Quick Intro: This guide compares five inline hot tub heaters and replacement heater elements suitable for common spa systems. It focuses on flow‑thru designs, compatibility with Balboa and other control systems, stainless/titanium construction, and inline mounting features to help you choose the right heater for repair or upgrade.
| Product | Type / Key Feature | Compatibility |
|---|---|---|
| SpaGuts 1.5KW Inline Heater Kit | Compact 110V flow‑thru with pressure switch | Universal small spas, 1.5″ plumbing |
| FATCANMA 4.0KW Flow‑Thru Assembly | 2″ x 15″ stainless manifold assembly | Jacuzzi, Sundance, Spa Builders style systems |
| Bonbo 58117 M7 Heater Assembly | Replacement for Balboa control systems | Balboa VS/EL/TS/GS/BP series |
| Xzionh 5.5KW 240V Element | Titanium 5.5kW flo‑thru heating element | Balboa, Gecko, Hydro‑Quip and others |
| Ximoon 5.5KW Titanium Element | Universal flo‑thru element with mounting kit | Broad compatibility with many manufacturers |
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SpaGuts 25-150-0001 Inline Heater Kit
This 1.5kW 110V inline heater is designed for compact spas and portable tubs that require a small flow‑thru heating solution. The unit measures about 7.0″ x 1.5″ and includes multiple plumbing fittings for 1.5″, 1.0″ and 3/4″ pipe sizes, making it adaptable to existing plumbing runs.
Key built‑in components listed include a pressure/vacuum switch to activate the heater, an automatic thermostat limited to 104°F, hi‑limit protection, a heater‑on indicator light, and reversible mounting capability. The kit ships with heater O‑ring gaskets and a 3ft NEMA cord for 110V connection.
For spas that use low‑power 110V heating or as a compact replacement in small circulating‑pump systems, the SpaGuts kit offers a self‑contained inline design and basic safety controls. Verify plumbing size and control interface compatibility before installation.
FATCANMA 4.0KW Flow‑Thru Heater Assembly
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The FATCANMA assembly is a stainless steel 2″ x 15″ flow‑thru manifold intended for mid‑sized spa systems. It includes split nut unions and tailpieces sized at 2″ for flange or union connections.
Manufacturer features emphasize compatibility with Jacuzzi, Sundance, Spa Builders and Pinnacle spa controls and robust materials suited for humid environments. The assembly functions as a housing that accepts a separate heating element and integrates into existing plumbing.
Because this product is a manifold assembly rather than an integrated electric unit, it’s often used when replacing a damaged flo‑thru housing or when converting plumbing to accept a standard element. Confirm the element dimensions and control requirements for your specific spa model before ordering.
Bonbo 58117 M7 Heater Assembly For Balboa
This heater assembly is listed as a direct replacement for Balboa part #58117 and is compatible with many Balboa control platforms including VS, EL, TS, GS and BP series. It supports 4.0kW at 240V or 1.0kW at 110–120V depending on the system configuration.
Specifications show the heater length is 15″ with a 2″ diameter, matching common flo‑thru housings. The product’s listing highlights broad model cross‑references to help identify interchangeability with other part numbers.
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For spa owners using Balboa electronics, a matched assembly reduces integration work and preserves factory control interactions such as temperature sensing and safety cutouts. Always verify the controlboard compatibility and wiring schematic to ensure correct power and sensor connections.
Xzionh 5.5KW 240V Flo‑Thru Element
The Xzionh element is a 5.5kW 240V titanium flo‑thru heating element marketed for Balboa, Gecko, Hydro‑Quip, Spa Builders and many other manufacturers. It lists multiple OEM replacement part numbers to aid compatibility checks.
Constructed of titanium, the element emphasizes corrosion resistance and extended service life. The listing recommends timely replacement to protect spa system longevity, particularly if existing elements show signs of wear or overheating.
This type of element is appropriate when the existing flo‑thru housing is functional and only the heating element needs replacement. Verify terminal nut sizes, O‑ring seating surfaces, and element length to ensure fitment into your current heater housing.
Ximoon 5.5KW Titanium Replacement Element
The Ximoon flo‑thru element is another 5.5kW titanium heater element that includes mounting hardware such as terminal nuts, O‑rings and jam nuts. The universal design targets a wide list of spa brands and flo‑thru housings.
Key advantages noted are the inclusion of basic mounting hardware and the use of high‑quality titanium material for improved durability against corrosive spa chemistry. The product listing advises keeping a spare element on hand for quicker service turnaround.
Use this element if your flo‑thru housing requires a new heater core and you want factory‑style mounting parts included. Confirm the element diameter, length and terminal layout to match your heater housing and control wiring.
Buying Guide: Choosing The Right Inline Hot Tub Heater
Purpose And System Compatibility
First, determine whether you need a complete inline heater kit or only a replacement flo‑thru heating element. Inline heater kits include the housing, pressure switches and controls; replacement elements assume the housing and sensors are intact.
Match the heater to your spa control system. Balboa, Gecko, Hydro‑Quip, Sundance and Jacuzzi controllers often require specific element sizes and sensor positions. Cross‑reference part numbers and measure the existing element length and diameter.
Power Rating And Voltage
Choose a power rating suitable for your spa volume and wiring capability. Common ratings include 1.5kW (110V) for small tubs and 4.0–5.5kW (240V) for larger hot tubs. Ensure your electrical supply, breaker and controlboard support the element’s amperage.
Material And Durability
Heating element materials matter in corrosive spa environments. Titanium elements offer superior corrosion resistance and longer life compared with standard alloys. Stainless steel housings are common for flow‑thru assemblies.
Plumbing Size And Housing Style
Measure the flo‑thru housing diameter and length or the inline heater’s plumbing connections. Plumbing fittings shown in product listings (1.5″, 2″, unions) must match your spa’s piping or union sizes to avoid machining or adapter use.
Built‑In Safety Features
Integrated switches and thermostats—such as pressure/vacuum switches, hi‑limit protection and automatic thermostats—help prevent dry firing and overheating. Kits with these features can simplify installation and reduce the need for external sensors.
Control Integration And Sensors
Replacement assemblies intended for specific boards include sensor ports and wiring compatible with those boards. Ensure the sensor type (NTC, thermistor) and wiring harness match the control panel for accurate temperature regulation.
Installation Considerations
- Turn off power at the breaker and verify no voltage before replacing elements.
- Ensure proper O‑ring seating and torque on terminal nuts to prevent leaks.
- Follow manufacturer wiring diagrams to maintain safety interlocks and GFCI/grounding requirements.
Comparative Perspectives
For small portable tubs or low‑power needs, compact kits like the SpaGuts 1.5kW unit provide integrated controls and easy plumbing adapters. For OEM‑style replacements, matching Balboa‑compatible assemblies such as the Bonbo 58117 helps maintain controlboard functionality.
If longevity in aggressive chemistry is a priority, titanium elements such as Xzionh or Ximoon reduce corrosion risk. When a damaged housing needs replacement, choose a matching stainless flow‑thru manifold like the FATCANMA assembly.
Spare Parts And Maintenance
Keep spare O‑rings, terminal nuts and a backup element on hand if your spa is used frequently. Regular inspection for scale, pitting or loose terminals prevents failures and extends heater life.
Tips for Getting the Best HVAC Prices
- Prioritize Quality Over Cost
The most critical factor in any HVAC project is the quality of the installation. Don’t compromise on contractor expertise just to save money. - Check for Rebates
Always research current rebates and incentives — they can significantly reduce your overall cost. - Compare Multiple Quotes
Request at least three estimates before making your choice. You can click here to get three free quotes from local professionals. These quotes include available rebates and tax credits and automatically exclude unqualified contractors. - Negotiate Smartly
Once you've chosen a contractor, use the proven strategies from our guide — How Homeowners Can Negotiate with HVAC Dealers — to get the best possible final price.
Final Checklist Before Buying
- Confirm element length, diameter and terminal positions.
- Verify voltage and power rating match the spa wiring and breaker.
- Check controlboard compatibility for sensor wiring and thermostatic limits.
- Ensure plumbing union sizes or supplied fittings match your spa piping.
- Choose material (titanium vs stainless) based on water chemistry and longevity needs.