💧 Balboa TP540 Topside Control Panel – Replacement for Legacy TP540, TP400 & TP400W Models

📟 Slim profile panel with Serial Standard display for BP Series systems

📋 Product Overview

The Balboa TP540 Topside Control Panel is a replacement panel specifically designed for discontinued legacy models including the TS-TP540, TS-TP400, and TS-TP400W. This ensures spa owners with older installations can maintain their systems with a current production replacement that offers full compatibility.

Featuring a slim, elongated profile measuring 210 mm × 63 mm, the TP540 provides an unobtrusive control solution with its 6-button interface. The Serial Standard display shows 4 large digits with scrolling text capability, delivering clear temperature readings and status information at a glance.

Operating at 12V, this panel is compatible with Balboa BP Series control boxes, including the BP601 and BP2100 systems. The current Balboa part number is G8454, which replaces previous TP540 models (57308, 57309, 57310). Please note that the overlay is not included and must be purchased separately.

✨ Key Features

• ✅ Legacy Model Replacement – Direct replacement for discontinued TS-TP540, TS-TP400, and TS-TP400W
• ✅ Balboa BP Series Compatible – Works with BP Series control boxes including BP601 and BP2100
• ✅ Serial Standard Display – 4 large digits with scrolling text for clear status information
• ✅ 6-Button Interface – Simple and intuitive control layout
• ✅ Slim Profile Design – Compact 210 mm × 63 mm footprint
• ✅ 12V Operation – Low voltage design for safe operation
• ✅ Current Production Model – G8454 replaces multiple legacy part numbers
• ✅ Maintains Compatibility – Works with same systems as discontinued models

⚙️ Technical Specifications

Specification	Value
Manufacturer	Balboa
Model	TP540
Current Part Number	G8454
Replaces Part Numbers	57308, 57309, 57310
Replaces Models	TS-TP540, TS-TP400, TS-TP400W
Compatible Systems	BP Series (including BP601, BP2100)
Model Series	TP
Display Type	Serial Standard Style
Display Format	4 Large Digits with Scrolling Text
Number of Buttons	6
Operating Voltage	12V
Dimensions (L × H)	210 mm × 63 mm
Connection Type	4 Black Plastic Pins (Grid Formation)
Overlay Included	No

🔌 Compatibility Guide

This Topside Control is Compatible With:

Control System	Series	Confirmed
BP601	BP Series	✅
BP2100	BP Series	✅
BP Series Control Boxes	BP Series	✅

Direct Replacement For:

Discontinued Model	Status
TS-TP540	✅ Replaced by this model
TS-TP400	✅ Replaced by this model
TS-TP400W	✅ Replaced by this model

How to Verify Compatibility:

• 📍 Check your existing topside for part number (G8454, 57308, 57309, or 57310)
• 📍 Identify if your current panel is a TP540, TP400, or TP400W model
• 📍 Confirm your spa pack is a Balboa BP Series (BP601, BP2100, or similar)
• 📍 Verify the connector type matches (4 black plastic pins in grid formation)
• 📍 Contact Parts4Tubs if you require confirmation

⚠️ Important: Topside controls are system-specific. Installing an incompatible topside will not work and may cause error codes.

🖥️ Display & Controls

Display Features:

Feature	Description
Display Style	Serial Standard
Digit Format	4 Large Digits
Text Display	Scrolling Text Capability
Readability	Large digits for easy viewing

Button Configuration:

The TP540 features 6 buttons. Specific button functions are determined by the overlay installed and spa pack configuration. Contact Parts4Tubs for compatible overlay options.

🛠️ Installation Guide

Before Installation:

• ⚠️ Disconnect power to spa at the isolator/breaker before any work
• ⚠️ Verify compatibility with your BP Series spa pack
• ⚠️ Confirm connector type matches your existing installation
• ⚠️ Ensure you have a compatible overlay (sold separately)

Installation Steps:

1. Turn off power at the isolator/breaker
2. Remove the existing topside panel from the mounting location
3. Disconnect the cable connector from the spa pack
4. Connect the new TP540 cable to the spa pack (4 black plastic pins in grid formation)
5. Install compatible overlay onto the panel
6. Mount the new topside panel in position
7. Restore power and test all functions

Mounting Information:

Specification	Detail
Panel Dimensions	210 mm × 63 mm
Profile	Slim elongated design
Mounting	Refer to installation manual for cutout requirements

⚠️ Professional installation recommended if you are unfamiliar with spa electronics.

⚡ Wiring & Connection

Connector Information:

Specification	Detail
Connector Type	4 Black Plastic Pins in Grid Formation
Operating Voltage	12V

Connection Location:

The TP540 connects to the topside port on Balboa BP Series control systems (including BP601 and BP2100).

⚠️ Never force the connector. If it doesn’t fit, verify compatibility with your control system.

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⚠️ Troubleshooting

Common Issues:

Problem	Possible Cause	Solution
Blank display	No power or loose connection	Check power supply and reseat cable connector
Error codes displayed	Various system issues	Refer to BP Series spa pack manual for error meanings
Buttons unresponsive	Overlay wear or moisture ingress	Inspect overlay condition; replacement overlay may be required
Incorrect readings	Temperature sensor issue	Check temperature sensor (separate component from topside)
Partial display	Display fault	Replacement may be needed
Scrolling text unclear	Display issue	Check connections; replacement may be needed

Error Codes:

Error codes are determined by the spa pack, not the topside panel itself. The TP540 displays error information via scrolling text from your BP Series control system. Refer to your spa pack manual for specific error code meanings.

🧹 Maintenance & Care

Routine Care:

Task	Frequency
Wipe with soft damp cloth	Weekly
Check button response	Monthly
Inspect cable connection	Annually
Check overlay condition	Annually

DO NOT:

• ❌ Use abrasive cleaners or scouring pads
• ❌ Submerge the panel in water
• ❌ Use solvent-based or chemical cleaners
• ❌ Press buttons with sharp objects
• ❌ Apply excessive pressure to the display

Overlay Information:

The TP540 is supplied without an overlay – the overlay must be purchased separately. If your existing overlay is compatible and in good condition, it may be reused with the new panel. Contact Parts4Tubs for compatible overlay options.

🎯 Ideal Applications

Application	Suitability
🔄 Replacement for faulty TP540 topside	✅ Ideal
🔄 Replacement for discontinued TS-TP540	✅ Ideal
🔄 Replacement for discontinued TS-TP400	✅ Ideal
🔄 Replacement for discontinued TS-TP400W	✅ Ideal
⬆️ Upgrade from earlier models (57308, 57309, 57310)	✅ Ideal
🎛️ Spas with BP601 control systems	✅ Compatible
🎛️ Spas with BP2100 control systems	✅ Compatible

Common Replacement Scenarios:

• 💔 Cracked or damaged display screen
• 🔘 Unresponsive buttons
• 💧 Water damage to existing panel
• 👁️ Faded or illegible display
• ⬆️ Replacing discontinued legacy panels

💬 Frequently Asked Questions

Q: How do I know if this topside is compatible with my spa?

A: The TP540 is compatible with Balboa BP Series control boxes, including BP601 and BP2100. It also serves as a direct replacement for discontinued TS-TP540, TS-TP400, and TS-TP400W models. Check your existing topside model or spa pack to confirm compatibility.

Q: Is the overlay included with this topside?

A: No, the overlay is not included with the TP540 and must be purchased separately. If your existing overlay is in good condition, it may be compatible with the new panel.

Q: What models does this replace?

A: The TP540 (G8454) replaces the discontinued TS-TP540, TS-TP400, and TS-TP400W models, as well as previous TP540 part numbers 57308, 57309, and 57310.

Q: What is the connection type?

A: The TP540 uses 4 black plastic pins in a grid formation to connect to your BP Series spa pack.

Q: What does the display show?

A: The TP540 features a Serial Standard style display with 4 large digits and scrolling text capability, providing clear temperature readings and status information.

Q: What are the dimensions?

A: The TP540 measures 210 mm (length) × 63 mm (height), featuring a slim elongated profile.

Q: Can I install this myself?

A: If you are comfortable working with spa electronics and can safely isolate power, DIY installation is possible. However, professional installation is recommended if you are unfamiliar with spa electrical systems.

Q: I have a TP400 panel – will this work?

A: Yes, the TP540 is designed as a replacement for the discontinued TS-TP400 and TS-TP400W models, maintaining compatibility with the same systems.

⭐ Why Choose the Balboa TP540

• ✅ Legacy Support – Replacement for discontinued TP540, TP400, and TP400W models
• ✅ Genuine Balboa Quality – Manufactured to Balboa’s exacting standards
• ✅ Clear Display – Serial Standard with 4 large digits and scrolling text
• ✅ Slim Profile – Compact 210 mm × 63 mm design
• ✅ Simple Operation – 6-button interface for straightforward control
• ✅ BP Series Compatibility – Works with BP601, BP2100, and other BP Series systems
• ✅ Current Production – G8454 ensures you receive the latest version

🇬🇧 Why Buy from Parts4Tubs

• ✅ UK-based company with local support
• ✅ Fast UK delivery
• ✅ Expert advice from spa specialists
• ✅ Legacy system compatibility assistance
• ✅ Full warranty support
• ✅ Easy returns within 30 days
• ✅ Compatible overlays available separately

💫 Summary

The Balboa TP540 Topside Control Panel (G8454) provides a current production replacement for discontinued legacy models including the TS-TP540, TS-TP400, and TS-TP400W. Featuring a slim 210 mm × 63 mm profile, Serial Standard display with 4 large digits and scrolling text, and a 6-button interface, this panel maintains full compatibility with BP Series control systems including BP601 and BP2100. The overlay is sold separately, allowing you to use an existing compatible overlay or purchase a new one. Order from Parts4Tubs for fast UK delivery, expert legacy system advice, and compatible overlay options.

Balboa BP Spa Packs

If you have a “BP” spa pack, you will find the name and model on the label, then you can use any of the “TP” range of topside controls, TP400, TP600 etc etc.

 

You can also use any of the “Spa Touch” graphical controllers on your Spa Pack. Spa Touch comes in versions 1-3 with 4 to be released very soon as well as the new “mini”.

 

The BP Spa Pack made things nice and easy so when you are replacing your topside control with one of these, it is straight forward enough.

 

Balboa VS & GS Spa Packs.

 

If you have an older hot tub that you are keeping alive with new parts, then the chances are you have an older spa pack in there too. This is where it gets a little more complicated in terms of compatibility.

 

Two of the popular models are the VS which stands for Value Series and was supplied to a lot of OEMs (manufacturers for hot tubs) to go into their tubs. Likewise, the GS (global series) was the same. Lots of different rebranded options, different names, but at the heart of things are these two packs.

 

What is key on these two models, is the combination of letters and numbers that make up the model number on the Spa Pack.

 

The VL range of topside controls was designed for both of these spa pack ranges; however, there are some “rules” we need to abide by in terms of compatibility.

 

VL Panels ending in D work with VS/GS systems ending in DZ

VL Panels ending in S work with VS/GS systems ending in SZ

The rest of the VL Panels work with VS/GS systems ending in Z (not SZ or DZ)

 

For example, a Spa Pack model VS501SZ would work nicely with a Topside that is model VL620S. However, that same topside control would not work with a spa pack model VS501Z. The connections are the same, it would plug in, but would not respond at all.

 

Another example, a Balboa GS500Z spa pack would work with the VL406T or the VL401 but would not work with the VL702S.

 

You get the patters. Topside ends in S or D, matches to Spa Pack ending in SZ (for S) or DZ (for D).

 

 

Balboa EL & GL Spa Packs

 

Before the birth of the BP range, the EL and GL Spa Packs did have some level of standardisation in terms of the topside controls.

 

All of the “ML” range of Balboa Topside Controls are designed to work with the EL and GL range of spa packs. They actually look very similar to the TP range, they just have a different type of connection to plug into the Spa Pack.