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HS-V6510 SERIES


INSTALLATION/OPERATION GUIDE




  http://www.MyPoolSpas.com Pool and Spa Parts
                    Wholesale                    920-925-3094
CONTENTS
Important Safety Instructions· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 2–3

INSTALLATION
Electrical· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 4
Temp Sensor Mounting· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 5
Sensor Placement at Circuit Board Connection · ·  ·  ·  ·  ·  ·  ·  ·  · 5–6
Equipment Connections · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 6–7
Wet Connections · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 7
Spa Light · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 7
Pressure Switch· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 7
Optional Equipment
Versi-Heat Heater · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 8
Circulation Pump - Installation Guide· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 8
Cord Adapter Kit· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 8
Less Heater Cord Connections· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 9

LOW LEVEL PROGRAMMING · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 10

SPASIDE CONTROL OPERATION· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 11

PROGRAMMING FILTRATION· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 12

OPERATIONAL CONSIDERATIONS
Warm Weather Conditions · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·                          12
Filtration System · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·           13
Winterizing· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·   13
Chemical Water Treatment· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·                          13

TROUBLESHOOTING · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 13–15

ERROR INDICATION·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 15–16
                 ·

SYSTEM DATA LABEL· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17

WARRANTY INFORMATION · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 17

PARTS LIST· ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 18

TOPSIDE MOUNTING TEMPLATE · ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  ·  · 19


                                  Wholesale  1
                http://www.MyPoolSpas.com Pool and Spa Parts                                                920-925-3094
IMPORTANT SAFETY INSTRUCTIONS
              READ AND FOLLOW ALL INSTRUCTIONS
DANGER To reduce the risk of injury, do not permit children to use this product unless
   they are closely supervised at all times.

WARNING - RISK OF CHILD DROWNING. Extreme caution must be exercised to prevent
   unauthorized access by children. To avoid accents, ensure that children cannot use a
   spa or hot tub unless they are supervised at all times.

DANGER To reduce the risk of injury to persons, do not remove suction fitting covers.

Spa location must accommodate sufficient drainage of water around the base of the
     structure, as well as the power source compartment.

Prolonged immersion in water that is warmer than normal body temperature can result
     in a dangerous condition known as HYPERTHERMIA. The causes, symptoms, and
     effects of hyperthermia may be described as follows: several degrees above the
     normal body temperature of 98.6˚F. The symptoms of hyperthermia include dizziness,
     fainting, drowsiness, lethargy, and an increase in the internal temperature 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 spa, (4) physical inability
     to exit spa, (5) fetal damage in pregnant women, (6) unconsciousness resulting in
     danger of drowning. WARNING The use of alcohol, drugs or medication can greatly
     increase the risk of fatal hyperthermia in hot tubs and spas.

DANGER - RISK OF ELECTRICAL SHOCK. Install at least 5 feet (1.5m) from all metal
   surfaces. (A spa may be installed within 5 feet of metal surfaces if each metal surface
   is permanently connected by a solid copper conductor attached to the ground bar
   on the terminal box that is provided for this purpose. Refer to NEC and local codes in
   effect at the time of installation.)

A ground or bonding bar is provided on the control box to permit connection of a solid
     copper bonding conductor between this point and any equipment, metal enclosures
     of electrical equipment, metal water pipe, or conduit within 5 feet (1.5m) of the unit as
     needed to comply with local requirements.

Bond accessible metal to the dedicated connector on the equipment grounding bus,
    bond the equipment ground bus to the local common bonding grid as part of the
    installation in the form of (1) a reinforced concrete slab for support, (2) a ground plate
    provided beneath the hot tub or spa, or (3) a permanent ground connection that is
    acceptable to the local inspection authority.

DANGER RISK OF ELECTRICAL SHOCK. Do not permit any electrical appliance such as
   a light, telephone, radio, or television, within 5 feet (1.5m) of a spa or hot tub.

To reduce the risk of injury:

The water in a spa or hot tub should never exceed 104˚F (40˚C). Water temperatures
    between 100˚F (38˚C) and 104˚F (40˚C) are considered safe for a healthy adult.
    Lower water temperatures are recommended for extended use (exceeding 10-15
    minutes) and for young children.
Excessive water temperatures have a high potential for causing fetal damage during the
    early months of pregnancy. Pregnant or possibly pregnant women should limit spa
    or hot tub water temperatures to 100˚F (38˚C).
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Before entering the spa or hot tub, the user should measure the water temperature with an
     accurate thermometer.

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

Persons suffering from obesity or with a medical history of heart disease, low or high blood
    pressure, circulatory system problems, or diabetes should consult a physician before
    using a spa or hot tub.

Persons using medication should consult a physician before using a spa or hot tub since
    some medication may affect heart rate, blood pressure, and circulation.

            For Units with a GFCI (Ground Fault Circuit Interrupter)
This appliance is provided with a ground-fault-circuit-interrupter located on the control box.
     Before each use and with the unit operating, push the test button. The unit should
     stop operating and the reset button should appear. Push the reset button. The unit
     should now operate normally. If the interrupter does not perform in this manner, a
     ground current is flowing indicating the possibility of electrical shock. Disconnect the
     power, or unplug from receptacle, until the fault has been identified and corrected.

                         For Cord and Plug Connected Units
Connect to a grounded, grounding type receptacle only. NEVER connect the spa to an
    extension cord.

Do not bury the cord.

WARNING To reduce the risk of electrical shock, replace damaged cord immediately.

                           For Permanently Installed Units
A terminal marked “G” or “ground” is provided in the wiring box located inside the
     equipment compartment. To reduce the risk of electric shock, connect the terminal
     or connector to the grounding terminal of your electrical service or supply panel with
     a continuous green insulated copper wire in accordance with National Electric Code
     Table 250-95 and any other local codes in effect at the time of installation.

        For Permanently Installed Units not Provided with an Internal
                          Disconnecting Method
The electrical supply for this product must include a suitably rated switch or circuit breaker
     to open all ungrounded supply conductors to comply with Section 422-30 of the
     National Electric Code, ANSI/NFPA 70 1978. The disconnecting means must be
     readily accessible to the tub occupant but installed at least 5 feet (1.5m) from the tub
     water.

                              For Units with Gas Heaters
WARNING - Do not install indoors. This unit uses a gas heater that requires proper
   ventilation and is intended for outdoor use only.

                        For UL Listed Equipment Assemblies
Install at least 5 feet (1.5m) from tub water using nonmetallic plumbing. If an air blower
     circuit is present, install blower no less than 1 foot (305mm) above the maximum
     water level to prevent water from contacting electrical equipment. Install in
     accordance with blower installation instructions.
To reduce the risk of drowning from hair and body entrapment, install a suction fitting(s) &
     cover(s) with a marked flow rate in gallons-per-minute that equals or exceeds the flow
     rate marked on the equipment assembly.
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INSTALLATION
Horizon Spa & Pool Parts Inc. assumes the person installing this control system is a
qualified Service Professional and is familiar with their local codes and regulations.


                                         Electrical
Use the illustrations and instruction below to connect your input power wiring. Always refer
to the wiring diagram provided with your control (located inside the hinged cover) prior to
connecting any wires.

WARNING - Secure wires as defined by the NEC and in compliance with any local
codes in effect at the time of installation. The system data label contains specific
electrical information required for installation. A wiring diagram is provided
with every system and is located inside the hinged cover of the control system.
The wiring diagram may contain “manufacturers notes” vital to your particular
installation. Typical 120-Volt and 240-Volt installations are depicted below.




                                       120-VOLT ELECTRICAL SERVICE REQUIREMENTS:

                                       Line 1, Neutral and Ground.

                                                                              Using Supplied
                                                                              Jumper,
                                                                              Connect
                                                              P51             between P51
                                                                              and P57.
                                                                  P57




                                       240-VOLT ELECTRICAL
                                       SERVICE REQUIREMENTS:

                                       Line 1, Line 2, Neutral and
                                       Ground.




                                       IMPORTANT: Always refer to the
                                       product data label (located on top of
                                       the control box) for specific electrical
                                       information.
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Temp Sensor Mounting

             1         2                  3                4                     5           6




Refer to the photos above. When installing the supplied temperature sensor drywell in the
wall of the tub, find a location as low as possible and close to a suction fitting. Try to stay
away from fittings returning water back to the tub. Drill a 1-3/16” hole from inside the tub
(1-2), install the supplied gasket onto the drywell and insert into the hole from inside the
tub (3-4), install the fastening nut from outside the tub shell and tighten 1/4 turn past hand
tight (5), and install the temperature sensor into the drywell (6).


A 3/8” drywell (sold separately as a
47-454-1000) can be installed in the
plumbing if necessary. Select an area that
is located within the suction lines between
the body of water and the filtration pump for
the most accurate temperature readings.




                  Sensor Placement at Circuit Board Connection
The diagram below shows the placement of the sensors at the circuit board connection.




                                                           jumpers



                                                                           topside

                   pressure switch


                                                                         temp sensor



                                                               hi-limit sensor




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Attention - Mounting the
temperature sensor at the heater is
not recommended due to the short
cycling caused by the temperature
difference between the body of
water and heater assembly. The
increased number of on/off cycles
will shorten the life of the heater
relays and may void the warranty.




                                   Equipment Connections
Voltage conversion - All equipment circuits in this control
system are convertible from 120v to 240v. There are
two diagrams available for this purpose: the one shown
below and the one displayed on the front cover of the
control box.

Pump 1 is a two-speed pump utilizing the red wire for low
speed and the black wire for high speed.

Pump 2 (Pink), Blower (Violet), and Ozone (Yellow) all
utilize the black wire for L1 voltage and the white wire for
neutral in 120v operation and L2 in 240v operation.



      P5                                                                          P22
      P1
 P4   P6                                                                          P23
 P37 P47                                             P43
                             P56




                                                                 33-0024B-R4
                P7
                                               P55
                P8 P35
                P9 P49
                   P51

                 P17 P53                 P33
                   P18 P36         P46
                   P19 P57
                                                           P12




                                     P15                                          JMP1
                                                                                  JMP2
                                                                                  JMP3




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RED                                          PURPLE
                                     Low Speed                                      Hot

   Pump 1/2-Speed                    High Speed        Air Blower

                                     Common                                         Common
                       PINK                                         YELLOW
                                     Common
                                                                                    Hot
   Pump 2/1-Speed                                       Ozonator
                                     Hot
                                                                                    Common




                              Wet (Plumbing) Connections
The Horizon Series control system can be installed wherever it may be convenient,
however, the Horizon Series control is supplied with a pressure switch. It is only possible
to install the heater on the pressure side of the of the plumbing system. (If you find it
necessary to install the heater on the suction side of the plumbing system, please contact
Horizon Spa & Pool Parts Inc. for further information).


                                           Spa Light
Your control may contain a high intensity,
low voltage light to enhance nighttime
use.

This illustration shows how and where
to find the bulb for replacement. It also
shows the mounted spa light with a
replacement (colored) lens. Colored
lenses will further the enhancement of the
light. Simply snap on or off to change the
mood of your spa.




                                     Pressure Switch
The Horizon Series Control System utilizes a 1.5-psi pressure switch and WILL NOT need
adjustment under normal installation conditions. If the water level is substantially above or
below the equipment, it is possible you will get one of the following error codes, and this
may require adjustment of the pressure switch:

FLC (pressure switch activated): a. Turn power off to your system. b. Use a volt/ohm
meter to check continuity between the two electrical connections on pressure switch (The
switch should read open) c. Utilizing a Torx bit (T-25), rotate the adjustment screw slowly
counter-clockwise until continuity through pressure switch is reading closed. d. Turn power
back on and monitor the topside to confirm that low speed pump comes on and no error
indicator is present. e. Turn pump on and off several times to be sure that the pressure
switch is opening and closing correctly.
FLO (pressure switch not activated): a. First, be sure there is good water flow from the
pump. The issue at this point could simply be a dirty filter or closed or partially closed
valves. b. With the low speed pump running, use a Torx bit (T-25) to rotate the adjustment
screw clockwise until the switch closes. The FLO error should also cease. c. Verify with the
volt/ohm meter that the pressure switch opens when the pump shuts off.

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Optional Equipment
Versi-Heat Heater:
The Versi-Heat Heater is supplied with
a 60” cord which allows for versatile
installations and locations with
multiple angles. BE SURE HEATER IS
INSTALLED ON PRESSURE SIDE OF
PUMP   .


Circulation Pump - Installation Guide:




 Locate Available Knockout       Remove Plastic Cover or        Slide Circ Pump Receptacle
                                   Clip Out Metal Tab                  Along Grooves


  P47                         P16        connect Black wire to P16
                                         with ozone wire

ground

              P54      for 120V connect White wire to P54

                                                                                         green
              P50      for 240V connect White wire to P50                        white
                                                                         black




                                                       move JMP3 to
                                                        position #2


Cord Adapter Kit:
                                         Horizon Series Cord Adapter Kits are available
                                         which allow you to quickly replace a control
                                         system without changing the original cords . These
                                         cord adapters allow you to take a 4-pin amp style
                                         plug from the component and quickly convert it
                                         to the molded lit mini plug for the Horizon Series,
                                         saving you hours of install time. Each HS-V6510
                                         cord adapter kit contains adapters for Pump-
                                         1/2spd (Red), Pump-2/1spd (Pink), Blower (Violet),
                                         and an Ozone Generator (Yellow).

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LH (Less Heater) Cord Connections:

Solid-State Units - Remote Heater Connection Instructions

WARNING - Disconnect all power prior to completing the cord installation. While your
wiring may differ, you must connect each component as shown below.

All existing jumpers and wires must be removed before attempting to connect circuits.

Failure to connect wires exactly as shown will cause an electrical malfunction that will result
in damage to the control and/or heater. This damage will not be covered under warranty.




1    HEATER - POWER CORD
     Note: Heater connection is rated                                                        Hold here
                                                                                             with 1/4"
     for 240VAC / 25Amps maximum.                                                            open end
                                                                                             wrench
                                                                                             while
                                                                                             tightening.
     Securely connect the Black/
     12AWG/ Line 1 wire to one of the
     heater connectors as shown. *

     Securely connect the White/
     12AWG/ Line 2 wire to the second
     heater connectors as shown. *

     Connect the Green/ Ground wire to an existing ground point (such as a metal
     enclosure).
     * Connections must be made without twisting or damaging heater (See heater diagram)

     HIGH-LIMIT SENSOR - CONTROL CORD
2    Secure the High-Limit sensor either in
     an existing location or on the heater
     vessel where elevated water temperature can easily be detected.


     PRESSURE SWITCH - CONTROL CORD
3    Note: Limited energy, No voltage present

     Connect Orange and Yellow
     Pressure Switch wire as shown.
     Ensure pressure switch is adjusted
     properly per information on page 7.



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LOW LEVEL PROGRAMMING
It is possible to change the parameters of the system by positioning specific jumpers
located on the system board (see illustration(s) below).




JUMPER 1 = Current Limiting:
Position 1 - (High Current 240vac): There is
no current restriction. This allows the heater
to operator with the pump in high speed.

Position 2 - (Low Current 120vac): The
system will not turn the heater on when the
pump is in high speed. The heater indicator
will flash on the spaside to tell the user that
there is a call for heat but the heater is not
allowed to start.

JUMPER 2 = Temperature Unit:
Position 1 - Fahrenheit

Position 2 - Celsius

JUMPER 3 = Circulation Pump:
Position 1 - System without a Circ. Pump

Position 2 - System with a Circ. Pump

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SPASIDE CONTROL OPERATION
These instructions apply to the ECO-3 (Large Rectangle, 6-Button panel) only, pictured
below. A mounting template can be found on page 19.

                              component indicators:
                              These triangular shaped indicator lights will illuminate when the
                              circuit of the affected icon is in the “on” status. For a description of
                              the conditions of illumination for each indicator light, please see the
                              icon key descriptions below.




          Pump 1 Key: (If the heater setting has been set above the actual water
          temperature, low speed will activate on its own as the water is heating) Press this
          key once to activate the low speed of the pump; press the key a second time to
          activate speed; press the key a third time to turn the pump off. The red triangle
          shaped indicator in the display window below the Pump 1 icon will illuminate
          while the pump is on. After 20-minutes the pump will shut off automatically
          unless done so manually.

          Pump 2 Key: Press this key to turn Pump 2 on and off. After 20-minutes the
          pump will shut off automatically unless done manually. The red triangle shaped
          indicator in the display window below the Pump 2 icon will illuminate while the
          pump is on.

          Air blower key: Press this key to turn Blower on and off. After 20-minutes the
          blower will shut off automatically unless done manually. The red triangle shaped
          indicator in the display window below the Blower icon will illuminate while the
          blower is on.

          Light key: Press this key to turn the light on and off. After 2-hours the light
          will automatically turn off unless done manually. The red indicator in the display
          window below the Light icon will illuminate while the light is on.

          Temperature set keys: Press (or press & hold) the Up/Down Arrow key to
          increase/decrease the water temperature. The temperature can be adjusted in
          1°F increments from 59°F to 104°F (5°C to 40°C). The triangle shaped Set Point
          indicator will illuminate in the display window when adjusting the temperature
          then revert back to the “current” water temperature display. The triangle shaped
          Heater On indicator will illuminate in the display window while the system is
          heating.

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PROGRAMMING FILTRATION
Programming Filter Cycles: Press & Hold the Pump 1 key to show the current setting.
Use the Up/Down Arrow keys to adjust the value to 1 (once a day), 2 (every 12-hours), or 3
(every 8-hours) starting the time the system is programmed.

Programming Filter Cycle Duration: Press & Hold the Light key to show the current
setting. Use the Up/Down Arrow keys to adjust the value to 60 (1-hour), 120 (2-hours),
180 (3-hours), or 480 (8-hours) per cycle. To start a filter cycle immediately, press & hold
the Light key. If no key is pressed within 5-seconds, the display will revert to the standard
monitoring mode.

* Note: If the spa is being used during the filter cycle, the cycle will be suspended for
a period of 40-minutes or until the spa is no longer in use.




 OPERATIONAL CONSIDERATIONS
The following describes situation you may encounter and situations to be aware of.


                               Warm Weather Conditions
Since your spa will normally be expected to maintain warm to hot water ready for use, a
great deal of attention has been directed to the energy conservation detail of insulation
so as to keep electrical costs down. Energy conservation efficiency may be achieved by
extensive insulation of the skirt, plumbing and spa shell, and in some climates full foam
insulation may have been provided.

This energy conservation feature may cause an inconvenience during warmer times
of the year. During warm periods of the year, the temperature within the equipment
compartment can elevate to a point that the pump will automatically turn off for a short
period of time (15-30 minutes) to allow the pump to cool down before automatically
restarting. This cool down feature will not harm your spa but serves only to protect the
pump from damage and as an indicator that it is too hot. To minimize this occurrence,
refrain from using your Hydrotherapy Jets for prolonged periods of time during warm
seasons.

The jet pump chosen for your spa has been specifically sized for maximum performance
and your Hydrotherapy enjoyment.

It is also important to limit the operation of your air blower to 20 minutes or less so as to
minimize the temperature rise in the equipment area.




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Filtration System
Please refer to your Spa Manufacturer’s owner’s manual regarding the operation,
maintenance, and cleaning of your filtration system.

Dirty or clogged filters can cause flow restriction and you may experience difficulty in
reaching and/or maintaining desired heat levels.


                                        Winterizing
When freezing weather and/or power losses are expected, contact your local spa dealer
for freeze protection or winterizing recommendations for both the spa and the equipment
system. Freeze related damage is not covered by the warranty.


                              Chemical Water Treatment
	    Your dealer is familiar with local water conditions and which chemicals are compatible
with and designed specifically for your spa. This is the best person to advise you on
proper water quality management.
	    The one thing you can do to insure years of trouble free equipment operation is to
maintain proper water chemistry.
	    Two basic goals of the chemical water treatment are sanitizing and balancing the
water.
	    Sanitizing simply means keeping the water free from living microorganisms including
algae, bacteria, and viruses. The current most popular chemicals for sanitizing include
chlorine, bromine, and ozone.
	    Balancing water means establishing a balance among pH, total alkalinity, and total
hardness. Water that is unbalanced can corrode the spa and it’s support equipment or
leave deposits of minerals. Properly balanced water is essential to allow the sanitizing
chemical to work effectively. There are numerous chemical additives to help you in
controlling pH, total hardness, and total alkalinity. NEVER use softened water when filling
your spa. Softened water is extremely corrosive to metal parts of the spa equipment and
may lead to unforeseen failure.
	    Sometimes, despite your most diligent efforts, your water may become too far out of
balance to be managed chemically. At this point it is probably better to drain and clean the
spa and start over with fresh water.
	    Equipment failure caused by improper water chemistry will not be covered under
warranty.




 TROUBLESHOOTING
The following describes situations and possible solutions to common problems you may
encounter as a spa owner.


                                    Nothing Operates
Main Breaker is OFF – Set to on.
Sub-Panel Break is OFF – Set to On.
Power switch is in OFF position – Set to on.
Component(s) are not plugged in – Plug in components.
Power cord not plugged in – Plug in power cord.
Over-Heat Protection is On – Refer to page 16.

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No, Low or Surging Water Flow
Air Lock in Plumbing System – “Bleed” the system
Restricted Flow – Insure that the water shut-off valves are open and that suction fittings are
                    not blocked by debris.
Dirty Filter – Clean or replace filter.
Low Water Level – Increase water level to recommended level.


                           No Low Speed Pump Operation
Low Level Programming Incorrect – Contact your local dealer.
Over-Heat protection On – Refer to page 16.
Pump Not Plugged- In – Plug in the pump.


                             No Jets or Blower Operation
Blower or Pump Not Plugged-In – Plug in the Blower or Pump.
Over-Heat Protection On – Refer to page 16.


                               No Therapy Jet Operation
Water Shut-off Valves are Closed – Open Shut-off valves.
Dirty Filter – Clean or replace filter.
Jets Not Properly Adjusted – Adjust jets.
Diverter Valve Not Properly Adjusted – Adjust diverter valve.
Thermal Overload Tripping – Check for restricted flow of water.
Over-Heat Protection On – Refer to page 16.


                                       Water Leaks
Spa overfilled – Adjust water level.
Too many people in the Spa – Adjust water level.
Drain-Valve left open – Close drain valve.
Couplings or Unions Loose – Tighten or contact your local dealer.
Pump Seal Leaking – Contact your local dealer.
Plumbing Connections Leaking – Contact your local dealer.
Water Leaking from Spa side Control – Contact your local dealer.
Water in Air Blower Plumbing – Contact your local dealer.


                                          No Heat
Temperature Not Set Correctly – Adjust Set Point.
Over-Heat Protection On – Refer to page 16.
Current limiting On – 120V Systems will not heat if High-speed or Blower is on. Contact
                      your Local dealer.
No Power – Reset breaker at service panel.
Low Water Flow – Clean or Replace filter.


                                        High Heat
Temperature Sensor Not in Dry-Well – Place sensor in dry-well.
Temperature Set Too High – Adjust Set Point.
High Ambient Temperature – Remove spa cover.

                            Wholesale 14
          http://www.MyPoolSpas.com Pool and Spa Parts               920-925-3094
GFCI Trips Occasionally
Lightning or Electrical Storm, Power Surge, Extreme Humid Conditions, or Radio
Frequency Interference – Reset GFCI.
NOTE: GFCI must be properly grounded and bonded.


                                   GFCI Trips Immediately
Defective Component – Contact a qualified
service technician for assistance.

If this is a new electrical installation verify
that the electrical service is wired as
described to the right with the neutral wire
from control box attached to the neutral
terminal on the load side of the GFCI
Breaker.




                                      No Light Operation
Light Bulb Defective – Replace bulb or contact your local dealer.
Reflector has fallen off – Replace reflector or contact your local dealer.
Light Not Plugged-In – Plug in the light.



 ERROR INDICATION
To assist the user in identifying problems with the spa, the system will display an error
message. These messages will be helpful when communicating with your local dealer or
qualified technician if a problem should arise.

                 Pressure or Flow Switch Activated – The flow or pressure switch
                 is sensing water pressure or flow while the pump is not running. To clear
                 the error, try cycling the pump through low and high speeds. If this error
                 does not clear when the pump is off......

                 Contact your local spa dealer


                 Pressure or Flow switch Not Activated – The flow or pressure
                 switch is not sensing water pressure or flow while the pump is running. To
                 clear the error, try cycling the pump through low and high speeds. If this
                 does not clear the error, the spa filter may be dirty, possibly obstructing
                 water flow. If, after cleaning the filter, cycling the pump through low and
                 high speeds does not clear the error....

                 Contact your local spa dealer

                             Wholesale 15
           http://www.MyPoolSpas.com Pool and Spa Parts              920-925-3094
Temperature sensor malfunction – This error will occur when
    a problem with the temperature sensor exists. This error may also occur if
    the system is activated while the water temperature is below 35°F. The best
    thing to do when this error occurs is to....

    Contact your local spa dealer



    Overheat or High-Limit Protection – There are three (3) stages of
    over heat:

    1 – The spa water has exceeded 112°F. The heater, pump and accessory
    will be deactivated until the water cools to 109°F. Be sure to check the
    actual temperature with an accurate thermometer.

    2 – The spa water has exceeded 119°F. The heater will deactivate while
    the pump and accessory will still operate. The air blower (if equipped) can
    be activated to help cool the water. WATER MUST BE BELOW 119°F AND
    POWER MUST BE RESET TO CLEAR THE “HL ERROR     ”

    A dirty spa filter can also cause restricted flow of water, so be sure the filter
    is cleaned regularly and ensure that all water shutoff valves are open.

    If the system has been operating normally until now, the pump may be
    overheating the spa. Refer to “Programming Filtration” on Page 12 and
    reduce the duration and/or number of cycles per day.

    3 – If you’ve eliminated items 1&2 as problems, the high limit sensor may
    have malfunctioned If this is the case, ...

    Contact your local spa dealer



    Freeze Protection – There are two (2) levels of freeze protection
    integrated into the system.

    1 – SMART WINTER MODE, this mode will activate anytime the water
    temperature falls below 59°F. This mode will be active for a period of 24
    hours. In this mode, if a pump has not been activated in the last 2 hours,
    the system will automatically turn it on for one (1) minute to prevent
    freezing. The “Filter Cycle” indicator will illuminate while the mode is active.

    2 – If the spa water temperature drops below 49°F, the heater & pump
    will be activated until the water temperature reaches 50°F. While freeze
    protection is active no other functions will be possible.




                  Wholesale 16
http://www.MyPoolSpas.com Pool and Spa Parts                920-925-3094
SYSTEM DATA LABEL
The system data label is located on the control box. This label is very important and
contains information you will need to establish your electrical service. The voltage and
amperage ratings are shown on the bottom of the label. Product, Model, Serial and Code
numbers are also shown on the label.

Note: This information will be necessary if you should ever have to request warranty or any
      other type of service.




    w w w.ho riz o npar t s.net                                  HS-V65xx

                                                                HOR03-xxxx-
                                                                120     240
                                                                16      40/48
                                                                HQ-6000
        HS-V6510-HC-LH01000                                     1 PHASE - 60Hz
    Refer to NEC for Breaker Sizing




 WARRANTY INFORMATION
To all original purchasers, Horizon Spa & Pool Parts Inc., as a distribution partner of
HydroQuip, warrants this product to be free from defects in material and workmanship for
a period of 3 years from the date of purchase.

Horizon Spa & Pool Parts Inc. will repair or replace a defective part, at our discretion.

This warranty excludes damage as a result of: normal wear, freezing, low voltage, chemical
abuse, accident, negligence, alteration, improper installation, use or care.

To obtain warranty service, contact your installing dealer within the warranty period and
have them return the defective equipment or parts to Horizon Spa & Pool Parts Inc.

The Horizon Series Limited Warranty is for service on the control box only. Purchaser is
responsible for removal or reinstallation labor, freight charges, or any other such costs
incurred in obtaining warranty service.

Horizon Spa & Pool Parts Inc. assumes no responsibility for incidental or consequential
damages. Some states do not allow the exclusion of incidental or consequential damages,
so the above limitations and exclusions may not apply to you. This warranty gives you
specific legal rights and you may also have other rights, which vary from state to state.

If you are the end user for this control system, the spa dealer may provide a different
warranty; contact your spa dealer for details and warranty information.



                            Wholesale 17
          http://www.MyPoolSpas.com Pool and Spa Parts                920-925-3094
PARTS LIST
Part Number   Description                    Control System
59-355-1098   Primary Circuit Board          HS-V6510 Series (ALL)
59-355-1020   Temperature Sensor, 10ft       HS-V6501-V6510 Series (ALL)
59-355-1025   Hi Limit Sensor, 14”           HS-V6501-V6510 Series
59-355-1026   Hi Limit Sensor, 76”           HS-V6501-V6510 Series -VH & -LH
59-355-1028   Pressure Switch Harness        ALL
47-439-1295   Pressure Switch                ALL
47-555-2070   Heating Element, 5.5kW, 240v   ALL
60-555-1155   Fuse 20A SLO BLOW Fuse         HS-V6501-V6510 Series
60-555-1157   Fuse 25A SLO BLOW Fuse         HS-V6501-V6510 Series
60-555-1187   Fuse, System, 750mA            HS-V6501-V6510 Series
60-555-1185   Fuse, Light, 2Amp              HS-V6501-V6510 Series
60-240-1020   High Current GFCI              ALL -HC
60-355-1000   Terminal Block                 HS-V6500 Series
60-240-1022   40A Contractor                 HS-V6500 Series -HC
57-315-1000   Light Bulb, 12v, Incadescent   ALL




                         Wholesale 18
       http://www.MyPoolSpas.com Pool and Spa Parts      920-925-3094
TOPSIDE MOUNTING
                                                   IMPORTANT - The
                                                   template on this
                                                   page is to be used
                                                   with HT-2, ECO-3, 7
                                                   & 8 series controls
                                                   ONLY. Refer to the
                                                   “Installation Manual”
                                                   for installation
                                                   details.




                                          6 3/8”




            2 5/8”
                     Wholesale 19
   http://www.MyPoolSpas.com Pool and Spa Parts   920-925-3094
NOTES




                    Wholesale 20
  http://www.MyPoolSpas.com Pool and Spa Parts   920-925-3094
NOTES




                    Wholesale 21
  http://www.MyPoolSpas.com Pool and Spa Parts   920-925-3094
NOTES




                    Wholesale 22
  http://www.MyPoolSpas.com Pool and Spa Parts   920-925-3094
07/08	                                                                 Rev. 1
         http://www.MyPoolSpas.com Pool and Spa Parts
                           Wholesale                    920-925-3094

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Hs v6510 manual-rev1

  • 1. HS-V6510 SERIES INSTALLATION/OPERATION GUIDE http://www.MyPoolSpas.com Pool and Spa Parts Wholesale 920-925-3094
  • 2. CONTENTS Important Safety Instructions· · · · · · · · · · · · · · · · · · · · · · · · 2–3 INSTALLATION Electrical· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4 Temp Sensor Mounting· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5 Sensor Placement at Circuit Board Connection · · · · · · · · · · 5–6 Equipment Connections · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6–7 Wet Connections · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7 Spa Light · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7 Pressure Switch· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7 Optional Equipment Versi-Heat Heater · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8 Circulation Pump - Installation Guide· · · · · · · · · · · · · · · · · · · · · · · 8 Cord Adapter Kit· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8 Less Heater Cord Connections· · · · · · · · · · · · · · · · · · · · · · · · · · · 9 LOW LEVEL PROGRAMMING · · · · · · · · · · · · · · · · · · · · · · · · · · 10 SPASIDE CONTROL OPERATION· · · · · · · · · · · · · · · · · · · · · · · · 11 PROGRAMMING FILTRATION· · · · · · · · · · · · · · · · · · · · · · · · · · 12 OPERATIONAL CONSIDERATIONS Warm Weather Conditions · · · · · · · · · · · · · · · · · · · · · · · · · · · 12 Filtration System · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13 Winterizing· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13 Chemical Water Treatment· · · · · · · · · · · · · · · · · · · · · · · · · · · 13 TROUBLESHOOTING · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13–15 ERROR INDICATION· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15–16 · SYSTEM DATA LABEL· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17 WARRANTY INFORMATION · · · · · · · · · · · · · · · · · · · · · · · · · · · 17 PARTS LIST· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 18 TOPSIDE MOUNTING TEMPLATE · · · · · · · · · · · · · · · · · · · · · · · 19 Wholesale 1 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 3. IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS DANGER To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times. WARNING - RISK OF CHILD DROWNING. Extreme caution must be exercised to prevent unauthorized access by children. To avoid accents, ensure that children cannot use a spa or hot tub unless they are supervised at all times. DANGER To reduce the risk of injury to persons, do not remove suction fitting covers. Spa location must accommodate sufficient drainage of water around the base of the structure, as well as the power source compartment. Prolonged immersion in water that is warmer than normal body temperature can result in a dangerous condition known as HYPERTHERMIA. The causes, symptoms, and effects of hyperthermia may be described as follows: several degrees above the normal body temperature of 98.6˚F. The symptoms of hyperthermia include dizziness, fainting, drowsiness, lethargy, and an increase in the internal temperature 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 spa, (4) physical inability to exit spa, (5) fetal damage in pregnant women, (6) unconsciousness resulting in danger of drowning. WARNING The use of alcohol, drugs or medication can greatly increase the risk of fatal hyperthermia in hot tubs and spas. DANGER - RISK OF ELECTRICAL SHOCK. Install at least 5 feet (1.5m) from all metal surfaces. (A spa may be installed within 5 feet of metal surfaces if each metal surface is permanently connected by a solid copper conductor attached to the ground bar on the terminal box that is provided for this purpose. Refer to NEC and local codes in effect at the time of installation.) A ground or bonding bar is provided on the control box to permit connection of a solid copper bonding conductor between this point and any equipment, metal enclosures of electrical equipment, metal water pipe, or conduit within 5 feet (1.5m) of the unit as needed to comply with local requirements. Bond accessible metal to the dedicated connector on the equipment grounding bus, bond the equipment ground bus to the local common bonding grid as part of the installation in the form of (1) a reinforced concrete slab for support, (2) a ground plate provided beneath the hot tub or spa, or (3) a permanent ground connection that is acceptable to the local inspection authority. DANGER RISK OF ELECTRICAL SHOCK. Do not permit any electrical appliance such as a light, telephone, radio, or television, within 5 feet (1.5m) of a spa or hot tub. To reduce the risk of injury: The water in a spa or hot tub should never exceed 104˚F (40˚C). Water temperatures between 100˚F (38˚C) and 104˚F (40˚C) are considered safe for a healthy adult. Lower water temperatures are recommended for extended use (exceeding 10-15 minutes) and for young children. Excessive water temperatures have a high potential for causing fetal damage during the early months of pregnancy. Pregnant or possibly pregnant women should limit spa or hot tub water temperatures to 100˚F (38˚C). Wholesale 2 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 4. Before entering the spa or hot tub, the user should measure the water temperature with an accurate thermometer. The use of alcohol, drugs, or medication before or during spa or hot tub use may lead to unconsciousness with the possibility of drowning. Persons suffering from obesity or with a medical history of heart disease, low or high blood pressure, circulatory system problems, or diabetes should consult a physician before using a spa or hot tub. Persons using medication should consult a physician before using a spa or hot tub since some medication may affect heart rate, blood pressure, and circulation. For Units with a GFCI (Ground Fault Circuit Interrupter) This appliance is provided with a ground-fault-circuit-interrupter located on the control box. Before each use and with the unit operating, push the test button. The unit should stop operating and the reset button should appear. Push the reset button. The unit should now operate normally. If the interrupter does not perform in this manner, a ground current is flowing indicating the possibility of electrical shock. Disconnect the power, or unplug from receptacle, until the fault has been identified and corrected. For Cord and Plug Connected Units Connect to a grounded, grounding type receptacle only. NEVER connect the spa to an extension cord. Do not bury the cord. WARNING To reduce the risk of electrical shock, replace damaged cord immediately. For Permanently Installed Units A terminal marked “G” or “ground” is provided in the wiring box located inside the equipment compartment. To reduce the risk of electric shock, connect the terminal or connector to the grounding terminal of your electrical service or supply panel with a continuous green insulated copper wire in accordance with National Electric Code Table 250-95 and any other local codes in effect at the time of installation. For Permanently Installed Units not Provided with an Internal Disconnecting Method The electrical supply for this product must include a suitably rated switch or circuit breaker to open all ungrounded supply conductors to comply with Section 422-30 of the National Electric Code, ANSI/NFPA 70 1978. The disconnecting means must be readily accessible to the tub occupant but installed at least 5 feet (1.5m) from the tub water. For Units with Gas Heaters WARNING - Do not install indoors. This unit uses a gas heater that requires proper ventilation and is intended for outdoor use only. For UL Listed Equipment Assemblies Install at least 5 feet (1.5m) from tub water using nonmetallic plumbing. If an air blower circuit is present, install blower no less than 1 foot (305mm) above the maximum water level to prevent water from contacting electrical equipment. Install in accordance with blower installation instructions. To reduce the risk of drowning from hair and body entrapment, install a suction fitting(s) & cover(s) with a marked flow rate in gallons-per-minute that equals or exceeds the flow rate marked on the equipment assembly. Wholesale 3 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 5. INSTALLATION Horizon Spa & Pool Parts Inc. assumes the person installing this control system is a qualified Service Professional and is familiar with their local codes and regulations. Electrical Use the illustrations and instruction below to connect your input power wiring. Always refer to the wiring diagram provided with your control (located inside the hinged cover) prior to connecting any wires. WARNING - Secure wires as defined by the NEC and in compliance with any local codes in effect at the time of installation. The system data label contains specific electrical information required for installation. A wiring diagram is provided with every system and is located inside the hinged cover of the control system. The wiring diagram may contain “manufacturers notes” vital to your particular installation. Typical 120-Volt and 240-Volt installations are depicted below. 120-VOLT ELECTRICAL SERVICE REQUIREMENTS: Line 1, Neutral and Ground. Using Supplied Jumper, Connect P51 between P51 and P57. P57 240-VOLT ELECTRICAL SERVICE REQUIREMENTS: Line 1, Line 2, Neutral and Ground. IMPORTANT: Always refer to the product data label (located on top of the control box) for specific electrical information. Wholesale 4 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 6. Temp Sensor Mounting 1 2 3 4 5 6 Refer to the photos above. When installing the supplied temperature sensor drywell in the wall of the tub, find a location as low as possible and close to a suction fitting. Try to stay away from fittings returning water back to the tub. Drill a 1-3/16” hole from inside the tub (1-2), install the supplied gasket onto the drywell and insert into the hole from inside the tub (3-4), install the fastening nut from outside the tub shell and tighten 1/4 turn past hand tight (5), and install the temperature sensor into the drywell (6). A 3/8” drywell (sold separately as a 47-454-1000) can be installed in the plumbing if necessary. Select an area that is located within the suction lines between the body of water and the filtration pump for the most accurate temperature readings. Sensor Placement at Circuit Board Connection The diagram below shows the placement of the sensors at the circuit board connection. jumpers topside pressure switch temp sensor hi-limit sensor Wholesale 5 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 7. Attention - Mounting the temperature sensor at the heater is not recommended due to the short cycling caused by the temperature difference between the body of water and heater assembly. The increased number of on/off cycles will shorten the life of the heater relays and may void the warranty. Equipment Connections Voltage conversion - All equipment circuits in this control system are convertible from 120v to 240v. There are two diagrams available for this purpose: the one shown below and the one displayed on the front cover of the control box. Pump 1 is a two-speed pump utilizing the red wire for low speed and the black wire for high speed. Pump 2 (Pink), Blower (Violet), and Ozone (Yellow) all utilize the black wire for L1 voltage and the white wire for neutral in 120v operation and L2 in 240v operation. P5 P22 P1 P4 P6 P23 P37 P47 P43 P56 33-0024B-R4 P7 P55 P8 P35 P9 P49 P51 P17 P53 P33 P18 P36 P46 P19 P57 P12 P15 JMP1 JMP2 JMP3 Wholesale 6 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 8. RED PURPLE Low Speed Hot Pump 1/2-Speed High Speed Air Blower Common Common PINK YELLOW Common Hot Pump 2/1-Speed Ozonator Hot Common Wet (Plumbing) Connections The Horizon Series control system can be installed wherever it may be convenient, however, the Horizon Series control is supplied with a pressure switch. It is only possible to install the heater on the pressure side of the of the plumbing system. (If you find it necessary to install the heater on the suction side of the plumbing system, please contact Horizon Spa & Pool Parts Inc. for further information). Spa Light Your control may contain a high intensity, low voltage light to enhance nighttime use. This illustration shows how and where to find the bulb for replacement. It also shows the mounted spa light with a replacement (colored) lens. Colored lenses will further the enhancement of the light. Simply snap on or off to change the mood of your spa. Pressure Switch The Horizon Series Control System utilizes a 1.5-psi pressure switch and WILL NOT need adjustment under normal installation conditions. If the water level is substantially above or below the equipment, it is possible you will get one of the following error codes, and this may require adjustment of the pressure switch: FLC (pressure switch activated): a. Turn power off to your system. b. Use a volt/ohm meter to check continuity between the two electrical connections on pressure switch (The switch should read open) c. Utilizing a Torx bit (T-25), rotate the adjustment screw slowly counter-clockwise until continuity through pressure switch is reading closed. d. Turn power back on and monitor the topside to confirm that low speed pump comes on and no error indicator is present. e. Turn pump on and off several times to be sure that the pressure switch is opening and closing correctly. FLO (pressure switch not activated): a. First, be sure there is good water flow from the pump. The issue at this point could simply be a dirty filter or closed or partially closed valves. b. With the low speed pump running, use a Torx bit (T-25) to rotate the adjustment screw clockwise until the switch closes. The FLO error should also cease. c. Verify with the volt/ohm meter that the pressure switch opens when the pump shuts off. Wholesale 7 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 9. Optional Equipment Versi-Heat Heater: The Versi-Heat Heater is supplied with a 60” cord which allows for versatile installations and locations with multiple angles. BE SURE HEATER IS INSTALLED ON PRESSURE SIDE OF PUMP . Circulation Pump - Installation Guide: Locate Available Knockout Remove Plastic Cover or Slide Circ Pump Receptacle Clip Out Metal Tab Along Grooves P47 P16 connect Black wire to P16 with ozone wire ground P54 for 120V connect White wire to P54 green P50 for 240V connect White wire to P50 white black move JMP3 to position #2 Cord Adapter Kit: Horizon Series Cord Adapter Kits are available which allow you to quickly replace a control system without changing the original cords . These cord adapters allow you to take a 4-pin amp style plug from the component and quickly convert it to the molded lit mini plug for the Horizon Series, saving you hours of install time. Each HS-V6510 cord adapter kit contains adapters for Pump- 1/2spd (Red), Pump-2/1spd (Pink), Blower (Violet), and an Ozone Generator (Yellow). Wholesale 8 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 10. LH (Less Heater) Cord Connections: Solid-State Units - Remote Heater Connection Instructions WARNING - Disconnect all power prior to completing the cord installation. While your wiring may differ, you must connect each component as shown below. All existing jumpers and wires must be removed before attempting to connect circuits. Failure to connect wires exactly as shown will cause an electrical malfunction that will result in damage to the control and/or heater. This damage will not be covered under warranty. 1 HEATER - POWER CORD Note: Heater connection is rated Hold here with 1/4" for 240VAC / 25Amps maximum. open end wrench while tightening. Securely connect the Black/ 12AWG/ Line 1 wire to one of the heater connectors as shown. * Securely connect the White/ 12AWG/ Line 2 wire to the second heater connectors as shown. * Connect the Green/ Ground wire to an existing ground point (such as a metal enclosure). * Connections must be made without twisting or damaging heater (See heater diagram) HIGH-LIMIT SENSOR - CONTROL CORD 2 Secure the High-Limit sensor either in an existing location or on the heater vessel where elevated water temperature can easily be detected. PRESSURE SWITCH - CONTROL CORD 3 Note: Limited energy, No voltage present Connect Orange and Yellow Pressure Switch wire as shown. Ensure pressure switch is adjusted properly per information on page 7. Wholesale 9 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 11. LOW LEVEL PROGRAMMING It is possible to change the parameters of the system by positioning specific jumpers located on the system board (see illustration(s) below). JUMPER 1 = Current Limiting: Position 1 - (High Current 240vac): There is no current restriction. This allows the heater to operator with the pump in high speed. Position 2 - (Low Current 120vac): The system will not turn the heater on when the pump is in high speed. The heater indicator will flash on the spaside to tell the user that there is a call for heat but the heater is not allowed to start. JUMPER 2 = Temperature Unit: Position 1 - Fahrenheit Position 2 - Celsius JUMPER 3 = Circulation Pump: Position 1 - System without a Circ. Pump Position 2 - System with a Circ. Pump Wholesale 10 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 12. SPASIDE CONTROL OPERATION These instructions apply to the ECO-3 (Large Rectangle, 6-Button panel) only, pictured below. A mounting template can be found on page 19. component indicators: These triangular shaped indicator lights will illuminate when the circuit of the affected icon is in the “on” status. For a description of the conditions of illumination for each indicator light, please see the icon key descriptions below. Pump 1 Key: (If the heater setting has been set above the actual water temperature, low speed will activate on its own as the water is heating) Press this key once to activate the low speed of the pump; press the key a second time to activate speed; press the key a third time to turn the pump off. The red triangle shaped indicator in the display window below the Pump 1 icon will illuminate while the pump is on. After 20-minutes the pump will shut off automatically unless done so manually. Pump 2 Key: Press this key to turn Pump 2 on and off. After 20-minutes the pump will shut off automatically unless done manually. The red triangle shaped indicator in the display window below the Pump 2 icon will illuminate while the pump is on. Air blower key: Press this key to turn Blower on and off. After 20-minutes the blower will shut off automatically unless done manually. The red triangle shaped indicator in the display window below the Blower icon will illuminate while the blower is on. Light key: Press this key to turn the light on and off. After 2-hours the light will automatically turn off unless done manually. The red indicator in the display window below the Light icon will illuminate while the light is on. Temperature set keys: Press (or press & hold) the Up/Down Arrow key to increase/decrease the water temperature. The temperature can be adjusted in 1°F increments from 59°F to 104°F (5°C to 40°C). The triangle shaped Set Point indicator will illuminate in the display window when adjusting the temperature then revert back to the “current” water temperature display. The triangle shaped Heater On indicator will illuminate in the display window while the system is heating. Wholesale 11 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 13. PROGRAMMING FILTRATION Programming Filter Cycles: Press & Hold the Pump 1 key to show the current setting. Use the Up/Down Arrow keys to adjust the value to 1 (once a day), 2 (every 12-hours), or 3 (every 8-hours) starting the time the system is programmed. Programming Filter Cycle Duration: Press & Hold the Light key to show the current setting. Use the Up/Down Arrow keys to adjust the value to 60 (1-hour), 120 (2-hours), 180 (3-hours), or 480 (8-hours) per cycle. To start a filter cycle immediately, press & hold the Light key. If no key is pressed within 5-seconds, the display will revert to the standard monitoring mode. * Note: If the spa is being used during the filter cycle, the cycle will be suspended for a period of 40-minutes or until the spa is no longer in use. OPERATIONAL CONSIDERATIONS The following describes situation you may encounter and situations to be aware of. Warm Weather Conditions Since your spa will normally be expected to maintain warm to hot water ready for use, a great deal of attention has been directed to the energy conservation detail of insulation so as to keep electrical costs down. Energy conservation efficiency may be achieved by extensive insulation of the skirt, plumbing and spa shell, and in some climates full foam insulation may have been provided. This energy conservation feature may cause an inconvenience during warmer times of the year. During warm periods of the year, the temperature within the equipment compartment can elevate to a point that the pump will automatically turn off for a short period of time (15-30 minutes) to allow the pump to cool down before automatically restarting. This cool down feature will not harm your spa but serves only to protect the pump from damage and as an indicator that it is too hot. To minimize this occurrence, refrain from using your Hydrotherapy Jets for prolonged periods of time during warm seasons. The jet pump chosen for your spa has been specifically sized for maximum performance and your Hydrotherapy enjoyment. It is also important to limit the operation of your air blower to 20 minutes or less so as to minimize the temperature rise in the equipment area. Wholesale 12 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 14. Filtration System Please refer to your Spa Manufacturer’s owner’s manual regarding the operation, maintenance, and cleaning of your filtration system. Dirty or clogged filters can cause flow restriction and you may experience difficulty in reaching and/or maintaining desired heat levels. Winterizing When freezing weather and/or power losses are expected, contact your local spa dealer for freeze protection or winterizing recommendations for both the spa and the equipment system. Freeze related damage is not covered by the warranty. Chemical Water Treatment Your dealer is familiar with local water conditions and which chemicals are compatible with and designed specifically for your spa. This is the best person to advise you on proper water quality management. The one thing you can do to insure years of trouble free equipment operation is to maintain proper water chemistry. Two basic goals of the chemical water treatment are sanitizing and balancing the water. Sanitizing simply means keeping the water free from living microorganisms including algae, bacteria, and viruses. The current most popular chemicals for sanitizing include chlorine, bromine, and ozone. Balancing water means establishing a balance among pH, total alkalinity, and total hardness. Water that is unbalanced can corrode the spa and it’s support equipment or leave deposits of minerals. Properly balanced water is essential to allow the sanitizing chemical to work effectively. There are numerous chemical additives to help you in controlling pH, total hardness, and total alkalinity. NEVER use softened water when filling your spa. Softened water is extremely corrosive to metal parts of the spa equipment and may lead to unforeseen failure. Sometimes, despite your most diligent efforts, your water may become too far out of balance to be managed chemically. At this point it is probably better to drain and clean the spa and start over with fresh water. Equipment failure caused by improper water chemistry will not be covered under warranty. TROUBLESHOOTING The following describes situations and possible solutions to common problems you may encounter as a spa owner. Nothing Operates Main Breaker is OFF – Set to on. Sub-Panel Break is OFF – Set to On. Power switch is in OFF position – Set to on. Component(s) are not plugged in – Plug in components. Power cord not plugged in – Plug in power cord. Over-Heat Protection is On – Refer to page 16. Wholesale 13 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 15. No, Low or Surging Water Flow Air Lock in Plumbing System – “Bleed” the system Restricted Flow – Insure that the water shut-off valves are open and that suction fittings are not blocked by debris. Dirty Filter – Clean or replace filter. Low Water Level – Increase water level to recommended level. No Low Speed Pump Operation Low Level Programming Incorrect – Contact your local dealer. Over-Heat protection On – Refer to page 16. Pump Not Plugged- In – Plug in the pump. No Jets or Blower Operation Blower or Pump Not Plugged-In – Plug in the Blower or Pump. Over-Heat Protection On – Refer to page 16. No Therapy Jet Operation Water Shut-off Valves are Closed – Open Shut-off valves. Dirty Filter – Clean or replace filter. Jets Not Properly Adjusted – Adjust jets. Diverter Valve Not Properly Adjusted – Adjust diverter valve. Thermal Overload Tripping – Check for restricted flow of water. Over-Heat Protection On – Refer to page 16. Water Leaks Spa overfilled – Adjust water level. Too many people in the Spa – Adjust water level. Drain-Valve left open – Close drain valve. Couplings or Unions Loose – Tighten or contact your local dealer. Pump Seal Leaking – Contact your local dealer. Plumbing Connections Leaking – Contact your local dealer. Water Leaking from Spa side Control – Contact your local dealer. Water in Air Blower Plumbing – Contact your local dealer. No Heat Temperature Not Set Correctly – Adjust Set Point. Over-Heat Protection On – Refer to page 16. Current limiting On – 120V Systems will not heat if High-speed or Blower is on. Contact your Local dealer. No Power – Reset breaker at service panel. Low Water Flow – Clean or Replace filter. High Heat Temperature Sensor Not in Dry-Well – Place sensor in dry-well. Temperature Set Too High – Adjust Set Point. High Ambient Temperature – Remove spa cover. Wholesale 14 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 16. GFCI Trips Occasionally Lightning or Electrical Storm, Power Surge, Extreme Humid Conditions, or Radio Frequency Interference – Reset GFCI. NOTE: GFCI must be properly grounded and bonded. GFCI Trips Immediately Defective Component – Contact a qualified service technician for assistance. If this is a new electrical installation verify that the electrical service is wired as described to the right with the neutral wire from control box attached to the neutral terminal on the load side of the GFCI Breaker. No Light Operation Light Bulb Defective – Replace bulb or contact your local dealer. Reflector has fallen off – Replace reflector or contact your local dealer. Light Not Plugged-In – Plug in the light. ERROR INDICATION To assist the user in identifying problems with the spa, the system will display an error message. These messages will be helpful when communicating with your local dealer or qualified technician if a problem should arise. Pressure or Flow Switch Activated – The flow or pressure switch is sensing water pressure or flow while the pump is not running. To clear the error, try cycling the pump through low and high speeds. If this error does not clear when the pump is off...... Contact your local spa dealer Pressure or Flow switch Not Activated – The flow or pressure switch is not sensing water pressure or flow while the pump is running. To clear the error, try cycling the pump through low and high speeds. If this does not clear the error, the spa filter may be dirty, possibly obstructing water flow. If, after cleaning the filter, cycling the pump through low and high speeds does not clear the error.... Contact your local spa dealer Wholesale 15 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 17. Temperature sensor malfunction – This error will occur when a problem with the temperature sensor exists. This error may also occur if the system is activated while the water temperature is below 35°F. The best thing to do when this error occurs is to.... Contact your local spa dealer Overheat or High-Limit Protection – There are three (3) stages of over heat: 1 – The spa water has exceeded 112°F. The heater, pump and accessory will be deactivated until the water cools to 109°F. Be sure to check the actual temperature with an accurate thermometer. 2 – The spa water has exceeded 119°F. The heater will deactivate while the pump and accessory will still operate. The air blower (if equipped) can be activated to help cool the water. WATER MUST BE BELOW 119°F AND POWER MUST BE RESET TO CLEAR THE “HL ERROR ” A dirty spa filter can also cause restricted flow of water, so be sure the filter is cleaned regularly and ensure that all water shutoff valves are open. If the system has been operating normally until now, the pump may be overheating the spa. Refer to “Programming Filtration” on Page 12 and reduce the duration and/or number of cycles per day. 3 – If you’ve eliminated items 1&2 as problems, the high limit sensor may have malfunctioned If this is the case, ... Contact your local spa dealer Freeze Protection – There are two (2) levels of freeze protection integrated into the system. 1 – SMART WINTER MODE, this mode will activate anytime the water temperature falls below 59°F. This mode will be active for a period of 24 hours. In this mode, if a pump has not been activated in the last 2 hours, the system will automatically turn it on for one (1) minute to prevent freezing. The “Filter Cycle” indicator will illuminate while the mode is active. 2 – If the spa water temperature drops below 49°F, the heater & pump will be activated until the water temperature reaches 50°F. While freeze protection is active no other functions will be possible. Wholesale 16 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 18. SYSTEM DATA LABEL The system data label is located on the control box. This label is very important and contains information you will need to establish your electrical service. The voltage and amperage ratings are shown on the bottom of the label. Product, Model, Serial and Code numbers are also shown on the label. Note: This information will be necessary if you should ever have to request warranty or any other type of service. w w w.ho riz o npar t s.net HS-V65xx HOR03-xxxx- 120 240 16 40/48 HQ-6000 HS-V6510-HC-LH01000 1 PHASE - 60Hz Refer to NEC for Breaker Sizing WARRANTY INFORMATION To all original purchasers, Horizon Spa & Pool Parts Inc., as a distribution partner of HydroQuip, warrants this product to be free from defects in material and workmanship for a period of 3 years from the date of purchase. Horizon Spa & Pool Parts Inc. will repair or replace a defective part, at our discretion. This warranty excludes damage as a result of: normal wear, freezing, low voltage, chemical abuse, accident, negligence, alteration, improper installation, use or care. To obtain warranty service, contact your installing dealer within the warranty period and have them return the defective equipment or parts to Horizon Spa & Pool Parts Inc. The Horizon Series Limited Warranty is for service on the control box only. Purchaser is responsible for removal or reinstallation labor, freight charges, or any other such costs incurred in obtaining warranty service. Horizon Spa & Pool Parts Inc. assumes no responsibility for incidental or consequential damages. Some states do not allow the exclusion of incidental or consequential damages, so the above limitations and exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which vary from state to state. If you are the end user for this control system, the spa dealer may provide a different warranty; contact your spa dealer for details and warranty information. Wholesale 17 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 19. PARTS LIST Part Number Description Control System 59-355-1098 Primary Circuit Board HS-V6510 Series (ALL) 59-355-1020 Temperature Sensor, 10ft HS-V6501-V6510 Series (ALL) 59-355-1025 Hi Limit Sensor, 14” HS-V6501-V6510 Series 59-355-1026 Hi Limit Sensor, 76” HS-V6501-V6510 Series -VH & -LH 59-355-1028 Pressure Switch Harness ALL 47-439-1295 Pressure Switch ALL 47-555-2070 Heating Element, 5.5kW, 240v ALL 60-555-1155 Fuse 20A SLO BLOW Fuse HS-V6501-V6510 Series 60-555-1157 Fuse 25A SLO BLOW Fuse HS-V6501-V6510 Series 60-555-1187 Fuse, System, 750mA HS-V6501-V6510 Series 60-555-1185 Fuse, Light, 2Amp HS-V6501-V6510 Series 60-240-1020 High Current GFCI ALL -HC 60-355-1000 Terminal Block HS-V6500 Series 60-240-1022 40A Contractor HS-V6500 Series -HC 57-315-1000 Light Bulb, 12v, Incadescent ALL Wholesale 18 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 20. TOPSIDE MOUNTING IMPORTANT - The template on this page is to be used with HT-2, ECO-3, 7 & 8 series controls ONLY. Refer to the “Installation Manual” for installation details. 6 3/8” 2 5/8” Wholesale 19 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 21. NOTES Wholesale 20 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 22. NOTES Wholesale 21 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 23. NOTES Wholesale 22 http://www.MyPoolSpas.com Pool and Spa Parts 920-925-3094
  • 24. 07/08 Rev. 1 http://www.MyPoolSpas.com Pool and Spa Parts Wholesale 920-925-3094