All-In Commercial Max Gen 2 - TH-1 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 4 thumb nuts
  • 2 just inside the left vent screen
  • 2 just inside the right vent screen

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 the two Hanna Auto-Doser wires and LED wire (press tab and pull from plastic base).

  • Locate the 10 pin connector labeled Hanna in the Ebox

  • Remove the splitter from the AC Input port 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 & Hanna wire out through its passthrough hole.

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

  2. Pump to Filter– right of water filter housing

  3. Filter to Heat Exchanger – 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. 

• 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.

Unplug & Remove Water Thermistor (TH-1) From E-Box

• Locate the water thermistor (TH1) labeled THRM 1 in the Ebox
• Using a flathead screw driver, press the tab down and pull the plastic connector the unplug the water thermistor (TH-1).
  • ⚠️Do not pull by the wire. ⚠️ 
• Remove the water thermistor (TH-1) wire from the E-box by feeding it through the hole in the back. 
  • ⚠️Do not pull by the wire. Puss the plastic connector ⚠️

Remove Wire TH-1 Wire From Ebox & Cut Zip Ties Securing it to the Chiller Chassis

• Cut the zip ties that are securing the TH-1 wire to the left side of the Ebox.
• Push/pull the TH1 wire through the port in the bottom left of the Ebox.
• Cut the zip ties securing the water thermistor (TH-1) wire to the chiller chassis. 
• Cut the two zip ties that are securing the protective sleeve to the group of wires near the compressor & heat exchanger.
• Slide the TH1 wire out of the protective sleeve. 

Remove The Water Thermistor (TH-1)

• Using pliers to disconnect the water thermistor (TH-1) from the heat exchanger

Install The Water Thermistor (TH-1)

• Using a pair of pliers screw in the water thermistor (TH-1) into the heat exchanger.

Run Wire into Ebox & Secure Wire to Chiller

• Feed the TH1 wire through the protective sleeve. 
• Feed the TH1 wire into the Ebox through the opening in the bottom right of the Ebox
• Secure the protective sleeve to the group of wires with Zip ties
  • Zip to each end of the protective sleeve
  • Ensure the protective sleeve is covering the wires when they pass between the heat exchanger and compressor
• Zip tie all the wires to the back rail of the water pump
• Group all the wires together and zip tie them to the clip on the back of the Ebox
  • Do not leave any dangling wires

Plug Water Thermistor (TH-1) Into E-Box & Secure With Zip Ties

• Locate the water thermistor (TH-1) plug inside the Ebox.
• Plug water thermistor (TH-1) into appropriate port.
  • 🚨Plugging water thermistor into the wrong port will result in the Plunge not functioning properly. 🚨
• Zip tie all the unsecured wires to the two clips on the left side of the Ebox

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.

Connect Chiller 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.🚨

Test 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.

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.

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.