Welcome to Backyardplus! In this post, we show you how to hardwire the heater in a Hot Spring Spa (1990-1994 Classic, Jetsetter, Prodigy, and Sovereign Spa). If the heater receptacle in your control box has been burned or damaged, you can bypass it by plugging the heater wires directly into the terminals inside the control box. Before we get started, let’s go over the tools and parts you will need.
Tools you will need:
- Phillips head screwdriver
- Flat blade screwdriver
- Knife
- Pliers
- 3/8” driver
- Wire stripper
- Wire cutters
- Ratchet crimper
Parts you will need:
- 20286.75-BYP Heater Replacement Kit
- 16-14 AWG Flag Terminal x 2
- 16-14 AWG Ring Terminal
Step 1. Disconnect Power from the spa.
Step 2. Remove the control panel and control box from the spa.
Step 3. Cut the plug off the new heater cord with the wire cutters.
Step 4. Turn the control box upside down and remove the back cover.
Step 5. Measure the length of the insulation you need to remove from the cord. It should be about 10”.
Step 6. Cut the insulation around the cord with a knife and remove the insulation.
Step 7. Strip the black, white, and green wires with the 12 AWG wire stripper about ¼” from the end.
Step 8. Crimp the ring terminal to the green wire and flag terminals to the black and white wires.
Step 9. Disconnect the black, white, and green heater wires from the terminals in the control box.
Step 10. Remove the heater receptacle from the control box.
Step 11. Pull the new heater wires through the heater receptacle opening or through the hole just to the left of the receptacle.
Step 12. Connect the black, white, and green wires to the heater terminals in the control box.
Step 13. Place some steel wool in the open space next to the cord to prevent critters from entering the box.
Step 14. Install the old heater receptacle back into its original position and cut the wires off (so that they don’t accidentally touch the other wires in the box).
Good job!
Watch The Video Here! “How to Hardwire the Heater in A Hot Spring Spa (1990-1994)”
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