Cal Flame A534 Hot Tub User Manual
Contents
1. www calspas com 2009 LMS Inc Contents Pre Delivery and Installation Checklist 1 Planning the Best Location eese ERK EER ener nana 2 Portable Spa Site Preparation eren 4 In Ground Spa Site Preparation eene 4 Getting the Spa I nto Your Yard ERK KERE EER KERR EE EK KEER EE 6 Electrical Requirements sis EE EK RR EK nn nnns 8 Electrical Requirements US and Canada 8 Electrical Installation Europe iese ee ee ee ee ee ee ee ee ee ke ke m 13 Installing the In Ground Shell eee 16 Equipment Pack Plumbing Connections 1 n Ground Spas 17 In Ground Plumbing Connections sss 19 Electrical and Electronic Connection 21 Pouring the In Ground Spa Deck 25 Spa Technical Specifications ssssmmsssmmmannemmnnnnennte 26 CONTACT INFORMATION Copyright 2008 2009 LMS Inc All rights For customer service please contact reserved Duplication without written your authorized dealer immediately If consent is strictly prohibited you need additional information and or assistance please contact Cal Spas is a registered trademark LMS Customer Service Department Due to continuous improvement pro 1462 East Ninth Street grams all models operation and or Pomona CA 91766 specifications are subject to chang2. Ground LTR20091024 Rev A 5 I nstalling the In Ground Shell In Ground Spa Deck Requirements SPA AND LIP MUST SET ON A SOLID BASE SUPPORTS MUST BE 12 MIN O C ON SEATS AND STEPS LIP MUST SET ON A SOLID SURFACE LTR20091024 Rev A Equipment Pack Plumbing Connections In Ground Spas The example shown below is typical for a system with two pumps with external heater and external filter Swim jet return Swim jet suction Ozone return Heat pump return Heat pump suction Designer Spa Specifications DIJ 401 and DIJ 405 Equipment pack weight 250 Ibs C DI J 407 3 Equipment pack weight 300 Ibs K 2 5 HP heat 5 eat pump 3 p 4 HP swim pump i s EQUIPMENT PACK DIMENSIONS Note Equipment pack cannot ex ceed 15 feet from spa LTR20091024 Rev A 7 0E9900 HEATER LTR20091024 Rev A In Ground Plumbing Connections IMPORTANT Always check local codes prior to any in ground spa instal lation Once the spa and equipment are properly located you will want to lay out the plumbing run Trenches should be deep and wide enough to allow all pipes to be buried below the frost line and should be in as straight a line from the spa to the equipment as possible Check local code requirements for underground pipes Always know what is under the ground before you dig anywhere You will need 2 flex or PVC lines for your suction intake and air line In ground spas have marked intake and suc
3. a 3 4 concrete slab pack Excavate the hole Install dedicated electrical supply Install dedicated NG line for gas heater Install sten ground instal equipment pack Connect plumbing Connect electrical compo nents na Pour the deck Install dedicated electrical supply After Delivery Place spa on slab Connect electrical compo nents LTR20091024 Rev A Planning the Best Location Safety first Do not place your spa within 10 feet 3 m of overhead power lines Make sure the spa is positioned so that access to the equipment compart ment and all side panels will not be blocked Be certain that your installa tion will meet all city and local safety codes and requirements Consider how you will use your spa How you intend to use your spa will help you determine where you should position it For example will you use your spa for recreational or therapeu tic purposes If your spa is mainly used for family recreation be sure to leave plenty of room around it for activity If you will use it for relaxation and therapy you ll probably want to create a specific mood around it Plan for your environment If you live in a region where it snows in the winter or rains frequently place the spa near a house entry By doing this you will have a place to change clothes and not be uncomfortable Consider your privacy In a cold weather climate bare trees won t provide much privacy Think of your s
4. a25 ous a340 tes cna ee 9e 307 a25 sus asus Lacan se 9e 397 a25 e00 tbs asao tes LTR20091024 Rev A A Dien of Unys Weil Supp lc CHANGING THE Way You FEEL Powered by GE Motors LMS Customer Service Department 1462 East Ninth Street Pomona CA 91766 Toll Free 1 800 CAL SPAS Fax 1 909 629 3890 www calspas com LTR20091024 Rev A 12 15 08
5. and can be connected to the suction side of the pump on the eguipment pack If any plumbing line is not properly marked or not marked at all follow either the air or water test procedure until all lines are identified prior to gluing LTR20091024 Rev A NOTE Once complete water test the plumbing run for at least three days prior to covering any plumbing trenches and back filling spa cavity completely NOTE Some local inspectors require pressure testing the plumbing lines Although the spa is pressure tested at the factory local inspectors may insist on pressure testing the plumbing run between the spa and equip ment pack Gate Slice Valves The use of gate valves is recommended on all plumbing lines both suction and return lines These valves are used to contain the spa s water in ei ther the equipment or the spa This will assist in the pump priming process and future servicing without needing to drain the spa NOTE When draining the spa to perform maintenance always close the gate valves prior to draining This will maintain the pumps prime Connecting Plumbing to Remote Equipment Connecting the plumbing from the spa to the equipment pack must be performed in accordance to local and city codes NOTE Most codes require plumbing to be rigid PVC schedule 40 or heavier in both above and below ground installations In most cases the use of flexible PVC plumbing is acceptable when properly buried in trenches Most w
6. the wiring diagram on page 15 The electrical wiring of this spa must meet the requirements of any ap plicable local state and federal codes The electrical circuit must be installed by an electrical contractor and approved by a local building electrical inspec tor RCD and Wiring Requirements The power supplied to the spa must be on a dedi cated RCD protected circuit with no other appliances or lights sharing the power Use copper wire with THHN insulation Do not use aluminum wire Use the table on the next page to determine your GFCI and wiring requirements When wires larger than 6 AWG are required install a junction box near the spa and use 6 AWG wire between the junction box and the spa Wire runs over 85 feet must increase wire gauge to the next lower num ber For example A normal 50 amp RCD with four 8 AWG copper wires run over 85 feet would require you to go to four 6 AWG copper wires Testing the RCD Breaker Test the RCD breaker prior to first use and periodically when the spa is powered To test the RCD breaker follow these instructions spa should be operating l Press the TEST button on the RCD The RCD will trip and the spa will shut off 2 Reset the RCD breaker by switching the breaker to the full OFF posi tion wait a moment then turn the breaker back on The spa should have power again LTR20091024 Rev A Spa Model GFCI Required Wires Required All 230V spas except 6205 con
7. to provide a proper foundation for the spa Place the spa on an elevated foundation preferably a 3 4 concrete slab Pavers gravel brick sand timbers or dirt foundations are not adequate to support the spa If you are installing the spa indoors pay close attention to the flooring beneath it Choose flooring that will not be damaged or stained If you are installing your spa on an elevated wood deck or other structure it is highly recommended that you consult a structural engineer or con tractor to ensure the structure will support the weight of 150 pounds per square foot To properly identify the weight of your new spa when full remember wa ter weighs 8 33 lbs per gallon For example an average 8 spa spa holds approximately 500 gallons of water Using this formula you will find that the weight of the water alone is 4 165 lbs Combined with the dry weight of the spa you will note that this spa will weigh approximately 5 000 Ibs when full of water Note It is strongly recommended that a qualified licensed contractor pre pare the foundation for your spa Your Cal Spas retailer can help you with your foundation and more Your retailer has a wealth of information and experience about how to get the most out of your spa and can provide you with a full line of accessories that are designed to complement your spa and increase your enjoyment I n Ground Spa Site Preparation e Ensure there is enough room for the spa and equip
8. voltage transformer must be located e atleast 8 20 cm above water level e atleast 4 10 cm above ground level and e atleast 48 121 cm away from the spa See figure below 48 min 8 min Junction Box or low Voltage Transformer Rigid ES Conduit 18 min to top of Lens 8 AWG Ground Connector bonded to rebar 6 0 tT To GFCI Circuit Breaker and Power Source LTR20091024 Rev A Light niche and any metallic items in a 5 152 cm radius must be properly bonded with 8 AWG grounding wire 1 Connect rigid conduit to the 3 4 hub located at the back of the light niche and run to a water resistant junction box or for 12 volt models to a low voltage transformer no further than 25 7 6m Remember this is a water cooled light so the conduit and all connections must be leakproof Feed the light cord through the rigid conduit to the junction box leav ing at least 4 feet of cord at the end of the light fixture This slack in the light cord will allow servicing without draining the spa in the fu ture Wrap light cord slack around back of light housing and attach light to niche with mounting screw Cut the cord at the junction box leaving at least 6 15 cm of cord to make connections Strip 6 15 cm of the out cord jacket to expose the three insulat ed wires Be careful not to damage the insulation on the three inner wires Connect the three wires to the corresponding circui
9. and are of no consequence LTR20091024 Rev A Getting the Spa Into Your Yard Check the Dimensions of Your New Spa The specification chart on page 26 lists your spa s model and its dimen sion as it sits on the delivery cart During delivery the spa must remain on the delivery cart at all times Compare the dimensions to the width of the gates sidewalks and doorways along the delivery route It may be necessary for you to remove a gate or partially remove a fence in order to provide an unobstructed passageway to the installation location Plan the Delivery Route Consider the following when planning your delivery route e Check the width of gates doors and sidewalks to make sure your spa will pass through unobstructed You may have to remove a gate or part of a fence to allow for adequate width clearance e Are there low roof eaves overhanging branches or rain gutters that could be an obstruction to overhead clearance e 8 spas need at least 42 wide gate and 9 height clearance e If the delivery route will require a 909 turn check the measurements at the turn to ensure the spa will fit e Are there protruding gas meters water meters or A C units on your home which will cause obstructions along the delivery path to your yard e Are there stairs in your delivery route If so you must consult your Cal Spas dealer prior to delivery to make adequate preparations Special Circumstances The use of a crane for delivery an
10. ater plumbing lines are 2 or larger and must be schedule 40 or heavier PVC When plumbing minimize the use of 90 elbows as much as possible The use of 45 elbows will increase the amount of jet pressure you will have over the use of 90 elbows The plumbing on the spa shell is labeled by the factory in the following manner Pump 1 Suction 2 line that connects the spa filter and bottom drain as sembly to the front of pump 1 Pump 1 Return 2 line that connects the top of pump 1 through the equipment filter and heater back to selected jets in the spa Pump 2 Suction 2 line that connects the spa filter and bottom drain as sembly to the front of pump 2 Pump 2 Return 2 line that connects the top of pump 2 back to selected jets in the spa Ozone Line 1 line that connects to a 1 flexible line extending off the bottom of the equipment pack filter canister through an ozone injector If ozone equipped and connected to ozone port on the spa Air Blower 1 1 2 line that is plumbed out of the air blower located on the equipment pack and extended up 18 above the spas water level to prevent water flooding the air blower LTR20091024 Rev A Air Venturi 1 2 line that is plumbed 18 above the spa s water level Topside Control Panel and Temp Sensor 1 line that connects to the bot tom of the control box located on the equipment pack rical and Electroni nnection Remote Equipment Topside Control Panel The nex
11. d flat concrete surface at least 4 thick as large as the bottom contact points Be sure not to seal the bottom off and making a sealed box You will need adequate water drainage for escape under the spa A gravel beds around the concrete base will help with this Site Excavation Sand Bottom With the spa area and all elevations planned including your decided type of decking you are now ready to proceed with the dig An ideal excavation is one that is as close as possible to the dimensions of the spa shell but with the following rules in mind The excavation should be 2 to 4 deeper than the actual spa for your sand bed The sand bed is to level the spa shell and provide a perfect support base with no voids when the spa is lowered into the hole Your excavation should be approximately one foot longer and one foot wider than the spa shell This will allow for a six inch over dig all the way around the spa once it is in place Additional hand excavation will be required to insure the skimmer will fit in the excavation when attached to the spa Sand or rock dust must be used to bed the shell into the excavation and for backfill In no event is dirt to be used One of the easiest ways to know how much sand is needed to be placed on the bottom of the excavation is to set a grade stake at all four corners and one on each side of the center line in the bottom of the hole If there are areas that are deeper than 2 to 4 these can be filled with sand
12. d installation may become necessary if you are unable to provide an adequate delivery route It is used primarily to avoid injury to your spa your property or to delivery personnel Your Cal Spas dealer may be able to assist you with the arrangements If your spa delivery requires the use of a crane the cost of a crane is generally not included in the standard delivery service LTR20091024 Rev A Check your width clearance Check all gates Protruding electric meters Gas meters A C units Do you have sufficient overhead clearance Check low roof eaves overhanging branches rain gutters Is the path clear Move away branches dog houses firewood etc BACKYARD If there is a 90 turn can we clear it The spa will not bend No stairs If there are stairs in the delivery route consult the dealer STREET LTR20091024 Rev A Electrical Requirements Electrical Requirements US and Canada 240 Volt Electrical Installation All 240V spas must be permanently connected hardwired to the power supply These instructions describe the only acceptable electrical wiring procedure Spas wired in any other way will void your warranty and may result in serious injury This is the only acceptable electrical wiring procedure Spas wired in any other way will void your warranty See the wiring diagram on page 11 When installed in the United States the electrical wiring of this spa must meet the require
13. e a weatherproof covered receptacle Receptacle shall be located not less than 5 ft 1 5 m from and not exceeding 10 ft 3 0 m from the inside wall of the spa Do not bury the power cord If your cord becomes damaged replace it before next usage All 120V spas must have a GFCI This can be either a 20 amp GFCI re ceptacle or a GFCI cord and plug kit as shown at right CKIT110 P N ELE09700086 Testing the GFCI Breaker Test the GFCI plug prior to first use and periodically when the spa is pow ered To test the GFCI plug version follow these instructions Spa should already be plugged in and operational l Pressthe TEST button on the GFCI The GFCI will trip and the spa will stop operating 2 Press the RESET button on the GFCI The GFCI will reset and the spa will turn back on The spa is now safe to use If the GFCI trips while the spa is in use press the RESET button If the GFCI does not reset unplug the spa and call your local Cal Spas dealer for service DO NOT USE THE SPA LTR20091024 Rev A Electrical Installation Europe 230 Volt Electrical Installation All 230V spas must be permanently connected hardwired to the power supply These instructions describe the only acceptable electrical wiring procedure Spas wired in any other way will void your warranty and may result in serious injury This is the only acceptable electrical wiring procedure Spas wired in any other way will void your warranty See
14. e with out prior notice Toll Free 1 800 CAL SPAS Fax 1 909 629 3890 LTR20091024 Rev A www calspas com 12 15 08 Pre Delivery and Installation Checklist Most cities and counties require permits for exterior construction and elec trical circuits In addition some communities have codes requiring resi dential barriers such as fencing and or self closing gates on property to prevent unsupervised access to the property by children under the age of 5 Your dealer can provide information on which permits may be required and how to obtain them prior to the delivery of your spa We strongly recommend you have a qualified licensed contractor perform the installation of your in ground or ported spa The installation instruc tions contained in the manual are for the use of a qualified contractor or installer Consumers who choose to install their own in ground spas bear sole re sponsibility for any performance or warranty issues and may void portions of their warranty as a result For this reason we strongly recommend they hire an experienced professional for their installation For additional operating and installation information please see your sell ing dealer Portable Spa I n Ground Spa Pre Delivery Checklist Pre Delivery Checklist Before Delivery Before Delivery mm Plan your delivery route Plan your delivery route Choose a suitable location Choose a suitable location for the spa for the shell and equipment Lay
15. ment e The equipment pack must be located within a maximum of 15 feet from the spa e Plan for proper electrical and gas service to both the equipment area and spa side e Ensure the required flat level foundation can be constructed in the area chosen LTR20091024 Rev A e The spa must be properly back filled with wet sand underneath and on all four sides e The final architecture must include permanent ground coverage within a 10 feet radius of the spa e Never place any spa in a sealed area Water must be able either to be absorbed into the surrounding area or channeled away Water build up under and or around the spa will cause the spa to float out of the ground Grading Prior to Excavation Selection of the Designer Spas site will determine how much grading will have to be accomplished prior to the actual dig for the spa Naturally a level area is best because it will require the least amount of preparation for the dig but in many cases there is no level area therefore the site must be prepared to accept the Spa prior to dig The spa site should be elevated slightly higher than the surrounding area When dealing with slopes the severity of the slope will determine if retain ing walls must be built in order to have a level area for the spa If the slope is relatively minor contact your local building safety Site Excavation Hard Bottom For hard bottom placement for in ground spas you will need a smooth an
16. ments of National Electric Code ANSI NFPA 70 2008 and any applicable local state and federal codes The electrical circuit must be installed by an electrical contractor and approved by a local building electrical inspector GFCI and Wiring Requirements The power supplied to the spa must be on a dedicated GFCI protected circuit as required by ANSI NFPA 70 with no other appliances or lights sharing the power Use copper wire with THHN insulation Do not use aluminum wire Use the table on the next page to determine your GFCI and wiring require ments When NEC requires the use of wires larger than 6 AWG install a junction box near the spa and use 6 AWG wire between the junction box and the spa Wire runs over 85 feet must increase wire gauge to the next lower num ber For example A normal 50 amp GFCI with four 8 AWG Copper wires run over 85 feet would require you to go to four 6 AWG copper wires Read and follow the heater manufac turer s safety and installation instruc tions prior to installation and operation Incorrect installation may damage the heater and void its warranty LTR20091024 Rev A Spa Model GFCI Required Wires Required All 240V spas except 6300 control boxes re Four 8 AWG copper quiring high amperage o A GI wires see below Spas with the 6300 control box when high amperage is selected on circuit board One 60 amp GFCI SEE CONFIGURATION INSTRUCTIONS ON NEXT PAGE F 2400 s
17. n experienced concrete finisher should always be used when pouring spa decks especially when you are doing a cantilevered deck as the forms must be taken off at the proper time to allow finishing of the inside of the form LTR20091024 Rev A Spa Technical Specifications All sizes on this chart represent outside dimensions Due to our continu ous improvements specifications size and pricing are subject to change without prior notice Avalon Series Avalon Series model wan Length Dent ations weige wee Weight Weight ass Qu er 3x aas oous 3307 bs ims ee er 3x 325 oous 3307 bs nw mer er 3x xs oous 3307 bs uns sr se som s eo tes 4390 bs uns amp r er som s 60 tes 4390 bs um ar er som 25 50 tes 4390 bs uL ar er som 025 50 tes 4590 bs aas ew ee 39 425 sso lbs 4390 os Lua ewe Bw 30 425 gsotbs 5901s Designer Series sege se mmm Modet width Length Depth Galons wene welsh orans mo sx 29 90 roux 8247165 LTR20091024 Rev A Classic Series Wi Length Depth allons wehe weige aus e le 3x us ses is 1576 Lbs ces oar se 3047 a25 501s 4390 Lbs cra se 9e 307 a25 sous 1390 Lbs Ges ear ear 3947 425 501s 1390 Lbs crso se se 307 a25 sous 1390 Lbs cr e ear ea 3047 a25 ssous 1390 Lbs Ge
18. pa s surroundings during all seasons to determine your best privacy options Consider the view of your neighbors as well when you plan the location of your spa Provide a view with your spa Think about the direction you will be facing when sitting in your spa Do you have a special landscaped area in your yard that you find enjoyable Perhaps there is an area that catches a soothing breeze during the day or a lovely sunset in the evening Keep your spa clean Prevent dirt and contaminants from being tracked into your spa by placing a foot mat at the spa s entrance where the bather s can clean their feet be fore entering your spa You may also consider keeping a small water filled basin nearby for bathers to rinse their feet before entering your spa In planning your spa s location consider a location where the path to and from the house can be kept clean and free of debris LTR20091024 Rev A Allow for service access Many people choose to install a decorative structure around their spa If you are installing your spa with any type of structure on the outside such as a gazebo remember to allow access for service It is always best to design special installations so that the spa can still be accessed Outdoor equipment pack in ground spas only The Designer Spa series requires an external equipment pack When locat ing the outdoor equipment pack you will want to consider the following The equipment pack must be located wi
19. pa with one Four 8 AWG copper Service 1 One 60 Service 1 Four 8 F2400 and FP2500 spas amp GFCI AWG copper wires with two 5 5 kW heaters service 2 One 30 Service 2 Three 8 amp GFCI AWG copper wires Service 1 swim Service 1 Four 8 side One 60 amp AWG copper wires GFCI Service 2 swim Service 2 Three 8 side One 30 amp AWG copper wires GFCI Service 3 spa side Service 3 Four 8 One 40 amp GFCI AWG copper wires Designer in ground spas Four 8 AWG copper with one 5 5 kW heater SUIS SU ap GEG wires Service 1 One 50 Service 1 Four 8 Designer in ground spas amp GFCI AWG copper wires with two 5 5 kW heaters service 2 One 30 Service 2 Three 8 amp GFCI AWG copper wires Service 1 One 60 Service 1 Four 8 amp GFCI AWG copper wires Service 2 One 30 Service 2 Three 8 amp GFCI AWG copper wires Portable Spas Four 8 AWG copper wires u o u a 9 c S iL v g 5 2 FP4700 spa In Ground Spas LTR20091024 Rev A Testing the GFCI Breaker Test the GFCI breaker prior to first use and periodically when the spa is powered To test the GFCI breaker follow these instructions spa should be operating 1 Press the TEST button on the GFCI The GFCI will trip and the spa will shut off 2 Resetthe GFCI breaker by switching the breaker to the full OFF posi tion wait a moment then turn the breaker back on The spa should have power again Configuring the 6300 Con
20. ram on the inside cover of the control box for proper placement Turn on the power supply to the spa equipment and briefly test all functions on the topside control panel to verify that both connections and extension loom are in working order before proceeding with the installation LTR20091024 Rev A NOTE Circuit board programming will not allow spa operation without both the temperature and high limit sensors being properly connected to the circuit board 7 Once topside panel operation is verified Turn off power disconnect the extension loom from the circuit board and GENTLY route through conduit to complete installation NOTE This loom and its connector are not meant to withstand heavy pull ing Make sure when routing the extension loom and temperature sensor lines through conduit you exercise extreme caution Once properly run through the conduit repeat steps 5 and 6 above In Ground Spa Light Installation Instructions On spas ordered with in ground lights the factory installs the light niche for you The next steps of installation should be performed by a qualified licensed electrician Always read and follow light manufacturer s safety and installation instruc tions prior to installation and operation Incorrect installation may damage the light and void its warranty The light circuit must be on a GFCI protected service alone or with a switch The water resistant junction box or for 12 volt models the low
21. s ear ea 3947 a25 0501s 4390 Lbs EE Gees ces s e s 900 moo ros 65e Tes Galaxy Series Dry Filled Weight Weight LTR20091024 Rev A Family II Series model it Lengen Dean stens weige wage eight eight E7308 84 aa 35 425 800Lbs 4340 Lbs F730L 84 aa 35 425 800Lbs 4340 Lbs F7328 84 84 35 425 800Lbs 4340 Lbs F732L 84 84 35 425 800Lbs 4340 Lbs F745B 8a aa 35 425 800Lbs 4340 Lbs Fz5L 8a s 35 425 800 Lbs 4340 Lbs r 48L 8a s 35 425 800Lbs 4340 Lbs Escape Series Bessie OOOO Mede width Length Depth Galons weine Welsh Fes ee se se us e00 ws 1540 Los Es ee ee 39 7 us 800 bs a340 Tes Fera ee ea 39 7 us ous 540 LTR20091024 Rev A Ultimate Fitness and Fitness Pro Series Modei wem Length Dept Gone wege vigne s rust or ur sr 2000 150 tes 20 1e ras se me sr 2500 erus 2705 ris Lan sr 2500 eos 2705 rum se aro sr 2000 180 tes 1860155 rss ser 200 str 2500 2000 tes 705 FP4700 EE 2000 2950 Lbs 21985 Lbs 285 Victory Extreme Series Vietory Extreme Ses Model Wi Length Depth Ganons weine weight aces 7e ear 3 xs meus serus na re se 3w meus 3572153 ones ee ear 39
22. t few steps to complete the installation should be performed along with installation of the temperature sensor and 12V spa light wiring if ap plicable All of these components are generally installed using the same conduit I Locate the topside control panel extension loom in the control box mounted with the equip ment pack This extension loom and attached black terminal connector see figure at right will be used to connect the top side control panel to the control box Connect one end of the black terminal connector to the top side control panel cable Connect the other end of the terminal connector to the extension loom NOTE This connection must be kept dry We recommend that a water proof junction box be used in installations where moisture could penetrate this terminal connector 4 Lay out the extension loom to verify that you have enough length to reach the control box Remember that conduit runs are not generally run in a straight line Every bend and up and down run consumes line length Take this into consideration when verifying electrical and plumbing runs Connect the extension loom to the control panel location on the circuit board located inside the control box You will also need to connect both the temperature and high limit sensors to the circuit board prior to testing See the temperature and high limit installation instruction on the next page for proper identification and see the wiring diag
23. t wires in the junc tion box and secure the junction box cover in place Replace the light assembly in the niche and tighten the special pilot screw Fill the spa until the underwater light is completely submerged in wa ter before operating the light for more than 10 seconds Turn on the main switch or circuit breaker as well as the spa light control to check for proper operation Important Make sure spa light is submerged in at least 18 of water prior to testing LTR20091024 Rev A Circular Clamp Orientation of Wire Clamp and Bolt Connection Pilot Screw Pilot Screw Bolt Is to be tightened at approx 90 degrees from the pllot screw on the face ring as shown above Clear lens Floodlamp Face ring chrome brass Gasket 4 diameter Screw stainless steel 10 24 x 3 8 6 required Pilot screw with captive gum washer Kwik change color lens Face ring assembly Wire spring clamp 1 4 20 x 5 8 bolt Uni tension wire assembly stainless steel with welded nut O NOU RUN C Use only the special pilot screw provided with this underwater light This screw mounts and electrically grounds the housing securely to the mounting ring and wet niche Failure to use the screw provided could create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock LTR20091024 Rev A Pouring the I n Ground Spa Deck It is recommended
24. that all electrical hook ups and all plumbing be com pleted before pouring the concrete Make certain all electrical inspections on lights bonding and all other electrical work have been completed and checked off by the local inspectors prior to proceeding with your concrete or finish work Tt is a good idea to run the spa for at least 24 hours before pouring the concrete to insure there are no leaks We understand you want to enjoy your spa now but a 24 hour period with your spa running will let you know of any problems before they will be extremely hard to fix The type of decking you have selected will have determined the grade of the spa If you are pouring a regular deck up to the spas coping then the top of the coping should be 4 above the surrounding area In either event it is recommended to dig out an area around the spa exposing the flange of the coping and just under it This is important as concrete should be packed under and over the flange of the spa as the deck is poured This will lock the spa into the concrete and provide for a much stronger bond of the spa to the deck It will also eliminate cracking of the deck where it meets the spa When setting your outside forms remember you want any water from rain or splash out to run off the deck not into the spa If your deck is going to tie into an existing deck than some type of drain system should be planned to handle the run off Proper drainage planning is very important A
25. thin a maximum of 15 feet from the spa Ensure the equipment running its normal filtration cycles does not make too much noise for spa owners and or neighbors Ensure the equipment can be easily serviced for filter cleaning and periodic inspections in the location chosen If you are using a gas heater you will need to consider wind and drafts as well as heater exhaust for proper heater placement See heater owner s manual for important location and safety information The equipment base and heater must be placed on either a 3 1 2 cement slab or 3 paving stones Make sure the equipment area selected will not be in an area where water could run or stand If the area receives direct sunlight you will want to provide some pro tection for the equipment portion of the equipment pack The equipment pack and heater are delivered separately Do not cover gas heaters unless properly vented See heater owner s manual for important safety information LTR20091024 Rev A Portable Spa Site Preparation Your spa needs a solid and level foundation The area that it sits on must be able to support the weight of the spa with water and the occupants who use it If the foundation is inadequate it may shift or settle after the spa is in place causing stress that could DAMAGE YOUR SPA SHELL AND FINISH Note Damage caused by inadequate or improper foundation support is not covered by the warranty It is the responsibility of the spa owner
26. tion lines making it easy find and connect to and from the spa and equipment pack The plumbing run should not be any longer than 15 feet to maximize water pressure Another way to maximize water pressure is to limit or even eliminate the use of 90 elbows in your plumbing run A more direct plumbing run using 45 elbows is more efficient and promotes increased water pressure I dentifying Plumbing Lines The spa s plumbing lines are clearly marked during water testing at the factory This is done to assist installers in properly identifying the installa tion We still recommend that the installers verify plumbing lines prior to gluing This can be done by using one of the following technigues Air Test The air test reguires a wet dry vacuum Locate the plumbing line you wish to identify and secure the vacuum hose to cut open end Turn on the vacuum enter the spa and listen for vacuum suction sound from inside the spa side filter canister If you hear the suction sound in the canister the line is properly marked and can be connected to the suction side of the pump on the eguipment pack Water Test The water test reguires a garden hose and water source Locate the plumbing line you wish to identify and secure the outlet side of the garden hose to cut open end Turn on the water supply to the garden hose enter the spa and look for water inside the spa side filter canister If you see water in the canister the line is properly marked
27. trol System The 6300 control system requires higher power than other 240V systems Dip switch 10 is factory set in the ON position This causes the heater to shut off when any pump is running in high speed To allow the heater to continue operating dip switch 10 must be set to the OFF position To ensure your spa functions properly ensure the following steps are per formed before starting your spa e When installing the electrical system use a 60 amp GFCI Follow the GFCI wiring diagram on the next page e Have your dealer or installer set dip switch 10 to the OFF position on the circuit board as shown below CLASS 6 FUSEXA rs AXE ds TEG Set dip switch10 to OFF position LTR20091024 Rev A GFCI Wiring Diagram House Breaker Box System Box ON ON dIE OFF RED HOT BLK HOT GFCI Breaker Box Front View of GFCT a r z Z 2 2 z z E g z Z e G WHITE NEUTRAL 2 BLK HOT 3 RED HOT 4 GREEN GROUND 5 WHT LOAD NEUTRAL GRN GROUND RED LOAD HOT LTR20091024 Rev A 120 Voit Electrical Installation Always follow applicable local state and federal codes and guidelines Use only a dedicated electrical line with a 20 amp breaker Cord and plug connections may not use a cord lon ger than 15 ft 4 6 m and must be plugged into a dedicated 20 amp GFCI connection Do not use extension cords Always us
28. trol boxes re One 32 amp RCD or Three 10 AWG cop quiring high amperage two 16 amp RCDs per wires see below Spas with the 6300 control box when high amperage is selected on circuit board One 32 amp RCD or Three 10 AWG cop two 16 amp RCDs per wires SEE CONFIGURATION INSTRUCTIONS ON NEXT PAGE F2400 spas with one 5 5 One 32 amp RCD or Three 10 AWG cop kW heater two 16 amp RCDs per wires Service 1 One 32 Service 1 Three 10 FP2500 spa with amp RCD or two 16 AWG copper wires one 5 5 kW heater and amp RCDs one 3 kW heater Service 2 One 32 Service 2 Three 10 amp RCD AWG copper wires Service 1 swim Service 1 Three 10 side One 32 amp AWG copper wires RCD Service 2 swim Service 2 Three 10 side One 32 amp AWG copper wires RCD Service 3 spa side Service 3 Three 10 One 32 amp RCD AWG copper wires Designer in ground spas One 32 amp RCD or Three 10 AWG cop with one 3 kW heater two 16 amp RCDs per wires Service 1 One 32 Service 1 Three 10 Designer in ground spa amp RCD or two 16 AWG copper wires with one 3 kW heater amp RCDs and one 5 5 kW heater Service 2 One 32 Service 2 Three 10 amp RCD AWG copper wires Portable Spas un Q u u u v c iL 9 z D 2 FP4700 spa In Ground Spas LTR20091024 Rev A RCD Wiring Diagram Value M 7 and 2000LE M 7 System Elite System In Spa System Box 2850600808 REEN Gi YELLOW
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