HydroQuip Universal Air Series User manual

To ensure that the system is installed properly,
provide your electrician with these instructions.
INSTALLATION
INSTRUCTIONS
Universal
Air Series
!! NOTE !!
Covers the following models:
9000 Series
6000 Series

1
ELECTRICAL INSTALLATION
A qualified and licensed electrician in accordance with the National Electric Code (NEC)
Article 680, Canadian Electric Code, and with any local codes must accomplish the electrical
installation.
All connections must be made according to the electrical installation label on the outside of the
control box. Follow the instructions from the label if they are different than the instructions in this
manual. If your electrician is not absolutely sure how to connect your system correctly, call your local
dealer. Any mistake may be costly and invalidate your equipment warranty.
The GFCI (Ground Fault Circuit Interrupter) is a mandatory electrical safety device required for
all portable spas and hot tubs as specified in the National Electrical Code Article 680-42. The
GFCI in your particular installation may be installed at the electrical service panel, a separate
sub-panel or built into your Hydro-Quip System.
Your spa equipment requires a DEDICATED CIRCUIT. No other appliances or lights can be on
this circuit. Refer to equipment data label for power supply requirements of your spa equipment.
Use copper conductors ONLY. The ground must be sized following the National Electric Code,
Table 250-95.
NOTE: Due to the electrical requirements of some models, it may be required to SPLIT the
incoming electrical service to accommodate the GFCI Circuit Breaker limits. Contact your
electrician if you need additional information on this topic.
15A 20A 30A 40A 50A 60A 70A 80A
12A
16A 24A 32A 40A 48A 56A 64A
14 12 10 86 4 44
Circuit & Breaker
Rating
Maximum Amps
Minimum Wire
Size
Universal Systems require a Neutral wire therefore the service required is as follows: 120-volt
systems require a three-wire electrical service including ground, consisting of Line 1 (Black),
Neutral (White) and Ground (Green) (system Line 2 (Blue) connected together with the
Neutral (White). 240-volt systems require a four wire electrical service including ground,
consisting of Line 1 (Black), Line 2 (Red), Neutral (White) and Ground (Green).
120 oV ls
t
1212
0
0Vo
Vol
ls
s
t
t
20Vlts
4
o
2
20
0V
Vltslts
44
oo
ROUND ROUND
LINE 2

2
ELECTRICAL CONNECTIONS
If your system was configured to include a 120VAC power cord, ensure that the proper
receptacle has been installed (a dedicated circuit is required). DO NOT under any circumstances
modify a 20 Amp plug to fit into a 15 Amp receptacle or use an extension cord. Doing so will
create hazardous conditions and/or void the warranty.
DO NOT
USE AN
EXTENSION
CORD
15 AMP
RECEPTACLE
20 AMP
RECEPTACLE
OPTION 1
15AMP CORDEND GFCI
15A / 120V OUTLET
PORTABLE SPA
DEDICATED
This illustration depicts a typical 15 AMP, cord-end GFCI installation.
(The spa must be installed on a dedicated circuit.)
Units with 15A GFCI Plug Connection
MAIN BREAKER PANEL

3
PORTABLE SPA
INLINE SPA DISCONNECT
OPTION 2
GFCI DISCONNECT
LINE 1
N
LINE 2
INLINE SPA DISCONNECT
OPTION 2a
20-60AMP HARDWIRED
Power from GFCI breaker installed into main service panel to a service disconnect within line-of-
site of the spa.
Power from main service panel to a GFCI subpanel within line-of-site of the spa. (Note: Most
local codes will allow a GFCI subpanel to be a disconnect. If this is not the case in your
installation, a disconnect must be provided.)
TO PORTABLE SPA
REFER TO GFCI WIRING DETAIL
REFER TO GFCI WIRING DETAIL
ELECTRICAL CONNECTIONS
MAIN BREAKER PANEL
LINE 1
N
LINE 2
20-60AMP
HARDWIRED
If the manufacturer of your homes main breaker panel makes a GFCI
breaker, you may be able to add it to an open slot in the panel.
GFCI Installed in Main Service Panel
Subpanel GFCI Installed
MAIN BREAKER PANEL

4
HEATER
ON
POWER
CONTROL
SWITCH
RefertoOperation
Manualfortesting
andoperational
procedures
Pump1
*Pump2
Air
*Pump3
*Aux.
Light
Ozone
*Circ.
*Aux.
SOLID-STATE
CONTROL SYSTEM
*Optional
MAIN BREAKER PANEL
PORTABLE SPA CONTROL w/BUILT-IN GFCI
INLINE SPA DISCONNECT
OPTION 3
BUILT-IN SYSTEM GFCI
Power from main breaker panel to service disconnect within line-of-site of the spa to portable spa
control equipped with buit-in GFCI.
Refer to the System Data Label for equipment voltage and maximum amperage draws.
Install proper size Ground Fault Circuit Interrupter (GFCI) or circuit breaker, then proper sized
wiring and bonding wire. For Power conductor size, refer to the National Electric Code Table 310-
16. For Ground conductor size, refer to the National Electric Code Table 250-122.
A bonding lug has been provided on the control box to allow connection to local ground points.
To reduce the risk of electrical shock, a solid copper bonding wire should be connected from this
lug to any metal ladders, water pipes or other metal object within 5 feet of the spa.
WARNING - BE SURE THAT YOUR POWER SUPPLY CIRCUIT CAN ADEQUATELY HANDLE
THE AMPERAGE YOU SELECT.
The control input power wiring may have been provided. Following NEC and local codes in effect
at the time of installation, connect (refer to wiring diagram located on the inside of control hinged
cover) the Black wire to input Line 1, Blue wire to input Line 2 (if applicable), White wire to
Neutral and the Green wire to ground.
ELECTRICAL INSTALLATION DETAILS
!
ELECTRICAL CONNECTIONS
IMPORTANT - The NEC and most local codes require that a “disconnect” be installed within
“line-of-site” of the spa.
ONON
OFFOFF
RESET
TEST Located on left side of control box.
N
Systems with GFCI Included
Your system may have an integrated GFCI located on the left side of the control box
as shown below. If a GFCI is present there is NO need for additional GFCI protection
illustrated in options 2 & 2a.

5
GFCI WIRING DETAIL
When a GFCI circuit breaker is used in the installation of your spa, it is important that it has been
properly installed. Often this component has been improperly installed causing the breaker to trip
the instant the system is turned on. Below is an illustration of a typical GFCI breaker installation.
WARNING: Refer to Circuit Breaker Manufacturers installation instructions. This illustration is
meant to be a guide for Field Technicians and is not intended to override or substitute the
instructions supplied with the circuit breaker.
GFCI
TEST
(Ground Fault Circuit Interrupter)
CIRCUIT BREAKER
NEUTRAL PIGTAIL
NEUTRAL BUS BAR
LINE 1
NEUTRAL
LINE 2
GROUND
GROUND BUS BAR
LINE LUG #1 LINE LUG #2
LINE 1
LINE 2
INCOMING
SERVICE
CONDUCTORS
FROM
MAIN
PANEL
NEUTRAL
GROUND
TO SPA CONTROL SYSTEM
LOAD
LOAD NEUTRAL MUST BE CONNECTED
DIRECTLY TO GFCI AS SHOWN

6
SYSTEM CONFIGURATION
Congratulations on your purchase of the Universal Series Control System from Hydro-Quip. This
series of controls has been developed to allow you complete flexibility during your installation.
This Control System is configured to allow you to choose the voltage for each circuit at the time
of installation. We highly recommend that all component cords be replaced at the time of
installation.
The Universal conversion procedure MUST be accomplished PRIOR to connecting input
service wiring. This control has been shipped from the factory with ALL circuits wired for
120 VAC.
VERIFY YOUR COMPONENT VOLTAGE REQUIREMENTS: 120 VAC will not harm a 240 VAC
component if operated temporarily. 240 VAC WILL harm a 120 VAC component almost
immediately. This is the reason we ship all circuits in the 120 VAC configuration. Hydro-Quip
cannot be held responsible for mis-wire related damage to components.
Note: To utilize the Universal circuitry (120/240VAC), incoming service must be 240V/4-Wire.
Hydro-Quip has made the conversion process simple and easy. After you have
determined the voltage of your components (pump(s), air blower, ozonator etc.), you are
now ready to complete the conversion process. Color-Coded Neutral Wire connectors
have been provided to easily distinguish the circuit to be converted. By simply moving a
Neutral wire from the Neutral side of the conversion terminal block, clearly marked and
located inside the control enclosure, to the Line 2 side completes the circuit conversion.
Follow the illustrations and step-by-step instructions.
Step 1
Circuit Color Chart
Red Connector = Pump 1 Brown Connector = Circulation Pump
(Optional)
Violet Connector = Pump 2 (Optional)
Note: Ozonator Circuit 120V ONLY
Blue Connector = Air Blower
Remove 2(ea) screws and open
front cover of enclosure. Locate
the conversion terminal block and
desired connector (using ‘Circuit
Color Chart” above). Carefully
remove connector from the Neutral
side.
Li e2
ner
l
t
Nua
0oot
m
4p
n
e
(s)
2V
C n pn
(2e s
Vo
10 C n)
ot
m
If you have a 3-wire/240V connected
system, you will not have the Universal
option
!
!
!

7
Lne
2
irl
a
Nt
eu
4t
0Cme
V
n
ns
2o)
(po (1o)
p
2ot
0Cme
V
n
ns
CONFIGURATION
Step 2
Reinstall the connector onto the
“Line 2” side. The conversion is
complete and the circuit is now
ready for a 240VAC component.
Note: Repeat this procedure for
each circuit. Refer to “Circuit
Color Chart” on previous page.
HEATER CONVERSION
Step 1
Your system can be set for
High Current (HC) or Low
Current (LC) operation (the
connection is pre-configured at
the factory for low current). In
the Low Current configuration
the heater will automatically
turn off when the high-speed of
the pump or the air blower is
activated. For unrestricted
High Current operation, simply
turn input power off, locate and
disconnect the conversion plug
and receptacle.
R
E
D
LC
120V
LC
OR
You will have either a two or four pin
conversion plug.

8
All systems include colored component receptacles for ease of identification. Match the
component plug with its mating receptacle using the “Receptacle Identification Chart” on the
following page.
CONNECTION
Step 2
Now reinstall the conversion
plug into the High Current (HC)
conversion receptacle. The
conversion is complete.
Reapply power and operate
the spa normally. When the
high-speed of the pump or the
air blower are turned on, the
heater will not shut off.
B
L
A
C
K
HC
HC
240V
OR
You will have either a two or four pin
conversion plug.

CONNECTION
9
RED
Pump 1 / 2-Speed
Below is an illustration showing our exclusive colored receptacles, located on the right side of the
control box. Use this illustration when connecting spa components.
Receptacle Color Chart
Assure that all plugs and receptacles are fully
connected. A loose connection can cause damage to
the system.
Note: Hydro-Quip utilizes the BLACK wire for
High-Speed and the RED wire for Low-Speed in
Two-Speed Pump Circuits. Keep this in mind
when connecting a Two-Speed pump that has not
been purchased with the system.
BROWN
Pump 2 / 2-Speed
PINK
Pump 1 or 2 / 1-Speed
VIOLET
Air Blower
YELLOW
Ozonator
LIGHT VIOLET
Switched Accessory
BLUE
Circulation Pump
WHITE
12V Light or
Firemans Switch
ORANGE
Fiber Optic
GREEN
“Hot” Accessory
RED
Pump 1 / 2-Speed
PINK
Pump 2 / 1 or 2-Speed
WHITE
Air Blower
YELLOW
Ozonator
GREEN
“Hot” Accessory
RED 3-Pin
Circulation Pump
WHITE 2-Pin
12V Light

10
CONNECTION
Spaside Control: If equipped, install the Spaside Control per the manufacturers instructions.
Once installed, connect the Spaside Control plug into the receptacle provided on the side of the
control box (as shown in the illustration below). If the Spaside Control includes a thermostat,
installed the temperature probe into the dry-well of the spa.
Spa Light: Using a suitable 2 ½ “ diameter hole-saw, cut a hole in the spa wall.
Cut from inside the spa wall toward the outside to prevent splintering the inner surface.
Remove any insulation material from around the hole (at least ½ “) at the outside spa wall.
Install the gasket onto the light body and install the light into the hole. Take care not to over tighten the
nut securing the light body. (Silicone sealant may be used in place of the gasket. Allow adequate time
for sealant to cure before filling the spa.)
Note: It is recommended that the water level be stopped just above the level of the spa light
until a thorough inspection for leaks can be completed.
Gasket
Light Body
Spa Wall
Light Bulb

11
SYSTEM STARTUP
Using the “System Operation Manual” provided with the unit, complete the following
procedures:
1) Read and familiarize yourself with the system Operation manual.
2) Unplug the power cord (120-volt system only) or turn the electrical power “OFF” at the service or
breaker panel (120 or 240 volt permanently connected units.)
3) Open all WATER shut-off valves.
4) For spas equipped with a hose bib or drain valve, make sure that it has been closed.
5) For spas equipped with in-line or pressure water filters, make sure that the filter nut, housing drain
plug, and air relief valve are closed and tight.
6) Using a standard water hose, fill the spa with fresh tap water to the level recommended by the spa
manufacturer.
7) Inspect all plumbing connections and lines for any sign of water leaks.
8) Close all AIR control valves. WARNING: Do not confuse with WATER shut-off valves.
9) Adjust temperature to the lowest setting.
10) Plug the unit into the proper outlet (120-volt system) or turn on the breaker at the electrical service
panel (240-volt system).
11) On units with a Ground Fault Circuit Interrupter (GFCI), check the GFCI by pressing the “Test”
button on the face of the device. The “Reset” button should pop out. The equipment should not
operate.
12) Activate the equipment by pressing the “Reset” button on the GFCI. (If the jet pump(s) or blower is
operating, switch them off).
13) Press the “JET PUMP” switch to run on high speed. Allow to run until you achieve a strong,
steady water flow (free of air bubbles).
14) On systems with a pressure filter, bleed off the trapped air by opening the Air-Relief valve. You will
notice a steady flow of water when the air has been bled completely.
15) Switch the “JET PUMP” off.
16) If equipped, switch the “AIR BLOWER” on to verify that it is working, then switch it off.
17) If equipped, switch the “LIGHT” on to verify that it is working, then switch it off.
18) If equipped, switch the “AUXILIARY PUMP” on to verify that it is working, allow to run until all air
is evacuated from the plumbing system, then switch it off.
19) Adjust temperature to the desired set point for comfortable use of the spa. The pump low speed
and heater will activate until the set point has been reached.
It is now time to turn over operation of the spa to the homeowner. See next section for basic
troubleshooting tips.
System Startup Procedures:

12
TROUBLESHOOTING
NOTHING OPERATES
The following describes situations and possible solutions to common problems may encounter as
a spa owner. Note: your system may not include all components listed.
Main Breaker is OFF - Set to On.
Sub-Panel Breaker Off - Set to On.
System GFCI Off - Set to On.
Power switch in Off position - Set to On.
Components not plugged in - Plug in components.
Power cord not plugged in - Plug in power cord.
NO, LOW OR SURGING WATER FLOW
Air Lock in Plumbing System - “Bleed” the system.
Restricted Flow - Insure that the water shut-off valves are open and that suction fittings are not
blocked by debris.
Low Water Level - Increase water level to recommended level.
NO LOW SPEED PUMP OPERATION
Pump 1 Not Plugged-In - Plug in Pump 1.
Pump 1 Fuse Blown - Contact you local dealer.
Pump 2 Not Plugged-In - Plug in Pump 2.
Pump 2 Fuse Blown - Contact you local dealer.
NO JETS OR BLOWER OPERATION
Blower or Pump Not Plugged-In - Plug in the Blower or Pump.
Pump or Blower Fuse Blown - Contact you local dealer.

13
NO THERAPY JET OPERATION
Water Shut-Off Valves are Closed - Open Shut-Off valves.
Jets Not Properly Adjusted - Adjust Jets properly.
Diverter Valve Not Properly Adjusted - Adjust diverter valve properly.
Thermal Overload Tripping - Check for restricted flow of water.
NO HEAT
Temperature Not Set Correctly - Adjust “Set Point” Temperature.
System Power Restriction - Depending on available power, the spa may have interlocks in place
to shut off the heater when the pumps are switched to high speed.
No Power - Reset breaker at service panel.
Low Water Flow - Clean or Replace filter.
Pressure Switch Not Adjusted Properly - Refer to “Pressure Switch Adjustment”.
HIGH HEAT
Temperature Sensor Not in Dry-Well - Place sensor in dry-well.
Temperature Set Too High - Adjust “Set Point” Temperature.
High Ambient Temperature - Remove spa cover.
NO LIGHT OPERATION
Light Bulb Defective - Replace bulb or contact your local dealer.
Reflector has Fallen Off - Replace deflector or contact your local dealer.
Light Not Plugged-In - Plug in the Light.
WATER LEAKS
Spa Overfilled - Adjust water level.
Drain-Valve Left Open - Close drain valve.
Couplings or Unions Loose - Tighten or contact your local dealer.
Pump Seal Leaking - Contact your local dealer.
Plumbing / Connections Leaking - Contact your local dealer.
Water Leaking from Spaside Control - Contact your local dealer.
Water in Air Blower Plumbing - Contact your local dealer.
GFCI TRIPS IMMEDIATELY
For correct GFCI breaker wiring, refer to page 5 for details.

14
SPECIAL CONSIDERATIONS
If your system is equipped with a pressure switch, the function of the pressure switch is to turn the
heater off if the pump stops operating or if there is a restricted water flow (dirty filter, obstruction in
the spa plumbing etc.).
The pressure switch has been preset at the factory to operate properly with your spas specific
plumbing. Adjustment or other service may be required if you observe a flow related problem (3
flashing dots on spaside display). If adjustment is required, follow the next steps carefully.
IMPORTANT: After any pressure switch adjustment, it is important to test the control by turning
on the pump low speed and heater. While operating, unplug the pump, the heater must turn off. If
the heater stays on, plug the pump back in and readjust the pressure switch to achieve proper
operation.
1) With power to system turned OFF, remove the wires from the pressure switch terminals
(secure wires safely to prevent any chance of electrical shock).
2) Use temperature adjustment key to move “set point” temperature to its lowest setting.
3) Turn power to the system ON and activate the low-speed pump.
4) Place an Ohmmeter across the pressure switch terminals to verify an OPEN circuit.
5) Rotate the pressure switch adjustment screw counter-clockwise until the Ohmmeter indicates
a CLOSED circuit.
6) Turn pump OFF and verify that the pressure switch circuit is once again OPEN.
7) Turn power to the system OFF and reconnect pressure switch wires. Reapply power to the
system and operate the spa or hot tub as normal.
1
2
3
P
S
I
Calibration Scale (1lb.)
Adjustment Screw
Adjustment

15
SYSTEM DATA LABEL
The system data label is located on the control box. This label is very important and contains
information you will need to establish your electrical service. The voltage and amperage ratings
are shown on the bottom of the label. Product, Model, Serial and Code numbers are also shown
on the label.
Note: This information will be necessary if you should ever have to request warranty or any
other type of service.
ORDER CODE:
MODEL:
CODE:
SERIAL:
VOLTS:
AMPS:
PRODUCT:
REFER TO NEC FOR
BREAKER SIZING

16
WARRANTY INFORMATION
To all original purchasers, HYDROQUIP warrants its products to be free from defects in material
and workmanship for a period of one year from the date of purchase.
HYDROQUIP will repair or replace the part, which in our opinion, is defective.
This warranty excludes damage as a result of: normal wear, freezing, low voltage, chemical abuse,
accident, negligence, alteration, improper installation, use or care.
To obtain warranty service, return defective products within the warranty period to HYDROQUIP.
Purchaser is responsible for removal or reinstallation labor, freight charges, or any other such
costs incurred in obtaining warranty service.
HYDROQUIP assumes no responsibility for incidental or consequential damages. Some states do
not allow the exclusion of incidental or consequential damages, so the above limitations and
exclusions may not apply to you. This warranty gives you specific legal rights and you may also
have other rights, which vary from state to state.
THE SPA DEALER MAY PROVIDE A DIFFERENT WARRANTY,
CONTACT YOUR SPA DEALER FOR DETAILS

17
Dealer:
Contact:
Address:
City:
Phone:
State: Zip:
Date of Install:
Notes:
NOTES
Use this section to jot down any information you may need at a later date.

85-0100B Rev.3 08/03