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Converting old Balboa TO 120v

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tfrasca:
Well, I got this thing running on 120v, but not without some issues.

Again, this is an old Balboa 2000 Value Series spa pack, which I've recently converted from 240 to 120, following the wiring diagram on the back of the cover panel.

This is a bit of a journey, so please bear with me.

To convert the board to 120, I removed the four 240 wires from the main power terminal block. I then hooked up my three wire 120 hot tub plug w/ GFCI. The red hot terminal was left empty based on the advice above.

Then, according to the diagram, I run a jumper wire between terminals J4 and J15. Lastly, I moved jumper J23 from 50a to 20a. This configuration ran everything perfectly, except the heater. No voltage was present at the copper tabs on the heater tube.

Upon further inspection, I noticed that the jumper between K1 and K4 relays (high limit and heater) was the reverse of what the wiring diagram showed. I switched the wire and now have voltage at the heater. The problem is that the heater will not turn off, and eventually triggers an OH error code and shuts down.

The pump seems to be flowing enough, and I even tried running it with no filter to rule that out. Both slice valves are fully open.

Any suggestions on what to try next? I'm sure it has something to do with either the high limit/heater relays or the jumper wire between the two. It seems weird that it was connected incorrectly, based on the diagram, but presumably worked well for years on 240v.

tfrasca:
Hi again. Just wanted to update this in case anyone has any advice. I'm still dealing with overheating on this old Catalina Spa/Balboa Value 2000 pack.

If I set the temp to say, 100, it'll heat all the way to 110ish then throw the OH code. If I let it get up to 100, then turn the temp down, it'll stop heating. This tells me that the thermostat is working, right?

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