Build A Spa ZEUS User manual

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THE ZEUS
BUILT INFRONT OF YOU . FOR YOU .
2019
SEL A SSEMBLY M A NU A L

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INTRODUCTION
CONGR A TUL A TIONS ON THE PURCH A SE O YOUR NEW SEL A SSEMBLY HOT TUB . BUILD A SP A A RE THE IRST IN THE WORLD TO BE O ERING A N
A CRYLIC HOT TUB , TH A T IS BUILT BY THE END CONSUMER . WE ' RE A BSOLUTELY CON IDENT TH A T WE ' RE M A KING POSITIVE CH A NGES A ND
STRIVES TO THE HOT TUB INDUSTRY IN THE EUROPE A N M A RKETPL A CE , A ND A D A M A NT TH A T BUILD A SP A WILL TR A NS ORM THE W A Y TH A T WE
PURCH A SE SP A S IN TOD A Y ' S M A RKETPL A CE .
WE ' RE SICK A ND TIRED O OTHER COMP A NIES OUT THERE CONTINUING TO CH A RGE EXCESSIVE PRICE POINTS TO THE ILL IN ORMED CONSUMER ,
A ND , R A NKLY , WITH LITTLE TO O ER TH A N A ' WORLD RENOWNED BR A ND ', OR ' US A/ C A N A DI A N M A DE ST A MPED ON IT '.
BUILD A SP A H A S T A KEN 4 M A JOR & RE A L LI E BUSINESS OVERHE A DS TH A T CONSTITUTE TOW A RDS THE PRICE YOU WILL P A Y OR A NY
PRODUCT , A ND , YES , YOU GUESSED IT ... TURNED THEM ON THEIR HE A D .
SEE BELOW:
PREM A DE & US A/ C A N A DI A N M A DE SP A
L A RGE A CTORY PREMISES , BUSINESS R A TES ,
O TEN HUNDREDS O A CTORY WORKERS
YOUR G A RDEN IS OUR A CTORY , SO WE REDUCE
M A SSIVELY ON OVERHE A DS
SHIPPING ROM US A/ C A N A D A/A SI A IS
EXPENSIVE ! IMPORT DUTIES , T A XES , SHIPPING
A GENTS . OREIGN EXCH A NGE
95 % O OUR SUPPLY CH A IN IS IN THE UK / EU . A ND
BEC A USE IT IS SENT TO YOU IN L A T P A CK , WE
CONSOLOD A TE OUR INVENTORY M A SSIVELY .
OVERSE A S A CTORIES SELL THROUGH A DISTRIBUTOR ,
A ND THEN A RET A ILER SELLS IT TO YOU . TH A T IS 3
COMP A NIES M A KING PRO IT BE ORE IT RE A CHES YOU !
WE ELIMIN A TE A LL COSTS ROM A CTORIES ,
DISTRIBUTORS , RET A ILERS & L A BOUR WORK ORCE .
OVERSE A S A CTORIES O TEN H A VE WORK ORCES IN
THE HUNDREDS
WHEN YOU SEL A SSEMBLE YOUR BUILD A SP A. YOU A RE
THE WORK ORCE !

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BE ORE YOU ST A RT
BE ORE WE LET YOU RUN A W A Y A ND BEGIN A SSEMBLING YOUR SP A. THERE ' S A EW S A ETY CONSIDER A TIONS YOU SHOULD M A KE . I YOU A RE
IN A NY DOUBT WH A TSOEVER , THEN PLE A SE C A LL US OR SEEK PRO ESSION A L A DVISE .
THE GLUE WE USE ON A LL O OUR SP A S IS GRI ON WD - 05 . IT IS A WET , DRY & EXTREMELY A ST SOLVENT WELD . THE
PRODUCT IS EXTREMELY L A M A BLE A ND IRRIT A NT ON CONT A CT WITH EYES . YOU SHOULD T A KE CONSIDER A TIONS A S TO THE
GRI ON WD - 05 MSDS WHICH IS A V A IL A BLE ONLINE , OR A SK OUR O ICE OR A N E COPY .
THE ZEUS BUILD A SP A REQUIRES A N ELECTRIC A L EED O 16 / 32 A MP . DURING THE A SEEMBLY PROCESS YOU WILL BE REQUIRED
TO CONNECT COMPONENTS ON YOUR SP A INTO A PRE TESTED MOTHERBO A RD . I YOU A RE IN A NY DOUBT DURING THIS
PROCESS , PLE A SE SEEK PRO ESSION A L & ELECTRIC A L A SSIST A NCE .
NOTE: A P A RT P QU A LI IED ELECTRICI A N IS REQUIRED TO CRE A TE THE SUPPLY TO YOUR SP A.
THE HE A VIEST COMPONENT DURING THE A SSEMBLY PROCESS IS THE SP A SHELL . THE SP A SHELL WEIGHS A ROUND 50KGS . IT IS
STRONGLY A DVISED TH A T YOU DO NOT LI T THIS OBJECT WITH A NY LESS TH A N 2 - 3 IT A ND A BLE PEOPLE TO A SSIST YOU . OR
A NY URTHER A SSIST A NCE ON M A NU A L H A NDLING O OUR PRODUCTS , PLE A SE C A LL OUR O ICE OR A DVISE
INHERENTLY , YOU WILL BE MIXING W A TER WITH ELECTRICITY DURING THE A SSEMBLY O YOUR SP A. DURING THIS PROCESS , IT
IS O THE UTMOST IMPORT A NCE TH A T THE SYSTEM REM A INS COMPLETELY DE A D UNTIL H A S BEEN PROVED O NO W A TER
LE A K A GE .
DURING THE BUILD PROCESS , YOU WILL BE REQUIRED TO USE V A RIOUS H A ND TOOLD DURING THE PROCESS . IT IS EXTREMELY
IMPORT A NT TH A T A LL TOOLS USED A RE USED IN A CCORD A NCE WITH THEIR M A NU A CTURERS S A ETY INSTRUCTIONS .
THE MINIMUM A MOUNT O PPE SHOULD BE CONSIDERED DURING YOUR BUILD . YOU SHOULD CONSIDER COVER A LLS / P A PER SUIT ,
NITRILE GLOVES , GL A SSES , S A ETY BOOTS ( STEEL TOE C A P )

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TOOLS REQUIRED
WE DO OUR BEST TO ISSUE YOU WITH A LL THE TOOLS A ND EQUIPMENT YOU WILL REQUIRE , HOWEVER THERE A RE SOME HOUSEHOLD
CONSIDER A TIONS TH A T YOU WILL NEED TO H A VE PRIOR TO THE COMPONENTS A RRIV A L .
POZI & PHILLIPS SCREWDRIVERS ,
MULTIPLE SIZES
KNI E BL A DE SCISSORS
M A X 60MM ' E A GLE BE A K ' GRIPS H A ND S A W H A ND DRILL
P A PER ROLL TO BE USED A S A DRIP
TR A Y
ST A PLER M A LLET

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PREP A R A TORY WORK
WE ' VE A LL HE A RD O THE 5P ' S O DIY ! PRIOR PL A NNING PREVENTS POOR PER ORM A NCE ! IT ' S IMPORT A NT TO ENSURE TH A T THE BELOW
PREP A R A TORY WORKS A RE COMPLETED PRIOR TO BEGINNING TO A SSEMBLE YOUR SP A IN ORDER TO M A KE SURE TH A T A LL WILL RUN
SMOOTHLY ON THE D A Y .
IT ' S IMPORT A NT TH A T YOU PREP A RE YOUR ROUTE ROM WHERE THE P A LLET O COMPONENTS WILL BE
DELIVERED INTO IT ' S IN A L DESTIN A TION . REMOVE A NY POTENTI A L SLIPS , TRIPS & A LLS ROM THE WORKING
A RE A A ND A LSO THE A CCESS ROUTE INTO YOUR G A RDEN .
ENSURE TH A T THE A RE A YOU A RE PL A CING YOUR SP A IS PREP A RED IRM , LEVEL & COMP A CT . THE HOT TUB IS
DESIGNED SPECI IC A LLY TO BE PL A CED ON A LEVEL GROUND . THERE A RE 2 M A JOR SUPPORTING A RE A S O THE
SP A. THE OOTWELL ( WHICH WILL TOUCH THE LOOR ), A ND THE OUTER PERIMETER O THE R A ME . I YOU
C A NNOT GET THE WHOLE A RE A TH A T THE SP A IS TO BE S A T ON L A T , THEN IT IS IMPORT A NT TH A T THESE 2
M A JOR PRESSURE LO A DED A RE A S A RE .
OFF
ON
CONSUMER UNIT
CONSUMER UNIT / USEBO A RD
SW A C A BLE L A RGE ENOUGH TO C A RRY 32 A ( 6MM )
32 A ROT A RY ISOL A TOR ( IP65 )
SY LEX C A BLE L A RGE ENOUGH TO C A RRY 32 A, TO
BE COILED UP A T A LENGTH TO RE A CH THE
URTHEST POINT A W A Y ON YOUR SP A.
A V A IL A BLE IN EITHER 16 / 32 A MP . YOU SHOULD CONSULT YOUR QU A LI IED ELECTRICI A N TO DECIDE WHICH YOU
A RE A BLE TO OPT OR .
YOU SHOULD PREP A RE THE OLLOWING CIRCUIT OR A 32 A MP MODEL . OR 16 A MP CIRCUIT , PLE A SE C A LL .

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WH A T ' S IN THE BOX !
WITH EVERY BUILD A SP A SEL A SSEMBLY KIT , YOU WILL RECEIVE THE BELOW COMPONENTS . IT ' S IMPORT A NT TH A T YOU V A LID A TE THIS LIST
A G A INST WH A T H A S BEEN SUPPLIED A T THE E A RLIEST OPPORTUNITY . I YOU H A VE ORDERED A NY A DDITION A L EXTR A S TO IT TO YOUR SP A,
THEY WILL NOT A PPE A R ON THE ST A ND A RD SHIPMENT LIST OUTLINED BELOW .
40X
1XSET
1XSET

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LET ' S GET ST A RTED !
STEP ONE - STRUCTURE A RRIV A L & POSITION
1 . M A RK OUT YOUR WORKING A RE A & DELIVER THE HOT TUB R A MEWORK , UPSIDE DOWN A ND POSITION
IT . THIS WILL M A KE YOUR WORKING A RE A.
2 . PL A CE THE HOT TUB SHELL ONTO THE TOP O THE HOT TUB R A ME . THIS SHOULD A LSO BE PL A CED UPSIDE DOWN LIKE THE PICTURES A TT A CHED .
IGURE 1 IGURE 2
IGURE 3IGURE 4

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LET ' S GET ST A RTED !
STEP TWO - PLUMBING THE JET WORK
LOC A TE THE DIVERTOR V A LVE WHICH LOOKS LIKE THIS . IT SHOULD BE M A RKED WITH A ' L ' OR ' R ' WHICH WILL
COINCIDE WITH THE REL A TING PIPEWORK WE USE L A TER . I IT IS NOT M A RKED WITH ' L ' OR ' R ', YOU C A N A SSUME
TH A T ' L ' IS THE LE T H A ND SIDE O THE V A LVE A S YOU A CE IT .
LOC A TE THE M A NI OLD CONNECTOR KITS . THERE A RE TWO O THEM . WE WILL IT THE SIDE M A RKED ' L ', IRSTLY . TO DO THIS , USING THE SOLVENT WELD
PROVIDED , A PPLY A GENEROUS CO A T ONTO THE PIPE A S A BOVE . THEN , A PPLY A SIMIL A RLY GENEROUS CO A TING OR THE EM A LE SIDE ON THE DIVERTER .
NEXT , PUSH DOWN THE M A NI OLD KIT INSIDE THE DIVERTOR SIDE TO CRE A TE THE CONNECTION . HOLD DOWN IRMLY OR A ROUND 5 - 10 SECONDS TO GIVE
THE SOLVENT WELD TIME TO SE A L .
NOTE: ENSURE TH A T THE M A NI OLD KIT IS A CING OUTW A RDS TOW A RDS THE CURVE O THE SHELL .
IGURE 5 IGURE 6
IGURE 7
IGURE 8
IGURE 9
IGURE 10

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LET ' S GET ST A RTED !
STEP TWO - PLUMBING THE JET WORK
WITH THE M A NI OLD KIT ON THE LE T SIDE NOW MOUNTED ONTO THE DIVERTOR , IT ' S TIME TO CONNECT THE PIPES . THE
PIPEWORK IS A LL PRE NUMBERED A ND LIKE IN THE PICTURE A BOVE , SHOULD CONNECT E A SILY . THERE A RE 12 PIPES TO
CONNECT . IT IS A DVIS A BLE A T THIS ST A GE TH A T YOU DO NOT PERM A NENTLY SECURE THEM WITH SOLVENT WELD UNTIL YOU
H A VE CONNECTED A LL PIPES TO THEIR A SSOCI A TED JETS A ND CON IRMED TH A T THERE A RE NO SP A RE PIPES / JETS WITHOUT A
CONNECTION .
ONCE CON IRMED A ND YOU H A VE CHECKED OVER THIS TWICE , YOU C A N SOLVENT WELD THEM IN POSITION . IT IS A DVIS A BLE TO
SOLVENT WELD THE JOINTS SEQUENTI A LLY ROM 1 - 12 R A THER TH A N THE JETS CLOSEST TO E A CH OTHER . TO SOLVENT WELD
THEM , YOU MUST REMEMBER TO A PPLY A CO A T ON THE SIDE O THE JET , A ND A CO A T ON THE INSIDE O THE PIPEWORK . HOLD
IN POSITION OR 5 - 10 SECONDS PER JET TO GIVE THE SOLVENT WELD ENOUGH TIME TO WELD THE CONNECTION .
REPE A T A LL O THESE STEPS OR THE RIGHT H A ND SIDE M A NI OLD
ROM THE PREVIOUS CHECKPOINT
IGURE 11 IGURE 12
IGURE 13

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LET ' S GET ST A RTED !
STEP THREE - PLUMBING THE HE A TING & JET SYSTEM
LOC A TE THE P A RT ON THE SHELL A S BELOW . IT IS DIRECTLY ON THE OPPOSITE SIDE TO THE M A NI OLD A ND DIVERTOR SYSTEM WE WERE
WORKING ON IN STEP TWO .
SOLVENT WELD THE 3 COMPONENTS HIGHLIGHTED IN STEP 2 INTO THE A SSEMBLY IN STEP 3 .
PL A CE INTO THE ILTER RING A S IN STEP 4 . IT IS A DVIS A BLE TH A T YOU DO NOT SOLVENT WELD THIS IN POSITION UNTIL L A ST ON THIS
STEP .
USING THE 60MM OUTSIDE DI A METER PIPE , CUT A LENGTH O TO CONNECT A 45
DEGREE ELBOW COMING ROM THE SUCTION NUT ON THE SHELL , TO MEET THE TEE
MODULE WE PRE M A DE IN THE L A ST STEP . YOU M A Y NEED TO PRE A NGLE A LL O
THESE PRIOR TO SOLVENT WELDING .
ONCE YOUR A SSEMBLY LOOKS LIKE THE IN A L IGURE ON THE LE T , YOU C A N
SOLVENT WELD A LL THE JOINTS . REMEMBER TO BE GENEROUS IN YOUR CO A TINGS
A T THIS ST A GE A ND W A IT 10 SECONDS OR THE JOINT TO WELD .
IT IS RE A LLY IMPORT A NT NOT TO RUSH THIS ST A GE A ND M A KE SURE A LL JOINTS
A RE SECURE .
IGURE 14
IGURE 15 IGURE 16
IGURE 17
IGURE 18
IGURE 19