Please bear with the long post. I'm at my wits end and want to give as much info as possible. Thanks for reading.

Spa Type: Gerico

Pump Type: Hayward

Electrical: 120V, single pump, no blower, GFCI protected

Spa Pack: Brett Aqualine

Controller: Techmark Topside, mechanical/pneumatic

Approximate Age: 15-20 years (I'm guessing)


Problem: I had an issue with overheating. The tub would heat up to 115F, and the limit switch would trip. THe pump would stay on, but the heater was de-energized, as it is supposed to be. After things settled down and temp dropped a bit, I was able to push the limit switch back in and the spa would heat and control normally.

So the fun began. I first replaced the topside control, which was garbage anyway, with a new techmark unit. The spa worked great for about a month. Then, the problem occurred again; the tub temp was 115 or so, the limit switch had tripped, but this time the pump kept running.

Funny thing was that I couldn't get the pump to turn off. The only way was to pull the plug; i.e. de-energize the unit.

So now I'm thinking the problem is a stuck relay. So I replace that, and while the spa pack is disassembled I decided to also replace the high-limit switch and the pressure switch, just to rule out as much as I could. The parts were cheap and the existing ones were old.

I also checked the continuity on the heater terminals, and got the expected 10-11 Ohms. I did not check voltage, as this was on my workbench, not in place and I had no power.

I get everything back together, made sure the wires were connected as they were before (I numbered the wires and the locations prior to disassembly), put the spa pack back and filled the tub.

Well, I plugged the unit in when the tub was empty, nothing happened; the pump did not go on, which is good, because it shouldn't if the pressure switch is working. So when the tub was full, or full enough to trigger the pressure switch, the pump came on. This is with the thermostat at the lowest setting on the dial. The 'heat' light on the topside lit up, but the heat light on the spa pack did not.

So the problem persists. I have no heat, and the pump cannot be turned off except for pulling the plug on the unit, in either mode (auto or manual). When I depress the 'jet' button, the jets come on. When I depress it again, they go off, and for a split second the red heat light on the spa pack comes on, then it goes off. Of course when the jets are off the pump comes back on again.

It is not likely that I made a mistake connecting the wires, nor is it likely that the heater is not getting power. I will check and re-check, just to be sure. And the contactor, high limit and pressure switch are brand new. The topside is 1 month old. I'm stuck !

Anyone have any ideas? If necessary, I can identify the electrical connections to and from each device (high limit, contactor, topside, etc).

Thanks everyone !!

What is the model number of the brett unit?

btw, the pressure switch doesn't stop the pump from turning on, it's job is to stop the heater from energizing without water pressure from the pump.

sorry pageup, don't have the model number. There is no ID on the unit anywhere.

I was thinking...I did not calibrate the pressure switch; that is, it is set in the middle of the range, about 2.5 psi. I should turn it counterclockwise until the heater (should) goes on and the relay is opened...?

Maybe that will solve the problem. I can't think of anything else that I did during the replacement that is not exactly the same as what was there before.

Also, would an airlock cause this problem?

Thanks pageup.

decided to just replace the spa pack. Talking to two different vendors, the pack is proably 20 years old, impossible to service and is very problematic.

Thanks.

NP, the sb1000 will impress you when you get it.

how did you know I ordered that one??

Because you ordered it from moi. These forums belong to Spapartsnet.

LOL well I guess that explains it..!! " title="Very Happy" />

Hey Brian, can you give the dimensions of the heater; i.e. from one end of the heater connection to the other? Just trying to plan.

Thanks.

Matt

Box is 10x8x3.5

Heater I believe is 12" total.

great. Thanks for all your help Brian

One more quick question Brian:

I'm logistically trying to figure out the best way to organize the cabinet with the new spa pack.

I have a suction system; pump pulls water thru the filter/drain, thru the heater then pumps it out to the jets.

I know it is critical to connect the filter/drain PVC line correctly to the side of the pump, and then the spa pack line to the top of the pump, but does it matter which side the water exits/enters the spa pack? In other words, could the distribution (post heater) be on the left or right, and vice versa for the line coming from the pump (pre-heat)?

Thanks again !

It'll work in either direction... No issues, no problems.

great. Thanks. I'll call if I have any issues with the install.