New SWCG Install in an Old Pool/Spa with No Automation

[SemperFly]

HI all!!

Goal: To self-install a Pentair IC40 (520555, 520556), to my existing 1988-vintage pool/spa.

Background: 16600 gal plaster pool w- spillover spa, built in 1988. Filter pump is a Pentair 011018 3HP VSP (installed 2017), Spa Jet pump is a Pentair 011514 1.5HP Single Speed (installed 2017), Heater is a Hayward H250FDN (installed 2018). There is no automation installed.

I've been doing a fair amount of thread reading lately to get as familiar as I can with these systems before I start asking questions, and I think I'm now ready to make my move! I think the plumbing with be more straightforward than the electrical, so I'll focus my initial questions on electrical.

From what I tell, the Filter Pump and the Heater are both on the same 220V/15A Non-GFCI circuit breaker, which flows through a switch and then through a T104R mechanical timer. The Spa Pump is on its own 220V/15A Non-GFCI circuit breaker, also flowing through a switch.

NEC is much different now than it was in 1988, so I'm trying to determine how much electrical modification must be done to accomplish the goal. I think that running new circuits would be impractical, but would it be unsafe to simply add the SWCG to the existing filter pump/heater circuit?

Thank you for your advice!

 

[wireform]

Take some pictures of the equipment pad from various angles and post so we can advise the best way for your install. You need the GFCI now. 15 amp is low if you need to add anything to it but you can't just switch it up unless you have the proper wire size there.

 

[SemperFly]

You asked for it!!

I've labelled them and tried to flow them in a nice order.



Electrical




Plumbing

 

[SemperFly]

Have I added enough info?

 

[proavia]

Have you considered the Circupool RJ45+ or RJ60+ instead?
They usually run a special to upgrade to the next larger unit for a few dollars more (presently $10 more).

In any case, your VS pump should receive continuous power (and it looks like it is wired that way).

The SWG would need to be controlled by the timer - 220v and leads put on timer terminals #2 and #4. The timer would need to be set to run within the pump run times. It is generally recommended for the timer to come on 30 minutes after the pump starts and shut off 30 minutes before the pump stops. The timer is your primary safety device and the flow switch is the secondary safety device with a SWG.

What's that black box above the timer?

 

[SemperFly]

I have already purchased the IC40. And, given the age of my pool, the electrical is not currently NEC compliant, but I'm wondering if adding the SWCG to it would make it any more unsafe than it is today (from a load perspective).

The black box above the timer is the air switch for the spa jet pump.

 

[proavia]

Both of the pump breakers in the main panel can be upgraded to GFCI breakers.
I see they are only 15 amp. The wire size should be 14AWG minimum.
Most pump circuits are 20 amp. The wire size should be 12AWG minimum.
It is possible the wire gauge should be increased if the wire run is long. How many feet from the main panel to the pool equipment?

The load carried should only be 80% of the circuit breaker capacity - as I recall.

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What is the amp rating of the VS pump?
What is the amp rating of the single speed spa pump?

 

[Ahultin]

Filter pump is a Pentair 011018 3HP VSP (installed 2017)

16 amp draw at full per specs

Spa Jet pump is a Pentair 011514 1.5HP Single Speed (installed 2017)

8.8 amp draw at full per specs

 

[Ahultin]

I think that running new circuits would be impractical, but would it be unsafe to simply add the SWCG to the existing filter pump/heater circuit?

How far from the main panel to the pool equipment?

 

[SemperFly]

How far from the main panel to the pool equipment?

About 60' horizontally. The main CB panel is about 15' higher than the pool deck. My house is a split-level, with the main CB panel on the main level and the backyard/pool on the lower level. The equipment pad is concrete and the existing 1/2" pvc conduit comes up through the concrete. Interestingly, the conduit exiting the the main CB panel is 3/4". I'm not sure where it transitions to 1/2".

 

[Ahultin]

The equipment pad is concrete and the existing 1/2" pvc conduit comes up through the concrete. Interestingly, the conduit exiting the the main CB panel is 3/4"

Granted, i'm looking at photos, but it looks to me like 1" at the panel and 3/4" a the pad. Best guess, since it enters the back of the main , is a 1" lb at the panel immediately reduced to 3/4 . I assume the main is at the garage? Is the interior finished or can you see the back?
Technically speaking the pump breaker is already overloaded, is the wire #12 or #14?
The spa pump is 8.8amps, the heater draw is either 5.5 if wired 120v or 3.0 if wired 220v so best case you are at 80% already on that circuit or almost 100% of 120v heater. Hopefully you have #12 an can just change to a 20a gfci beaker.

About 60' horizontally. The main CB panel is about 15' higher than the pool deck

Plan b, were it my home, would be to pull #6 from main to pad with a 50amp breaker (assuming 3/4 conduit) or #8 with a 40 amp breaker (assuming 1/2 conduit) and install an inexpensive subpanel at the pad with 2 gfci breakers and 1 standard breaker.
Feed the circ pump of gfci breaker 1, swg and heater thru timer off gfci breaker 1 . Spa pump of gfci breaker 2, gfci convenience outlet off standard breaker feeding lights thru the load side of gfci