Ask 'Dr. Spa' Q & A Message Board

Have you checked the board for stuck heater relays?

John

: I have a 2000 Sundance Cameo. I had a "FLO" error and replaced
: the Flow switch which solved that problem. Later on, the tub had been
: tripping the GFCI every so often and had a small leak (I'm guessing
: about 1-2 gallons a day), and I never knew why. This went on for
: almost a year. I just kept adding water to the tub. THe circulation
: pump went out and I replaced it. Things worked well although I still
: had the small leak and occassional GFCI trip (very sensitive switch,
: especially during lighting storms).

: This winter I went out and the tub was shut off and the flow lines by
: the flow switch casing had broke and the tub was about 1/3rd drained.
: I immediately drained the water out of the tub (it is outdoors in
: Nebraska) and opened all valves to keep it from freezing. I ordered
: and replaced the flow switch assembly, but when filling up the tub, I
: noticed it was still leaking profoundly from the heater housing onto
: the circulation pump. I believe this was my original problem that may
: have been causing the GFCI to trip. I redrained the tub, took out the
: heater assembly, and took it apart and sure enough, there was a
: 1/8" sized-hole in the heater housing. I'm guessing the hole got
: worst but that it was the source of my original leak and GFCI
: tripping problem as the heater sits directly above the circulation
: pump. Probably why the old circulation pump went bad also.

: I ordered a new heater assembly (another two weeks went by with the
: hot-tub drained again in cold weather). I installed the heater,
: refilled the tub, and hit the GFCI. The pumps sounded off, but things
: appeared frozen. I immediately shut the thing off and decided I
: better wait until warmer weather when the tub could thaw out.

: When the weather warmed up, I refilled the tub and reset the GFCI. The
: main pumps worked and pumped water water. But after about 30 seconds,
: the heater housing melted to an ugly mass and I had ugly burnt
: plastic smelling smoke. That brand new $200 heater assembly was
: ruined.

: My questions are:
: 1. why did that happen? I thought the heater wasn't even suppose to turn
: on unless the circulation pump was pushing water through it and
: making the flow switch contacts touch. The only thing I can think of
: is that the flow switch was faulty (shorted), but then why didn't the
: high-limit sensor switch shut it off before that much damage was
: done?

: 2. How can I test the High-limit sensor switch?

: 3. What's the best way to test my fairly new circulation pump?

: I have ordered a new heater assembly and will install it, but I will NOT
: hook up the main leads to it until I can verify things are in order.
: I don't want another melt-down.