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Understanding Hot Tub Equipment Control
Systems
Your guide to picking the perfect replacement Spa Pack!
| Every year, many otherwise
perfectly serviceable spas are discarded because of
worn-out or obsolete control systems. Often times
these hot tubs are in great shape, and could be brought
back to life by simple replacement of the old spa pack
with a new, dependable control unit... saving thousands compared to
buying a new spa. When selecting a new spa pack, be sure
to buy a quality unit. You'll save money and
effort in the long run. For easiest installation,
check out our EasyPak with VersiHeat detached heater
manifold |
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NOTE:
Replacing a spa pack is not as simple as
changing a light bulb, but it's not rocket
science. The quality controls that we
sell come with a detailed instruction
manual, and are the easiest spa packs to
install. Our toll-free tech support
team is happy to help, if you get stuck!
CAUTION:
Working with electricity can be dangerous.
Observe all safety measures & electrical code
requirements. Disconnect power at
service panel before servicing or installing
equipment. Obtain the services of a
qualified spa tech and/or electrician, if
you are not qualified to perform the
replacement. |
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| The term
Spa Pack refers to the equipment which controls the
functions of a hot tub spa. In addition to the control
box, a system will typically include a heater, and
circuits for blower, light, ozonator, second pump if
needed, and GFCI if appropriate. Our EasyPak
replacement controls feature universal voltage
adaptability. Models with VersiHeat
separate heater manifold are easiest to install. Think
of the Spa Pack as the brain of your hot tub. |
Inside the
spa's brain
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Electronic vs. Air Switch |
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a choice
of technologies... |
Today's spa packs come in
either air switch (electro-mechanical) or
electronic
versions.
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Air Switch
Control System |
EasyPak
air switch electro-mechanical units are supplied with
new air-button controls and air tubing for each
controlled component. You can upgrade with a
spa-side control unit featuring thermostat heater
control, air button array, and visual indicators. |
 
Air
buttons or spa side control
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Advantages
of Air Switch systems:
Electromechanical (air
switch) systems have low lifetime repair costs because
individual components can be easily replaced at modest cost,
if necessary. The hardy construction is very forgiving
of voltage spikes and current variations, moisture and
foreign object intrusion. Less chance of failure due
to nearby lightning strikes. Ability to set many
different on/off times for the filtration cycle with the
24-hour electromechanical clock.
Disadvantages of Air Switch systems:
There are fewer
error indicators. Filter cycles cannot be controlled
from the topside, but must be set on the control box itself.
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Electronic
Control System
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EasyPak
electronic spa controls feature state-of-the-art
solid-state, microprocessor-controlled circuitry.
Electronic units must be used with digital electronic
spa side controls, which are included at no extra
charge, when you buy the EasyPak brand.
Some others charge extra for this. |
Spa side
control with adapter plate
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Advantages
of Electronic systems:
You'll have much
greater control from the topside for filter cycle and
programming features. Features time out and automatic
freeze protection, purge mode, etc. With its
microprocessor, error codes are displayed, alerting to
potential failures, as well as diagnostics for simple
problems. No need to open the equipment cabinet to
change settings, modes, cycles, etc.
Disadvantages of Electronic systems:
Entire circuit
boards may have to be replaced in the event of a failure.
Electronic systems can be a bit more susceptible to failure
from voltage spikes and current variations, foreign object
intrusion and moisture.
|
 EasyPak
Comparison Guide
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|
selecting
the perfect spa pack for your hot tub... |
- Our EasyPak spa
controls are arranged by from factor, with dimensional
information listed below. EasyPak systems are
Universal-- configurable for 110v or 220v electrical
service. All have circuits for 2-speed pump, blower,
and ozonator, in any combination of voltages, plus 12v light
circuit! Add optional second pump circuit to most
models. Voltages are factory-set to order, but are
easily changed later, if necessary-- unlike some other
brands which are fixed.
- Form factor series 9000 have
integrated high current GFCI
option (hence the larger size)-- form factor series 6000
have no GFCI, which allows for the smaller case size.
- Your spa's heater operates
at the service voltage, either 110V or 220V. Full-size
spas are normally 220V. (Some lightweight portables
operate at 110V). EasyPak controls and their
heaters are universal, meaning they can be configured for
either voltage. 220V spas have several advantages, one
of which is that they will heat up much faster, since the
heater wattage will run considerably higher than it would at
only 110V.
EasyPak
Comparison Guide
 Go
to Spa Pack store
to order.
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Control System
configurations (electronic or air switch models)
Pick a form factor from these
choices. VersiHeat models are the easiest to position
and install.
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Form
Factor 6000
Attached heater, no GFCI option
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Form
Factor 6000
Detached VersiHeat, no GFCI option
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Form
Factor 9000
GFCI option & attached heater
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Form
Factor 9000
GFCI option & detached VersiHeat
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Form
Factor 5000
Pump Top Mount with integrated heater |
NOTE:
When plumbing
Control Systems, please remember that the heater must be
mounted on the pressure side (output) of the pump.
The heater will not function correctly if installed
prior to the pump (suction side). Heater manifold
connections are 2" plumbing. |
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EasyPak
Comparison Guide
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EasyPak's Advanced
Built-in Diagnostics...
makes installation and future
maintenance much easier!
VDS™
Diagnostics
Our EasyPak's exclusive Visual
Diagnostics System gives instant indication of hook-up
or operation problems, and eliminates hot tub equipment
installation errors. Now you don't need to be a
spa expert to identify and correct future maintenance
issues! VDS makes them simple to diagnose, saving
time & money.
(VDS not available on Series 5000) |
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SmartCord™ Diagnostics
The first
step in troubleshooting virtually any electrical
component, is to determine if it is receiving power.
EasyPak's
state-of-the-art SmartCords glow when their circuit is
on, giving a positive indication when external
components such as spa pumps, blowers, ozonators, etc.
are energized. If the component is receiving power and
not functioning, the problem is most likely with that
part, or the connection to it. Component failure
detection made easy! Conversely, if the circuit
should be activated, but the cord does not glow, the
malfunction is likely in the pack itself (blown fuse,
bad contactor, etc.) |
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hooking up
your new spa pack... |
Plumbing considerations
First, determine the
size of your hot tub's plumbing. Your spa will
normally have either 1-1/2" or 2" pipes. Most
connections are made using PVC fittings and flex and/or
rigid pipe, using PVC cement which is available from any
home center or plumbing supply.
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Identify and
connect the suction side of the
pump
to the suction lines from your spa. These
lines originate from the floor drain and
skimmer/filter, and join before entering the
pump.
-
Identify and
connect the discharge side of the
heater
to the return line which leads to your spa jets.
Heater manifolds are 2" nominal plumbing size
(slip fittings).
- If you have an
electric blower, identify and connect the blower to
your existing blower tube. Install a new check
valve for safety. Sheet metal screws can be
used to permanently connect the blower components.
Never use glue to connect your blower. The
solvent fumes can explode.
- Install individual
top side air buttons, or spa side control pad.
Connect the air tubes from the control box to the
corresponding air button topside or command center,
or connect control cable, as appropriate for air
switch or electronic control system.
Refer
to:
 Spa
Anatomy for a basic understanding of spa
plumbing configuration.
Heater
Variations
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Pump's
discharge (B) connects to heater at (C) with
heater-to-pump union assembly. Heater assemblies
normally have 2" slip tailpieces (C) at each end.
If you select an EasyPak
with VersiHeat, you may place the control box
virtually anywhere in the equipment compartment.
Makes installation & service easy in cramped quarters! |
Pump Union (A)
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Conventional Attached Heater |
VersiHeat with 60" cable |
Pump Top Mount |
- If your spa has
1.5" plumbing: connection to (A) will be
straightforward. For the connection at heater
output 2" slip tailpiece you may adapt to 1.5" with
a Reducer Bushing if necessary.
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#BX9901
2" PVC
reducer to
1.5" spa plumbing
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- If your spa has
2" plumbing: connection to heater output will be
straightforward. For the connection at the
1.5" pump suction slip tailpiece (A), you will need
to attach a short section of 1.5" PVC pipe and a
Reducer Bushing & 2" coupling.
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#BX9901
1.5" PVC
attached to (A) with reducer
& 2" coupling to 2" spa plumbing
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Is it 1.5" or 2" PVC pipe?
How to size spa PVC plumbing:
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Since specified pipe sizes are nominal,
and not actual dimensions, finding the
correct pipe size can be confusing.
Follow this guide to easily determine
whether your hot tub spa uses 1½" or 2"
PVC plumbing. |
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1.5"
nominal pipe size will have a circumference
(distance around) of just under 6 inches.
The actual outside diameter (O.D.) of 1½" PVC
pipe will be about 1 7/8". |
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2"
nominal pipe size will have a circumference
(distance around) of more than 7 inches.
The actual outside diameter (O.D.) of 2" PVC
pipe will be about 2 3/8". |
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NOTE:
When plumbing Control
Systems, please remember that the heater should be mounted
on the pressure side (output) of the pump. The heater
will often not function correctly if installed prior to the
pump (suction side).
Spa
Pack Components, Unions, Fittings
Plug It In
Our control systems make it easy to hookup your spa's
components: pumps, light, blower, ozonator, spa side
control, etc. Each connection has its own J&J
receptacle, labeled as to function-- so hookup is a
snap!
EasyPak systems
come with new SmartCords
for pump(s), and blower, ozonator and 12v light.
Detailed installation and operation manuals are also
supplied with every system we sell. |
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Electrical Considerations
All electrical
connections to the equipment control box must be
accomplished by a qualified electrician in accordance
with the National Electrical Code, and in compliance
with any local codes.
GFCI note: A ground-fault circuit
interrupter, or GFCI is an important safety
device which can prevent electrical shock.
The optional GFCI used in EasyPak
systems is much different from the garden variety
you might find in your home...
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...It is a special high-current GFCI,
meaning it protects both the low and
high-current components of your system,
providing you maximum safety. It
accomplishes this task by utilizing both a
special inductive GFCI
-and- high-current switching contactor.
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This is expensive technology, so not all
manufacturers use it. If the electrical
service to your spa is already properly GFCI
protected, an integrated GFCI in the spa pack is
not necessary. |
- 110-120 Volt
Service
Requires a dedicated 20-amp two wire
electrical service, plus ground (line 1, neutral,
and ground). Heater operates at 110-120V. See
GFCI notes below.
- 220-240 Volt
Service
Requires a dedicated 50-amp three wire
electrical service, plus ground (line 1, line 2,
neutral, and ground). Heater operates at 220-240V.
See GFCI notes below.
- GFCI
For safety, all spa control systems must be
GFCI-protected. If the electrical service to
your spa is not already GFCI-protected, purchase a
control system with integrated
high-current GFCI option, or add a GFCI
disconnect box, as appropriate. (Test
the GFCI per product instruction manual).
- Wiring
Use copper wire only; approved pressure-type wire
splicing or connectors suited for the size and of
wiring used. Field provided conductors and
circuit breakers must be sized to accommodate the
total amperage load of the equipment connected to
the equipment.
- Electrical
service
The electrical supply must include a suitably
rated circuit breaker to open all ungrounded supply
conductors. The disconnecting device must be
within sight, and readily accessible to the user of
the hot tub spa, but installed at least 5 feet
(1.5m) from the spa. Observe local code
requirements.
- Bonding Conductor
Connect a #8 AWG (8.4mm) solid copper bonding
conductor between the spa equipment control box
bonding lug and all other electrical equipment and
exposed metal in the vicinity, as may be needed to
comply with local code requirements.
Consult your Building Dept. for information on local
electrical codes.
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Need help or additional information?
Our Certified Spa Technician is here to
assist you. Call toll free:
(800) 823-3638
Monday - Friday
8:00 AM to 5:00 PM Pacific Time Zone |
Need help
selecting?
EasyPak
Comparison Guide
See:
Spa
Equipment Troubleshooting for a for spa repair
information.
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Spa Packs, Pumps, Blowers & Controls
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We feature these quality components: |
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Spa
Packs |
Quality EasyPak Spa Control Systems. |
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Ozonators |
Clarathon and
Eclipse Ozonators for your hot tub. |
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Pumps |
Replacement pumps in various sizes/voltages. Best
buys! |
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Blowers |
Complete blowers for less cost than replacement motors! |
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Spa
Pack Components |
Topside control, PVC reducers, GFCI Disconnect, Pump
unions |
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In-Line
Filters |
This hot tub pressure filter is a Best Buy. |
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|
The
Parts Bin |
Common spa parts at uncommonly low prices! |
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Other
Spa Parts |
Thousands of quality replacement spa parts. |
Quality Spa Packs, Parts & Pumps at the
planet's best prices, guaranteed!
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