Cal Spas Inground Series Owner's Manual

LTR20081002, Rev. A
1/28/08
Read This First!
Cleaning and Maintaining Your Spa
Important Safety Instructions. . . . . . . . . . . . . . .3
Basic Spa Information. . . . . . . . . . . . . . . . . . . . .3
Preparing for Your New Spa
In-Ground Spa Installation Checklist. . . . . . . . .5
Planning the Best Location For Your Spa . . . . .5
In-Ground Spa Site Preparation . . . . . . . . . . . . .6
Electrical Requirements – US and Canada . . . .7
Electrical Installation -- Europe . . . . . . . . . . . . .9
Installing the In-ground Shell . . . . . . . . . . . . . .11
Equipment Pack Plumbing Connections. . . . .12
Plumbing Connections . . . . . . . . . . . . . . . . . . .12
Electrical and Electronic Connection . . . . . . .14
Pouring the Deck . . . . . . . . . . . . . . . . . . . . . . . .17
Operating Your Spa
9800 Electronic Control Operation. . . . . . . . . .18
Adjustable Jets . . . . . . . . . . . . . . . . . . . . . . . . .22
Cleaning and Replacing the Filter . . . . . . . . . .24
Cleaning the Cover, Shell and Pillows. . . . . . .25
Prior to Spa Start-Up and Relling. . . . . . . . . .26
Filling and Powering Up Your Portable Spa . .26
Draining Your Spa . . . . . . . . . . . . . . . . . . . . . . .27
Winterizing (Cold Climate Draining). . . . . . . . .27
Water Quality Maintenance
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . .28
Chemical Overview . . . . . . . . . . . . . . . . . . . . . .29
Chemical Descriptions . . . . . . . . . . . . . . . . . . .30
Traditional Chemical Start Up. . . . . . . . . . . . . .32
Bromine Clear Water Plan. . . . . . . . . . . . . . . . .33
Chlorine Clear Water Plan. . . . . . . . . . . . . . . . .33
Del Zone Eclipse Ozonator . . . . . . . . . . . . . . . .34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Appendix
Diverter Knobs . . . . . . . . . . . . . . . . . . . . . . . . . .22
Air Venturis. . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Removing and Reseating the Pillows . . . . . . .23
Spa Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Waterfalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Copyright 2008 Lloyds Material Supply, 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.
LTR20081002, Rev. A 1/28/08
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . .35
Keeping Fit with your Cal Spa . . . . . . . . . . . . .37
Cal Spas™ Chemicals. . . . . . . . . . . . . . . . . . . .39
CONTACT INFORMATION For customer service, please contact
your authorized dealer immediately. If you need additional information and/or assistance, please contact:
C.A.I. Customer Service Department 1462 East Ninth Street Pomona, CA 91766.
Toll Free: 1-800-CAL-SPAS Fax: 1-909-629-3890
www.calspas.com

Read This First!

Read This First!

Important Safety Instructions

When installing and using this electrical equipment, always follow basic safety precautions. Following these
instructions will help make your rst spa session a
pleasurable one.
READ AND FOLLOW ALL INSTRUCTIONS NOTE: A licensed electrician may be required to upgrade
your standard receptacle and/or circuit breaker. DANGER -- RISK OF ACCIDENTAL DROWNING:
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 procedures.
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 replace
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 attempt 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, circulatory system problems or diabetes should consult a physician before using the spa.
Persons using medications should consult a physician 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 internal
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 include 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 medication can greatly increase the risk of fatal hyperthermia.

Basic Spa Information

The following operating and maintenance instructions are very important and must be followed carefully. With the proper care and maintenance, your Cal Spa will provide you with years of satisfaction and performance.
Do not be afraid to push buttons or turn knobs to learn about your new Cal Spa, as it is built with quality materials and excellent craftsmanship.
Your new Cal Spa has been engineered with a high­powered water pump that pushes water through various
2008 Inground Spa Owner’s Manual Page 3
LTR20081002, Rev. A
Read This First!
therapy jets, which will relax even the tightest muscles. In addition to the water pressure, you can add air into the spa water with air venturi handles located seat-side that increase the intensity of your massage.
The ltering of this spa is very important. It will minimize
cleaning time and the amount of chemicals needed to keep your spa water balanced. The two daily pre-
programmed lter cycles of four hours in duration can be
increased if the need arises. This can be accomplished through the topside control panel.
IMPORTANT: Keep the spa covered when not in use!
Covered spas use less electricity while maintaining
• a set temperature.
Covering your spa will protect your spa’s nish from
• the sun’s ultraviolet rays.
You are required to keep the spa covered to maintain
• warranty coverage.
Covering your spa helps prevent children from
• drowning in the spa.
Your new Cal Spa comes equipped with an electric heater. Following the directions listed below will ensure
the most efcient operation:
NOTE: This method is only for spa usage under two hours a week.
Keep the spa’s operating temperature 5˚ F below
• the desired usage temperature when not in use. One or two hours before use, set the temperature to the desired temperature.
The air venturis should be used sparingly. When
• open, water temperature drops quite rapidly and can also dissipate chemicals.
Allowing the water temperature to lower more than 10˚F
below the desired usage temperature and reheating it prior to usage will cause the heater to operate longer than it normally would maintaining the desired temperature. Doing this will increase your operating cost and makes your heater work more than necessary.
The lter needs to be cleaned or changed on a regular
basis. This process takes only a few minutes and the result is increased water clarity and equipment longevity.
Water level is very important to the operation of your spa. If the water level is too low or too high, your spa will not operate properly. The water level should be to the middle of the skimmer area when the spa is not being used.
We recommend that your spa water be changed every
3 to 4 months. You may nd the need to change your
spa water more frequently with heavy use. When empty, your spa should be cleaned with a non-abrasive cleaner, such as Cal Spas™ All Surface Cleaner, and then rinsed thoroughly.
See the section “Cleaning and Maintaining Your Spa” for instructions on draining your spa.
When lling your spa, always ll through the skimmer lter canister. Use only regular tap water.
WARNING: DO NOT USE SOFT WATER.
If the spa usage exceeds two hours a week, the set
• temperature should remain at the desired usage temperature.
Page 4 2008 Inground Spa Owner’s Manual LTR20081002, Rev. A
Preparing for Your New Inground Spa

Preparing for Your New Spa

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™.

In-Ground Spa Installation Checklist

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
Install shell in ground Install equipment pack Connect plumbing Connect electrical components Pour the deck

Planning the Best Location For Your Spa

Here are some of the things that you will need to consider when determining where to place your new spa.
Safety First
Do not place your spa within 10 feet (3 m) of overhead
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 determine 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 recreation, 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 during all seasons to determine your best privacy options. 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 during 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 entrance 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 gazebo, remember to allow access for service. It is always best to design special installations so that the spa can still be accessed.
Consider the Best Place for the Outdoor Equipment Pack
The Designer Spa series requires an external equipment pack. When locating the outdoor equipment pack, you will want to consider the following:
2008 Inground Spa Owner’s Manual Page 5
LTR20081002, Rev. A
Preparing for Your New Inground Spa
The equipment pack must be located within a
maximum of 15 feet from the spa.
Ensure the equipment running its normal ltration
• 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 location
chosen. If you are using a gas heater, you will need to consider
• wind and drafts as well as heater exhaust 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 separately. Do not cover gas heaters unless properly
vented. (See heater owner’s manual for important safety information.)

In-Ground Spa Site Preparation

Ensure there is enough room for the spa and
• equipment.
The equipment pack must be located within a
maximum of 15 feet from the spa.
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.
The nal architecture must include permanent
• ground coverage within a 10 feet radius of the spa.
Never place any spa in a sealed area. Water must
• be able either to be absorbed into the surrounding area or channeled away. Water build-up under 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 preparation 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 relatively minor, contact your local building safety.
Site Excavation – Hard Bottom
For hard bottom placement for in-ground 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 escape under the spa. A gravel beds around the concrete base will help with this.
Site Excavation – Sand Bottom
With the spa area and all elevations planned including 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 required 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.
Page 6 2008 Inground Spa Owner’s Manual LTR20081002, Rev. A

Electrical Requirements – US and Canada

Preparing for Your New Inground Spa
240 Volt Electrical Installation
All 240V spas must be permanently connected (hard wired) to the power supply. These instructions describe
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 diagram on page
8.
When installed in the United States, the electrical wiring of this spa must meet the requirements of National Electric Code, ANSI/NFPA 70-2008 and 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.
GFCI and Wiring Requirements
The power supplied to the spa must be on a dedicated 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 wiring requirements.
When NEC requires the use of wires larger than #6 AWG, install a junction box near the spa and use #6 AWG wire between the junction box and the spa.
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 copper wires. Read and follow the heater manufacturer’s safety and
installation instructions prior to installation and operation. Incorrect installation may damage the heater and void its warranty.
Testing the GFCI Breaker
Test the GFCI breaker prior to rst use and periodically
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 will
1. trip and the spa will shut off.
Reset the GFCI breaker by switching the breaker
2. to the full OFF position, wait a moment, then turn the breaker back on. The spa should have power again.
Spa Model GFCI Required Wires Required
Designer in-ground spas
with one 5.5 kW heater
Designer in-ground spa
with two 5.5 kW heaters
One 50 amp GFCI Four #8 AWG copper wires
Service 1: One 50 amp GFCI
Service 2: One 30 amp GFCI
Service 1: Four #8 AWG copper wires Service 2: Three #8 AWG copper wires
2008 Inground Spa Owner’s Manual Page 7
LTR20081002, Rev. A
Preparing for Your New Inground Spa
GFCI Wiring Diagram
Page 8 2008 Inground Spa Owner’s Manual LTR20081002, Rev. A

Electrical Installation -- Europe

230 Volt Electrical Installation
All 230V spas must be permanently connected (hard wired) to the power supply. These instructions describe
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 10.
The electrical wiring of this spa must meet the requirements 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 dedicated RCD protected circuit with no other appliances or lights sharing the power.
Use copper wire with THHN insulation. Do not use aluminum wire.
Preparing for Your New Inground Spa
When wires larger than #6 AWG are required, install a junction box near the spa and use #6 AWG wire between the junction box and the spa.
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 copper wires.
Testing the RCD Breaker
Test the RCD breaker prior to rst use and periodically
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 will
1. trip and the spa will shut off.
Reset the RCD breaker by switching the breaker
2. to the full OFF position, wait a moment, then turn the breaker back on. The spa should have power again.
Use the table below to determine your GFCI and wiring requirements.
Spa Model GFCI Required Wires Required
Designer in-ground spas with one 3 kW heater
Designer in-ground spa with one 3
kW heater and one 5.5 kW heater
One 32 amp RCD or two 16 amp RCDs
Service 1: One 32 amp RCD or two 16 amp RCDs
Service 2: One 32 amp RCD or two 16 amp RCDs
Four #10 AWG copper wires
Service 1: Four #10 AWG copper wires
Service 2: Three #10 AWG copper wires
2008 Inground Spa Owner’s Manual Page 9
LTR20081002, Rev. A
Preparing for Your New Inground Spa
RCD Wiring Diagram
Page 10 2008 Inground Spa Owner’s Manual LTR20081002, Rev. A

Installing the In-ground Shell

Preparing for Your New Inground Spa
2008 Inground Spa Owner’s Manual Page 11
LTR20081002, Rev. A
Preparing for Your New Inground Spa

Equipment Pack Plumbing Connections

The example shown below is typical for a system with two pumps with external heater and external lter.
Designer Spa Specications
DIJ401 – DIJ406:
Equipment pack weight = 250 lbs.
DIJ407:
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 underground pipes. Always know what is under the ground before you dig anywhere.
You will need 2” ex or PVC lines for your suction,
intake, 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 maximize
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 installers 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.
Page 12 2008 Inground Spa Owner’s Manual LTR20081002, Rev. A
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