Gen 1 (1.43) Chiller to Gen 2 Chiller Upgrade

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 the splitter and set aside to install into the 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.

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 & Auto-Doser 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.
• Run the Hannah auto-doser wire connector(s) (there can be two if a splitter was installed on the previous chiller) through the grommet in the bottom right of the e-box.
•  

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 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
• 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

• 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.