Digital Spa Control System

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Digital Spa Control System
Installation & Service Manual
Version 1.3 • 10/30/2008
Presair Number DSC7001
Presair Number DSC7009 ver.1.0 12/28/2010

© 2007 Presair LLC — All Rights Reserved.
The copyright laws of the United States and other countries specifically protect this material in its entirety. It may not be
reproduced, distributed, or altered in any way without the expressed written consent of Presair, LLC.
Notice
Every effort was made to ensure that the information in this booklet was accurate at the time of printing. However, all
information is subject to change without notice.
Mandatory Customer Information — Federal Communications Commission (FCC) Statement
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee
that interference will not occur in a particular installation.If this equipment does cause harmful interference to radio or
television reception,which can be determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the
equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an
experienced radio/TV technician for help.
Contact Information
To contact us, please refer to the information below:
Presair, LLC
1009 W. Boston Post Road
Mamaroneck, NY 10543, USA
Telephone (USA and Canada): 800-431-2625
Telephone (Outside the USA and Canada):914-698-2026
Facsimile: 914-698-9456
General Information
Email: info@presair.com
Visit us on the Internet
www.presair.com
DISCLAIMER: This booklet describes the Presair Digital Spa Control System and it contains information,
which is reasonable and customary for this type of application. No representations or warranties are
made as to the accuracy or completeness of the information contained in this booklet.
3
Table of Contents
Preface .................................................................................................................................4
Warnings & Safety Tips ........................................................................................................ 4
Tools Required .....................................................................................................................5
Ground Fault Circuit Interrupter (G.F.C.I.) ............................................................................ 6
System Description ...............................................................................................................9
Presair Controller ....................................................................................................... 9
Spa Controller System ............................................................................................. 10
System Details.........................................................................................................10
System Modes ......................................................................................................... 11
Topside Controller Display ....................................................................................... 12
Electrical and Temperature Specifications ............................................................... 13
Installation Instructions .......................................................................................................15
Jumper Settings.......................................................................................................16
Connections Diagrams ............................................................................................. 17
Spa Equipment Wiring .............................................................................................21
Fuses ..................................................................................................................................24
Status & Error Displays ...................................................................................................... 25
Topside Control Panel Check ............................................................................................. 25
Spa Controller Connections Check ..................................................................................... 26
Troubleshooting Flow Charts ..............................................................................................26
Topside Control Has No Power ............................................................................... 26
Pump Not Working ................................................................................................... 27
Aux Not Working ...................................................................................................... 28
Ozonator Not Turning On ......................................................................................... 29
Light Not Turning On ................................................................................................ 30
G.F.C.I. Is Tripping .................................................................................................. 30
Spa Heater Does Not Go On ...................................................................................31
Spa Water Is Not Heating To Set Temperature ....................................................... 31
Overheat Condition .................................................................................................. 32
Spare Parts Kit ...................................................................................................................33
4
Figures
Figure 1 - Presair Model TP400 Topside Controller ............................................................. 9
Figure 2 - Presair Model TP500 Topside Controller ............................................................. 9
Diagrams & Drawings
Connections Diagram CD-1 for 120V (North America) ....................................................... 17
Connections Diagram CD-2 for 240V (North America) ....................................................... 18
Connections Diagram CD-3 for 230V (Europe) .................................................................. 19
Component Installation Drawing ......................................................................................... 23
Tables
Table A - Electrical Specifications (Relay Ratings).............................................................13
Table B - Electrical Specifications (Electrical Outputs) ....................................................... 13
Table C - Temperature Specifications................................................................................ 14
Table D - Controller Designation Per EN 60730-1..............................................................14
Table E - Jumper Settings .................................................................................................. 16
Table F - Spa Equipment Wiring ......................................................................................... 21
Table G - Fuses ..................................................................................................................24
5
Preface
This booklet contains information about the Presair Digital Spa Control System and related
equipment. It is intended for use only by properly licensed and qualified technicians.The
information included is to aid in the proper installation and service of this system.
Warnings & Safety Tips
IMPORTANT GENERAL WARNINGS
This system should be serviced by qualified personnel only.
The system MUST NOT be altered or modified in any way.
Do NOT create any opening in any system component.
Install the system components rigidly on solid surfaces to minimize mechanical
vibrations.
This system is certified as a component only. The finished product, which will
incorporate this system, should be certified by the proper agency as a finished product.
Under no circumstances should the fact that the system is certified as a component be
considered sufficient for the finished product to comply with certification requirements.
The spa or hot tub manufacturer is solely responsible for ensuring that the finished
product complies with all applicable laws and regulations.
Do NOT connect any equipment to this system other than equipment and/or
accessories that are specified or approved by Presair LLC for each output.
This system is provided with a pre-calibrated pressure switch.
IMPORTANT WATER DAMAGE-RELATED WARNINGS
The relay pack is to be installed below the spa skirt. This unit should NOT be washed
down or exposed to water.
Do NOT submerge the temperature probe in water. It is to be installed in a dry-type
thermowell.
IMPORTANT ELECTRICAL WARNINGS
The electrical load for connections to this system MUST NOT exceed the ratings
specified by Presair, LLC. Failure to ensure compliance with proper electrical
specifications may cause hazardous operating conditions and/or decrease the life span
of the control system.
Low voltage or improper wiring may cause damage to this control system. Read and
follow all wiring instructions when connecting the system to a power supply. Failure to
follow the manufacturer’s installation procedures could result in damage to the controls
or cause unsatisfactory performance.
Use proper precautions whenever working on our around breaker boxes, G.F.C.I.s or
service disconnects.
6
IMPORTANT ELECTRICAL WARNINGS (Continued)
This system MUST be protected with a Ground Fault Circuit Interrupter (GFCI) to be
provided by the installer. All connections MUST be made by a licensed electrician in
accordance with the National Electrical Code and any state, province or local electrical
codes in effect at the time of the installation.
If used with 120 Volts, the Relay Pack/Power Control MUST be connected only to a
grounded receptacle.
All supply circuits MUST be disconnected before obtaining access to the Relay
Pack/Power Control terminals. The cover MUST be opened ONLY by a qualified
technician. Do NOT operate the spa when the cover is opened.
Use copper wiring ONLY when installing the system.
The system’s power input cable should always be secured in place with a proper strain
relief.
If a fuse requires replacement, it MUST be replaced ONLY with a fuse of the same
type and rating.
NOTE: DSC with metal enclosure is ETL listed and has been tested to comply with UL
1563 and other related standards. The unit has been tested to EN 60730-1 and EN
60730-2-9 standards and meets CE Mark requirements.
SAFETY TIPS
Keep children and pets away.
Be aware of your surroundings. Working in wet conditions puts you at serious risk of
electrical shock and avoid working in crowded or cramped conditions.
Use the proper tools for the work being performed.
Tools Required
 Digital Multi-meter
 Ammeter
 Wire Cutters
 Straight Slot Screwdriver
# 2 Phillips Screwdriver
 Long-nose Pliers
 3mm Hex Key
 Fuse Puller
 1” Open-end Wrench
 Straight Slot Torque Screwdriver with range of 0-25 in. lbs.
 Padlock to secure electrical disconnect during service
 Digital Thermometer (health care type)
7
Ground Fault Circuit Interrupter
IMPORTANT
As of January 1994, a Ground Fault Circuit Interrupter (G.F.C.I.) is required for all electrical
spa and hot tub installations. The National Electrical Code also states that a service
disconnect must be conveniently located near the spa equipment compartment but a
minimum of 5 feet away. A G.F.C.I. can be used for this purpose.
G.F.C.I. LINE-IN WIRING
Verify that the spa is supplied by a dedicated circuit with no other appliances or devices
connected to it.
Verify that the black and red supply wires feeding the G.F.C.I. are connected to a properly
sized circuit breaker. Also verify that the white wire is connected to the neutral bar and the
green or bare copper wire is connected to the ground bar.
Proper wiring of the G.F.C.I. is essential.Inside the G.F.C.I. enclosure, the black supply wire
should be connected to the LINE-IN #1 terminal and the red supply wire to LINE-IN #2. The
white wire is to be connected to the neutral bar and the green or bare copper wire to the
ground lug inside the G.F.C.I. enclosure.
G.F.C.I. LINE-OUT WIRING FOR 240V 3-WIRE CIRCUIT
A 240V 3-wire circuit may be used for spa installations if the system does not operate any
120V components. Under these circumstances the white load neutral wire is not required.
The black wire of the cable supplying power to the spa controller should be connected to
LOAD-OUT #1, the red wire to LOAD-OUT #2 and the green wire to the ground lug inside the
G.F.C.I. enclosure.
G.F.C.I. LINE-OUT WIRING FOR 120/240V CONVERTIBLE SYSTEM 3/4-WIRE CIRCUIT
If the spa is equipped with a 120/240V control system, a white load neutral wire is required in
addition to other three wires referenced above. The white load neutral wire must be
connected to the LOAD NEUTRAL OUT terminal. Proper installation of the neutral wire is
essential for system operation. If not wired correctly, the G.F.C.I. will trip when a 120V
component is turned on.
8
System Description
PRESAIR CONTROLLER
The information in this booklet applies to the regular Presair Digital Spa Control System
model.
The Presair Model TPW500 Topside Controller is shown in Figure 1. This model features
controls for a light, jets, auxiliary equipment and temperature.
Figure 1 - Presair Model TPW500 Topside Controller

9
SPA CONTROLLER SYSTEM
The Spa Controller system package consists of the following:
 A Topside Controller with push buttons to control devices such as pumps, an air
blower or other auxiliary equipment, a light and a heater. The Topside Controller is
designed for installation on top of the spa or tub. Topside Controller features include:
o Back lighting
o Status indicating LEDs
o Raised nibs for operation by touch
o Up and down buttons to change temperature settings
o Temperature and functionality display
 A Relay Pack/Power Control designed for installation below the spa’s skirt. It includes
the following features:
o 120/240 VAC power input
o Outputs for devices such as pumps, blower, light, ozone and heater
o Signals from sensing switches
o Signals from temperature sensors
o An RJ45 Communication Cable to connect the Topside Controller and the
Relay Pack/Power Control
 Two Temperature Sensors. One is installed in spa water to monitor water temperature
and the second is installed on the heater surface to provide overheat/freeze protection.
SYSTEM DETAILS
The system has been designed to meet the following conditions under all circumstances:
 The heater can only turn ON after the pump has been ON for five seconds and the
flow sensing pressure switch is closed.
 After the heater is shut OFF, the pump MUST continue to run for one minute. Do not
disconnect the main power until this occurs.
 When the water temperature is lower than the set point, the low speed of the jet pump
will automatically turn ON; the pressure switch will close, then the heater will turn ON
after five seconds.
 The ozone generator will turn ON only when the jet pump is running in low speed. The
ozone generator will shut OFF if the jet pump is switched to high speed.
10
SYSTEM MODES
The system has four operational modes as detailed below.
Normal Operation
In normal operation, upon pressing the Jets button, the pump will operate continuously for 30
minutes, it then cycles to go on and off with the heater to maintain the set temperature. To
reactivate the pump for another 30 minutes, press the Jets button again. (Note: The AUX 3
Jumper must be ON for the heater to automatically shut off when the pump is switched to
high speed.) Pump Hi, Aux and light will also timeout 30 minutes after activation. The jet
pump and heater will continue to cycle and maintain the set temperature. The jet pump will
always run for one minute after the heater shuts off.
“If the Pressure Switch does not close when the pump comes on, “FL” will be displayed and
the system will shut off the pump after 5 seconds.It will make four additional attempts,
turning on the low speed pump for 5 seconds every 20 seconds.If the pressure switch does
not close after five attempts, an alarm will sound and the system will not be operational.”
Freeze Protection Mode
When the freeze sensor detects temperature below 45°F (7°C), the unit will go to freeze
protection mode and turn ON the low speed pump followed by the heater. The display will
alternate between the spa temperature and “Fr” at 2 second intervals. The low speed pump
and the heater will stay ON until the water temperature reaches 50°F (10°C).
If the water temperature goes below 36°F (2°C), the low jets pump and the heater will both
shut OFF to protect the spa components and an alarm will sound for approximately five
minutes.A device connected to the AUX output will continue to be operational in this mode.
Overheat Mode & Manual Reset
When the water temperature is higher than 112°F (44°C), the display shows “HI”. The heater
is shut OFF and an alarm begins sounding at fifteen second intervals. When the temperature
falls by 5°F (3°C) to 107°F (41°C) the display stops showing “HI”. Press any button to shut
off the alarm. The heater remains OFF until the temperature goes below its set point. If the
freeze sensor temperature reaches 120°F (49°C), all outputs stay off even if the temperature
falls below the set temperature until a button on topside is pressed (i.e. Manual reset).
However, if the temperature reaches 45°F (7°C), the low speed pump and heater will go on.
Filter Cycle Mode & Purge Cycle
The filter cycle begins when the main power is first applied and after the system self-
diagnostics are completed. The purge cycle goes on for 15 seconds. The filter cycle runs
twice in 24 hours and the cycle time is programmable by the user from 1 - 12 hours.
NOTE: To prevent the start of the initial filter cycle when the system is powered up, press and
hold the pump button while power is being applied.
To put the filter cycle in program mode, push and hold both the temperature UP & DOWN
buttons at the same time for 3 seconds. The display will start flashing the presently
programmed filter time. If no action is taken by pressing the UP or DOWN temperature
11
buttons within 5 seconds, the unit will leave the program mode and revert back to normal run
mode. While in the program mode, the filter time can be increased or decreased by one hour
each time the UP or DOWN button is pushed and stops upon reaching the 1 hour minimum
or the 12 hour maximum limit. Pushing any of the other buttons except the temperature UP &
DOWN will take the unit out of the filter cycle program mode and save the present settings.
The filter cycle is factory set for a 2-hour duration. During the filter cycle “FC” and the water
temperature are alternately displayed on the Topside Controller. Also, the low speed jet pump
and ozone generator are both ON. The user can activate the high speed jet pump at any
time, but the ozone generator will shut OFF. Upon disconnecting power, the filter cycle goes
back to the factory default setting of 2 hours. If a different filter cycle duration is desired,
reprogramming is needed. The program will not take effect until the next filter cycle.
TOPSIDE CONTROLLER DISPLAY
System self-diagnostics run whenever power is applied to the System. The system checks for
the connection to a Topside Controller. If the connection is NOT verified, spa operation is not
possible.
When a Topside Controller is detected at power up, all segments of the Temperature Display
and Status LEDs illuminate for two seconds. The default water temperature setting is 100°F
(38°C). The displayed temperature will be shown in either degrees Fahrenheit or degrees
Celsius. This is determined by the setting of the TemSel jumper setting on the spa controller
circuit board. The temperature shown on the display is the water temperature as measured
from the sensor in the spa.
Table — Status Displays
Display
Er
HI
Lo
FC
FL
FL blinking
Fr
Reason/Description
Topside Controller, OR Control Unit failure, OR Temperature Sensors are NOT connected
Water temperature is greater than 112°F (44.4°C).
Water temperature is less than 45°F (7.2°C).
Filter cycle
Flow Error OR Pressure Switch failure – will make 5 attempts to start pump
Pressure Switch stuck closed
Freeze Mode – indication of very low temperature
12
ELECTRICAL AND TEMPERATURE SPECIFICATIONS
Table A - Electrical Specifications (Relay Ratings)
Component Specifications
Pump Relays 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Blower Relay 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Heater Relay 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Ozone Generator Relay 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Table A and B below. Temperature specifications are detailed in Table C.
The maximum system power input is 120 VAC or 240 VAC, 50Hz/60Hz, 40 Amps
maximum, use # 6 AWG copper wire only.
IMPORTANT: The total current output of all devices combined MUST never
exceed the input rating.
Table A - Electrical Specifications (Relay Ratings)
Component Specifications
Pump Relays 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Blower Relay 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Heater Relay 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Ozone Generator Relay 30 A (maximum) @ 240 VAC Continuous Duty 221°F (105°C)
Table B - Electrical Specifications (Electrical Outputs)
Component Specifications
Pump (HI) 14 A @ 120 VAC and 12 A @ 240 VAC
Pump (LO) 10 A @ 120 VAC and 8 A @ 240 VAC
AUX*
Ozone Generator
Light
Heater**
4 A @ 120 VAC and 4 A @ 240 VAC
3 A @ 120 VAC and 2 A @ 240 VAC
1 A @ 12 VAC
2 KW @ 120 VAC and 4 KW@ 240 VAC
13
*Aux can control a higher current rating such as 10 A @ 120/240 VAC provided the TOTAL
current draw of all devices combined does NOT exceed the maximum 40 AMP rating. The
total input to Pump, Aux and Ozone combined may not exceed 30 amps. Note Ozone is only
ON when the Pump LO is ON.
**The heater wattage can be higher than indicated above (up to 5.5 KW) as long as the total
combined current draw of all devices does NOT exceed the maximum 40 amp rating. For
example, a 5.5 KW @ 240 VAC heater can be used if total current draw of the pump LO, Aux,
light, ozone generator and heater combined is less than 40 amps.
Table C - Temperature Specifications
Display
Temperature Indicating Range
Temperature Setting Range
Factory Set (Default at startup)
Display Accuracy
Temperature Accuracy
Overheat Temperature
Freeze Temperature
Specification/Range
30°F - 130°F (1°C - 55°C )
50°F - 104°F (10°C - 40°C)
100°F (38°C)
±1 Degree
±2°F (±1°C)
112°F (44.5°C)
45°F (7°C)
Table D - Controller Designation Per EN 60730-1
Description Rating
Type of controller Type 1
Type of action A
Rated impulse voltage 1500 V
14
Installation Instructions
STEP 1: INSTALL SPA TOPSIDE CONTROLLER
To mount the topside controller you will need to locate a flat area around the rim of the spa
and cut a hole for the bezel base and cable to fit through.A cutout template is furnished for
your convenience.
Note: Make sure to choose a location that allows the 6’ cable to easily reach the controller
system box.
Once the hole is cut, clean with a 50/50 mixture of isopropyl alcohol and water around the
area so that all dust and contaminates are removed. Peel the paper backing off the bottom
bezel rim exposing the adhesive.Feed the cable through the hole and place bezel over the
hole pressing it firmly and evenly to get good contact.
STEP 2: INSTALL SPA CONTROLLER SYSTEM
1.Find a sturdy location to mount the spa pack.It must be close to the heater so as to
minimize the wire length between the control box and the heater.
2.Disconnect the two screws holding the spa pack cover and pivot it back to open.The
cover can be removed from its hinge, if desired.
3.Determine the type of input power (120/240 VAC US or 230 VAC Europe).
 For input power connection details, see Step 3. Also refer to the attached applicable
Connections Diagram CD-1 (120 VAC), CD-2 (240 VAC) or CD-3 (230 VAC, Europe).
 For setting jumpers inside the spa controller, refer to the Jumper Settings section
below and to the applicable Connections Diagram (CD-1, CD-2 or CD-3) as noted
above.
4.Set jumpers J12, J19, J22 and J26.
 For 120/240 VAC US operation (default) - Jumpers are connected J12 to J26 and J19
to J22.
 For 230 VAC Europe, only one jumper is needed, connected from J12 to J19.
 If power to the relay pack is 240 VAC, use only a 240 VAC heater.For 120 VAC input,
the heater must be 120 VAC.
 The Pump, Ozone and Aux/Blower can each be jumpered as needed to operate on
120/240 or 240 VAC, depending on their requirements, when the input is 240 VAC.
15
JUMPER SETTINGS
Make sure all jumpers are set properly as indicated in Table E below.Also refer to the
applicable Connections Diagram (CD-1, CD-2 or CD-3).
Table E – Jumper Settings
Configuration Setting
HEATER
120 VAC or 230 VAC Europe J15 to J7
240 VAC No Jumper
PUMP
120 VAC or 230 VAC Europe J18 to J5
240 VAC J18 to J17
AUX
120VAC or 230 VAC Europe J20 to J6
240 VAC J20 to J16
OZONE
120 VAC or 230 VAC Europe J21 to J8
240 VAC J21 to J14
AUX 3
Heater shuts off when HI pump is on. Jumper ON
Heater stays ON when LO or HI pump is ON.Jumper OFF
TempSel
Temperature is displayed in
0
F Jumper ON
Temperature is displayed in 0C Jumper OFF
16
17
18
19
20
SPA EQUIPMENT WIRING
Route and connect spa equipment to the controller.Power cables for these components are
not included with the spa controller. Table F below specifies the pin configuration and wiring
requirements for each output.
Table F – Spa Equipment Wiring
120VAC/240VAC 230VAC EUROPE
PUMP
1 2 3 4 1 2 3 4
Hi Low Neutral Ground Hi Low Neutral Ground
Red Black White Green Black Brown Blue Gr/Ylw
1 2 3 4 1 2 3 4
OZONE
Output Neutral Ground Output Neutral Ground
Black White Green Brown Blue Gr/Ylw
1 2 3 4 1 2 3 4
AUX
Output Neutral Ground Output Neutral Ground
Black White Green Brown Blue Gr/Ylw
1 2 1 2
LIGHT
Output Neutral Output Neutral
Black White Brown Blue
The PUMP, OZONE and AUX outputs require the following connector:
Housing:AMP part number 350779-1 or equivalent Pins:AMP part number 350547-1
The LIGHT output uses the following connector:
Housing:AMP part number 350777-1 or equivalent Pins:AMP part number 350547-1
HEATER
Connect the black and white heater wires to the spa controller circuit board terminals J30 and
J31.Connect the green heater wire to the grounding plate.
FLOW SENSOR/PRESSURE SWITCH
Refer to Fig. 1 on the Component Installation Drawing.
1.If not already present, apply Teflon tape to the threaded fitting on the flow sensor/pressure
switch.
2.Screw the flow sensor/pressure switch into the threaded port on the heater.
3.Use care when tightening.Use no more than 7-8 in.lbs. of torque.Over-tightening may
result in stripped threads or a cracked housing.
4.Connect the cable provided in the package to the tabs on the flow sensor/pressure switch
and to terminal J1 on the spa controller circuit board.For help in locating terminal J1,
refer to the Connections Diagram.
NOTE:The heater will not turn on unless the Flow Sensor/Pressure Switch is connected and
sufficient water flow is established.
21
THERMOWELL
The thermowell should be located approximately 10” below the normal water level of the spa
when not occupied. Install it on a flat vertical surface in a location which will allow the 60”
sensor cable to reach the connection point on the circuit board inside the spa controller.
1.Drill a 1-1/8” diameter hole in the spa shell for the thermowell.
2.Install the thermowell through the hole with the o-ring on the wet side of the spa.
3.Tighten the plastic nut on the back threads of thermowell to approximately 8 in.lbs.Do
not over tighten as this may crack the thermowell.
TEMPERATURE SENSOR
Refer to Fig. 2 and Fig. 3 on the Component Installation Drawing.
The temperature sensor is the sensor with the larger 3/8” diameter stainless steel probe and
longer cable. The spa temperature sensor is to be installed in a thermowell.
1.Remove the rubber cable grommet on the back of the thermowell and install the sensor
fully into the well so that the stainless steel probe touches the front of the thermowell.
2.Note that the rubber cable grommet has a longitudinal slit. Slide the grommet around the
sensor cable and push it into the back of the thermowell.
3.Connect the temperature sensor cable to terminal J4 on the spa controller circuit board.
For help in locating terminal J4, refer to the Connections Diagram.
4.Completely insulate the thermowell to protect it from exterior temperatures that may cause
faulty readings. Use the following procedure or another similar method for insulating.
I.Slit a disposable foam or paper cup along one side to the bottom center.
II.Fill the cup with spray insulating foam.
III.Slide the sensor cable into the slit and then slide the cup over the thermowell.
IV.Hold or tape the cup in place until the foam sets up.
FREEZE SENSOR
Refer to Fig. 1 and Fig. 2 on the Component Installation Drawing.
The freeze sensor is the sensor with the smaller 1/4” diameter stainless steel probe and
shorter cable.
1.Insert the freeze sensor into the groove located on the heater tube under the clip. Push it
all the way in.
2.Make sure that the sensor is completely covered by the foam gasket under the clip.
3.Connect the freeze sensor cable to terminal J3 on the spa controller circuit board.For
help in locating terminal J3, refer to the Connections Diagram.
TOPSIDE CONTROLLER
Connect the topside controller to the modular jack labeled JP1.
NOTE:The system will not operate if the sensors and topside controller are not connected.
22
23
STEP 3: CONNECT MAIN POWER
You are now ready to connect the main input power to the spa control box. Start by removing
the cap plug on the side of the box; affix a standard 1¼” cable clamp into the hole, then route
main power wires into the box.
For 120 VAC (US) route the white neutral wire to the terminal labeled NEUTRAL WHITE, the
black (hot) wire to BLACK (HOT) and the green or bare wire ground wire to the green
grounding screw on the ground buss bar.
For 240 VAC (US) route the white, black & green wires the same as for 120 V, then route the
red (hot) wire to the terminal labeled RED (HOT).
For 230 V (Europe), route the blue neutral wire to the terminal labeled NEUTRAL WHITE, the
brown (hot) wire to the terminal labeled BLACK (HOT) and the green wire with a yellow stripe
to the grounding buss bar.
Make sure that all wires and cables are routed away from sharp edges or moving objects and
are tightly secured to prevent any damage from occurring over time.
Once all connections and settings have been established replace the lid and tightly secure
with the screws removed earlier.
Fuses
Refer to Table G below for a list of the fuses located on the spa controller circuit board.For
help in locating fuses, refer to the Connections Diagram.
Table G - Fuses
FUSE CIRCUIT SERIES/TYPE RATING
F1 DC Power In 312/3AG 2A/250VAC
F2 Transformer Power In 312/3AG 300mA/250VAC
F3 Heater 314/3AB 30A/250VAC
F4 Pump, Aux & Ozone 314/3AB 30A/250VAC
F5 Spa Light 312/3AG 3A/250VAC
24
Status & Error Displays
The Topside Controller temperature display is also used to alert the user to the system
operating status. The system may operate with reduced functionality whenever status
displays are shown. Explanations for each of the various displays are listed below.
“Er” Display:System error. When indicated, spa operation is not possible.
Possible Causes: • Unplugged sensor
• Cut or damaged controller or sensor cables
• Loose, dirty or corroded cable connectors
• Topside controller, spa controller or sensor failure
“HI” Display: Water temperature is greater than 112°F (44.4°C).
Possible Causes: • Slice/ball valves are not fully open
• Poor cabinet ventilation
• Temperature sensor is not properly insulated
“Lo” Display:Water temperature is less than 45°F (7.2°C).
Possible Causes: • Spa has just been refilled with cold water (normal condition).
• Pump, heater or sensor failure
“FL” Display:A flow error or pressure switch failure has been detected.
Possible Causes: • Flow sensor/pressure switch failure
• Flow sensor/pressure switch improperly calibrated
• Air lock in heater tube
• Cut or damaged sensor cable
• Loose, dirty or corroded cable connectors
• Suction fittings, filter or skimmer are dirty or blocked
• Slice/ball valves are not fully open
“FL” Blinking:The pressure switch is stuck closed
“FC” Display:The system is currently in Filter Cycle Mode (normal condition).
“Fr” Display:The system is currently in Freeze Protection Mode.
Topside Control Panel Check
A Topside Controller that is not functioning properly may exhibit the following symptoms:
 Blank or partially blank display
 Non-functional buttons
 Non-functional indicator lights
Possible Causes:Cut or damaged topside controller cable
Loose, dirty or corroded cable connectors
Blown fuse on spa controller circuit board
Topside controller or spa controller failure
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Spa Controller Connections Check
If Spa Controller functional problems are encountered, a check of all wiring connections and
fuses should be a part of your initial troubleshooting procedures.Always consider and check
the following:
 Loose, dirty, corroded or burnt wire terminals
 Improperly inserted pins on component power cable plugs
 Missing or blown fuses
 Missing or incorrectly positioned jumpers or jumper wires
Troubleshooting Flow Charts
TOPSIDE CONTROL HAS NO POWER
Restore power. Problem solved?
Yes
Yes
No
No
Is the cable from the topside control panel
plugged in to JP1 on the circuit board?
Replace the topside panel.
No
Yes
Replace the topside panel. Problem solved?
Restore connection. Problem solved?
Yes
Yes
No
No
Is the cable from the topside control panel
cut or damaged?
Did you check for power at the main power
input terminals J23 and fuses F1 and F2?
Yes
Replace control system.
No
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PUMP NOT WORKING
Replace control system.
Yes
No
Replace pump.
Did you check for power at Fuse F4?
Check/replace fuse. Problem solved?
Yes
Yes
No
No
Have you checked the pump power cable
and the plug on the end of it?
Replace topside panel. Problem solved?
Yes
Yes
No
No
First check for proper voltage on pins 1 & 3
for high speed and pins 2 & 3 for low speed
at J25 then connect an identical pump.
Does it work?
Repair or replace. Problem solved?
Yes
Yes
No
No
Does the “JETS” indicator illuminate when
the button is pressed on the topside control?
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AUX NOT WORKING
Replace control system.
Yes
No
Replace the AUX component.
Did you check for power at Fuse F4?
Check/replace fuse. Problem solved?
Yes
Yes
No
No
Have you checked the AUX component
power cable and the plug on the end of it?
Replace topside panel. Problem solved?
Yes
Yes
No
No
First check for proper voltage on pins 1 &3 at
J28 then connect an identical AUX
component. Does it work?
Repair or replace. Problem solved?
Yes
Yes
No
No
Does the “AUX” indicator illuminate when the
button is pressed on the topside control?
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OZONATOR NOT TURNING ON
Replace control system.
Yes
No
Replace the ozonator.
Did you check for power at Fuse F4?
Check/replace fuse. Problem solved?
Yes
Yes
No
No
Have you checked the ozonator power cable
and the plug on the end of it?
Check for proper voltage. Problemsolved?
Yes
Yes
No
No
Connect an identical ozonator to J29.Does
it work?
Repair or replace. Problem solved?
Yes
Yes
No
No
Did you check for power on pins 1 & 3 at J29
when the pump was running in low speed?
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LIGHT NOT TURNING ON
G.F.C.I. IS TRIPPING
Have you replaced the light bulb?
Replace bulb. Problem solved?
Yes
Yes
No
No
Have you checked the spa light power cable
and the connectors on each end?
Replace topside panel. Problem solved?
Yes
Yes
No
No
Replace control system.
Repair or replace. Problem solved?
Yes
Yes
No
No
Does the “LIGHT” indicator illuminate when
the button is pressed on the topside control?
Check/replace fuse. Problem solved?
Yes
No
No
Did you check for power at fuse F5?
Yes
Unplug all spa components. Is the G.F.C.I.
still tripping?
Replace the G.F.C.I. Problem solved?
Yes
No
Yes
No
Replace control system.
Is the G.F.C.I. properly wired?
Review the wiring instructions and rewire the
G.F.C.I. properly. Problem solved?
Yes
Yes
No
No
Reconnect each spa component until the
G.F.C.I. trips then replace that component.
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SPA HEATER DOES NOT GO ON
Did you check for an error condition on the
topside control panel?
Correct error condition. Problem solved?
Yes
Yes
No
No
Have you checked that the control setting is
higher than the actual water temperature?
Replace heater.
No
Yes
Replace control system.
Adjust temperature setting. Problem solved?
Yes
Yes
No
No
Is there power at J30 when the pump is
running in low speed?
SPA WATER IS NOT HEATING TO SET TEMPERATURE
Did you check for an error condition on the
topside control panel?
Correct error condition. Problem solved?
Yes
Yes
No
No
Is the temperature probe full inserted in the
thermowell and is it properly insulated?
Properly position and insulate the
temperature probe. Problem solved?
Yes
Yes
No
No
Replace the temperature sensor.
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OVERHEAT CONDITION
Is the actual spa water temperature over
112°F (44°C)?
Insure proper cabinet ventilation. Problem
solved?
Yes
No
Yes
No
Pump is overheating the water during the
filter cycle. Reduce cycle duration.
Replace control system.
No
Yes
Is the outdoor air temperature extremely
high?
Remove the spa cover to prevent
overheating. Problem solved?
Yes
No
Yes
No
Is the temperature probe full inserted in the
thermowell and is it properly insulated?
Properly position and insulate the
temperature probe. Problem solved?
Yes
Yes
No
No
Replace the temperature sensor. Problem
solved?
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Spare Parts Kit
Keep the following list of spare parts on hand to insure your ability to properly troubleshoot
and repair abnormal spa conditions:
 Topside Control Panel
 Spa Heater Assembly
 Temperature Sensor
 Freeze Sensor
 Flow Sensor/Pressure Switch
 Flow Sensor Wire Assembly
 Spa Light Bulb
 Fuses – Type 312/3AG – 300mA, 2A and 3A
 Fuses – Type 314/3AB – 30A
For updates and additional information, visit our website at www.presair.com
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