85 0066-b rev 2 hq ultimate series installation

If you encounter any problems or need assistance, don’t hesitate to call our

Technical Support staff.

HydroQuip 13345 Estelle Street Corona, CA 92879

On the Web: www.hydroquip.com Email: [email protected]

Phone: (909) 273-7575 Fax: (909) 273-7550

“T H E S M A R T C H O I C E”

85-0066-B Rev.1 05.22.01 http://www.MyPoolSpas.com Wholesale Pool and Spa Parts 920-925-3094

Ultimate Series Spa Control Contents

Ultimate Series Installation Considerations

General Considerations 2 Pump Considerations 2 Blower Considerations 3

Ultimate Series Installation Configuration

Pump 1 3 Pump 2 4 Accessory 4 Ozone 5 Circ. Pump 5

Ultimate Series Installation Electrical Connection

Circuit Breaker and Rating 6 Input Wiring 6

Ultimate Series Installation Special Considerations

Spaside Control 7 In-House Remote 7 Auxiliary Control 8 Infrared Sensor 8 Air Blower 9 Spa Light 9

Ultimate Series Programming Low Level Programming

Parameters 10

Ultimate Series Operation Start Up & Test

Power Up 11 Pump 1 Key 11 Pump 2 Key 11 Accessory Key 11 Light Key 12 Light Key (with Fiber Optic) 12 Temperature Set Keys 12

Ultimate Series Troubleshooting Error Messages

FLO Message 13 FLC Message 13 Prr Message 13 PrH Message 13 HL Message 13 Pressure Switch Adjustment 14

Ultimate Series Troubleshooting Pressure Switch

If your System is equipped with a pressure switch, the function of the pressure switch is to shut the heater off if the pump is turned off or if there is restricted water flow (dirty filter, obstruction in the spa plumbing etc.). If the heater is installed more than two (2) feet below the spa water level, adjustment of the pressure switch may be necessary. The following procedures and illustrations outline the adjustment of the pressure switch. CAUTION: Remove all power to the unit prior to completing the steps below:

Adjustment • Shut off power to the System prior to accomplishing any adjustments to the pressure switch.

• Remove wires from

pressure switch terminals. • Place an Ohmmeter across

the pressure switch terminals to verify an OPEN circuit.

• Rotate the pressure switch adjustment screw counter-clockwise until the Ohmmeter indicates a CLOSED circuit.

• Finally, rotate the pressure switch adjustment screw clockwise until the Ohmmeter indicates an OPEN circuit again.

• Apply power to the unit at this time and operate the spa or hot tub as normal.

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Ultimate Series Installation Considerations

Hydro-Quip solid-state control packs were designed exclusively for installation into the equipment compartment of a portable spa. The skirting of the portable spa, with suitable equipment compartment doors securely fastened, serves as a barrier to prevent a spa user from coming in direct contact with any part of the system.

• The Equipment System must be installed on a firm, level surface. (Example, concrete pad)

• Locate the Equipment System as close to the spa as practical but no more than 25’ away form it. Consult local codes for minimum distance between equipment and spa.

• The area where the Equipment System is mounted must have adequate drainage to prevent flooding the equipment under all circumstances.

• Provide adequate access around and above the Equipment System for service and

maintenance. Three feet (3’) of clearance around the equipment is recommended.

• The pump(s) provided with the Equipment System may be self-priming or non self-priming. Non self-priming pump(s) must be installed below the normal water level.

• All components such as the pump(s),

air blower and light are connected using Amp or J & J connectors located inside the component connection compartment on the left side of the control box.

Pump Considerations

To assure adequate performance, the spa plumbing must be 1 ½ “ minimum. The use of 2” is recommended. A good grade of fresh PVC-to-PVC primer and solvent should be used for all water plumbing connections.

There may be three separate plumbing systems in the spa. Verify the function of each pipe. • Suction Side Plumbing – this plumbing

will connect to the spa’s skimmer, main drain and suction fittings. This plumbing connects to the open end of the pump on your Equipment System.

• Discharge Side Plumbing – this plumbing will go to the spa’s hydrotherapy jet and message fittings. This plumbing connects to the open end of the heater to your Equipment System.

• Air Blower Plumbing – this plumbing will go to an air channel under the floor or to an air distribution manifold of the spa. This plumbing connects only to an air blower.

Ultimate Series Troubleshooting Error Messages

If at any time during start up an error indication of 3 flashing dots appears below the temperature display, use the following procedures to identify and correct the problem: (Note: There is an LED error indicator on the systems printed circuit board inside the field wiring enclosure. If the LED is illuminated in conjunction with the 3 flashing dots, an Over Temperature condition has occurred.)

Pressure or Flow Switch Activated

• If the 3 flashing dots appear while the pump used to circulate the water is not operating, this indicates that the pressure or flow switch has been activated and requires adjustment (refer to page 13).

• If the LED error indicator located on the systems printed circuit board is illuminated, refer to the Over Temperature section below.

(Note: Models manufactured prior to June 2001 will show an FLC in the lower display window.)

Pressure or Flow Switch Not Activated

• If the 3 flashing dots appear while the pump used to circulate the water is operating, this indicates that the pressure or flow switch has not been activated although there is water flowing through the heater and requires adjustment (refer to page 13).

• If the LED error indicator located on the systems printed circuit board is illuminated, refer to the Over Temperature section below.

(Note: Models manufactured prior to June 2001 will show an FLO in the lower display window.)

Refer to the section on pressure switch adjustment for proper calibration procedures.

Temperature Sensor

• If after start up the temperature display reads a constant 33°F with no increase, this is an indication of a temperature sensor failure.

• Insure that the temperature sensor is properly connected at the printed circuit board located inside the field wiring enclosure.

(Note: Models manufactured prior to June 2001 will show a Prr in the lower display window.)

Over Temperature

• If the 3 flashing dots appear in the lower display window in conjunction with the illumination of the LED error indicator located on the printed circuit board, an Over Temperature condition has occurred.

• Check the heater housing. If the housing is hot to the touch there is not adequate water flow.

• Ensure that all water shut-off valves are open and that the

air has been adequately purged from the plumbing. • Power to the spa must be turned off then back on to reset

the system.

(Note: Models manufactured prior to June 2001 will show an HL in the lower display window.)

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a

Blower Considerations

CAUTION: The air blower must be connected ONLY to the spa’s air distribution plumbing. Connecting the air blower to any air piping associated with the hydrotherapy jets will create a h zard by providing a path for high-pressure water to be forced into the blower motor. This will result in damage to the air blower and create an electrical shock hazard.

• The air blower must be installed to ensure that water cannot enter the air blower motor.

This can be accomplished by installing a single or double air loop that incorporates a check valve. (See Illustration on Page 9)

Ultimate Series Installation Configuration

Congratulations on your purchase of the Universal Series Control System from Hydro-Quip. This series of controls has been developed to allow you complete flexibility during your installation. This Control System is configured to allow you to choose the voltage for each circuit at the time of installation.

The conversion procedure MUST be accomplished PRIOR to connecting input service wiring. This control has been shipped from the factory with ALL circuits wired for 120 VAC.

VERIFY YOUR COMPONENT VOLTAGE REQUIREMENTS: 120 VAC will not harm a 240 VAC component if operated temporarily. 240 VAC WILL harm a 120 VAC component almost immediately. This is the reason we ship all circuits in the 120 VAC configuration. Hydro-Quip cannot be held responsible for mis-wire related damage to components.

Note: To operate components which require different voltages (for example: Primary Pump 240 VAC, Air Blower 120VAC etc.) the Input Service must be 240 VAC.

Pump 1 (Red Receptacle) Primary Pump

Assure that ALL power is OFF.

a) Refer to the Wiring Diagram located inside the Control Panel Wiring Compartment.

b) Locate the White Wire w/Red Terminal End as identified by the Wiring Diagram.

c) Move the White Wire w/Red Terminal End from the Neutral (P45) position to the Line 2 (P32) position as identified by the Wiring Diagrams details.

120VAC 240VAC

Ultimate Series Operation Start Up & Test

NOTE: On multiple speed components, the Icon associated with it will flash when it is in Low and Medium speed and come on solid in High speed. On single speed components, the Icon associated with it will come on solid while it is running.

Light Key • Press the Light Key: Light High intensity will activate.

Light Icon will appear solid on Spa-Side control. • Press the Light Key again: Light Medium intensity will

activate. Light Icon will flash on Spa-Side control. • Press the Light Key again: Light Low intensity will

activate. Light Icon will flash on Spa-Side control. • Press the Light Key again: Light will shut Off.

Light Key • Press the Light Key: “L1” will be displayed. Pressing the

Up Arrow Key will allow you to set the intensity to High, Medium, Low and Off.

(With Fiber Optic) • Press the Light Key Again: “F1” will be displayed.

Pressing the Up Arrow Key will allow you to select Fiber Optic light and wheel On, Light Only, then both Off.

• Press the Light Key Again: The Spa-Side will return to the normal mode, showing the temperature and time.

Temperature • Press the Up Arrow Key to obtain a temperature

higher than the present temperature: The pump low speed will activate. The Heater Icon will flash on the Spa-Side control for 5 seconds, the Heater will then activate and the Icon will appear solid. On systems equipped with a circulation pump, the system will act as above without the pump turning on. (The circulation pump will be operating.)

• Press the Down Arrow Key to achieve a temperature lower than the present temperature: Heater will turn off, Pump will operate in low speed for 20 seconds.

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Ultimate Series Installation Configuration Pump 2 (Pink Receptacle) Primary Pump

Assure that ALL power is OFF.

a) Refer to the Wiring Diagram located inside the Control Panel Wiring Compartment.

b) Locate the White Wire w/Violet Terminal End as identified by the Wiring Diagram.

c) Move the White Wire w/Violet Terminal End from the Neutral (P44) position to the Line 2 (P28) position as identified by the Wiring Diagrams details.

120VAC 240VAC

Blower (White Receptacle) Primary Pump

Assure that ALL power is OFF.

a) Refer to the Wiring Diagram located inside the Control Panel Wiring Compartment.

b) Locate the White Wire w/Blue Terminal End as identified by the Wiring Diagram.

c) Move the White Wire w/Blue Terminal End from the Neutral (P41) position to the Line 2 (P25) position as identified by the Wiring Diagrams details.

120VAC 240VAC

Ultimate Series Operation Start Up & Test

• Read and familiarize yourself with the Equipment System Operation. • Turn the electrical power “OFF” at the service or breaker panel. • Open all WATER shut-off valves. • For spas equipped with a hose bib or drain valve, make sure that it has been closed. • For spas equipped with in-line or pressure water filters, make sure that the filter nut, housing

drain plug, and air relief valve are closed and tight. • Using a standard water hose to fill the spa with fresh tap water to the level recommended by

the spa manufacturer. • Inspect all plumbing connections and lines for any sign of water leaks. • Connect a garden hose to the bib or drain-valve and run it away from the equipment

compartment. Open the hose bib or drain valve to bleed off any air that may have been trapped in the plumbing system during the filling operation. After a steady flow of water appears, close the hose bib. After closing the hose bib, remove the garden hose from the hose bib. Be sure to dry off any excess water around the electrical compartment before proceeding to the next step.

• Close all Air Control Valves. Warning – Do not confuse with Water shut-off valves. • Turn on the breaker at the electrical service panel. • On units with a Ground Fault Circuit Interrupter (GFCI), check the GFCI by pressing the

“Test” button on the face of the device. The “Reset” button should pop out. The equipment should not operate.

• Activate the equipment by pressing the “Reset” button on the GFCI. You have now completed all of Hydro-Quip’s steps for start up. You are now ready to enjoy your spa.

The following is a Test procedure designed to assure the Equipment System will operate properly upon initial start up.

Power Up • Apply power to system: Display shows temperature

flashing. Press any key to continue. Pump 1 Key

• Press the Pump 1 Key: Pump 1 low speed will activate, Pump1 Icon will flash on Spa-Side control.

• Press Pump 1 Key again: Pump 1 high speed will activate. Pump 1 Icon will appear solid.

• Press Pump 1 Key again: Pump 1 will shut Off.

Pump 2 Key

• Press the Pump 2 Key: Pump 2 low speed will activate, Pump 2 Icon will flash on Spa-Side control.

• Press Pump 2 Key again: Pump 2 high speed will activate. Pump 2 Icon will appear solid.

• Press Pump 2 Key again: Pump 2 will shut Off.

Accessory Key • Press the Accessory Key: Blower will activate in high

speed. Accessory Icon will appear solid on the Spa-Side control.

• Press Accessory Key Again: Blower will switch from high to medium Speed. Accessory Icon will flash.

• Press the Accessory Key again: Blower will switch to low speed. Accessory Icon will flash.

• Press the Accessory Key Again: Blower will shut Off.

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Ultimate Series Installation Electrical Connection Ozone (Yellow Receptacle) Primary Pump

Assure that ALL power is OFF.

a) Refer to the Wiring Diagram located inside the Control Panel Wiring Compartment.

b) Locate the White Wire w/Yellow Terminal End as identified by the Wiring Diagram.

c) Move the White Wire w/Yellow Terminal End from the Neutral (P39) position to the Line 2 (P22) position as identified by the Wiring Diagrams details.

120VAC 240VAC

Circ. Pump (Brown Receptacle) Primary Pump

Assure that ALL power is OFF.

d) Refer to the Wiring Diagram located inside the Control Panel Wiring Compartment.

e) Locate the White Wire w/Brown Terminal End as identified by the Wiring Diagram.

f) Move the White Wire w/Brown Terminal End from the Neutral (P37) position to the Line 2 (P19) position as identified by the Wiring Diagrams details.

120VAC 240VAC

Ultimate Series Programming Low Level Programming

It is possible to change the parameters of the Equipment System by completing the following steps. This is to be accomplished by Hydro-Quip factory or authorized personnel.

To access the Low Level Programming, press and hold the Program Key for 20 seconds. After this period you will enter the first Parameter Code of “P1” followed by a value. Use the Light Key to move from one parameter to the next. Use the Up & Down Arrows to change the Value. You must go through all parameters to exit this mode. If you do not want to change a value, press the Program Key to enter the next Parameter Code.

P1 Pump 1 Value 1 = Single Speed Pump Value 2 = Dual Speed Pump

P2 Pump 2 Value 0 = No Second Pump Value 1 = Single Speed

Value 2 = Dual Speed

bL Blower Value 0 = No Blower Value 1 = Single Speed 20 min. timeout Value 2 = Two Speed 20 min. timeout Value 3 = Three Speed 20 min. timeout Value 4 = Single Speed 2 hour timeout Value 5 =Single Speed 6 hour timeout Value 6 = Single Speed 12 hour timeout

L1 Light Value 1 = No Light Value 1 = 12V Light (one intensity)

Value 2 = 12V Light (three intensities) Value 3 = 120V Light

03 Ozone Value 0 = No Ozonator Value 1 = On during filtration Value 2 = Always On

AU Fiber Optic Value 0 = No Fiber Optics Value 1 = Fiber Optics Installed

Ti Time Value 12 = Standard Format Value 24 = Military Time (24 hour clock)

Cu Current Value 0 = Heater Off with high speed pump Value 1 = No Heater

Restriction

CP Circ. Pump Value 0 = No Circulation Pump Installed Value 1 = Regulated with spa Temperature Value 2 = Always On

r Calibration Value can be adjusted from 46.0 to 55.9

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Ultimate Series Installation Electrical Connection

A qualified and licensed electrician in accordance with the National Electric Code (NEC) Article 680, Canadian Electric Code, and with any local codes must accomplish the electrical installation at the time of the installation. All connections must be made according to the electrical installation label inside the control box. Follow the instructions from the label if they are different than the instructions in this manual. If your electrician is not absolutely sure how to connect your system correctly, call your dealer. Any mistake may be costly and invalidate your equipment warranty. The Ground Fault Circuit Interrupter (GFCI) is a mandatory electrical safety device required for all portable spas and hot tubs as specified in the National Electrical Code Article 680-42. A High-Current GFCI has been built into your Equipment System. Your spa equipment requires a DEDICATED CIRCUIT. No other appliances or lights can be on this circuit. Refer to equipment data label for power supply requirements of your spa equipment. Use copper conductors only. Grounding – See National Electric Code Table 250-95 for ground.

Circuit Breaker and Rating

15A 20A 30A 40A 50A 60A 70A 80A Maximum Amps

12A 16A 24A 32A 40A 48A 56A 64A Maximum Amps

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Four Wire Input (240VAC) Three Wire Input (120VAC)

• 240-volt / four wire electrical service

including ground is required, consisting of Line 1, Line 2, Neutral and Ground.

• 120-volt / three wire electrical service including ground is required, consisting of Line 1, Neutral and Ground. (Line 2 to Neutral jumper must installed)

Ultimate Series Installation Special Considerations Blower

CAUTION: The air blower must be connected ONLY to the spa’s air distribution plumbing. Connecting the air blower to any air piping associated with the hydrotherapy jets will create a hazard by providing a path for high-pressure water to be forced into the blower motor. This will result in damage to the air blower and create an electrical shock hazard.

• The air blower must be installed to ensure that water cannot enter the air blower motor.

This can be accomplished by installing a single or double air loop that incorporates a check valve.

Spa Light

An optional 12V-spa light is available with Hydro-Quip Equipment systems.

• Select a mounting location for the spa light in a flat area on the spa wall. Make sure there is

no plumbing, wiring or other obstructions, that will interfere with the installation on the outside spa wall.

• Using a suitable 2 ½ “ (65mm) diameter hole-saw, cut the hole in the spa wall. Cut from inside the spa wall toward the outside to prevent splintering the inner surface.

• Remove any insulation material from around the hole for a distance of ½ “ (13mm) at the outside spa wall.

• Install the gasket onto the light body and insert into the hole. Take care not to over tighten the nut securing the light body. Silicone sealant may be used in place of the gasket. Allow adequate time for sealant to cure before filling the spa.

• Note: It is recommended that the water level be stopped just above the level of the spa light until a thorough inspection for leaks can be completed.

Line 2 To Neutral Jumper Line 2 Line 1

69

Line 1 Neutral Ground Neutral Ground

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Ultimate Series Installation Special Considerations

Select the desired location for the Spaside control.

Spaside Control • Cut out a hole 2 5/8” X 6 3/8”. • Clean the area and insert Spaside control and cable. • Turn the lock tab screws on the face of the spaside control clockwise to engage locks. • If there is poor access, it is recommended to use a silicone sealant instead of the supplied

support tabs. Leave approximately 12 inches of cable to facilitate removal. • After Spaside installation is complete, connect spaside cable to the system circuit board.

Spaside Overlay Installation Tools Required: Paper Towels, rubbing alcohol and heat gun (or blow dryer) • The first step is to peel off the plastic film that protects the LCD window. Save the film for

reuse. • Clean the surface with an alcohol saturated paper towel. • Peel off the protective paper from the overlay. • Gently heat the back of the overlay with the heat gun (or blow dryer). • Heat the surface of the keypad. • Place the overlay on the keypad starting with one side. Make sure the overlay is well aligned

and rests perfectly on the recess of the keypad. Insure that the overlay is properly glued by pressing your finger over the entire surface.

In-House Control • Select the location in which to install the control. The control can be installed up to 300 feet

away from the Equipment System inside the home or pool cabin. • Using the back plate as a template, mark the openings with a pencil. • Make the rectangular opening in the wall as large as the opening in the back plate. For

plaster walls, drill two ¼” holes and insert plastic anchors for the mounting screws. • Install the back plate onto the wall and run the connecting cable. • Connect the cable, making sure to follow the color code, and snap the control into

place.

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Ultimate Series Installation Special Considerations Auxiliary Control

• Drill two 1” (25.4mm) diameter holes, 2 5/8” (66mm) apart. Cut the material between the two

holes. • Clean the area and insert auxiliary control panel and cable. Secure using the mounting plate

provided. If utilizing rectangular control, peel off protective paper and secure to mounting surface.

• Select a location for the sensor and drill a 7/8” diameter hole in the edge of the spa above the water level.

The Hand Held remote control has an effective range of 15 feet. It must be pointed in the direction of infrared sensor. It should be installed on the interior wall of the spa above the water level at a location easily reached by the infrared beam.

• Apply silicone around the hole and insert the sensor and tighten the nut securely. • Wipe off any excess silicone. Connect the infrared cable to the system circuit board.

Infrared Sensor

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