1.43 Chiller Replacement

Power Down The Plunge

• Pause the chiller by pressing the pause button on the UI
  • ⚠️ Powering down the Plunge while it's in a cooling cycle can damage the chiller. 
• Press the test button on the GFCI outlet to power down the Plunge.
• Unplug the GFCI outlet from the outlet.

🚨 Important: Do not power down the Plunge before pausing the chiller.

🚨Close Auto-Doser Ball Valves🚨

• Close the two auto-doser ball valves (perpendicular to the piping).
• Important note: Not closing the ball valves will cause the auto-doser probe to dry out and need a recalibration.

Drain The Plunge

• Remove the right ventilation screen. Opposite of the filter housing. 
• Locate the main drain manifold at the bottom and remove the cap from the spigot.
• Attach a garden hose or inline pump to the spigot 
• Turn the valve on the spigot and the water should flow out
• Turn the valve to close the spigot and install the cap back on.

Remove Chiller Vents and Thumb Nuts

• Remove both chiller vent panels.

• Unscrew all 5 thumb nuts:

  • 3 from the left chiller vent

  • 2 from the right chiller vent

• Note: Bottom-right nut may be an 8mm hex nut—use socket if necessary.

Remove Rear Cover

• Slowly pull and wiggle the rear cover out through the vent openings.

Remove Chiller Mounting Nuts

• Using a 10mm socket remove the 4 nuts securing the chiller to the base frame:

  • 2 on each side of the chiller base.

Remove E-Box Cover

• Use a 2.5mm hex screwdriver to remove the 4 screws securing the e-box cover.

Disconnect Electrical Components

• Disconnect Hanna Auto-Doser and LED connectors (press tab and pull from plastic base).

  • Hanna wires: blue, brown, green/yellow.

  • Some setups may use a Y-splitter. Remove Y-splitter and set aside to install onto new chiller.

• Disconnect UI ribbon cable from back of UI (spread wing tabs to release).

• Thread the LED wire out through its passthrough hole.

  • Tip: To free space, disconnect other wires from the hole temporarily and push them aside.

• Warning: Never pull wires directly. Use only connectors to disconnect.

Cut Electrical Zip Ties

• Cut zip ties securing:

  • LED wire

  • Power cord (if tied to the frame)

Disconnect Plumbing Manifolds

• Remove the 4 manifolds connecting chiller to tub:

  1. Main Drain – under e-box, connects to lower plumbing

  2. TH-1 – right of water filter housing

  3. Flow Meter – connects from rear of water filter to bottom of heat exchanger

  4. Heat Exchanger to Jet – top of heat exchanger to lower plumbing union

Remove Chiller

• Warning: Move slowly. Use 2 people if needed.

• Grab handles on both sides of the chiller base.

• Carefully lift and walk the unit forward.

• Angle the top of the chiller back to clear the e-box from the tub wall.

Install Plumbing Manifolds on New Chiller

• Use the new pre-installed manifolds on the replacement chiller:

  • TH-1: L-shaped with gray wire; attach to top of pump with elbow toward e-box.

  • Flow Meter: Circular meter with wire; bottom union connects to top of heat exchanger.

  • Heat Exchanger to Jet: Smallest manifold; connect to bottom of heat exchanger.

• Note: Confirm all unions have black o-rings. Hand tighten only—do not use tools.

Install New UI Ribbon Cable to 

• Always replace with new cable.

• Connect new ribbon cable—red stripe faces down.

• Pinch wing tabs closed to lock.

Install New Chiller

• Tilt the top of the chiller so the e-box can clear the top of the tub.

• Walk the base of the chiller to the base of the frame.

• Lift and place the chiller onto the frame of the chiller cabinet.

• Line up and slide the bolts to the holes in the chiller base.

Connect Plumbing to Tub

• Reconnect the 4 manifolds from the new chiller to the tub:

  1. Main Drain → under e-box to tub plumbing

  2. TH-1 → right side of filter housing

  3. Flow Meter → rear of filter housing

  4. Heat Exchanger to Jet → bottom plumbing union

• Note: Confirm o-rings are present on the 2 unions connecting to lower plumbing.

Connect Ribbon Cable To UI

• Locate the UI ribbon cable coming from the back of the electrical box.

• Ensure the red stripe on the ribbon cable is facing down

  • 🚨 If it’s facing up, the UI will not function.

• Open the wing tabs on the UI connector to allow for cable insertion.

• Insert the ribbon cable into the UI connector until it clicks into place.

• Close the wing tabs around the ribbon cable to secure the connection.

Connect Electrical Components

• Refer to PCB board diagram to ensure all electronics are plugged into the proper ports.

• Reconnect all components to their correct ports.

• Install the Hanna auto-doser splitter from the previous chiller (if applicable)
  • The splitter plugs into the AC In port of the PCB board. 

• Double check all plugs before continuing.

• Note: Do not install e-box or rear cover yet—testing comes next.

Test New Chiller

Follow standard testing protocol:

• Fill the tub until the water level is 1/2 inches above "min" line on skimmer.
  ⚠️ Running the system with low water may damage the pump.
• 🚨 Open the auto-doser ball valves.🚨 
  • ⚠️ Running the system with the ball valves closed will damage the chiller.
• Plug in the tub and press the Reset button on the GFCI.
• Set target temperature to 50°F.
  • Confirm the blue cooling arrow turns on.
• Listen for compressor operation.
• Allow the system to run for 10 minutes.
• Inspect all plumbing connections for leaks.
  ⚠️ Keep hands and tools away from the exposed chiller fan.
• Confirm no UI error codes:
• "CF" = Change Filter
• "OR" = Out of Range (sensor is reading outside 37–104°F range)
• If “OR” appears, thermistor replacement may be needed.
• Verify that water temperature is decreasing.

Power Down The Plunge

• Pause the chiller by pressing the pause button on the UI
  • ⚠️ Powering down the Plunge while it's in a cooling cycle can damage the chiller. 
• Press the test button on the GFCI outlet to power down the Plunge.
• Unplug the GFCI outlet from the outlet.

🚨 Important: Do not power down the Plunge before pausing the chiller.

Prepare for Rear Cover Installation

• Reattach e-box cover (4 screws).

• Secure chiller to frame using the 4 base nuts.

• Pre-install the upper thumb nut (near filter housing) loosely—this area is tight with cover on.

Install Rear Cover

• Carefully slide rear cover over chiller.

• Ensure power cord is routed through the correct side.

• Reinstall all 5 thumb nuts to secure rear panel.

• Attach the left and right chiller vents.

Finalize Installation

• Follow the End-of-Job Checklist to ensure all tools, connections, and cleanup steps are complete.