Sundance Spas Spas User manual

Sundance®Spas
SPA
EQUIPMENT
SYSTEM
Installation
Instructions
P/N 6530-456 Rev. A

Contents
Important Notices 1
Important Safety Instructions 2
Where to Place the Equipment System 3
Connecting Pipes Between Spa and Equipment 3
Electrical Installation Instructions 5
Power Supply Requirements 7
Use of External Heater 8
External Electric Heater 8
Gas Heater--Electronic Ignition 9
Gas Heater--Pilot Type 9
Use of External Heater's Controls 10
Piping Through External Heater 10
Installing the Sentry Control Panel 11
Connecting the Spa Light 11
Connecting the Temperature Sensor 12
Remote Freeze Protection Sensor 12
Start Up 13
Testing the Installation 14

Important Notices
These instructions apply to the spa equipment systems and
preplumbed spa shells designed and manufactured by Sundance Spas.
If this equipment system is to be connected to a spa made by a
manufacturer other than Sundance Spas, certain instructions may not
apply.
FCC Notice
This equipment has been tested and found to comply with the limits
for a Class B Digital Device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment
generates, uses and radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation.
If this equipment does cause harmful interference tp radio or television
reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or
more of the following measures: 1) Rearrange or relocate the receiving
antenna. 2) Increase the separation between the equipment and the
receiver. 3) Connect the equipment into an outlet on a circuit different
from the circuit connected. 4) Consult the dealer or an experienced
radio/TV technician for help. Changes or modifications not expressly
approved by the party responsible for FCC compliance could void the
user’s authority to operate this equipment.
1

Important Safety instructions
1. Read all instructions before installing this spa equipment
system.
2. Danger – A wire terminal marked “ground” is provided within the
power box (Ill. 1, Item 13). To reduce the risk of electrical shock,
connect this terminal to the grounding terminal of your electrical
supply panel with a continuos green insulating copper wire equivalent
in size to the circuit conductors supplying this equipment, but no
smaller than No. 8 AWG.
3. Danger – Risk Of Electrical Shock. Install at least five feet from spa.
(This equipment system may be installed within five feet of the spa if,
in accordance with the National Electrical Code, ANSI/NFPA 70-1990,
each metal surface is permanently connected by a No. 8 AWG copper
conductor attached to the wire connector on the terminal box provided
for this purpose – Ill. 1, item 4.)
4. CAUTION – This equipment system must be hardwired to the
household electrical service box only. Do not use an extension cord or
any other disconnectable power cord. The use of an extension cord or
a disconnectable power cord is highly dangerous and will void all
warranties.
5. This equipment system must be installed in such a manner as to
provide drainage of casual water, such as rainwater, away from all
electrical components.
6. The electrical supply for this product must include a suitably rated
switch or circuit breaker to open all ungrounded supply conductors to
comply with Section 422-20 of the National Electrical Code, ANSI/NFPA
70-1990.
7. The electrical circuit supplied for the spa must include a suitable
ground fault circuit interrupter (GFCI) as required by NEC Article 680-
42.
8. READ AND FOLLOW THE OWNER OPERATING INSTRUCTIONS
PROVIDED BEFORE USING THE SPA.
9. SAVE THESE INSTRUCTIONS.
2

Where To Place The Equipment System
The equipment system must be located within forty (40)-running feet
of the spa. If an existing gas heater is to be used, this equipment
system should be placed near the gas heater.
If the equipment system is to be installed above the spa’s normal
water level, it will require the available strainer pot housings to help
achieve prime. Order and install two each of part numbers 6472-619,
6560-006, and 6560-004.
The equipment system base should not be set on the ground. A
separate concrete pad is preferred, but any platform which serves to
permanently keep the system from contact with the ground is
acceptable. Do not install the equipment system in a depression where
casual water may stand after a rain or lawn sprinkling.
If the equipment system is to be exposed to direct sunlight and you
are in a hot climate, you will need to shade the equipment system to
protect it from the excessive temperatures of the mid-day sun.
Connecting Pipes Between Spa And
Equipment
Water piping between the spa and the equipment system should be 2”
diameter or larger Schedule 40 PVC or heavier. The use of 90 degree
elbows should be minimized. Instead use two 45 degree elbows or,
better still, gradual flex hose sweeps to make turns when possible.
The pipes on the Sundance spa shell are color coded. Connect the
equipment components to these pipes as follows:
Dual-speed Pump-Suction----------Red
Dual-speed Pump- Discharge-------Blue
Single-speed Pump-Suction---------Orange
Single-speed Pump-Discharge-------Yellow
Air Blower-----------------------------Green
Check with the local Building Department to ensure that your planned
installation meets the code requirements.
3

Blower Loop—If the equipment system is installed at a level lower
than the maximum water level of any spa besides a Sundance spa,
measures must be taken to keep water from backing up into the air
blower. When connecting the pipe from the air blower to the spa, route
the pipe so that it rises at least 12 inches above the maximum water
level of the spa. This raised “loop” can be located anywhere between
the spa and the air blower, however, it is generally preferable to locate
it as close to the spa as possible. Do not plan to rely on a check valve
as sole protection against water back up as they can fail over time.
(NOTE: This loop is not required on Sundance spas because they
contain built-in protection against the possibility of water backing up
into the air blower.
Isolation Valves—In cases where equipment is below the water
level, consider installing valves in the water pipes on both the suction
and discharge sides of the equipment system so that the system can
be isolated for serving without draining the spa.
Drain Valve—The simplest method for the spa owner to employ
periodic draining the spa is to use a submersible pump. However, for
the owner’s convenience, some installers install a valve or valves on
the discharge side of the single-speed pump to provide a means of
draining the spa.
IMPORTANT: Provide specific instructions to the owner regarding
proper draining procedures.
Connecting The Ozone Supply Tube
See instructions supplied with the spa shell.
4

Electrical Installation Instructions
1. This spa equipment system must be permanently connected (hard-
wired) to the power supply. No plug-in connections or extension
cords are to be used in conjunction with the operation of this
equipment system. Supplying power which is not in accordance with
these instructions will void the manufacturer’s warranty.
2. The power supplied to this equipment system must be a dedicated
circuit with not other appliances or lights sharing the power
provided by the circuit.
3. All electrical work must be done to National Electrical Code (NEC)
and any other applicable electrical codes.
4. The electrical circuit must be installed by a qualified electrician and
checked by a local building/electrical inspection authority.
5. The electrical circuit supplied for the spa must include a suitable
ground fault circuit interrupter (GFCI) as required by NEC Article
680-42.
6. Determine the current, voltage and wire size required. Refer to the
table titled “Power Supply Requirements” (Ill. 2) for current and
voltage required. Select wire type and size based on the power
requirements and the length of electrical run per National Electrical
Code requirements. (Note: When using wire larger than #6, add a
junction box near the equipment system and reduce to short
lengths of #8 to connect to system.)
7. All wiring must be copper to ensure reliable connections. Do not use
aluminum wire.
8.To gain access to the main terminal connection for the spa
equipment system, remove the front cover of the control box.
9. Using a connector feed the cable through the opening provide on
the bottom of the control box (Ill. 1, item 2).
10. Connect wires, color to color, on the terminal strip (Ill.
1, item 13). TIGHTEN SECURELY! All wires must be
hooked up. Do not neglect to run the ground line as
serious damage could result.
5

11. To provide an additional measure of safety, connect a separate
#8 solid copper bonding wire between the spa equipment system
current collector (grounding buss bar inside the control box—Ill. 1,
item 1) and a local UL-recognized ground rod fully driven into the
ground.
Ill. 1
Sentry Control Box
1. External Ground Buss 8. Daughter Board
2. Power Supply Entrance 9. Sensor Harness
3. Light Terminal Strip 10. Heater Relays (e)
4. Internal Ground Buss 11. 4-Position Terminal Block
5. Control Wiring Entrance 12. Freeze Sensor Connection (JP20)
6. Cover Screw 13. Main Terminal Connection
7. Ozone Check Valve
6

Power Supply Requirements
The power supply required by the equipment system depends on
certain variables as indicated in the table below. Note that these
requirements are for the equipment system only. Power for an
external electric heater, if used, must be separate from, and in
addition to, the power supplied to the equipment system. For gas
heaters, add the power requirements to these figures.
Ill. 2
Power Supply Required
For Equipment System Only
Using Integral In-Line Heater?
NO YES YES
Circuit Breaker 30A dual
p
ole 50A* dual
p
ole 60A dual
p
ole
Number of Wires 3 3 3
Current Draw
(
Am
p
s
)
24 40 48
If the home’s electrical service does not have the full 50A, 240V power
available, the spa may be connected to 30A, 240V service if a minor
circuit board modification is performed by the dealer. In this
configuration, the heater will yield the same rate of temperature
increase as in 50A operation, but will not operate while the high speed
of either pump or the air blower is operating. This could result in rapid
cooling of the water while the spa is being used during periods of cold
ambient temperatures.
*In 50A configurations, the heater will not operate while both pumps
are operating at high speed.
7

Use of External Heater
If a heater other than the in-line electric heater included in the
Sundance equipment system is used, certain issues must be addressed
to assure optimum operation of all components. These issues include:
(1) supplying power, (2) connecting the Sentry controls, (3) water
piping and (4) heater sizing. Note: If an external gas heater is to be
used, Sundance Spas recommends against using a heater rated at
more than 250,000 BTU.
External Electric Heater
Follow the heater manufacturer’s instructions for installation of
the external electric heater. Use a power source separate from
that supplied to the equipment system.
Ill. 3
Connecting External Electric Heater to Sentry Controls
If an external electric heater is to be used, you must supply a
separate 240V relay in a listed box. Connect wires (min. #16
AWG) from the heater 4 position terminal block on the Sentry
circuit board to energize the relay coil (Ill. 3). Run separate
power to the heater through the normally open contacts on this
relay.
8

Gas Heater (Electronic Ignition)
Make certain that the voltage of the heater employed is 240V to
match that of the equipment system and that current supplied to
the equipment system is sufficient to also satisfy the power
requirements for both the heater and the equipment system.
Ill. 4
Connecting Gas Heater with Electronic Ignition to Sentry
Controls
Connect wires (min. #16 AWG) from the heater 4-position
terminal block on the Sentry circuit board (Ill. 4) to the
appropriate power terminals in the gas heater. Consult your
heater owner’s manual.
Gas Heater (Pilot Type)
Completely remove the red and black wires that connect 4-
position terminal block (Ill. 1, item 11) to the main terminal (Ill.
1, item 13). Connect wires (min. #16 AWG) from the heater 4-
position terminal block on the Sentry circuit board (Ill. 5). Cut
into the heater’s control wiring harness and connect these wires
in series with the heater’s controls.
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Ill. 5
Connecting Gas Heater with Pilot to Sentry Controls
Use of External Heater’s Controls
The control systems in the external heater should not be
disconnected. Instead, set the external heater’s thermostat at
maximum. Failure to do this may result in the heater turning off
before the temperature set at the Sentry control panel is
reached.
Piping Through External Heater
The water flow capacity of any external heater used must be at
least 120 gpm. If the heater’s flow capacity is not adequate, a
bypass system must be installed to prevent damage to the

heater and to ensure proper jet performance. Follow the heater
manufacturer’s instructions for installing and adjusting the
bypass system. (NOTE: A bypass system may enhance jet
performance even if the heater’s flow capacity rating is sufficient
according to the above specifications.
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Ill. 6
Typical Bypass Plumbing for External Gas
Heater
(Consult Heater Owner’s Manual for Specific Instructions)
Installing the Sentry Control Panel
If the equipment system is being installed in a location away
from the spa, the control panel cable should be installed in a
conduit to provide protection for the cable and make it
convenient to remove should it ever need servicing or
replacement.
Cut or drill an appropriate size hole where the control panel is to
be mounted and install the conduit from this point to a point
under the control box of the equipment system. Using a fish tape
or similar means, carefully pull the cable through the conduit.
Then feed the plug through an opening on the bottom of the
control box (Ill. 1, item 5) and plug the connector into the
daughter board on the inside right wall of the control box (Ill. 1,
item 8). Finally, peel the backing from the adhesive on the back
of the control panel, align the panel in the position desired and
press firmly.
11
Connecting the Spa Light
Your Sundance Spa Shell comes equipped with a dry-niche, low-
voltage spa light installed. The cable from this light should be
run through the opening provided in the bottom of the control

box (Ill. 1, item 5) and connected to the terminal strip labeled
“Spa Light” (Ill. 1, item 3).
For spa shells other than Sundance brand, other low voltage spa
lights can be connected in this manner to be operated by the
Sentry controls provided that the 12-volt, one amp power is
sufficient for the light selected.
Connecting the Temperature Sensor
The temperature sensor required for operation of this equipment
comes pre-installed in the Sundance spa shell. The cable from
this sensor should be routed through conduit and run through
the opening provided in the bottom of the control box (Ill. 1,
item 5), then connected to the sensor harness (Ill. 1, item 9).
IMPORTANT: If this equipment system is being connected to a
spa shell other than a Sundance brand, you must order the 45’
remote temperature sensor accessory (P/N 6600-135) and install
it into the spa shell.
Remote Freeze Sensor
The Sundance spa equipment system contains a temperature
sensor, which automatically turns on the system to protect
against freeze damage. This sensor is located in the heater
housing, which is the most vulnerable to freezing in a typical
outdoor installation.
If the equipment system is to be installed in an area where
temperatures may be greater than the temperatures to which
any other part of the circulation system is exposed, an available
remote freeze protection sensor must be installed (order P/N
6472-005). For example, if the spa is installed outdoors and the
equipment system is installed in a basement or garage, the
remote sensor should be placed on the piping in area which is
likely to be the most susceptible to freezing. If in doubt, multiple
sensors may be installed in parallel circuit.
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Ill. 7
Remote Freeze Sensor Installation

To install the remote freeze sensor, secure the sensor to the pipe
where the temperature is to be sensed using plastic tie straps. If
needed, the wire may be lengthened by splicing-in additional
wire making certain that the splices are tight. The wire must be
protected to ensure that it cannot be accidentally disconnected
or broken. Run the connector through an opening in the bottom
of the control box and plug it into the JP20 connection on the
Sentry circuit board (Ill. 1, item 12).
To test the remote freeze sensor, place an ice cube on it before
strapping it on the pipe. Both pumps should come on within a
minute or two. IMPORTANT: Do not perform this test unless
the spa is full of water and the spa installation is fully
operational.
Start Up
Follow the start up instructions in the “ Owner Operating
Instructions” supplied with this equipment system.
13
Testing the Installation
Once the installation is complete, but prior to filling in the
trenches or decking around the spa, the installation should be

thoroughly tested so that any leaks or other problems can be
detected.
We recommend filling the spa to an identifiable level and
covering it to avoid water loss through evaporation. For one 24-
hour period, the spa should be operated continuously,
occasionally switching the dual-speed pump to high speed and
turning on the single-speed pump and the air blower to test the
pressure-side pipes. For another 24-hour period, the spa should
be completely inactive to test the suction and venturi lines. If the
water level has not changed and no other problems have been
detected after either of these tests, you are ready to complete
the installation by filling the trenches, etc.
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