1.32 Heat Exchanger To Jet Manifold Replacement

Power Down 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.

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 side chiller vent panels.
• Unscrew all 6 thumb nuts securing the rear panel:
  • 3 on the left vent
  • 3 on the right vent

Remove Rear Cover

• Grab the rear cover by the vent openings and slowly pull and wiggle the rear cover free. 

Remove Chiller Mounting Nuts

• Using a 10mm socket/wrench remove the 4 nuts securing the chiller to the base:
  • 2 on each side of the chiller base plate.

Disconnect Electrical Components

• Disconnect all electrical components by unscrewing the threads and pulling.
• The LED wire should be moved to the back of the chiller and set aside.

Disconnect Plumbing Manifolds

• Disconnect the 4 chiller plumbing manifolds from the tub:
  1. Main Drain – Located on the right hand side connecting the main drain manifold to the underneath plumbing.
  2. TH-1 – Connects to the right of the water filter housing
  3. Flow Meter – Runs from the back of the water filter to the bottom of the heat exchanger
  4. Heat Exchanger to Jet – Connects from the top of the heat exchanger to the lower plumbing union

Cut Power Cord Zip Ties

• If the power cord is zip tied to the frame of the tub, cut the zip ties and move the power cord out to the right of the chiller.

Remove Chiller

• Grab the handles on each side of the chiller base.
• Carefully lift the chiller off the bolts secured to the base.
• Slowly walk each side of the chiller to pull the chiller out.

Remove Heat Exchanger to Jet Manifold From Heat Exchanger

• Disconnect the heat exchanger to jet manifold from the back of the heat exchanger.

Clean Heater Exchanger

• Disconnect the flow meter manifold from the back of the heat exchanger.
• Disconnect the threaded adapters in the back of the heat exchanger.
• Using tweezers clean out any debris inside of the heat exchanger 

Connect Heat Exchanger to Jet & Flow Meter Manifold to Heat Exchanger

• Screw on the two threaded adapters to the in-port and out-port of the heat exchanger.
• Screw on the heat exchanger to jet manifold back onto the original port of the heat exchanger.
• Screw on the flow meter manifold to the original port of the heat exchanger.

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

Install New Chiller

• Lift the chiller from the chiller handles and set the base of the chiller on the bolts.
• Walk the base of the chiller into place.
• Line up the chiller base holes with the mounting bolts and lower the unit down onto the frame bolts.

Reconnect Plumbing to Tub

Reconnect the 4 plumbing manifolds:

1. Main Drain → On the right side behind the fan connecting to underneath plumbing.
2. TH-1  → right of the filter housing.
3. Flow Meter → rear of the filter housing.
4. Heat Exchanger to Jet → bottom plumbing union below the LED.

⚠️ Double-check for black o-rings on lower plumbing unions before tightening.

🚨 If the Heat Exchanger to jet manifold does not line up to underneath plumbing you will need to follow Step 11-B below to retrofit the plumbing. Click the step below to go to the retrofit work instructions.

Counter Current to Co-Current Plumbing Retrofit (link to retrofit article)

Reconnect Electrical Components

• Plug in all electrical connectors to their labeled receptacles.
• Identify each component by the labels on the wires
• Ensure all components are secured screwed and pushed in.

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.
• 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 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

• Using zip ties, secure the power cord back to the original place it was attached to the frame.
• Secure the 4 chiller mounting nuts to the base of the chiller.
  • Each nut will have two washers.
• Pre-thread the two upper thumb nuts loosely before installing the rear panel — space is tight once the panel is in place.
• Confirm all wiring and plumbing connections are secure and tidy.

Install Rear Cover & Chiller Vents

• Slide the rear cover into place.
• Install all 6 thumb nuts (3 per side).
• Reinstall left and right vent panels.