| Heater Element Replacement, Flow-Through Style,
Cal-Spa |
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Safety Warnings!
| Remove Power from the spa/hot tub BEFORE performing this
procedure. Failure to comply with this requirement, can lead to
electrical shock and/or electrocution! |
Disclaimer
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| The
instructions here are intended for general reference only. Many hot tubs and spas
are different from the one depicted here, and may require more or less
mechanical effort or knowledge in order to achieve the desired
results. |
READ FIRST BEFORE YOU
CONTINUE
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Note that this section is intended for replacement of a standard
flow  through heater element that is contained within a stainless steel
housing.
In this particular example, we are
demonstrating the procedure as done on a 1995 model Cal-Spa, with a Cal-Spas electro-mechanical spa
control system.
While most spas that have stainless steel flow
through heaters are almost identical, your heater and/or control system may not be, so, this
procedure used may not work for your unit. Your particular heater element may require more
effort and technical knowledge to replace. If this displayed procedure is inconsistent with
your system design, then do not use this information to service your spa. This is page 2 of this
procedure.
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| This is quite easy if you don't have
too much corrosion built up on the heater element retaining nuts. Simply use a wrench to
loosen the nuts and remove them. If so, click
here to continue. In this case
though, we will show the worst case scenario, and that is, a heater element that can't be removed
because the fused element junction is turning with the nut, and requires extra effort in order to
remove it. If both heater retaining nuts come off ok, then you can skip the next few
steps. |
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Now we're getting down to the reason
why I am in business.... corrosion. Water quality. If you don't maintain it, you
lose it. Your spa that is. Everything that comes in contact with the water is subject
to destruction if you fail to maintain proper water
quality. If you can't remove the nuts that secure the heater element to the heater tube ,
the best solution is to use a grinding/cutting wheel attached to a drill or hand-held
grinder. A skilled operator of an acetylene torch would also be successful at removing the
nut, however I prefer the grinder/cutter method simply because the amount of heat that the heater
tube has to endure.
Caution!
| This is a VERY tricky procedure and requires
extreme control to ensure that you don't cut into the stainless steel heater casing! Note
that these images are for illustration only! If you do not have the physical and mental
dexterity to properly control this type of tool, then DO NOT USE IT! |
Caution! |
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| A pretty destructive procedure,
however it gets the job done. All that's necessary is to cut through enough of the element
retaining bolt and the element threads to release the "hold" that corrosion has made on
the unit. Right image; Note the worn out cutting wheel laying on the deck (under the label on
the heater tube). |
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| The retaining nut comes off very easily once its
hold has been broken. |
| With both nuts removed. It's time to get the
old element out of here! Note all the "skids" and nicks made by the operator (me)
losing control of the cutting wheel... (to the left) |
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