How to Select a Replacement Spa Pack

If your spa pack has stopped working, isn’t heating properly, or you’re just looking for an upgrade, then this guide is for you. While replacing a spa pack isn’t overly complicated, there are a few important considerations to keep in mind to ensure everything runs smoothly.

Here’s everything you need to know about selecting a replacement spa pack.

Let’s dive in!

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Replacing and selecting a new spa pack is something you can do yourself, but it requires careful attention to a few key details.

1. Direct Replacement

The first thing to check is whether you can find a direct replacement for your current spa pack. For newer models, this might be straightforward, but for older hot tubs, finding an exact match can be more challenging.

If the model number isn’t the same, you’ll need to check compatibility with your topside controller. Just because you purchase a newer model from the same manufacturer doesn’t guarantee it will work with your existing controller.

Pro Tip: Opt for a bundled package that includes the spa pack and the topside controller. This will save you money and ensure compatibility between the two.

2. Count the Accessories

If you can’t find the same model and have to go for a different one, you’ll need to count how many accessories your current spa pack supports. Accessories can include jet pumps, ozone generators, lighting, or additional pumps like a circulation pump.

Make sure that the new spa pack you choose has the same number of connections and can support all your existing accessories.

3. Check Voltage

Next, you’ll need to verify the voltage of your current spa pack. This information is usually printed directly on the spa pack itself. If you can’t find it, here’s a general rule of thumb:

• If the spa pack has four wires, it’s likely designed for 230-240V.
• If it has three wires, it’s probably rated for 115V in the USA. (All EU models are 230V on 3 wires)

Ensure that your replacement spa pack matches the voltage of your current system to avoid electrical issues.

4. Heater Size

The heater size is another critical factor when choosing a replacement. Here’s a simple breakdown:

• For 115V systems, the heater will usually range between 1-1.4kW.
• For 230V systems, the heater size typically ranges from 2-5.5kW.

You can upgrade or downgrade the heater size when replacing the spa pack, but make sure the voltage matches your system and you have the additional amount of AMPS (current) available.

Important: If you adjust the heater size, verify that your breaker can handle the new power requirements. If you’re unsure, consult an electrician to ensure everything is set up safely.

5. Flow-Through Heater

Most spa packs include a flow-through heater, the standard for modern hot tubs. This heater should fit into the existing plumbing with minimal hassle.

However, if your hot tub uses an inline heater or an older heating system, you may need to modify your plumbing to accommodate the new flow-through heater.

Conclusion

That’s a quick overview of how to select and replace your spa pack. Keep in mind:

• Always check for a direct replacement first.
• Ensure compatibility with your accessories and voltage requirements.
• Verify the heater size and flow-through compatibility.

With these tips, you should be able to confidently replace your spa pack and get your hot tub running efficiently again!

In case you’re looking for a the Ultimate guide to hot tub SPA packs then you can check out a video I did on it here!

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Thanks - Andi

 

Hi, Andi here. I own Buildahottub.com and also write all of the articles and info pages on the site. Some years back now, I built my own hot tub but struggled to find the information I needed. So, once my tub was complete, I started this website to help others in their own pursuit of hot tub and plunge pools DIY building information.

Fast forward to 2025, I've helped over 1400+ DIY customers just like you all over the world build hot tubs and pools. Have a good look around the site, there are lots of resources here. Please do get in touch if I can help you. - Cheers, Andi