STEAMPRO Steam Generator Troubleshooting and Service Guide
TABLE OF CONTENTS Page PREFACE... 1 I. STEAMPRO STEAM GENERATOR SYSTEM...2 II. PLUMBING AND ELECTRICAL...3-4 III. SYSTEM OVERVIEW... 5-10 IV. CONTROL SYSTEM CHECKS... 11-14 1. Tank Fill Solenoid Valve...11 2. Water Level Sensor... 11 3. Optional Steam Control Devices...12 4. Heater Relay...12 5. Hi-Limit Switch...13 6. Heating Element...13 7. Automatic Drain Valve (Optional)...14 V. REMOVAL AND REPLACEMENT PROCEDURES A. Tank Fill Solenoid Valve...15 B. Cleaning Filter Screen...15 C. Water Level Sensor...16 D. Heating Element...16 E. Hi- Limit Switch...17 LIST OF FIGURES Figure 1. Plumbing Diagram...3 Figure 2. Wiring Diagram...4 Figure 3. S1 Automatic Drain Timing Switch...6 Figure 4. S2 Temperature Readout Settings...7 Figure 5. Optional Controller Diagrams...8 Figure 6. System Block Diagram...9 Figure 7. Component Diagram...10 Figure 8. Exploded Parts...18
PREFACE This manual is provided to aid the qualified service technician in troubleshooting and servicing the STEAMPRO Steam Generator manufactured by Jacuzzi Whirlpool Bath. Refer to the STEAMPRO Installation and Operating Manual (E596000) for detailed instructions on the installation and operation of system OPTIONS available for this unit. Also available is a STEAMPRO Parts Catalog (G354000) for parts breakdown and corresponding Jacuzzi Whirlpool Bath part numbers. Tools required: Voltmeter Amprobe Ohmmeter Screwdrivers (Phillips head, flat head) Pliers (slip joint, needle nose) 8 pipe wrench Adjustable or open end wrenches System components required: Fill Solenoid Valve (PN: D909000) Automatic Drain Valve (PN: D917000) Hi-Limit Switch (PN: D737000) Heater Element w/hi Limit Assy 4 kw (PN: E516000) 6 kw (PN: E517000) 9 kw (PN: E518000) Heater Relay (PN: D906000) PC Board Assy, Steamer (PN: D742000) PC Board Assy, Accessory (PN: D745000) DANGER: SHOCK HAZARD. DO NOT PROCEED IF UNQUALIFIED IN WORKING WITH HIGH VOLTAGE. STEAM/HOT WATER USE CAUTION. NOTICE: All repairs should be performed by a qualified technician. Proper use of electrical diagnostic tools such as voltage and amperage meters is required. Any consequential damage or injury resulting from the misuse or improper handling of equipment, is not the responsibility of Jacuzzi Whirlpool Bath. Should you have questions regarding the Warranty, or service of this product, please contact our Service Support Department at 1-800-288-4002. 1
I. STEAMPRO STEAM GENERATOR SYSTEM GENERAL DESCRIPTION SteamPro steam generators from Jacuzzi Whirlpool Bath are designed for compact size, easy installation and provide full, high volume steam for luxurious steam bathing. The accessories and control options have been designed for easy plug-in installation and function with all sizes of SteamPro generators. For residential use only. SPECIFICATIONS Dry Weight 24 lb. (10.9 kg) Filled Weight 29 lb. (13.2 kg) AVAILABLE DIMENSIONS Generator Rating Amperage Requirements Size of Enclosure SIZES LxWxH 240 VAC / 208 VAC 240 VAC/208 VAC 240 VAC/208 VAC 4 kw (E204000) 15 _ x 6 x 12 _ 4 kw / 3 kw 30 Amps - 3 Wire 60-100 / 60-80 6 kw (E206000) 6 kw / 4.5 kw 30 Amps - 3 Wire 110-180 / 80-130 9 kw (E209000) 9 kw / 6.8 kw 50 Amps - 3 Wire 180-390 / 130-210 Note: size of enclosure is in cubic feet. 2
FIGURE 2. WIRING DIAGRAM 4
III. SYSTEM OVERVIEW (See System Block Diagram, Fig. 6, Pg. 9). The SteamPro Steam Generator is designed for residential use and is available in three models with a variety of control options. The 4kW, 6kW and 9kW models all share the same control circuits and, except for the element, the same hardware. Models E2040 (4 kw) and E2060 (6 kw) require a 208/240, 3 wire, 30 Amp supply circuit, while the Model E2090 (9 kw) requires a 208/240, 3 wire, 50 Amp supply circuit. Various control packages are available for use with the steam generator (refer to the SteamPro Installation and Operating Manual-Pages 9 through 12 and Page 8 of this document). The available control packages are: A. 30 minute mechanical timer B. 30 minute mechanical timer with optional air switch. C. 30 minute digital timer. D. Digital time and temperature controller package. E. Digital time and temperature controller package with optional secondary digital controller. The functions of the above controller packages are to provide the System Control Board a status signal to start or stop the Steam Generator. This signal is routed through the Steam ON/OFF Control section to supply the Steam Request signal to the Heater Control section and start the operation of the Steam Timer/Sequencer Circuit. Water level in the Stainless Steel Tank is controlled by the Water Level Sensor and Water Fill Control. The Fill Solenoid Valve is turned on and off by the Water Fill Control to reach and maintain the proper water level on the Level Probe. Initial filling of the tank occurs when conditions 1, 2 and 4 listed below are met. The Heater Control Circuit is used to coordinate the operation of the Heating Element Relay in order to heat the tank water for steam generation. To energize the Heating Element, the following four conditions must be met: 1. The Hi-Limit Control output must indicate that the HI-Limit Sensor Switch is closed. 2. Steam ON/OFF Control Circuit must generate a Steam Request signal which is initiated from control package switches being closed. 3. The Water Level Sensor must send a signal indicating the Water Level Probe has sensed a FULL tank condition. 4. A Steamer ON signal must be received from the Steam Timer/Sequencer Circuit to begin a time down sequence. This Steamer ON signal has a duration of 45 minutes. If the Control Package Switch has not opened and canceled the Steam Request signal by this time, the Steamer ON signal will go OFF and the Heater Control Circuit will stop the unit from heating. 5
When all four conditions on Page 5 are met, 208/240 VAC is applied to the coil of the Heater Relay, to energize the relay and allow current to flow through the element coils. Any one of the above four conditions can cancel the Heating Element Relay activation, disconnecting voltage to the Heating Element The Steam Timer/Sequencer Circuit provides timing for the 45 minute Steamer ON signal as described above, and provides the initial timing signal to the Auto Flush Timing Control. If the Digital Controller Package is added to the SteamPro this circuit also interacts with the Accessory Circuit Board to provide system timing functions. Timing for the optional Automatic Drain Valve is controlled by the Auto Flush Timing Control. This control circuit starts a Drain Down timing sequence that activates the Drain Solenoid of the Automatic Drain Valve 2 hours after the Steam Request signal ends. The Drain Solenoid, has 12 VDC on one side of its coil continuously. Once the 2 hour delay has passed, the circuit applies the circuit ground to the coil, completing the coil circuit. The circuit ground is applied to the coil for 20 minutes to open the Drain Valve and allow the tank to empty. After the 20 minutes has elapsed the ground is removed from the solenoid coil, allowing the valve to return to its Normally Closed condition. Note: The S1 Switch located on the board (see Fig. 2, Pg. 4) should be in the On/Off condition shown in the wiring diagram for the proper timing sequence. To TEST the Automatic Drain Valve operation, S1 can be momentarily reversed to an Off/On setting (see Fig. 3). This will allow the Drain Valve to momentarily OPEN and to check on the operation prior to the normal 2 hour delay. 6
The Digital Controller Package addition to the SteamPro requires the installation of the Accessory Circuit Board (refer to Installation and Operating Manual, Pg. 14). This Accessory Board controls the Steam Request signal to the Heater Control and the Steam Timer/Sequencer Circuits of the System Control Board. The status of the Steam Request signal generated for the System Control Board is controlled by a remote Digital Timer and Temperature Controller. In addition to this remote controller a Secondary Digital Controller or Temperature Sensor may be added. If two Digital Timer and Controllers are used, both controllers work in parallel and have identical readings. The controller or Temperature Sensor located inside the Steam Enclosure controls the Steam Request in accordance to the temperature limit set in the Digital Controller. The Steam Request will cycle On/Off with the temperature level set by the controller and will completely turn Off with the completion of the time setting. The Accessory Circuit Board connects to the System Control Board by means of a 6-pin connector that connects to P1 on the Accessory Board and to J1 on the System Control Board. The Primary Digital Timer and Temperature Controller is connected through a 15 pin cable connector into Port # 1, located on the end of the Accessory Circuit Board. This Primary Controller can be located inside or outside of the Steam Enclosure. If located outside of the Enclosure, a Secondary Digital Controller or a Temperature Sensor must be located inside the Steam Enclosure and connected to Port #1 and the outside controller connected to Port #2. Note: Fahrenheit or Centigrade readout on the Digital Controller by setting S2 switch positions: 7
30 MINUTE MECHANICAL TIMER WITH OPTIONAL AIR SWITCH SYSTEM CONTROL BOARD 1 2 3 4 P2 BK BK WT R R 30 MINUTE DIGITAL TIMER 15 PIN CONNECTOR SYSTEM CONTROL BOARD 1 2 3 4 GREEN BLACK ON OFF P2 (G024000) DIGITAL TIME AND TEMPERATURE CONTROLLER ACCESSORY CIRCUIT BOARD (TOP) SYSTEM CONTROL BOARD (BOTTOM) NOTE: Port #1 is primary Port#2 is secondary (See page 14 of Installation and Owners Manual for details) PORTS #1& 2 ACCESSORY CIRCUIT BOARD P1 J1 SYSTEM CONTROL BOARD 15 PIN CONNECTOR CORD STEAMPRO 30 105 POWER FIGURE 5. OPTIONAL CONTROLLER DIAGRAMS 8
FIGURE 6. SYSTEM BLOCK DIAGRAM 9
S1 DIGITAL TIME AND TEMPERATURE ACCESSORY CIRCUIT BOARD S2 HEATER RELAY 208/240V 50/60 HZ COIL 1.16K P1 ACCESSORY PORT #1 AND #2 STEAM GENERATOR CIRCUIT BOARD P5 325 F HI-LIMIT SWITCH S1 J1 FILL SOLENOID VALVE 12 VDC N.C. COIL 11.5 STEAM OUTPUT PRESSURE RELIEF VALVE HEATING ELEMENT 4KW/6KW/9KW USE #18 BARE COPPER WIRE TO SECURE HI-LIMIT TO ELEMENT (3 PLACES). TWIST WIRE MINIMUM THREE FULL TURNS. BEND TWISTS FLAT TO COIL. AUTO DRAIN DOWN SOLENOID VALVE 12 VDC N.C. COIL 10.5 NOTES: SWITCH "S2" ON ACCESSORY BOARD 1,2,3,4,5 "ON" & 6,7,8,9 "OFF" = FAHRENHEIT 6,7,8,9 "ON" & 1,2,3,4,5 "OFF" = CENTIGRADE ON 1 2 SWITCH POSITION "S1" (BOTH BOARDS) FIGURE 7. COMPONENT DIAGRAM 10
IV. CONTROL SYSTEM CHECKS Tank Water Fill Solenoid The Tank Water Fill Solenoid is operated by the SteamPro Circuit Board. The Water Fill Control provides circuit ground to the solenoid coil to open the valve for water input to the tank (Note: 12 VDC remains on one side of the coil). The operation of the valve is controlled by the Water Level and Heater Control Circuits (see Fig. 6, Pg. 9). TROUBLESHOOTING CHART FILL PROBLEM PROBLEM PROBABLE CAUSE REMEDY A. Tank takes too much time to fill. A. Drain valve not closed A. Inspect drain end of drain pipe from drain valve. If water is flowing, close or repair drain valve. (If Auto Valve - see, Pg. 14) B. Debris in filter screen located in inlet of Fill Solenoid Valve. B. Disconnect water supply at inlet to Fill valve and clean screen.(see B, Pg. 15) B. Does not fill at all. A. No power to unit A. Check white and black wire on Heater relay (Fig. 2, Pg. 4) for 208/240 VAC. B Bad Fill Solenoid Note: With power off, check solenoid coil for 11.5 ohms C. Steam Control Switch not on D. No 12 VDC to solenoid and Steam Control Switch OK B. Check the Red and Black wires going to the solenoid (Fig. 2, Pg. 4) for 12 VDC. If 12 VDC is present, replace solenoid valve. C.(See Optional Controls, Pg.12) D. Check connections P2. Replace bottom circuit board (D742000). Water Level Sensor Operation of the Water Level Sensor is controlled by the Water Level Sensor Circuit (see Page 5). The circuit sends an oscillating signal to the center probe contact and receives ground loop Detect signals back from the metal tank. When the water level fills to the proper height on the center probe, the circuit sends a signal to the Fill Control Circuit to turn off the Water Feed Solenoid. TROUBLESHOOTING CHART Water Level Sensor PROBLEM PROBABLE CAUSE REMEDY A. Water Fill Solenoid erratic A. Poor connection on probe or tank. A. Check connections to Probe, Tank and to P5 on board. Note: Eye connector of brown wire should be under fiber insulator for better direct contact to metal disk and the stainless tank. B. Weep holes on Probe housing are not on the opposite side of the Fill Solenoid ( C Fig. 8, Pg. 18). B. Remove three screws at top of Probe housing and remove assy. checking that weep holes are not clogged and face the heater coil side of the tank. C. Scale buildup on probe. C. Replace Probe (E708000). 11
Optional Steam Control Devices The Control Devices A, B and C (listed on page 5) are used to simply close a switch(s) and activate the steam function through the P3 connector. Figure 5 on Page 8, shows the pins used on P3 which can be shorted to initiate the Steam Request signal to the board. Control Devices D and E on Page 5 are to provide the same Steam Request signal, but control the request to a temperature level set by the operator. Temperature sensors used are of the Transistor type and can have a high resistance in the mega-ohm range. They can be checked for a change of resistance with temperature variation. Ohmmeter should be in 20 Meg-Ohm range (note polarity, conducts in one direction). TROUBLESHOOTING CHART PROBLEM PROBABLE CAUSE REMEDY A. Unit does not fill when turned On (A-C). A. Poor connection to P3 A. Check connections. (See Fig. 2, Pg. 4) B. Optional switching device to P3 is bad. B. Jumper white and black wires at P3. Replace switching device if necessary. B. Unit does not fill when turned On (D,E) A. Poor connection from Control Device to Port #1 or Port #2. B. Poor connection from Accessory Circuit Board to Control Circuit Board. C. Board or Controller may be bad. A. Try another Digital Controller. Check 15 pin cable connection. If using two controllers reverse Port #1 and Port #2 connections for test. B. Check connector from Accessory Circuit Board to J1 of Control Circuit C. Disconnect Accessory Board at J1 and jumper pins 3 & 4 of P3. (See Fig. 5, Pg.8). If unit works, either the Controller or Board needs to be replaced. HEATER RELAY Once all of the conditions have been met by the Heater Control Circuit, the Control Board sends voltage to energize the Heater Relay Coil. The coil voltage sent to the Heater Relay is 208/240 VAC. Supply voltage is then applied through the relay to the Heating Element. TROUBLESHOOTING CHART PROBLEM PROBABLE CAUSE REMEDY A. Unit fills but does not produce steam. A. Steamer heating up A. Allow 2-5 minutes for steam to flow. B. Heater Relay Bad (D906000) (See Fig. 7, Pg. 10) Note: If voltage is present at the relay coil and contactors are not down, replace relay. If no voltage is present and Hi- Limit checks OK, replace Control Board. B. With steam time selected and unit filled, Check for 208/240 VAC across Heater Relay Coil (red & black 20ga wires). Then visually inspect the relay to see if the center contactors are pulled down. With power off check coil for 1.1 K Ohms. 12
HI-LIMIT SWITCH Temperature for the tripping of the safety Hi-Limit Switch is 325 f. If the temperature in the stainless tank exceeds this level the switch will open. This switch is self-resetting when the temperature drops significantly below the 325 f level. The switch is normally in the closed position. TROUBLESHOOTING CHART PROBLEM PROBABLE CAUSE REMEDY A. Unit does not fill A. Hi-Limit switch not closed A. Measure continuity of Switch at P1. If open, replace Hi-Limit Switch (D737000). B. Check Control Device or Fill B. See Optional Steam Solenoid. Control Devices, Pg. 12 (A,B). B. Steam generator will fill and produce steam, but will boil water away without refilling and shuts itself off. After unit cools, this symptom repeats. B. There is a high concentration of mineral buildup in the tank water because of continued use without draining the tank. Safety switch will trip until the unit cools down. B. Remove Heating Element and Level Sensor Probe and inspect, clean if necessary. HEATING ELEMENT The Heating Element used in the SteamPro unit is accessible by removing the stainless case surrounding the tank (See Removal D Procedure Page 16). All measurements can be obtained from the Heater Relay. TROUBLESHOOTING CHART PROBLEM PROBABLE CAUSE REMEDY A. Unit fills and Heater Relay contacts are closed with 208/240 VAC present on the two high temperature wires to the Element, but there is still no steam. (See Fig. 2, Pg. 4) A. Open Heating Element A. Clip amprobe around one of the high temp black wires going to element. If there is proper current going to the element, check to insure drain valve is closed. If no current is flowing, disconnect power cord, and measure the Heating Element resistance. B. No current flowing through Heating Element. (Use Amprobe) Caution: No voltage should be present when checking Resistance B. 4 kw Element measurements: 17 Amps and 15 Ohms 6 kw Element measurements: 25 Amps and 10 Ohms 9 kw Element measurements: 38 Amps and 7 Ohms 13
Automatic Drain Valve (Optional) The Optional Automatic Drain Valve is recommended to ensure the tank is emptied each time after use. Connector P6 provides 12 VDC to the coil of the solenoid valve and the ground to the coil is switched ON or OFF by the Control Board Circuitry. The activation of the solenoid valve occurs 2 hours after the end of the Steam Request. Auto Flush Timing Control from the Control Board times the solenoid activation keeping the valve OPEN for 20 minutes. After that time the circuit ground is switched off and the solenoid valve should CLOSE. This valve is Normally Closed (NC). Note: 12 VDC remains on one side of the coil. TROUBLESHOOTING CHART PROBLEM PROBABLE CAUSE REMEDY A. Unit does not drain after 2 hours. B. Putting S1 in the Test mode does not OPEN the valve. A. Bad Auto Drain Solenoid Valve (D917000) (See Fig. 7, Pg. 10) If the valve does not open for a few seconds in Test replace the valve. Note: Make sure that S1 is put back into the Normal switch position B. Solenoid valve or Control Board may be bad. If 12 VDC is not measured out of the board in the Test, replace the Control Board (D742000). A. Start the steam unit and wait until the unit is full. Switch S1 on the Control Board to Test as shown in Fig. 3, Pg. 6. The Auto Drain Valve should momentarily OPEN and start the unit draining. B. Unplug the P6 connector and check valve coil resistance for 10.5 Ohms. If this resistance is OK, try the Test above while metering P6 for the momentary 12 VDC. 14
V. REMOVAL PROCEDURES (Note: power and water must be OFF during these procedures.) A. Tank Fill Solenoid 1. Remove 8 screws securing top cover, and lift it off. 2. Pull off coil wire connectors (red & black). 3. Remove 6 screws from the back side of the unit and 4 bottom screws securing backplate. Take off the back panel and remove the insulation batting. 4. Locate the 1/2 tubing below the Fill Solenoid Valve output and move the spring clamp back that secures the valve. 5. Remove top bracket screws securing the valve to the chassis, and twist the valve out of the 1/2 plastic tubing. 6. Reverse procedures to install Fill Solenoid Valve replacement. B. Cleaning Filter Screen 1. Complete Steps 1 through 5 listed above. 2. Remove the 4 hex bolts securing the brass input nipple to the plastic valve housing. 3. Use needle nose pliers to carefully pull out the metal screen. 4. Clean the screen and replace it back into the valve body. 5. Apply a slight amount of lubricant to the rubber O-Ring and reconnect the input nipple. 15
C. Water Level Sensor 1. Remove 8 screws securing top cover and lift it off. 2. Unplug P5 from the Control Circuit Board. Refer to C in Exploded Parts illustration (Fig. 8, Pg. 18) for assembly details. 3. Through the access hole in the top of the unit, unscrew the three Phillips head screws attaching the Water Level Sensor Probe to the tank. 4. Remove probe from tank housing. Check probe for mineral buildup and clean or replace if necessary. 5. Check orientation of the Probe Dampening Sleeve to ensure the Weep Holes face the Heating Element side of the tank. This will help to keep the wave action in the sleeve to a minimum. 6. Replace the probe or its replacement in reverse order of steps 1-3. Note: The brown wire connection lug should be under the fiber washer and touching the metal ring at the top of the sensor. D. Heating Element 1. Remove top cover and back panel (Procedure A, steps 1 & 2, Page 15). 2. Remove screws securing the stainless enclosure. REMOVE ENCLOSURE 3. Slightly pull out enclosure to expose the Heating Element area, opposite the plumbing end. 4. Disconnect the high temperature wires from the two element post, and the two wires from the Hi-Limit Switch. 5. Remove the 8 screws securing the Heating Element to the stainless steel tank. 6. Pull out the Heating Element Assembly. 7. Inspect the inside of the tank for chemical deposits and clean out the area. 8. Reverse process with new Heating Element making sure not to get any Teflon sealant on the screw threads. Use cross pattern while installing screws for an even seal. 9. Test for leaks. 16
E. Hi-Limit Switch 1. Complete Steps 1 through 7 listed on previous page. 2. Clip the #18 gage copper wire securing the Hi-Limit Thermostat to the heater coil. 3. Unscrew the brass compression fitting sealing the thermostat to the element end plate. 4. Repeat the process in reverse for installing the new Hi-Limit Switch, being careful not to bend the thermostat more than necessary. 5. Reinstall the Heating Element and test for leaks. Note: 1. When ordering a Heating Element be sure to specify the same wattage as the element removed. Hi-Limit Switches are included in Heating Element Assemblies. 17
C P5 Attach brown wire under fiber washer Weep Holes WATER LEVEL PROBE A FILL SOLENOID VALVE Attached to side panel B (To access filter screen, remove 4bolts securing bracket to valve) P1 STAINLESS STEEL TANK HIGH LIMIT D To Heater Relay E HEATING ELEMENT ASSEMBLY FIGURE 8. EXPLODED PARTS 18
PRODUCT SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. USE INSTALLATION INSTRUCTIONS SUPPLIED WITH PRODUCT. Jacuzzi Whirlpool Bath has obtained applicable code (standards) listings generally available on a national basis for products of this type. It is the responsibility of the installer/owner to determine specifc local code compliance prior to installation of the product. Jacuzzi Whirlpool Bath makes no representation or warranty regarding, and will not be responsible for any code compliance. JACUZZI WHIRLPOOL BATH Jacuzzi Whirlpool Bath National Headquarters P.O. Drawer J, Walnut Creek, CA 94596 (510) 938-7070 Service Support: (800) 288-4002 Copyright 1996 Jacuzzi Whirlpool Bath F617000A 4/97 Printed in the U.S.A.