1.43 Main Drain Manifold 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.

🚨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.
• 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. pull only from 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.

Remove Main Drain Manifold From Water Pump

• Disconnect the main drain manifold from the in-port of the water pump.

Connect Main Drain Manifold To Water Pump

• Screw on the main drain manifold to the in-port of the water pump.

⚠️ Important: Ensure the black o-ring is in place under the ab union. No o-ring will result in a leak. 

Install Chiller

• Warning: Take your time—use two people if necessary.
• Tilt the top of the chiller back and slide the base into the cabinet.
• Lift and shift the unit until bolt holes align with frame.
• Slide bolts through 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 UI Ribbon to E-Box

• Plug ribbon into back of e-box—red stripe faces away from you (toward tub).
• Close the wing tabs to secure the cable.
• Route LED wire under left copper tube, across fan, and through original passthrough hole.
• Zip tie LED wire to bundle in front of fan.
• Route:
  • TH-1 and Flow Meter wires through back of e-box.
  • Hanna Auto-Doser wires behind chiller and into back of e-box cutout.

Connect Electrical Components

• Reconnect all components to their correct ports.
  • Refer to PCB board diagram.
• Double check all plugs before continuing.
• Note: Do not install e-box or rear cover yet—testing comes next.

Test for Leaks & Error Codes

⚠️ Warning: The chiller fan is exposed during testing. Keep hands, tools, and loose items away from the fan to avoid injury or equipment damage.

• Fill the Plunge up with water so the water line is 6" below the edge of the tub.
• 🚨 Open the auto-doser ball valves🚨
  • ⚠️ If chiller is turned on while auto-doser ball valves are closed it can damage the chiller.⚠️
• Plug in the Plunge and press the “Reset” button on the GFCI plug to power it on.
• Set temperature to 50 degrees so pump powers to 100%.
• Allow the Plunge to run and observe the chiller plumbing union connections.
• Carefully inspect all union fittings for any signs of leaking while the system is running.
• If a leak is found, pause the system and recheck that the union is properly seated and hand-tightened.
• Confirm no error code on UI

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.

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.