Gen 1 (1.32) Chiller to Gen 2 Chiller Upgrade

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.

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

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.

Disconnect Ozone Tubing from Venturi

• Slowly pull the Ozone tube from the venturi located on the jet venturi manifold.
• You way need to rotate/wiggle to remove it.

Disconnect Water Filter Housing From Tub

• Wrap the hex bolt driver in a towel or rag to protect the plastic nut from damage.
• Locate the notched corner of the plastic nut securing the water filter housing and align the wrapped hex bolt driver with the notch.
• Loosen the Plastic Nut by using a rubber mallet or hammer and GENTLY TAP the end of the wrapped driver

  • 🚨 Apply soft, controlled strikes — go slow and steady to avoid cracking the plastic

• Once the nut is loose enough, finish unthreading it by hand.
• Use one hand to support the bottom of the water filter housing as the nut is removed and set aside water filter housing.

Remove E-box From Tub

• Cut 2 zip ties securing the power cord to the frame near the electrical box.
• Using an 8mm hex driver, remove the 4 mounting nuts securing the e-box to the tub.
• Remove E-Box from the tub

Remove LED From Tub

• Remove the LED from the LED bulkhead by pulling on the wire. 

Install LED Into LED Bulkhead

• Locate the LED that arrived in the box with the replacement chiller.
• Place the LED into the LED bulkhead and press in until it is fully seated.

Install Plumbing Manifolds to Chiller

• Install the three plumbing manifolds that come in the box but disconnected from the chiller
• Locate the Water Pump to Water Filter Manifold (Large L with no sensors). Screw the union connected to the long flex hose to the outport of the Water pump.
• Locate the Filter to Heat Exchanger Manifold (U shaped with 1 sensor and flow meter). Screw the union nearest to the flow meter into the "in" port (top) of the heat exchanger.
• Locate the Heat Exchanger to Tub Manifold (Smallest with one sensor). Screw the ab union into the "out" port (bottom) of the heat exchanger.

Install Chiller Into Tub

• 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.

Remove E-Box Cover

• Using a 2.5 mm hex bolt driver remove the 4 bolts securing the E-box cover.
• Set aside as they will be needed to secure E-box cover.

Plug LED into E-box

• Run the connector of the LED through the grommet in the bottom right of the e-box.
• Plug the LED into the port labeled LED.

Install Ozone Tube Onto Venturi

• Pull the Ozone tube to the back of the chiller
• Press the Ozone tube onto the venturi until it if fully seated.
• Tuck the Ozone tubing behind the chiller and make sure there are no kinks or obstructions. 

Install New Water Filter Housing To Tub

• Slide the water filter housing into place through the side of the chiller frame. 

  • ⚠️ Move slow and ensure you do not hit and damage the copper tubing to the compressor.

• Position the replacement water filter housing in the same orientation as the original.

  • Lower threaded manifold is facing toward the basin of the tub.

  • Upper threaded manifold is facing toward the condenser fan.

• Lift the water filter housing and align it with the threaded post on the tub.

  • 🚨 Ensure the two nodes on top of water filter housing line of with two cutouts where the water filter housing mounts to the tub.

• Begin threading the plastic nut onto the post by hand, ensuring it is not cross-threaded.

• Once the nut is hand-tight, wrap a towel or rag around a hex bolt driver to protect the plastic.

• Place the wrapped driver against one of the nut’s notches and gently tap with a rubber mallet to snug it into place.

• Apply light, controlled taps until the nut is fully tightened and the water filter housing is secure.

• Ensure the housing is firmly seated and does not move or shift when lightly pushed.

Connect Plumbing to Tub

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

  1. Main Drain & Pump Manifold -> Connects to underneath plumbing. 

  2. Water Pump to Water Filter Manifold -> Connects to back of water filter

  3. Water Filter to Heat Exchanger -> Connects to side of water filter

  4. Heat Exchanger to Jet → Connects to underneath plumbing

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

🚨 In the event the Heat Exchanger to Jet Manifold and/or the Drain and Pump Manifold does not line up with the underneath plumbing a AB Union replacement will be needed. Go to the next step if this is necessary.🚨

A/B Union Replacement

• For the full step by step instructions on how to do an A/B union replacement go to: A/B Union Replacement

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.

Test New Chiller

Follow standard testing protocol:

• Fill the tub until the water level is:
  • Residential: 6" below the edge of the tub.
  • Commercial Basic: 1/2 inches above "min" line on skimmer.
    ⚠️ Running the system with low water may damage the pump.
• 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
• Press the light button on the UI to ensure the light functions properly.

Update Firmware From 1. to 2.2+

Follow instructions in the Firmware Update for V3 Gen 1 UI with V3 Gen 2 Chiller article. 

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.

Attache E-Box Cover

• Using a 2.5 mm hex bolt driver screw in the 4 bolts to securing the E-box cover.

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 only one of the upper thumb nuts loosely before installing the rear panel — space is tight once the panel is in place.

  • The upper thumb nut near the e-box will no longer be utilized to secure the rear cover.

• Confirm all wiring and plumbing connections are secure and tidy.

Install Rear Cover & Chiller Vents

• Slide the rear cover into place.

• Install all 5 thumb nuts.

• Reinstall left and right vent panels.