| 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 3 of this
procedure.
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| With both element bolts removed, push
the studs out through the heater tube holes and into the tube itself, and slide the element
out. Take the new element and push it into the tube, trying not to put too much pressure on
the wire studs sticking out of the element. It may take a bit of calculated effort to
accomplish this, but by using a little common sense, a screwdriver and needle nose pliers, you
should be able to get the new element back in to place rather quickly. |
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| With the new element in place, thread
on the element retainer nuts and tighten until you get good pressure on the housing. If your
element has the whitish plastic insulators on the bottom of the element studs, (on the right inside
the tube), tighten the element until they begin to squeeze against the inside of the shell of the
tube. One way to ensure that the element is tight enough is to look at the outside where the
nuts go onto the element studs, and there will be less than 1/16" between the top of the stud
and the top edge of the nut. |
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| Don't forget to put the high limit
sensor bulb back into its captive area, then reposition the heater tube back into the spa
pack... |
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| Re-attach the nuts that hold the heater tube to
the spa pack. |
| Re-attach the heater wire lugs to the element,
preferably using a flat washer underneath them, using appropriate care to prevent the twisting of
the lug. |
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| The rest is simply reassembly of the
spa pack and plumbing, reverse of the removal sequence. Be sure to tighten the heater
plumbing connections properly. Once the power is reapplied to the spa, be sure to check for
water leakage around the heater element retaining nuts. If you find leakage, remove power and
retighten them as required. |
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