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How to Hardwire the Heater in A Hot Spring Spa (1990-1994)

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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 1. Disconnect power 120 volt 1-

Step 2. Remove the control panel and control box from the spa.

Step 2. Remove the panel and box 1-

Step 3. Cut the plug off the new heater cord with the wire cutters.

Step 3. Cut off the plug-

Step 4. Turn the control box upside down and remove the back cover.

Step 4. Remove the back-

Step 5. Measure the length of the insulation you need to remove from the cord. It should be about 10”.

Step 5. Measure the length to cut-

Step 6. Cut the insulation around the cord with a knife and remove the insulation.

Step 6. Cut the insulation-

Step 7. Strip the black, white, and green wires with the 12 AWG wire stripper about ¼” from the end.

Step 7. Strip the wires with a wire stripper-

Step 8. Crimp the ring terminal to the green wire and flag terminals to the black and white wires.

Step 8. attach the ring and flags-

Step 9. Disconnect the black, white, and green heater wires from the terminals in the control box.

how to hardwire the heater in a hot spring spa

Step 10. Remove the heater receptacle from the control box.

Step 10. Remove the receptacle-

Step 11. Pull the new heater wires through the heater receptacle opening or through the hole just to the left of the receptacle.

Step 11. Pull the new wires-

Step 12. Connect the black, white, and green wires to the heater terminals in the control box.

Step 12. Connect the heater wires-

Step 13. Place some steel wool in the open space next to the cord to prevent critters from entering the box.

Step 13. Insert steel wool-
Step 13. Steel wool zoom out-

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).

Step 14. Reinstall receptacle-
Step 14.1. Cut the receptacle wires-

Good job!

Good job 1-

Watch The Video Here! “How to Hardwire the Heater in A Hot Spring Spa (1990-1994)”

https://youtu.be/8ONNcB22Cao


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