Bl 40 combo

ALLIED INNOVATIONS, LLC BL-40 UNIVERSAL
Manufacturing the Product Lines of Len Gordon
7215 Bermuda Rd Las Vegas NV 89119-4304 CIRCUIT BOARD
REPLACEMENT KIT
IMPORTANT INSTALLATION INSTRUCTIONS - PLEASE READ!

The BL-40 Universal Circuit Board Replacement Kit replaces Catalina Controls Corporation models RC34, RC4,
RC4a, RC4Pa, RMQ4, RC7, RC7a, RC7E and Brett Aqualine models BL-40 and BL-40TC circuit boards. This
booklet contains installation instructions and wiring diagrams to assist you in installing the BL-40 circuit board.
Please review these instructions in advance to confirm that you have all necessary tools and components, which
may not be included in this kit. For any questions not covered, you may contact the Allied Innovations, LLC
Technical Service Department between 8:00 a.m. and 5:00 p.m. PST at (702) 361-0600 or e-mail
technical@lengordon.com. Terminals 1 and 2 are for line voltage which can be 120V or 240V. The BL-40 Board
will automatically detect the voltage and adjust accordingly.

STEP ONE - CONFIGURE THE CIRCUIT BOARD (DIP SWITCH SETTINGS):

The BL-40 incorporates 8 mode selection (DIP) switches to configure the circuit board. The switches are located
on the circuit board (SW1) and are preset at the factory to the “OFF” (down) position. Each switch is assigned a
number from 1 through 8. To activate the desired mode, use a ball point pen and push the switch to the “ON” (up)
position. Factory DIP SWITCH setting: 2 & 6 ON; 1, 3, 4, 5, 7, 8 OFF.

“DIP” SWITCH SETTINGS
Select one of the following setup configurations listed below: 1 2 3 4 5 6 7 8

Single-speed pump(s) installed M OFF

U
Two-speed pump installed ON N
S
O
Enable optional second light and aux pump T ON
T
Select any of the following options listed below: B
U
For continuous circulation pump operation ON E
S
Disable 30 minute extended filtration feature ON E
O
D
Enable thermostatic control of pump and heater ON F
F
Disable heat if jets/blower is on (120V units) ON

NOTE: 1. If using a 2-speed pump, Dip Switch #6 must be “ON” for Filtering and Jets.
2. Switches “4" and “7" are not used and MUST be set to “OFF” position for proper operation.
3. If using a stand-alone heater, Dip Switch #5 (a separate gas or electric power source) should be “OFF”.

STEP TWO - INSTALL THE CIRCUIT BOARD:

WARNING: To prevent electric shock, make sure all power is off prior to attempting installation. Remove the
old circuit board (making note of where the wires are connected) and install the BL-40 universal replacement board.
Models with integral time clock may require the use of the four 1/4" standoff extensions provided for clearance
between the top of the circuit board and the bottom of the time clock.

STEP THREE - LOW VOLTAGE CONNECTIONS:

Using the “LOW VOLTAGE CONNECTION” table on the following page, reconnect all low voltage connections to
the BL-40 universal circuit board receptacles. IMPORTANT NOTE - DO NOT install freeze SENSORS or JUMPER
plugs from model RC4, RMQ4, or RC7 circuit boards to the BL-40 universal circuit board.

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

LOW VOLTAGE CONNECTIONS
Connect to
From:
From: BL-40
From: RC4a,
RC4, RC34 Universal COMMENTS
RC7 RC4Pa and
and RMQ4 Circuit
RC7a
Board
‘RMT SPA Some older circuit boards use 8-pin spa-side connections. The BL-40 uses a 9-pin
P1 P1 ‘SPA PNL’ PANEL’ spa-side connector. To use an existing 8-pin spa-side, shave off the plug ‘nub’ closest
P1 to the green wire. The other ‘nub’ will act to align the connector correctly.
‘RMT Some older circuit boards use 8-pin in-house connections. The BL-40 uses a 9-pin
MSTR Master panel connector. To use an existing 8-pin Master panel, shave off the plug
P2 N/A P2
PANEL’ ‘nub’ closest to the green wire. The other ‘nub’ will act to align the connector correctly.
P2
‘DC TIME Optional - Filtration time receptacle. Use terminal “P8" for low voltage clock
IN’ P8 OR connection, or “P10" for high voltage (120 VAC or 240 VAC) clock connection. A
N/A P2 P13
‘AC CLK IN’ pigtail cable kit (Item# 060380) is available for high voltage connection to terminal
P10 “P10".
‘HEATER’ 120/240 volt conversion jumper receptacle (not on all models).
N/A P3 ‘HEAT’
P11
Optional - Heating timer receptacle. Note: ”P9" requires the use of a 9-pin connector.
‘OPTIONS’
N/A P4 P12 Using the 9-pin connector and crimp-on splices provided in the kit, remove the 3-pin
P9
plug, and splice wires to 9-pin connector (polarity is not important).
Temperature Sensor Receptacle. A temperature sensor (Item# 070840 or 38-0400A)
must be connected to “P3” for heater operation. IMPORTANT: Older temperature
sensors may have reversed plug wiring and will not function with the BL-40. The
‘WATER’ correct temperature sensor plug wiring is: pin one = cable shield (not used on all
P4 P5 ‘TEMP’
P3 models); pin two and three = sensor (reference point - pin one will be located adjacent
to nine pin receptacles P1 and P2). If temperature sensor plug wiring is not correct,
replace sensor or use a small flat blade screwdriver to pry wires one and three out of
plug and reverse. Use screwdriver to full reinsert wires into plug.
Pressure/Flow Switch Receptacle. A pressure switch or flow switch, flow switch, or
‘FLOW SW’ bypass jumper must be installed for heater operation. IMPORTANT: If a pressure or
P5 P6 ‘FLOW’
P4 flow switch is not connected to this receptacle, a jumper plug (Item# 080040) must be
connected for heater operation.
‘FREEZE Optional Freeze SWITCH Receptacle. IMPORTANT: DO NOT move jumpers or
P3 P7 --- 1&2' freeze SENSOR used on RC4, RMQ4, or RC7 circuit boards to the BL-40. Only use
P6 AND P5 optional freeze SWITCH (Item# 070120) if freeze protection is desired.

STEP FOUR - HIGH VOLTAGE CONNECTIONS:

Using the WIRING DIAGRAMS on the following pages, reconnect all high voltage-wiring connections to the BL-40
universal circuit board replacement terminal block. “Quick Disconnect” terminals are provided to replace model
RC7a circuit boards. Reapply power and check for proper operation.

NOTE: There are many possible wiring configurations. The attached diagrams show “typical” installations. Jumper
wires (not provided) may be required for terminal to terminal connections. Use minimum #14 AWG jumper wires
for this purpose. For common connections, such as multiple neutral connections, use wire nuts (not provided) or
other suitable connector approved for size and number of conductors being spliced together. All connections are
to be made in accordance with the National Electrical Code and local codes in effect at the time of installation.

TROUBLESHOOTING (Most common problems):

Heater Does Not Operate, no HEAT indicator light on spa side panel:

Make sure a pressure or flow switch or bypass jumper is connected to terminal P4. If a pressure or flow switch is
connected, ensure that the switch is operating correctly.

Make sure system is operating in a heat mode and the spa side control thermostat is set to HOT. If the system is
equipped with an optional in-house master control, ensure that this thermostat is also set to HOT.

Make sure temperature sensor is connected to terminal P3. Older temperature sensors may have reversed plug
wiring and will not function with the BL-40. The correctPool and Spa Parts
http://www.MyPoolSpas.com Wholesale temperature sensor plug wiring is pin one = cable shield (not
920-925-3094

used on all models); pin two and three = sensor (reference point - pin one will be located adjacent to nine pin
receptacles P1 and P2). If temperature sensor plug wiring is not correct, replace sensor or use a small flat blade
screwdriver to pry wires one and three out of plug and reverse. Use screwdriver to full reinsert wires into plug.

Heater does not operate, HEAT indicator light on spa side panel is illuminated:

Make sure the heater is operational.

Check wiring at high voltage terminals P11 and P12. The correct wiring will be power in (line) terminal 11 and power
out to heater (load) terminal 12.

Pump not operating correctly:

Make sure the DIP switch settings are correct for the type of pump used (single or two speed motor). Make sure the
high voltage wiring is connected properly (jumper wires must be installed between terminals 2, 3 and 6).

Pump runs continuously:

Make sure filtration timer is OFF.

Make sure the temperature sensor is connected to terminal P3. See Low Voltage Connections table for correct
temperature sensor wiring.

Remove any devices connected to ‘FREEZE 1 & 2', terminals P5 and P6. If the pump stops operating, the problem
may have been caused by a jumper or freeze sensor installed in these positions. Discard jumper or replace freeze
sensor installed in these positions with freeze switch (Item# 070120).


TEMPERATURE vs RESISTANCE TABLE
TEMP THERM TEMP THERM TEMP THERM
(degrees F) KOHM (degrees F) KOHM (degrees F) KOHM

32 32.7 56 16.9 80 9.25
33 31.8 57 16.5 81 9.03
34 30.9 58 16.0 82 8.82
35 30.0 59 15.6 83 8.61
36 29.2 60 15.2 84 8.41
37 29.4 61 14.8 85 8.22
38 27.6 62 14.5 86 8.03
39 26.8 63 14.1 87 7.84
40 26.1 64 13.7 88 7.66
41 25.4 65 13.4 89 7.48
42 24.7 66 13.1 90 7.31
43 24.0 67 12.7 91 7.14
44 23.3 68 12.4 92 6.98
45 22.7 69 12.1 93 6.82
46 22.1 70 11.8 94 6.67
47 21.5 71 11.5 95 6.52
48 20.9 72 11.2 96 6.37
49 20.4 73 11.0 97 6.23
50 19.8 74 10.7 98 6.09
51 19.3 75 10.4 99 5.96
52 18.8 76 10.2 100 5.83
53 18.3 77 9.95 101 5.70
54 17.8 78 9.71 102 5.57
55 17.3 79 9.48 103 5.45
104 5.33
105 5.22
TEMPERATURE SENSOR AND HIGH LIMIT the temperature sensor (by attaching the VOM
SENSOR CHECKOUT PROCEDURE probes to the leads that correspond with the wire
connections on the temperature sensor).
The temperature sensor and high limit sensor utilize a " Use an accurate thermometer and check the spa
thermistor which changes resistance as a function of water temperature. The acceptable range is 2EF
temperature. In order to troubleshoot the thermistor, below the actual spa water temperature. See the
you must know what the resistance should be at a given example below.
temperature
" Refer to the Temperature vs Resistance Table
Use a standard VOM (Volt/Ohm Meter) set to read R above and compare the spa water temperature to
x 10,000: determine if the resistance readings are within the
acceptable range.

" Disconnect the sensor from Example: Temperature vs Resistance range
J2 (temperature sensor) or 92 6.98
J3 (high limit sensor) on the -2EF! 93 6.82 •
Control circuit board.
Attach a 3 pin base to the
94 6.67 Acceptable
sensor plug to provide male Water Temp! 95 6.52 Resistance
contact points for resistance 96 6.37 Range
reading, or insert probe tips +2EF! 97 6.23 –
into the back of plug until 98 6.09
contact is made.

" Using the VOM, record the resistance reading of

WARRANTY
Allied Innovations, LLC warrants its products to be free from defects in workmanship and
material under normal use and conditions for a period of one year from the date of original
manufacture. Should repair be required by reason of any defect or malfunction during the
warranty period, Allied Innovations, LLC will repair, or at their discretion, replace this product
without charge, subject to verification of the defect or malfunction, upon delivery of the product
to the attention of:

Technical Service Department
Allied Innovations, LLC
7215 Bermuda Rd
Las Vegas, NV 89119-4304

If repair is required after the expiration date of the warranty period, Allied Innovations, LLC will
repair this product and bill for any necessary replacement parts, shipping and handling.

This warranty is void if: 1) the unit is not installed per the instructions; 2) is hooked up to
improper voltage; 3) is subjected to chemical corrosion; 4) is mechanically or electrically
altered in any way; 5) is subjected to water or immersion; 6) contacts show evidence of short
circuiting, or the unit has been visibly damaged by accident or misuse or which has been
damaged by wind, rain, lightning, freezing or other cause; or upon which the serial number or
manufacture date has been altered, effaced or removed. There is a charge for replacement
parts if the defective unit is returned for any of the reasons listed above.

Allied Innovations, LLC shall not be liable for any inconvenience, loss of time, or incidental
expenses incurred. Allied Innovations, LLC shall not be liable for any labor charges associated
with the removal or re-installation of any so-claimed defective products.

This is the only warranty expressed or implied by Allied Innovations, LLC. Warranties implied
under state law, including any implied warranty of merchantability or fitness for a particular
purpose, shall be limited to one year from the date of manufacture.

Allied Innovations, LLC disclaims any liability for any incidental or consequential damages.

Ship as follows:

1. Pack the unit in a well padded, heavy corrugated box.
2. Include name, return address, and daytime phone number
along with a short description of problem with control.
3. Mail the unit, prepaid, to the above address.

Some states do not allow the exclusion or limitation of incidental or consequential damages,
therefore the above limitation may not apply to you.

62580D-0 © 2002 Allied Innovations, LLC 02/02


ALLIED INNOVATIONS, LLC
Manufacturing the Product Lines of Len Gordon ATTENTION
7215 Bermuda Rd Las Vegas NV 89119-4304
INSTALLER
This unit was shipped from the factory with a mini jumper (Item
#400190, shown at right) installed in the “Flow Switch” (P4)
receptacle. Make sure that this jumper is secure prior to installing
the unit. If a connection to an external pressure or flow switch is
desired, use optional Pressure/Flow Switch Cable (Item #070110)
in place of this jumper. The heater circuit will not operate
without this jumper or an external pressure or flow switch
connected to (P4) receptacle.
650080-0 © 2002 Allied Innovations, LLC 03/02


Bl 40 combo

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