I have a 2004 CalSpa with a life time warranty on the heat exchanger. The dealer wanted to charge me $170 in labor to come out and replace it. I pulled the heater core myself and took it to a store where they swapped it for me. I wrote down which wires when where when I removed it, but I could not find the paper when I returned with the heater. So, I could use some assistance in hooking this back up properly.

There are 4 wires coming out of the heat exchange casing. Two larger gauge wires go to the lugs on the power supply control board. There are two smaller white coated wires, one with a male spade end and one with a female spade end. There are two other wires in question coming from a connector on the control board. One of these is red with a female spade connector, and the other is black, also with a female spade connector.

I know the male end connection wire coming from the heat exchange unit will plug into either the red or black female connector wire coming from the control board. I also know the other female connector wire coming from the heat exchange will plug into one of the male spade connectors on the pressure switch. The other red, or black female connected wire coming from the control board will plug into the second male spade connector on the pressure switch.

I do not know wether the black or red wire connects to the male connector wire coming from the heat exchange. I don't know which male spade connector on the pressure the remaining red or black wire goes to, or which other male connector on the pressure switch gets the female end wire coming from the heat exchange.

I have looked, but not found any kind of a wiring diagram, or picture on the net to use as an example. I believe these are all low voltage wires, so it may not hurt anything if I wire it up wrong to test it out. But, I'd rather not take the chance on frying anything on the controller board, or possibly ruining the pressure switch if I get the wiring wrong.

Can you help with any details, diagrams, or photos showing which wires go where in respect to the heat exchanger, and pressure switch? Your assistance would be much appreciated... thank you in advance. I can take a picture, and attach it here, of the heat exchange/pressure switch, and these 4 wires in question if it would help.

Yeah instead of all of that, you need to post photos.

Additionally, there should be a diagram for it on the back of the cover plate that will assist you.

Pageup, there is a schematic on the inside of the panel, however it only shows two wires going from the controller board to the pressure switch, it does not indicate which wire goes to which connector. Maybe it doesn't matter. However, since there are two white coated wires coming from the heat exchange box, one with a male end, and one with a female end, I actually suspect the male connector goes to either the red or black wire, and the other wire to one of the connectors on the switch. It does not make sense to me that those two wires would exit the box, and connect to themselves... why even have them terminated external to the exchange case?

I attached a photo, (if I did it properly)... maybe that will help. The gal who exchanged the heater core called me for the model and serial number for manufactuer's credit on the warranty exchange just a moment ago. She said she'd have the technican call me in a little while. I tried this route yesterday, but thier customer support rep said they didn't have any consumer technical support. If I find out from him when he calls, I will let you know the results.

Pageup... The tech just called and said it doesn't matter which wires go where. One of the white wires coming out of the heat exchange case does go to either the red or black wire, the other wire goes to one of the connectors on the switch. The remaining red or black wire connects to the remaining switch terminal, and it doesn't matter which one. The white wires coming out of the heat exchange unit go to a sensor. They all just simply complete one large loop between the sensor, the switch, and the control board. I could have gone with my intitution and just tried it out like I thought it should be, but I've seen too often where a $400 board protects a 50 cent fuse... better safe than sorry.

I do appreciate your quick response. It's a comfort to know there is outside assistance available to the average consumer. I will come back here if I need help in the future.

Whoa whoa whoa!

NO IT DOES NOT.

Do NOT do what you are saying you're going to do! You will destroy the board!

The two white wires DO NOT GO to any sensor!

They go to the main circuit board power supply for the heater!

The two small red/black connect to the top two terminals on the pressure switch. I'm referring to what's in the photo.

Pageup, I have already connected the two thicker guage wires to the power supply. There are actually 4 wires coming from the heat exchange box. The two white wires in the photo are additional wires coming out of the metal casing, that the technician told me go to a sensor. The wires going to the power supply both have round metal lugs on them... they are secured by metal scews, and are already in place. Those two power supply wires are not in the photo, since they go directly from the heater to the power supply via two holes in the back of the controller box.

Thanks again, and I do appreciate your concerned response.

Ok, well you were talking about putting everything in a loop with the pressure switch, and because we don't have board photos, or your diagram, the way you made it sound - as if you were going to put 230v in series with the pressure switch and back to the board again....

Glad it worked.

Pageup, no worries. I understand why you thought that. Although, I will add that my original note mentioned there were 4 wires coming out of the heat exchange box, with two of those already being identified as going to the power supply on the controller board. I just never mentioned those wires again since they weren't part of my cornfuzion.

Your assistance is appreciated sir, as is your due diligence in being effecient, and complete in your responses.