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The Mechanical Operation and Repair of
Gatsby, Blue Ridge, and Swift River
®
Spas built by Jacuzzi
ONLY for the Following ELECTRONIC Spas Made 1999-2002 with this Topside:
(does not Apply to ANY Model using other topsides)
Published by GatsbySpaParts.com
©Copyrighted. All Rights Reserved. B.Bouman and Company, LLC
2010
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Table of Contents
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Summary of Contents for Jacuzzi Gatsby
- Page 1 The Mechanical Operation and Repair of Gatsby, Blue Ridge, and Swift River ® Spas built by Jacuzzi ONLY for the Following ELECTRONIC Spas Made 1999-2002 with this Topside: (does not Apply to ANY Model using other topsides) Published by GatsbySpaParts.com ©Copyrighted.
- Page 2 Every effort has been made to be accurate and complete but note we cannot guarantee specific accuracy. Throughout this manual reference to part numbers are Jacuzzi/Gatsby Spa numbers, . If the part number prefix is “CC” the part is our own number and available on our website.
- Page 3 Table of Contents Words and Their Meaning. Introduction Overview Section One: Equipment and Parts Chapter One: Pumps and Motors Chapter Two:Heaters Chapter Three: Control System Chapter Four: Air Blowers Chapter Five: Pressure Switch: Flow Switch Chapter Six: Sensors Chapter Seven: Topside Control Chapter Eight: Ozonators...
- Page 4 Words and Their Meaning. “Spa”; typically means same as hot tub. Often get confused with indoor jetted bath. But spas normally are outside, require heating, and are operationally 24/7. “Pump”; Generally only applies to “wetend” or part that moves the water. Attaches to “motor”.
- Page 5 Introduction I started servicing Jacuzzi Whirlpool Bath spas in 1995. I first started by working for a friend who was an Authorized Service Center for Jacuzzi Whirlpool Bath. Shortly after that I purchased the spa repair business from him and became the owner.
- Page 6 Overview Who is Gatsby? Gatsby was a manufacturer of hot tubs in Plant City, Florida. For years they built entry level spas sold throughout the SE states. They produced a number of spa models under brand names like Gatsby, Blue Ridge, Swift River, and Imperial Spas.
- Page 7 Paneling The paneling of spas has changed over the years. Initially redwood slates were the common siding. In an attempt to economize the cost of panels, Gatsby built panels with various stained wood. Some of the late production was synthetic...
- Page 8 plastic panels or slats. These are becoming popular even though they can be as costly as redwood or cedar. But they are able to withstand the elements with little care. Typically you should re-stain pine panels every year. Newer spas with synthetic siding require little upkeep other than cleaning. I have seen spas where the heat of the sun causes the panels to bow and lose shape.
- Page 9 I. Circulation Pump (see more later) Most Gatsby built spas used either the less common 115v small circulation pump or the more common 230v circulation pump. This pump runs 24/7. It avails the homeowner with a system that keeps water clean by constant filtering.
- Page 10 If you do, the motor will have a early failure. It’s like driving a large car with an undersized motor. Best bet is to match. Gatsby used one and two speed 115v motors and one and two speed 230v...
- Page 11 motors. They all were 48y frame motors. Lastly, in the industry the motor is motor only, pump is the wetend, and when they are together, they are called pump complete. PUMP/MOTOR The motor takes electrical current and turns the shaft clockwise. Although individual parts may be available, usually bad motors are replaced not repaired.
- Page 12 Circulation Pump: Most Gatsby models have a 24 hour circulation pump. It sits next to the heater. When power is applied to the spa the control unit turns on the circ pump. So it runs all the time.
- Page 13 2 screws holding the pump to the mounting frame on the old and new. Swap and done. It is fairly easy. Jacuzzi has updated their inventory to carry only the newer “E” pump from the same manufacturer. This pump has several advantages. First, its expected to last longer because it draws less current and doesn’t get as hot.
- Page 14 Chapter TWO HEATER Function: The heater is a simple device. Electricity is applied to the heater element. Because the element is made to resist the current but not completely, the heater’s resistance causes the element to glow. The result is heat. Overview: The heater does just what’s name says, heats the water.
- Page 15 The canister heater is either 4.0kw or 5.5kw. Both operate on either 115v or 230v. FYI: Gatsby engineers built spas that operated on 115v with 5.5kw heaters; and spas operating on 230v with 4.0kw heaters. Jacuzzi engineers had the opposite approach.
- Page 16 heater is typically mounted with 3 screw/bolts. Remove. Disconnect heater hose off the heater, swap, and install. Plug in cords. Attach ground wire. Done.
- Page 17 They are design both to make operation of the spa easier, keep the water cleaner, and filter the water on a regular basis. The Steps the Board Takes to Come On: Gatsby circuit boards typically go through the same routine. When you turn on...
- Page 18 power the spa does a self test to make sure internally everything is operating properly. At this time the 24hr circ pump comes on or the low speed on the #1 pump does. When the board is going through it test it will look to confirm the board’s integrity is fine.
- Page 19 b. Remove the screws holding the lower finger boards to the lower terminal. c. On the wires connecting to the board on the left, it’s easy to mix up the wires. So note which wires go to which connection. It would make sense to label the wires.
- Page 20 Chap Four: AIR BLOWER: Few models have an air blower system besides the water flowed plumbing. It is separate then from the normal forced water jets. The blower is turned on and the air is forced into the spa as bubbles. Between the air blower and the method of air disbursement is a looping system to stop water from flowing back to the air blower.
- Page 21 Chap FIVE: Pressure/Flow Switches PRESSURE SWITCH How It Works: The lower chamber of the switch is physically attached to the water flow of the plumbing system. The pressure internal to the plumbing is also manifested in this chamber. This chamber expands to push a post toward a microswitch.
- Page 22 direction of water flow matches the design of the flow switch. Flow switch usually have arrows pointing the direction of the flow but if not, it’s easy to understand. The armature will be toward the water flow so when the flow comes, it moves to the post.
- Page 23 Chapter SIX: SENSORS TEMP/OH SENSORS: HOW IT WORKS: Sensors work by reacting to temperature at the bulb. As the temperature raises or lowers, the resistance inside the sensor bulb changes. The board reads the resistance of the temperature and knows what the temperature of the spa is.
- Page 24 To Replace: Gatsby used 2 types of Temp Sensors. The most common is the “dry well” sensor. The spa has a plastic assembly housing attached to the spa shell. The sensor inserts into this housing and the sensor bulb never touches water.
- Page 25 Overlays come in a variety of designs. They can have the brand label such as GATSBY or IMPERIAL on the overlay. They can have one or two jets labeled. On a few there is a “blower” label. All overlays will work since they are simply a cover and perform no function than cosmetic.
- Page 26 As the ozonated bubbles rise to the surface of the spa they sanitize the water. GATSBY used the UV bulb generation. You can either continue to use or switch to the more popular CD ozonator. You MUST confirm the voltage to the spa.
- Page 27 have EITHER 115 or 230v ozonator. You must check either the power to the ozone socket or the label on the old ozonator.
- Page 28 Chapter Nine: SPA MOOD LIGHTS: Most spas have some type of mood light system. The simpler method is with a light bulb and lens. The board applies 12vac to the bulb. You usually have the option to put a colored lens over the clear lens or leave the clear lens. The replacement bulb is a standard older car dome light you can purchase at your local automotive supplier.
- Page 29 Chapter Ten: Plumbing Spas are made up of several zones. First is the heater zone. On spas with circulation pumps the piping from the filter, through the circ pump and heater, and back to the spa is typically 1”. The suction side of the spa is how the jet pumps draw water from the suction fittings on the spa and filter.
- Page 30 filter, through the circulation pump, through the heater, through the ozone injector if you have one, and back into the spa. Usually there are 2 ports where the heated water returns to the spa. b. Zone Two and maybe Three. The one or two larger jet pumps will draw from the filters AND the suction fittings.
- Page 31 Either silicone or a gasket is used to seal the housing. Gatsby used a large variety of jet designs… almost at times changing as they went. The following are the most common jets: Euro Jet Swirl 2”...
- Page 32 Micro Jet II Swirl 3” Face; 3 ¼” Length Micro Jet II Directional 3” Face; 3 ¼” Length See these and more on our website, www.gatsbyspaparts.com...
- Page 33 SECTION TWO: TROUBLESHOOTING: Warning: I need to repeat the warning given at the beginning of this manual. If you don’t have a working knowledge of electricity and can safely work with electricity, then you should have a licensed electrician or properly trained service repairman handle electrical problems.
- Page 34 TROUBLESHOOTING SECTIONS: Trips GFCI or GFI. Doesn’t Heat III. Motor hums Pump Leaks Error Codes on the Topside:...
- Page 35 I. Trips GFCI First, check the equipment and electrical connections for any water. Water dripping onto equipment will cause the gfci to trip. Most common cause is the heater. If the gfci pops instantly its almost always the heater. To isolate, do the following: Turn off power.
- Page 36 II. Doesn’t Heat If the heater light is solid and the spa is not heating, it’s likely the heater. Remember, spas plugged by a cord into an outlet only gain 1-2 degrees per hour. Spas hardwired to 220-240vac will gain 5-6 degrees per hour. You might not be able to feel a different temperature of water coming out of the heater nozzle.
- Page 37 light is on all the time, you have voltage, and the resistance on the heater was correct even with the power off, then it’s likely the board. What can happen is the heater relay although closed and applying voltage to the heater, it’s not allowing enough current to reach the heater element to heat.
- Page 38 III. Motor Hums Why does the motor hum? Because it doesn’t know the words…. Sorry, just had to say that. Humming motors is typical of a failed motor. Can internal parts be replaced? If a tech was trying to save the motor he might start with a new discharge capacitor. But other parts also can be near failure including bearings.
- Page 39 IV. Pump Leaks Pumps can leak for several reasons. The most likely is the seal on the pump. The seal is a 2 section construction. Basically the seal has ½ of the seal that’s a ceramic ring with a rubber boot to seal in a seat on the main body or bracket of the seal.
- Page 40 Board sees failure of the temperature sensor. FIX: Likely means failure of the sensor. COULD mean failure of the board but typically and cheaper is the sensor. Gatsby spas have 2 type of temp sensors; dry well and wet well. Dry well means the sensor inserts into a housing that goes through the spa’s wall.
- Page 41 Most pressure switches used by Gatsby can be hand removed and replaced. They use a plastic threaded switch. The new may have red pipe dope already on the thread. If not, you must add plumbers putty or Teflon tape on the thread to avoid leaks. Only tighten to slightly snug. If over tighten you will damage the threads and worst, break the pressure switch inside the heater.
- Page 42 pump. If it detects the draw is below what it expects, it’s a good indication your circulation pump or 2 speed pump is failing. Board sees cold water FIX: Means Freeze Control. It’s automatic. It comes on when water goes below 60 degrees (such as when you change the water).
- Page 43 Temp Sensor Failure. FIX: Replace sensor (might be a board failure but more likely the sensor). The most common temp sensor on this model is a gray stud that is located on the spa shell. To replace, drain the water below this sensor stud.
- Page 44 Water is going over 110 degrees FIX: If the water IS overheating, then either the temp sensor or the board has failed. If the heater is NOT getting hot, then the Temp sensor has failed. - - - Watchdog mode. FIX: Water heated to 120 degrees or board has internal faults.
- Page 45 Copyrighted 2010 All Rights Reserved Any Reproduction, Copying, or Distributing of any part or pictures of this Manual without the written consent of B. Bouman and Company, LLC, is prohibited by law.