Calspas LTR20121002 User manual

LTR20121002, Rev. A
12/30/11

Preparing for Your New Inground Spa
Inground Spa Installation Checklist.......4
Planning the Best Location For Your Spa...4
Planning the Best Place for the Outdoor
Equipment Pack.......................5
Inground Spa Site Preparation...........5
Spa Shell Dimensions and Side Views .....6
Electrical Requirements – US and Canada 13
GFCI Wiring Diagram .................14
Electrical Installation -- Europe.........15
RCD Wiring Diagram ..................16
Installing the Inground Shell ...........17
Equipment Pack Plumbing Connections...18
Plumbing Connections ................18
Electrical and Electronic Connection .....20
Pouring the Deck.....................23
9800 Electronic Control Operation
Diagnostic Messages..................27
Adjustable Jets ......................29
Diverter Knobs.......................29
Clear Water Plan
The Key to Clear Water ................30
Testing and Adjusting Spa Water........31
Sanitation...........................32
Filter Cleaning .......................33
Bather Load . . . . . . . . . . . . . . . . . . . . . . . . .34
Starting the Spa with Fresh Water.......34
Maintenance Schedule ................35
Cleaning and Maintenance
Removing and Reseating the Pillows.....36
Spa Cover...........................36
Draining Your Spa ....................37
Cleaning and Replacing the Filter........37
Winterizing (Cold Climate Draining) .....37
Cleaning Your Spa ....................38
Appendix
Replacement Parts ...................39
Warranty ...........................39
Copyright 2011 LMS, Inc. All rights reserved. Duplication without written consent is strictly
prohibited.
Cal Spas®is a registered trademark.
Due to continuous improvement programs, all models, operation, and/or specications are
subject to change without prior notice.
LTR20121002, Rev. A
12/30/11
100-1074
CONTACT INFORMATION
For customer service, please contact
your authorized dealer immediately. If
you need additional information and/
or assistance, please contact:
LMS Customer Service Department
1462 East Ninth Street
Pomona, CA 91766.
Toll Free: 1-800-CAL-SPAS
Fax: [phone]
www.calspas.com

Inground Spas
LTR20121002, Rev. A
Read This First!
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When installing and using this electrical equipment,
always follow basic safety precautions. Following
these instructions will help make your rst spa ses-
sion a pleasurable one.
READ AND FOLLOW ALL INSTRUCTIONS
NOTE: A licensed electrician may be required to up-
grade your standard receptacle and/or circuit break-
er.
DANGER -- RISK OF ACCIDENTAL DROWN-
ING: Do not allow children to be in or around a spa
unless a responsible adult supervises them. Keep
the spa cover on and locked when not in use. See
instructions enclosed with your cover for locking pro-
cedures.
DANGER -- RISK OF INJURY: The suction ttings
in this spa are sized to match the specic water ow
created by the pump. Should the need arise to re-
place the suction ttings, or the pump, be sure the
ow rates are compatible.
DANGER -- RISK OF INJURY: Never operate the
spa if the suction tting or lter baskets are broken
or missing.
DANGER -- RISK OF INJURY: Never replace a
suction tting with one that is rated less than the
ow rate marked on the original suction tting.
DANGER -- RISK OF ELECTRIC SHOCK: Install
the spa at least ve feet (1.5 meters) from all metal
surfaces. As an alternative, a spa may be installed
within 5 feet of metal surfaces if each metal surface
is permanently bonded by a minimum #8 AWG solid
copper conductor to the outside of the spa’s control
box.
DANGER -- RISK OF ELECTRIC SHOCK: Do
not permit any external electrical appliances, such
as lights, telephones, radios, televisions, and etc.,
within ve feet (1.5 meters) of the spa. Never at-
tempt to operate any electrical device from inside
the spa. This does not apply to lights built in to the
spa as factory options from Cal Spas™.
WARNING -- RISK OF INJURY
The spa water should never exceed 104˚F (40˚C).
Water temperatures between 100˚F (38˚C) and
104˚F (40˚C) are considered safe for a healthy
adult. Lower water temperatures are recommended
for young children and when spa use exceeds 10
minutes.
High water temperatures have a high potential for
causing fetal damage during pregnancy. Women
who are pregnant, or who think they are pregnant,
should always check with their physician prior to spa
usage.
The use of alcohol, drugs or medication before or
during spa use may lead to unconsciousness, with
the possibility of drowning.
Persons suffering from obesity, a medical history of
heart disease, low or high blood pressure, circula-
tory system problems or diabetes should consult a
physician before using the spa.
Persons using medications should consult a physi-
cian before using the spa since some medications
may induce drowsiness while others may affect
heart rate, blood pressure and circulation.
Hyperthermia Danger
Prolonged exposure to hot air or water can induce
hyperthermia. Hyperthermia occurs when the inter-
nal temperature of the body reaches a level 3˚F to
6˚F above the normal body temperature of 98.6˚F
(or 2˚C to 4˚C above 37˚C). While hyperthermia
has many health benets, it is important not to allow
your body’s core temperature to rise above 103˚F
(39.5˚C). Symptoms of excessive hyperthermia in-
clude dizziness, lethargy, drowsiness and fainting.
The effects of excessive hyperthermia may include:
Failure to perceive heat•
Failure to recognize the need to exit spa or hot• tub
Unawareness of impending hazard•
Fetal damage in pregnant women•
Physical inability to exit the spa•
Unconsciousness•
WARNING: The use of alcohol, drugs, or medi-
cation can greatly increase the risk of fatal hyper-
thermia.
Important Safety Instructions

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Most cities and counties require permits for exterior construction and electrical circuits. In addition, some
communities have codes requiring residential barriers such as fencing and/or self-closing gates on property to
prevent unsupervised access to the property by children. Your dealer can provide information on which permits
may be required and how to obtain them prior to the delivery of your Cal Spa.
Inground Spa Installation Checklist
Preparing for Your New Inground Spa
Before Delivery
Plan your delivery route
Choose a suitable location for the shell and
equipment pack
Excavate the hole
Install dedicated electrical supply
Install dedicated NG line for gas heater
After Delivery
Remove spa from shipping platform
Install shell in ground
Install equipment pack
Connect plumbing
Connect electrical components
Pour the deck
Planning the Best Location For Your Spa
Safety First
Do not place your spa within 10 feet (3 m) of over-
head power lines.
Make sure the spa is positioned so that access to the
equipment compartment and all side panels will not
be blocked. Be certain that your installation will meet
all city and local safety codes and requirements.
Consider How You Will Use Your Spa
How you intend to use your spa will help you de-
termine where you should position it. For example,
will you use your spa for recreational or therapeutic
purposes? If your spa is mainly used for family rec-
reation, be sure to leave plenty of room around it for
activity. If you will use it for relaxation and therapy,
you’ll probably want to create a specic mood around
it.
Plan for Your Environment
If you live in a region where it snows in the winter
or rains frequently, place the spa near a house entry.
By doing this, you will have a place to change clothes
and not be uncomfortable.
Consider Your Privacy
In a cold-weather climate, bare trees won’t provide
much privacy. Think of your spa’s surroundings dur-
ing all seasons to determine your best privacy op-
tions. Consider the view of your neighbors as well
when you plan the location of your spa.
Provide A View With Your Spa
Think about the direction you will be facing when
sitting in your spa. Do you have a special landscaped
area in your yard that you nd enjoyable? Perhaps
there is an area that catches a soothing breeze dur-
ing the day or a lovely sunset in the evening.
Keep Your Spa Clean
Prevent dirt and contaminants from being tracked
into your spa by placing a foot mat at the spa’s en-
trance where the bather’s can clean their feet before
entering your spa. You may also consider keeping a
small water-lled basin nearby for bathers to rinse
their feet before entering your spa.
In planning your spa’s location, consider a location
where the path to and from the house can be kept
clean and free of debris.
Allow For Service Access
Many people choose to install a decorative structure
around their spa. If you are installing your spa with
any type of structure on the outside, such as a gaze-
bo, remember to allow access for service. It is always
best to design special installations so that the spa can
still be accessed.

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The Designer Spa series requires an external equip-
ment pack. When locating the outdoor equipment
pack, you will want to consider the following:
The equipment pack must be located within a•
maximum of 15 feet from the spa.
Ensure the equipment running its normal ltra-• tion cycles does not make too much noise for spa
owners and/or neighbors.
Ensure the equipment can be easily serviced for•
lter cleaning and periodic inspections in the lo-
cation chosen.
If you are using a gas heater, you will need to• consider wind and drafts as well as heater ex-
haust for proper heater placement. (See heater
owner’s manual for important location and safety
information.)
The equipment base and heater must be placed• on either a 3 1/2” cement slab or 3” paving
stones.
Make sure the equipment area selected will not• be in an area where water could run or stand.
If the area receives direct sunlight, you will want• to provide some protection for the equipment
portion of the equipment pack.
The equipment pack and heater are delivered sepa-
rately. Do not cover gas heaters unless properly vent-
ed. (See heater owner’s manual for important safety
information.)
Ensure there is enough room for the spa and• equipment.
Plan for proper electrical and gas service to both• the equipment area and spa side.
Ensure the required at, level foundation can be • constructed in the area chosen.
The spa must be properly back-lled with wet • sand, underneath and on all four sides.
Never place any spa in a sealed area. Water must• be able either to be absorbed into the surround-
ing area or channeled away. Water build-up un-
der and/or around the spa, will cause the spa to
oat out of the ground.
Grading Prior to Excavation
Selection of the Designer Spas site will determine
how much grading will have to be accomplished prior
to the actual dig for the spa. Naturally, a level area is
best because it will require the least amount of prep-
aration for the dig, but in many cases there is no level
area, therefore, the site must be prepared to accept
the spa prior to dig. The spa site should be elevated
slightly higher than the surrounding area.
When dealing with slopes, the severity of the slope
will determine if retaining walls must be built in order
to have a level area for the spa. If the slope is rela-
tively minor, contact your local building safety.
Site Excavation – Hard Bottom
For hard bottom placement for inground spas, you
will need a smooth and at concrete surface at least
4” thick as large as the bottom contact points. Be
sure not to seal the bottom off and making a sealed
box. You will need adequate water drainage for es-
cape under the spa. A gravel beds around the con-
crete base will help with this.
Site Excavation – Sand Bottom
With the spa area and all elevations planned includ-
ing your decided type of decking, you are now ready
to proceed with the dig. An ideal excavation is one
that is as close as possible to the dimensions of the
spa shell, but with the following rules in mind. The
excavation should be 2” to 4” deeper than the actual
spa for your sand bed. The sand bed is to level the
spa shell and provide a perfect support base with no
voids when the spa is lowered into the hole. Your
excavation should be approximately one foot longer
and one foot wider than the spa shell. This will allow
for a six inch over dig all the way around the spa once
it is in place. Additional hand excavation will be re-
quired to insure the skimmer will t in the excavation
when attached to the spa.
Sand or rock dust must be used to bed the shell into
the excavation and for backll. In no event is dirt to
be used. One of the easiest ways to know how much
sand is needed to be placed on the bottom of the
excavation is to set a grade stake at all four corners,
and one on each side of the center line in the bottom
of the hole. If there are areas that are deeper than
2” to 4”, these can be lled with sand and are of no
consequence.
Planning the Best Place for the Outdoor Equipment Pack
Inground Spa Site Preparation

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Spa Shell Dimensions and Side Views
IG-401

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IG-402

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IG-403

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IG-404

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IG-405

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IG-406

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IG-407

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All 240V spas must be permanently connected (hard
wired) to the power supply. These instructions de-
scribe the only acceptable electrical wiring procedure.
Spas wired in any other way will void your warranty
and may result in serious injury. See the wiring dia-
gram on page 14.
When installed in the United States, the electrical
wiring of this spa must meet the requirements of Na-
tional Electric Code, ANSI/NFPA 70-2008 and any ap-
plicable local, state, and federal codes. The electrical
circuit must be installed by an electrical contractor
and approved by a local building / electrical inspec-
tor.
GFCI and Wiring Requirements
The power supplied to the spa must be on a dedi-
cated GFCI protected circuit as required by ANSI/
NFPA 70 with no other appliances or lights sharing
the power.
Use copper wire with THHN insulation. Do not use
aluminum wire.
Use the table below to determine your GFCI and wir-
ing requirements.
Spa Model GFCI Required Wires Required
Designer inground spas
with one 5.5 kW heater
One 50 amp GFCI Four #6 AWG copper wires
Designer inground spa
with two 5.5 kW heaters
Service 1: One 50 amp GFCI
Service 2: One 30 amp GFCI
Service 1: Four #6 AWG copper wires
Service 2: Three #8 AWG copper wires
Wire runs over 85 feet must increase wire gauge to
the next lower number. For example: A normal 50
amp GFCI with four #8 AWG Copper wires run over
85 feet would require you to go to four #6 AWG cop-
per wires.
Read and follow the heater manufacturer’s safety and
installation instructions prior to installation and op-
eration. Incorrect installation may damage the heater
and void its warranty.
Testing the GFCI Breaker
Test the GFCI breaker prior to rst use and periodical-
ly when the spa is powered. To test the GFCI breaker
follow these instructions (spa should be operating):
Press the TEST button on the GFCI. The GFCI will1. trip and the spa will shut off.
Reset the GFCI breaker by switching the breaker2. to the full OFF position, wait a moment, then turn
the breaker back on. The spa should have power
again.
Electrical Requirements – US and Canada

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GFCI Wiring Diagram

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All 230V spas must be permanently connected (hard
wired) to the power supply. These instructions de-
scribe the only acceptable electrical wiring procedure.
Spas wired in any other way will void your warranty
and may result in serious injury.
This the only acceptable electrical wiring procedure.
Spas wired in any other way will void your warranty.
See the wiring diagram on page 16.
The electrical wiring of this spa must meet the re-
quirements of any applicable local, state, and federal
codes. The electrical circuit must be installed by an
electrical contractor and approved by a local building
/ electrical inspector.
RCD and Wiring Requirements
The power supplied to the spa must be on a dedi-
cated RCD protected circuit with no other appliances
or lights sharing the power.
Use copper wire with THHN insulation. Do not use
aluminum wire.
Use the table below to determine your GFCI and wir-
ing requirements.
Wire runs over 85 feet must increase wire gauge to
the next lower number. For example: A normal 50
amp RCD with four #8 AWG copper wires run over
85 feet would require you to go to four #6 AWG cop-
per wires.
Testing the RCD Breaker
Test the RCD breaker prior to rst use and periodical-
ly when the spa is powered. To test the RCD breaker
follow these instructions (spa should be operating):
Press the TEST button on the RCD. The RCD will1. trip and the spa will shut off.
Reset the RCD breaker by switching the breaker2. to the full OFF position, wait a moment, then turn
the breaker back on. The spa should have power
again.
Electrical Installation -- Europe
Spa Model GFCI Required Wires Required
Designer inground spas with one 3
kW heater One 32 amp RCD or two 16 amp RCDs Four #10 AWG copper wires
Designer inground spa with one 3
kW heater and one 5.5 kW heater Service 1: One 32 amp RCD or two 16 amp RCDs
Service 2: One 32 amp RCD or
two 16 amp RCDs
Service 1: Four #10 AWG copper
wires
Service 2: Three #10 AWG copper
wires

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RCD Wiring Diagram








GREEN/
YELLOW
(Ground)
GREEN/
YELLOW
(Ground)







GREEN/
YELLOW
(Ground)
CIRCUIT BOARD

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Installing the Inground Shell

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Equipment Pack Plumbing Connections
Equipment Pack Specications
All Inground spas except IGJ-407:
Equipment pack weight = 250 lbs.
IGJ-407:
Equipment pack weight = 300 lbs.
One 2.5 HP heat pump
One 4 HP swim pump
Note: Equipment pack cannot exceed 15 feet from
spa.
Plumbing Connections
IMPORTANT! Always check local codes prior to any
inground spa installation.
Once the spa and equipment are properly located, you
will want to lay out the plumbing run.
Trenches should be deep and wide enough to allow
all pipes to be buried below the frost line and should
be in as straight a line from the spa to the equipment
as possible. Check local code requirements for under-
ground pipes. Always know what is under the ground
before you dig anywhere.
You will need 2” ex or PVC lines for your suction, in-
take, and air line. In ground spas have marked intake
and suction lines, making it easy nd and connect to
and from the spa and equipment pack.
The plumbing run should not be any longer than 15
feet to maximize water pressure. Another way to max-
imize water pressure is to limit (or even eliminate) the
use of 90˚ elbows in your plumbing run. A more direct
plumbing run using 45˚ elbows is more efcient, and
promotes increased water pressure.
Identifying Plumbing Lines
The spa’s plumbing lines are clearly marked during
water testing at the factory. This is done to assist in-
stallers in properly identifying the installation. We still
recommend that the installers verify plumbing lines
prior to gluing. This can be done by using one of the
following techniques.
Air Test
The air test requires a wet/dry vacuum. Locate the
plumbing line you wish to identify and secure the vac-
uum hose to cut open end. Turn on the vacuum, enter
the spa and listen for vacuum suction sound from in-
side the spa side lter canister. If you hear the suction
sound in the canister, the line is properly marked and
can be connected to the suction side of the pump on
the equipment pack.
Water Test
The water test requires a garden hose and water
source. Locate the plumbing line you wish to identify
and secure the outlet side of the garden hose to cut
open end. Turn on the water supply to the garden
hose, enter the spa and look for water inside the spa
side lter canister. If you see water in the canister the
line is properly marked and can be connected to the
suction side of the pump on the equipment pack.
If any plumbing line is not properly marked or not
marked at all, follow either the air or water test proce-
dure until all lines are identied prior to gluing.
NOTE: Once complete, water test the plumbing run
for at least three days prior to covering any plumbing
trenches and back-lling spa cavity completely.
NOTE: Some local inspectors require pressure test-
ing the plumbing lines. Although the spa is pressure
tested at the factory, local inspectors may insist on
pressure testing the plumbing run between the spa
and equipment pack.

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Gate/Slice Valves
The use of gate valves is recommended on all plumb-
ing lines (both suction and return lines). These valves
are used to contain the spa’s water in either the equip-
ment or the spa. This will assist in the pump priming
process and future servicing without needing to drain
the spa.
NOTE: When draining the spa to perform mainte-
nance, always close the gate valves prior to draining.
This will maintain the pumps prime.
Connecting Plumbing to Remote
Equipment
Connecting the plumbing from the spa to the equip-
ment pack must be performed in accordance to local
and city codes.
NOTE: Most codes require plumbing to be rigid PVC
schedule 40 or heavier in both above and below
ground installations. In most cases, the use of exible
PVC plumbing is acceptable when properly buried in
trenches.
Most water plumbing lines are 2” or larger and must
be schedule 40 or heavier PVC. When plumbing, mini-
mize the use of 90˚ elbows as much as possible. The
use of 45˚ elbows will increase the amount of jet pres-
sure you will have over the use of 90˚ elbows.
The plumbing on the spa shell is labeled by the factory
in the following manner:
Pump 1 Suction: 2” line that connects the spa lter
and bottom drain assembly to the front of pump 1.
Pump 1 Return: 2” line that connects the top of pump
1, through the equipment lter and heater back to
selected jets in the spa.
Pump 2 Suction: 2” line that connects the spa lter
and bottom drain assembly to the front of pump 2.
Pump 2 Return: 2” line that connects the top of pump
2 back to selected jets in the spa.
Ozone Line: 1” line that connects to a 1” exible line
extending off the bottom of the equipment pack lter
canister through an ozone injector (If ozone equipped)
and connected to ozone port on the spa.
Air Blower: 1 1/2” line that is plumbed out of the air
blower (located on the equipment pack) and extended
up 18” above the spas water level to prevent water
ooding the air blower.
Air Venturi: 1/2” line that is plumbed 18” above the
spa’s water level.
Topside Control Panel and Temp Sensor: 1” line that
connects to the bottom of the control box located on
the equipment pack.

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Remote Equipment Topside Control
Panel
The next few steps to complete the installation should
be performed along with installation of the tempera-
ture sensor and 12V spa light wiring (if applicable). All
of these components are generally installed using the
same conduit.
Locate the topside control panel extension loom1. in the control box mounted with the equipment
pack. This extension loom and attached black ter-
minal connector (see gure at right) will be used
to connect the topside control panel to the control
box.
Connect one end of the black terminal connector2. to the topside control panel cable.
Connect the other end of the terminal connector3. to the extension loom.
NOTE: This connection must be kept dry. We recom-
mend that a waterproof junction box be used in instal-
lations where moisture could penetrate this terminal
connector.
Lay out the extension loom to verify that you have4. enough length to reach the control box. Remem-
ber that conduit runs are not generally run in a
straight line. Every bend, and up and down run
consumes line length. Take this into consideration
when verifying electrical and plumbing runs.
Connect the extension loom to the control panel5. location on the circuit board located inside the
control box. You will also need to connect both
the temperature and high limit sensors to the cir-
cuit board prior to testing. (See the temperature
and high limit installation instruction on the next
page for proper identication and see the wiring
diagram on the inside cover of the control box for
proper placement.)
Turn on the power supply to the spa equipment6. and briey test all functions on the topside control
panel to verify that both connections and exten-
sion loom are in working order before proceeding
with the installation.
NOTE: Circuit board programming will not allow spa
operation without both the temperature and high
limit sensors being properly connected to the circuit
board.
Once topside panel operation is veried. Turn off 7. power, disconnect the extension loom from the
circuit board and GENTLY route through conduit
to complete installation.
NOTE: This loom and its connector are not meant to
withstand heavy pulling. Make sure, when routing the
extension loom and temperature sensor lines through
conduit, you exercise extreme caution.
Once properly run through the conduit, repeat steps
5 and 6 above.
Electrical and Electronic Connection