I have an old CalSpa hottub with a Classic Controls spa pack that I am trying to rebuild. It appears that all the components are still functional, but some of the wiring has been removed that connected everything together. It is an older unit from the early 90's and utilized air switches at the tub side, as well as timers etc. at the spa pack to turn on/off light, pump, blower etc.

The components I am needing to connect are:
two speed pump
blower
heater
light w/ low voltage transformer
airswitch for pump (which appears to consist of (3) seperate SPDT switches activated by a ratcheted mechanism that I'm guessing is a mechanical stepper of some sort)
(2) main dbl. pole relays(1 for heater, 1 for pump)
thermostat control
heater timer and bypass switch
filter timer and bypass switch
pressure switch
airswitch for blower
airswitch for light
GFCI(This one I understand already]
heater "on" indicator light
"High Limit" switch

Everything is currently set up for 110v

I am very familiar with electronics and electrical circuits, but I am not familiar with the typical configuration for spa components. I'm not looking for any specific model schematic, but instead just a generic diagram of how these components are typically interconnected. The biggest mystery for me is which components are active for each of the operating conditions, such as:

Is the heater operational during Hi, Lo or both speeds of pump operation?

The pump has a red(Lo) wire, a black(Hi) wire and a white(Common) wire. Is the red wire always hot whenever the pump is running with the addition of power to the black(Hi) wire to switch the pump into high speed mode, or does the red (Lo) lead need to be de-energized when the (Hi) lead is hot?

I would like to add an ozonizer to the system as well. Should this only be active under certain conditions, or turned on continuously while the pump is running in either speed?

Does the on/off status of the blower effect, or is it effected by, the operation of any of the other components mentioned?

Any and all answers to these questions, as well as any help in diagramming the hook-ups of the components listed would be greatly appreciated. Thank you in advance for any replys.

~A~

Is the heater operational during Hi, Lo or both speeds of pump operation?

I am almost postive that it you are running a 115 volts the heater will remain off when you are set to high. When you are set to low the heater will trun back on.

If you were running a 230 all would work, all at the same time.

On a 110V setup, your heater will only operate on low cycle. Your blower can be set up to operate independently, regardless of pump mode. The red wire is typically High speed of the pump, and the black is typically Low speed of the pump. AT NO TIME SHOULD BOTH BE ENERGIZED AT THE SAME TIME! An ozonator is typically on ONLY when the heating/filtering timer is active. I have a couple links you will find very helpful regarding wiring up that cam switch (make careful note of the color of the cam and if it's version "a" or "b") and for a general wiring setup for a hot tub. The sequence of the cam switch will dictate what is on at any given time, and you will notice that the high speed switch also goes through the low speed switch, and this is for redundancy... it makes a mechanical interlock so you can't have both on at the same time. Be careful when you install your timers so you don't inadvertantly engage the low speed operation during the high speed cycle. Use the N/C contact on the high speed switch for the interlock for your timers! http://www.spasupport.com/diagrams/spacontrol1.html and http://www.spapartsltd.com/index.asp?Pa... tom&ID=319 and http://www.partypools.com/parts/parts/a... agrams.htm With this information, you should be able to make your control cabinet. Jer

Just a quick note, I may have accidentally reversed the low and high colors... red being low, black being high... please keep that in mind.