Replaced the wet end recently and fixed several jet leaks. While trying to install a cooling fan under skirt (motor running hot), I blew the main 30A power fuse (dumb mistake). Replaced the fuse and started having problems with the controller signalling the motor to start on high instead of low. No other electrical problems found.

Checked all wiring and everything seems to be as built, but the motor now seems to be in a reverse cycle where it starts on high and I have to manually switch it to low where it runs for 15 minutes and then switches back to high. That is opposite of the operation that is has done since new in 05. If I do not switch it to low, it will run on high speed continuously with no break. Electrician thinks it is the controller but have no other indications or codes of a problem. Spa Assemblers (manuf.) is out of business. Any ideas??

Do you possibly have the motor connections reversed?

That was the first thing I thought of. We tried that just in case of a brain fart and the motor just hummed loudly and would not start. Plus, it is wired to the schematic on the pump and the controller correctly. With little tech help in the area, it is quickly becoming an expensive fish pond. I did notice that the motor runs extremely hot, but a local rebuilder said those spa pump motors do run hot normally. Lost for ideas at this point with no way to check the controller.

Well my thinking is there is something wrong with the motor. Its not a 2 speed controller, all the controller does is act as a traffic cop and route the voltage (thru a relay) to the proper terminal, its a 2 speed motor, so it has a high speed winding and a low speed winding. Its simply a matter of getting the voltage to the proper winding. Either its hooked up wrong or there is something wrong on the electrical side of the motor. The motor also should not run so hot you can't touch it. Its normal for it to be warm, but not hot. Take it apart and have a look.

Thanks Denny. Which relay are you speaking about? I just got the latest wiring schematics online tonight so I will recheck again tomorrow.

Honestly I don't know anything specific about Balboa. But there has to be a relay (or relays) that kick on the pumps. I'd disconnect the motor and check the voltage to see if the board is supplying voltage to it.