Hot tub helper: five ways to update aging hot tubs with a controller retrofit kit

Pool & Spa News, Sept 5, 2005 by Zuzana Prochazka

Updating old hot tubs is a good business that has gotten easier with new spa controller system retrofit kits. There are several manufacturers selling kits today that are compatible with about 95 percent of existing hot tubs.

Bringing an old tub into the 21st century is cheaper for the customer than buying a new one. It also enhances the customer's experience and increases his use of an existing unit, which is likely to lead to future projects and referrals.

Between product markups and service time, an average retrofit can bring in $500 to $800. But the potential value of an ongoing revenue stream from weekly hot tub service can be substantially more than that over time.

A good kit allows the service tech to stock minimal inventory, tying up less space and money. Though it can vary, it should take no more than 11/2 to two hours for a complete system installation involving minimal tools.

Use the following five tips to pick a kit that fits your needs:

1 Consider plumbing issues. Is the plumbing of the older hot tub on the suction or pressure side of the pump? If it is on the suction side, then a system with a vacuum switch on the heater is needed. If it is on the pressure side, then a pressure switch on the heater should be used.

However, there are systems manufactured today that use electronic sensing for water flow, which eliminates the need for pressure or vacuum switches. This gives the service technician the flexibility to use the same kit for pressure or suction systems. Not having to know in advance what kind of installation will be needed and not having to excessively manipulate the plumbing will save quite a bit of time during the retrofit process.

2 Opt for more flexibility. Another consideration is whether the system components are wired for different voltages, such as a 240V pump with a 120V blower. In the past, a technician would have to know the voltage of not only the input wiring, but also individual components when ordering a retrofit system. Newer controls have electrical systems that can be converted from 120V to 240V on the input as well as the component wiring. This allows the tech to use the same system for any voltage arrangement.

In addition, techs need to know not only the voltage, but the amperage as well. Is the system wired for 120V/15, 120V/20, 240V/30 or 240V/50 amps? Many retrofit spa kit systems have the flexibility of allowing the technician to choose the amperage at the job site, eliminating the need to know this information beforehand.

3 Think about system size. System size matters because many older tubs might have odd configurations below the skirt. This can create space issues during installation. The good news is that many of the older pneumatic systems are considerably larger than their newer electronic counterparts, which tend to be compact and fit into tighter spaces.

Also, a kit with flexible (left/right) plumbing options will open up space and make the job go more smoothly.

4 Focus on features. Older pneumatic systems were limited on features. However, current electronic ones allow the technician to upgrade not only the system but also the interaction between the consumer and the unit via the spa-side control panel.

Updating the hot tub usually enhances the safety features. For example, it provides more accurate electronic temperature sensors. This allows programming to be done via the panel as opposed to having it under the unit with the temperature displays on the spa side, where they are visible to the consumer. Many newer systems also are encased in plastic enclosures, which provide longer life spans and less corrosion than older metal models.

5 Cover all your bases. There are few things more frustrating than stopping a job due to incorrect or incomplete parts.

A good, comprehensive retrofit kit with all the components you'll need is a must. The kit should include a spa system with all the attributes already mentioned, a topside panel with multiple bezel options so it will fit into and cover the hole created by the existing control overlay, and all of the cords needed to complete the installation.

Clearly differentiated kits should be easy to order. If issues arise during the job, tech support should be reachable by cell phone. A one-stop shopping experience will minimize frustration and maximize profits.

Prochazka is director of marketing at Balboa Instruments, a manufacturer of pool and hot tub controls and sanitization products in Tustin, Calif.