System intothe equipment compartment, and provide the necessary accessspace for regular maintenance and service activities in the future.

7. It is mandatory that an insulated spa cover be used on the portable spa to which the Control System is connected. There areseveral benefits:a. The spa water will be cleaner, free from air-borne particles and

require far less sanitizing chemicals.b. The Control System will be able to maintain the desired

temperature of the spa water with significant savings in electricity.

c. The cover will provide a barrier to prevent access to smallchildren and to all intruders if the cover has a locking feature.

8. If the Control System is installed in a spa that is subjected tofreezing temperatures, consideration must be given to protectingthe portable spa’s plumbing from freeze damage. Thetemperature of the water in the spa may be maintained at a pointabove freezing throughout the freezing period, or the spa may bedrained and taken out of service.

The steps to drain the spa vary with the spa manufacturers, andmay entail the use of an auxiliary sump pump, the use of a siphonhose, or possibly by attachment of a drain hose to a fitting withinthe spa plumbing.

Be sure all pump drain plugs have been removed and unionsloosened as required to drain the heater and all related spaplumbing. Any remaining water must be removed withcompressed air.

1313

Primary Pump Installation

NOTE: The amperage requirements of the pump must be added to the amperage requirements of all otherelectrical components in order to complete theelectrical installation. See page 38, ElectricalConnections (3), for details.

BalboaSystem

PowerSwitch

Shut-offValve

Shut-offValve

Water to Spa

Bonding lugs

Heater

Suction from Spa

Pump 1

PressureSwitch

A1- or 2-speed, 120V or 240V, hydrotherapy booster pump,commonly referred to as “Pump 1,” may be connected to all

Balboa Systems. The System will provide 120V/240V electrical powerand control circuitry for the pump. The receptacle will be labeled“Pump 1.”

An existing pump, rated 120V or 240V with an Amp rating notexceeding 15 amps, may be connected to the System if equipped withthe correct electrical cord and connecting plug.

If you are replacing Pump 1 or replumbing thespa, be sure that the following installationinstructions are followed.

1. To assure the safest operation of the spa, the suction fittings connected to the suctionport of the pump must be listed orapproved for the purpose.

2. Each pump must be provided with a minimum of twosuction fittings or a pump can be provided with a suctionfitting and a skimmer. Pump 1 is generally connected to a suctionfitting and a skimmer while pump 2, if applicable, is generallyconnected to two suction fittings.

3. Secure the pump with appropriate screws. Remember to provide 4" of clearance between the spa supporting surface (concrete slabor deck) and the pump motor.

4. Electrical connection to the pump is accomplished by inserting theattachment plug at the end of the pump cord into the receptaclelabeled “Pump1” on the side of the Power System enclosure. Be sure the output voltage of the Control System matches thevoltage rating of the pump. Also, be sure the low-speed and high-speed wires in the pump power cord plug are arranged to matchthe same outputs from the Control System receptacle. Push theplug firmly into the receptacle until the locks on each side of theplug snap into place.

Note: Typically a Balboa System with a 2-speed pump will usethe white wire for common, the black wire for low speed, the red wire for high speed, and the green wire for ground.A 1-speed pump will use the white wire for common, the black wire for high speed, and the green wire for ground.

5. A bonding wire must be connected from the bonding lug on the pump to the bonding wire terminal block on the side of theControl System enclosure. Solid copper wire (no smaller than #8 AWG) is required for this bonding connection (#6 AWG in Canada).

Drain Plug

14 14

2nd Pump Installation

2nd Pump

Suction Port Water IN

Discharge Port Water OUT

Bonding Lugs

Shut-off Valves

NOTE: The amperage requirements of the 2nd pump must be added to the amperage requirements of all otherelectrical components in order to complete theelectrical installation. See page 38, ElectricalConnections (3), for details.

An optional single-speed, 240V, hydrotherapy booster pump,commonly referred to as “Pump 2,” is available for connection to

some models of the Balboa Control Systems. Those models having anoutput receptacle labeled “Pump 2,” can have an optional 2nd pumpconnected. The Control System will provide 240V of electrical powerand control circuitry for the 2nd pump.

An existing 2nd pump, rated at 240V with an amp rating not exceeding10 amps, may be connected to the Control System if equipped with thecorrect electrical cord and connecting plug.

If you are replacing Pump 2 or replumbing the spa, be sure that thefollowing installation instructions are followed.

1. To assure the safest operation of the spa, the suction fittingsconnected to the suction port of the 2nd pump must be listed or approved for the purpose.

2. Each pump must be provided with a minimum of two suctionfittings or a pump can be provided with a suction fitting and askimmer. Pump 1 is generally connected to a suction fitting and a skimmer while pump 2 is generally connected to twosuction fittings.

3. Secure the pump with appropriate screws. Remember to provide4" of clearance between the spa supporting surface (concrete slabor deck) and the pump motor.

4. Electrical connection to the 2nd pump is accomplished byinserting the attachment plug at the end of the 2nd pump cordinto the receptacle labeled “Pump 2” on the side of the ControlSystem enclosure. Be sure the output voltage of the Control Systemmatches the voltage rating on the pump. Also, be sure the low-speed and high-speed wires in the pump power cord plug arearranged to match the same outputs from the Control Systemreceptacle. Push the plug firmly into the receptacle until the lockson each side of the plug snap into place.

5. A bonding wire must be connected from the bonding lug on the pump to the bonding wire terminal block on the side of the Control System enclosure. Solid copper wire (no smaller than #8 AWG) is required for this bonding connection (#6 AWG in Canada).

1515

Air Blower Installation

Double Air Loop1

Plumbing Connectionto the Air Blower

4

Loops must be ABOVEMaximum Water Level

11/2" Pipe

Check Valve

Screw Screw

NOTE: The amperage requirements of the air blower must be added to the amperage requirements of all otherelectrical components in order to complete theelectrical installation. See page 38, ElectricalConnections (3), for details.

An optional air blower is available for connection to some of theBalboa Control Systems. An existing air blower, if equipped

with the correct electrical cord and connecting plug, may also be used.The Control System will provide electrical power and control circuitry forthe air blower.

The following installation instructions apply to any air blower that mightbe used:

1. The air blower may be mounted either vertically or horizontally andmust be positioned in such a manner as to ENSURE THAT WATERCANNOT ENTER THE AIR BLOWER MOTOR. This can beaccomplished by installing a double air loop that incorporates acheck valve, as shown in illustration #1 on this page.

2. The air blower must be connected ONLY to a spa’s air distributionpiping which is connected to air holes in the floor or seats of the spa.Connection of the air blower to any air piping associated with the spahydrotherapy jets will create a hazard by providing a path for high-pressure water to be forced back into the air blower. This will result in damage to the air blower and possibly create anelectrical shock hazard.

3. The air blower must be securely mounted to a structural member ofthe spa to prevent movement during operation.

4. Do NOT use any form of solvent cement or glue when connecting thespa piping to the air blower. Instead, install screws supplied with theblower to mechanically fasten the blower to the piping.

5. Electrical connections to the air blower are accomplished by insertingthe attachment plug at the end of the air blower cord into the properreceptacle on the side of the Control System. Be sure the outputvoltage of the Control System matches the voltage rating of the blower.Also, be sure the electrical conductors in the blower power cord plugare arranged to match the common, hot, and ground wires from theControl System receptacle. Push the plug firmly into the receptacleuntil the locks on each side of the plug snap into place.

Note: A typical Balboa System equipped with a blower will use the white wire for common, the black wire for high speed, and the green wire for ground.

6. If the air blower is equipped with a bonding lug, a bonding wire must be connected from that bonding lug to the bonding wireterminal block on the side of the control system enclosure. Solidcopper wire (no smaller than #8 AWG) is required for this bonding connection (#6 AWG in Canada).

16

Spa Light Installation

Spa Light Kit

Light Assembly

Light Body & Lens Nut

Gasket Clean Area to exposefiberglass or stablespa shell surface

Reflector

Bulb & Socket

NOTE: If a light is not to be installed, a figure of 0.1 ampmay be deducted from the total amperagerequirement of the Control System. See page 38,Electrical Connections (3), for details.

NOTE: If there is an existing light in the spa, an attemptshould be made to mate the new reflector and/or bulband socket parts from the spa light kit to the existinglight's body. This will eliminate the need for removingthe existing light body from the spa wall. Skip toinstruction #7 if an existing light body is to be used.

Electrical Connection 9

Ground Connection

An optional 12V spa light is available for connection to the BalboaControl Systems. An existing 12V spa light, if equipped with the

correct electrical cord and connecting plug, may also be used. TheControl System will provide electrical power and control circuitry forthe spa light.

If you are installing a new light, the following instructions will apply.

1. Select the mounting location for the spa light in a flat area of thespa wall. Many spas have a flat area molded into the spa wall forthis purpose.

2. Inspect the outside (plumbing side) of the spa wall at the selected point to assure that there is no plumbing, wiring, or other obstructions that would interfere with the installation of the light body.

3. Using a suitable 2 1/2" (65 mm) diameter hole-saw, cut the hole in the spa wall. Cut from the inside (water side) of the spa walltoward the outside to prevent splintering of the spa wall’s inner surface.

4. On the outside of the wall, remove any insulating material or othercoating from around the hole for a distance of 1/2" (13 mm).

5. Place the gasket onto the light body, then insert into the hole.Alternately, discard the gasket and seal the light body to the spawall with an appropriate silicone sealant for use with polycarbonateand ABS plastics.

6. Install the nut onto the light body and tighten clockwise. Do notover tighten the nut; doing so might break the light body.

7. Push the reflector onto the end of the light body and twist clockwiseuntil it snaps into place.

8. Push the bulb and socket assembly into the hole on the rear of thereflector and twist clockwise. The assembly will snap into place inthe reflector.

9. Insert the attachment plug at the end of the light wires into thereceptacle labeled “Light” on the side of the Control System controlenclosure. Push the plug firmly into the receptacle until the lockson each side of the plug snap into place.

10. When filling the spa, it is recommended that the water level bestopped just above the level of the spa light until a thoroughinspection determines that there are no leaks around the light. Ifsilicone sealant is used to seal the light to the spa wall, be sure toallow adequate time for the sealant to cure before filling the spa.

11. Replacing the spa light bulb: With access to the back of the spa, turn off all electric power to thespa. Twist the bulb and socket assembly counter-clockwise and pullthe assembly out of the reflector. Do not pull on the wires. Pull thebulb straight out of the socket and replace with a standardautomobile type #912 bulb.

16

17

Ozone Generator Installation

Electrical Connection1

Bonding Terminal

#8 Bonding wire to Ozone

Generator

NOTE: The amperage requirements of the ozone generatormust be added to the amperage requirements of allother electrical components in order to complete theelectrical installation. See page 38, ElectricalConnections (3), for details.

All of the Control Systems provide control circuitry and electricalreceptacles for connection of an ozone generator.

An existing ozone generator may be connected providing that the ozonegenerator is equipped with the correct cord and connecting plug and isthe correct voltage. The plug used is commonly referred to as a “4-PinAMP Plug,” and mates with the 4-pin AMP receptacle on the side of theControl System enclosure. The wiring connections to the plug mustalign with the receptacle diagram shown on the right.

Follow the installation instructions from the manufacturer of the ozonegenerator pertaining to the mounting of the unit, installation of venturisor injectors, and the connection of all required piping, tubing and check valves.

The following instructions apply to the connection of all ozonegenerators to the Control System:

1. Electrical connections to the ozone generator are completed byattaching the plug at the end of the ozone generator cord into theproper receptacle on the side of the Control System. Be sure theoutput voltage of the Control System matches the voltage rating ofthe ozone generator. Also, be sure the electrical conductors in theozone generator cord plug are arranged to match the common,

hot,and

ground wires from the Control System receptacle. Push the plugfirmly into the receptacle until the locks on each side of the plugsnap into place.

Note: A typical Balboa System equipped with an ozone generator will use the white wire for common, the black wire for high speed, and the green wire for ground.

2. If the ozone generator is equipped with a bonding lug, a bondingwire must be connected from that bonding lug to the bonding wireterminal block on the side of the Control System enclosure. Solidcopper wire (no smaller than #8 AWG) is required for this bonding connection (#6 AWG in Canada).

17

Ozone GeneratorReceptacle

18

Section Title

T here may be several Balboa top-side panels available dependingon the Balboa Control System you have selected. The top-side

panel is specifically designed to withstand the harsh spa environmentand is intended to be mounted in a location on, or close to the spa, inorder to provide the spa user with the greatest convenience whencontrolling the spa equipment. When selecting a mounting location forthe top-side panel, several factors should be considered:

• Select a location that is easily accessible. The user should be able to reach the panel without stretching or getting into an awkward position.

• The mounting location should allow the user to see all of thevisual indicators and display features of the top-side panel without strain.

• The panel’s connecting cable must reach the Control Systemwithout stretching or being forced against any sharp corners. A“dry run” is highly recommended. Hold the top-side panel at thedesired mounting location and route the connecting cable towardthe Control System to determine that the 7' cable is long enoughto allow it to be connected inside of the unit.

• The mounting area must be above the maximum water level of the spa and in an area with good drainage to prevent theaccumulation of any water. The top-side panel must not be submerged.

• If the top-side panel must be mounted underneath a spa cover,select a mounting location that will prevent the cover from resting directly upon the panel, but will allow the cover to sealwhen closed.

Top-side Panel Installation

Top-side panels

Available for M-2 systems

Available for M-1 Systems

Supplied with Lite Digital systems

1919


Available for Value Systems

Available for 2000LE Systems

Available for M-3 systems

20 20

Complete the installation of the top-side panel as follows:

1. Cut a mounting hole with the dimensions shown on the right. Tryto insert the top-side panel into the hole. Make sure the hole isthe proper size before proceeding.

2. Remove all dust and particles from the mounting surface aroundthe hole. A clean smooth surface that is dry and oil free isrequired for the adhesive on the back of the panel to attain a good bond.

3. Remove the paper backing from the adhesive on the rear of thepanel. All of the adhesive should be exposed.

4. Route the connecting cable through the opening and place thetop-side panel into the opening. Align the panel and press firmlyonto the mounting surface.

5. Remove the front cover from the Control System control enclosureand route the connecting cable through the hole in the bottom ofthe front left corner as shown in illustration #5 on this page.

6. Route the connecting cable upward along the left side of thecontrol enclosure to the top-center of the unit.

7. Plug the connecting cable into the correct socket:

Lite Leader = Bottom left side of boxM-1 = J4M-2/M-3 = J1Value = J12000LE = J1

Mounting Hole for Top-side Panel1

2 3/8”

6 3/8”


ConnectingCord Plug

5

Insert LockingLatch into Bottomof Socket

Adapter Bezel

Adapter Bezels

If mounting holes already exist, but the mounting hole is not theproper size, adapter bezels are available.

You can attach a smaller panel to an already existing, larger mounting surface by applying an adapter bezel before installing the top-side panel.

Simply remove all dust and particles from the mounting surfacearound the hole. Remove the paper backing from the adhesive on therear of the bezel. Align the bezel so that all edges are equallyoverlapping the mounting hole.

After you have secured the adapter bezel, you may follow thedirections above to install the top-side panel into the mounting hole ofthe bezel.

5 3/8”

3 1/2”

1 5/16”

1 1/4”

21

B alboa sensor mounts are designed to be mounteddirectly into the spa wall. Installation instructions

are as follows:

Caution: Always route sensor wires away from high voltage wires.

1. Drill a 1.0” diameter hold through spa wall, approximately 10-12”below water level.

2. Install Balboa sensor mount body from the inside of the spa usingsilicone as sealant. Make sure contents of silicone are compatiblewith polycarbonate materials, such as GE RTV6800 series orequivalent (i.e. does not contain methylethylketone, acedtic acid,etc.). See Figure 1.

3. Install the “flange nut” (#1) and tighten.

Sensor/Sensor Mount Instructions

4. Insert the sensor into the sensor mount until the tip of the sensorcomes into contact with the retaining bar. On models without aretaining bar, insert sensor until it stops.

5. Tighten the “water tight cap” (#2) to securely retain sensor.

6. Insulate back of sensor mount completely with spray foaminsulating material. The density of the foam should be 1.75 ± .25 lb/cu. ft. or greater.

Sensor Assembly

Figure 1: Balboa sensor mount assembly

NOTE: Mount sensor where water is actively moving when heater ison and where occupants will not lay against it. Do not mount in theflow pattern of a water inlet.

10"-12"

22

Auxiliary Freeze Sensor(Not Available on All Systems)

Installation

Caution: Always route the freeze sensor wire away from high voltage wires.

1. Turn off the power to the spa.

2. Gain access to the equipment compartment of the spa and exposethe circuit board located in the system box.

3. Run the optional freeze sensor wire through the same hole as theregular sensors and pressure switch wires.

4. Install the optional freeze sensor connector onto the control board(To identify the correct installation location on the circuit boardspecific to your model, refer to Appendix A)

5. Install the optional freeze sensor in the area most likely to freeze,using a zip tie or wire strap as shown below.

6. Insulate the optional freeze sensor completely with spray foaminsulating material. the density of the foam should be 1.75 - 2.0lb/cu.ft.

7. After the optional freeze sensor has been installed, replace thesystem box cover and skirt panels of the spa.

8. Restore power to the spa.

23

IMPORTANT: The pH sensor is a very delicate measuringdevice. Keep the wetting cap on until you reach step 7 of theprocedure. Any small scratch on the bulb will ruin the sensor.Due to possible problems caused by static electricity, please donot touch any component on the pH circuit board. Handle onlyby the outer edges of the board.

INSTALLATION

1. Turn the system power off.

2. Remove the system box cover and close both slice valves (if applicable).

3. Install a 1 1/2" x 1 1/2" x 1/2" FPT or 2" x 2" x 1/2" FPT reducer tee (depending upon size of pipe configuration) upstream in the circulation system from the heater. If possible,position the tee so that the through parts are horizontal and the 1/2 fpt port is rotated 45°from vertical.

4. Press the two stand-offs into the digital control board.

5. Remove the pH jumper from the 4-pin connector (J20 for circuit board #25500 or J11 for circuit board #25501) on the control board.

6. Install the pH board onto the control board.

Important! The pH board must be installed component side up. Make sure that J20 or J11 andthe two stand-offs snap fit into the pH board.

7. Remove the wetting cap by twisting it counter-clockwise and gently easing it off. It is recommended that this cap be retained for future long-term storage.

8. Rinse the measuring end of the sensor with distilled water.

9. Remove any air bubbles in the bulb by pointing the pH bulb downward and shaking the sensor two or three times.

10. Install the pH sensor into the 1/2" FPT port of the tee previously installed by turning the sensor clockwise. Hand tighten only.

11. Feed the BNC connector (from the outside of the control box) through a hole on the bottom LEFT side of the box for a horizontally-mounted system.Pass the BNC connector through a hole on the bottom RIGHT side of the control box for a vertically-mounted system.

12. Connect the BNC connector to the pH board. Firstalign it with its mated connector, then press them together and then twist to lock them into place.

13. Install the system box cover and open the slice valves (if applicable).

14. Turn the system power on.

Note: If the spa is to be winterized, the pH sensorwill need to be removed from the spa. Fill the wetting cap with distilled water and reinstall it onto the sensor. Store the sensor in an appropriate area to prevent freezing. Call Balboafor detailed instructions.

23

Ph Sensor(Only Available on M-2 and M-3 Systems)

24 2424

Section Title Printed Circuit Board Jumper Settings

Jumper orientationand configuration Logic

Jumper

Open(Jumper on one pin)

Shorted(Jumper on two pins)

Feature “ A ” Enabled Feature “ B ” Enabled

T he printed circuit boards of Balboa Control Systems utilizejumpers that control the operation of the Control System

depending upon the model of the system and the top-side controlpanel being used. The jumpers are identified on the board with theletter “J” followed by a number. These jumpers are positioned at thetime of manufacture for specific Control System configurations. Forconfigurations other than described; call Balboa Instruments.

Important!The illustrations at left indicate how the logic jumpers are used. If ajumper is installed on two pins, it is completing a circuit across thetwo pins. If it is installed on one pin, the circuit between the twopins is open. Sometimes a logic jumper will be used on a group ofthree pins and depending on which two pins have been connectedby the jumper, feature “A” or “B” will be enabled.

M-1 Board

2525

Jumper Settings Lite Leader Control System

LITE LEADER Chart 1.0 KW/4.0 KW heater

Portion of PC board for Lite Leader showinglocation of jumpers

Note: The Jumper symbols shown here are oriented to correspond to their actualpositions on the printed circuit board as installed.

= Open Jumper = Jumper Shorted = Selectable Function Jumper

J23 Selects 20A/50A logic (20A logic selected)

J32 Selects 50HZ, ºC / 60HZ, ºF operation (60hz, ºF operation selected) 1 pin

J33 2hr/5hr filtration set 1 pin = 2 hr filtration selected

Jumper # Function of Jumper Position

J32 J23J33

26

Lite Leader Electrical Schematics

2727

Jumper Settings M-1Control System

M-1 Chart 5.5 KW heater

Portion of PC boardfor M-1 showinglocation of jumpers


= Open Jumper = Jumper shorted = Selectable Function Jumper

J7 Selects A: circ / B: non-circ pump option (B: Non-circ pump selected)


J26 Disables pump 2 (Pump 2 disabled)

J13 Selects 50HZ, ºC / 60HZ, ºF operation (60hz, ºF operation selected)

J12 Selects 12V/120V Light 12V selected


J26

J7

J8

J13

28

M1 Electrical Schematics

29

J6 Selects A: circ / B: non-circ pump option (B: Non-circ pump selected) 1 pin

J7 Selects top-side panel being used (A: Deluxe, or B: Standard) (B: Standard panel selected)


*J10 Disables pump 2 (Pump 2 disabled)

J16 Disables O3 message (03 message disabled)

J24 Disables ORP (ORP disabled)

J25 60HZ, ºF operation only (60hz, ºF operation selected)

J36 Allows memory storage and resets memory (Memory storage allowed)

J17 Selects 120V Fiber optic Fiber optic selected

J12 Selects 12V/120V Light 12V light selected

J11 PH/orp

* No Jet 2 option on M-2 system; J10 must always be jumped.

29

Jumper Settings M-2 Control System


Portion of PC boardfor M-2 showinglocation of jumpers




J11

J6J25J17J10J16J7J36

J9

J24

J12

30 30

M-2 Electrical Schematics

31

Jumper Settings M-3 Control System


Portion of PC board for M-3 showinglocation of jumpers

Note: The Jumper symbols shown here are oriented to correspond to their actualpositions on the printed circuit board.


Jumper # Function of Jumper PositionJ6 Selects A: circ / B: non-circ pump option (B: Non-circ pump selected) 1 pin

J7 Selects top-side panel being used (Standard panel selected)


J10

J16 Disables O3 message (03 message disabled)

J24 Disables ORP (ORP disabled)

*J25 Selects 50HZ, ºC / 60HZ, ºF operation (Standard panel) (60hz, ºF operation selected)

J36 Allows memory storage and resets memory (Memory storage allowed)

J17 Selects 120V Fiber optic Fiber optic selected

J12 Selects 12V/120V Light 12V light selected

J11 PH/orp

*When Deluxe panel is used, J25 is used for 1- or 2-pump operation

J11

J6J25J17J10J16J7J36

J9

J24

J12

Standard Panel: 2pins=7-button with 2 pumps / 1 pin = 6-button with 1 pumpDeluxe Panel: 2 pins=2 2-speed pumps / 1 pin = 1-spd + 2-spd pump

Standard Panel: 7-button selected w/2 pumpsDeluxe Panel: 2 2-speed pumps selected

60HZ = 2 pumps50HZ = 1 pump

32

M-3 Electrical Schematics

33


Jumper Settings Value Control System

Value Chart 1.4KW/5.5 KW heater

Portion of PC board for Value showinglocation of jumpers


J21 Selects top-side panel being used (Duplex panel selected)


(software only) 60HZ, ºF operation only (60hz, ºF operation selected)

J22 Selects 12V/120V light (12V light selected)


J-24

J22 J23

J21

34

Value Electrical Schematics

35

Dip Switch Settings 2000LE Control System

2000LE Chart 5.5 KW heater

Portion of PC board for 2000LE showinglocation of dip switches

S3 Selects circ/non-circ pump option OFF (Non-circ pump selected)

S1 Selects 30A/50A logic ON (30A logic selected)

S9 Disables pump 2 ON (Pump 2 disabled)

S8 50HZ, ˚C / 60HZ, ˚F operation OFF 60HZ selected

S2 12V Light/Fiber optic OFF (J12 in 12V position) 12V selected

S5 Selects pump 1 / 1 spd or 2 spd OFF (2 spd selected)

S7 Selects pump 2 / 1 spd or 2 spd ON (1 spd selected)

Dip Switch Function of Jumper Position

Dip SwitchesRight side

of box

S1 MODE OF OPERATION ON OFFS10 N/A N/A N/AS9 1 OR 2 PUMPS 1PUMP 2PUMPSS8 DEG C/Fº cº FºS7 PUMP2 1SPD/2SPD 1SPD 2SPDS6 N/A N/A N/AS5 PUMP1 1SPD/2SPD 1SPD 2SPDS4 AUX. FREEZE MUST BE OFFS3 CIRC/NONCIRC CIRC NONCIRCS2 F.O./SPA LITE F.O. SPA LITES1 30/50A 30A 50AJ12

36

2000LE Electrical Schematics

37

All of the electrical wiring methods and materials used to completethe electrical installation of the Balboa Control Systems must be in

accordance with the National Electrical Code or the Canadian ElectricCode, as well as any local electrical codes in effect at the time ofinstallation.

The selection of electrical materials required to accomplish thisinstallation and the installation of the Control System must beaccomplished by, or be under the direct supervision of, a qualifiedelectrician.

These Control Systems are classified as “continuous duty appliances”and are intended primarily for installation at a single family dwelling.The installation recommendations and instructions contained in thismanual are directed solely toward these issues. Different or additionalelectrical requirements may exist if these products are installed otherthan as instructed.

GFCI Requirements

A Ground-Fault Circuit Interrupter (GFCI) is required to be installed inthe electrical supply circuit connected to these products. GFCI’s areultra-sensitive switching devices, providing the ultimate in safety. Themost common style of GFCI also provides high-current protection as acircuit breaker.

One of the two configurations of GFCI’s, as depicted on the left, will berequired for your installation, depending upon the options selected.

and 38, Electrical Connections (2) and (3), provide guidancefor selecting the correct GFCI.

Electrical Disconnect

A disconnect must be installed where readily accessible and within sightof the spa, but at least 5’ (1.5 meters) from the inside wall of the spa.

The disconnect must open all ungrounded conductors of the electricalsupply connected to the spa.

If the main panel meets the sight-line and distance criteria, a GFCIcircuit breaker installed in that panel may be used as the disconnect,as shown in option (A) to the left.

If a new sub-panel must be installed to meet the sight-linerequirements, as shown in option (B) two possible arrangements exist:

1. The GFCI circuit breaker may be installed in the main panel, and a suitable switch, circuit breaker or other disconnecting deviceinstalled in the sub-panel. (OR)

2. The GFCI circuit breaker may be installed in the sub-panel,and a suitably rated circuit breaker (non-GFCI) installed in themain panel.

Electrical Connections (1)

Circuit Breaker

Option A

Option B

Main Panel NOTwithin sight

from the spa.

NEW Sub-panelwithin sightfrom the spa.

Main Panel, with GFCIinstalled, is within sight from the spa.

120V, singlepole GFCI circuit

breaker, withload neutral

terminal

Load neutralterminal to

PowerSystem

240V, doublepole GFCI circuit

breaker, withload neutral

terminal

To line neutralconnection or

neutral bar

5’ minimum

Load neutralterminal to

Power System

38 38

120V, singlepole GFCI circuitbreaker, withload neutralterminal rated20 Amp.

Load neutral terminalto Control System

Line neutralconnection atneutral bar

S tarting below, select the correct voltage for your Control Systemand follow the arrows across the page to the right. The path

corresponds to the desired operating voltage of the Control System, and the voltage of any added components such as an air blower, ozonegenerator, or a 2nd pump.

The arrows will direct you to the correct wiring configuration and adescription of the correct Ground-Fault Circuit Interrupter (GFCI) typecircuit breaker to be installed.


240V, DoublePole GFCI CircuitBreaker, withLoad NeutralTerminal. See page 10 to determine Amp rating.

Load neutral terminalto Control System

Line NeutralConnection atNeutral Bar

NOTE: All of the GFCI’s shown here have a Line Neutral connecting wire attached.(The white coil or pigtail in the lower left of each Circuit Breaker drawing.)

All components are 120V but the heateroperates at 240V.

This requires a two pole GFCI with a load neutral terminal built into the unit, as well. No other GFCI will work withConfiguration #2.

Some components are120V and othercomponents are 240V

Configuration 2Three-wire, plus ground

Control System

Control System 240V

Control System 120V

Control System 240V

Control SystemConfiguration 1Two-wire, plus ground

All components are 120V.

This requires a single pole GFCI. All single pole GFCI'shave a load neutralterminal as a standard feature.

Ground/Green

Line 1/Black

Line 2/Red

Neutral/White

Ground/Green

Line 1/Black

Neutral/White

39

T he next step in making the correct electrical connections to theBalboa Control System is to determine the total electrical

requirements of the complete package, including any added optionssuch as an air blower, ozone generator, or a 2nd pump. For a system operating at 120V, the maximum total Amp draw is controlled by the Control System and is limited to 16 Amps +10%. It does this by preventing combinations of electricalloadsthatwouldexceed

16 Amps from being energized at the same time. For example, whenthe high pump and blower are running, the heater does not run. Or, ifthe low pump, heater, and the ozone generator are running and theblower is activated; the heater automatically turns off. This allows thesystem operating at 120V, to use a GFCI circuit breaker rated for 20Amps. For this reason, if you add a blower, it must be rated 120V andnot exceed 7 Amps. If you add an ozone generator, it must be rated at

120V and notexceed2 Amps. For allother Series Control

20

25

30

35

40

45

50


0 A to 16 A*

16 A to 20 A*

20 A to 24 A*

24 A to 28 A*

28 A to 32 A*

32 A to 36 A*

36 A to 40 A*

Total ampere rating of ControlSystem from the form above

#12 AWG

#10 AWG

#10 AWG

#8 AWG

#8 AWG

#6 AWG

#6 AWG

Supply wire size**Use Copper ONLY,

with 90º C insulation

If a spa light is not connected, subtract 0.1 amps

Ampere rating of GFCI Circuit-breaker

**These wire sizes assume a total wire lengthnot exceeding 100’ (30 m). For longerdistances, increase wire size accordingly.

*These amperages may be exceeded by no more than 10%

Neutral/White

Line 1/Black

Line 2/Red

Ground/Green

40 40


T he electrical installation of the Balboa Control System can now becompleted using the electrical materials and components

selected on pages 36, 37 & 38.

1. Install the proper sized conduit into the entrance hole on the leftside of the Control System. Generally a transition from rigid conduitto flex conduit is appropriate as the conduit enters the spa cabinet.

2. Pull the required conductors into the Control System. Cut theconductors to provide for convenient routing and connection tothe terminal block.

3. Connect the conductors to the terminal block as described below.

Conduit to main panel or

sub-panel

Strip 3/8 inch (10mm) ofinsulation from conductors.

Insert fully into terminal block,making sure that all strands

are captured and tighten eachscrew firmly.

NOTE on Wire Color Coding:

Neutral conductors MUST be white or natural gray.Ground conductors MUST be green or green/w yellow stripe.Line and Load conductors may be any color other than white,neutral gray, green or green/w yellow stripe.

Customarily, black is used for line 1 and red for line 2.

1

2

Ground/Green

Line 1/Black

Neutral/White

Ground/Green

Line 1/Black

Line 2/Red

Neutral/White

Ground/Green

Line 1/Black

Neutral/White

Line 2/Red

WARNING: DO NOT USE ALUMINUM WIRING!

Using aluminum wiring may cause fire or damageto the electronic components of the board.

InstrumentsBalboaIncorporated

1382 Bell AvenueTustin, CA 92780

714.384.0382800.645.3201

DM906 09/2002

Generic install manual4

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