Hi.. I moved into a home with an older spa and had the pump replaced three years ago. The controller is about 10 years old as I understand. The repairman said at the time of the pump replacement that it would soon be time to get a controller, but that it would probably last me a few more years. At that time, he inspected the spa and gave an "okay" on all the parts, including the heater, controller, pneumatic control panel, electrical, plumbing, shell, etc. The pump had seized, and that was all that needed to be replaced.

The spa has worked fine for the three years I've lived here (Northwest Florida, so it doesn't get much use.) I just filled and cleaned it and it won't start... no electricity. The circuit breakers in the electrical panel are all okay and have not "tripped". However, it has an on-board GFCI switch by Levitron that I believe needs to be replaced. The TEST and RESET buttons feel just worn out, and don't "click" when pressing either one. It's my understanding that they can wear out over time, and need replacing. While inspecting the GFCI, I then see there is a burned out wire in one of the power cables as well. It attaches to the GFCI and goes into a square power "clip". (Pics attached.)

My question is this: I am sure I probably need a new controller, but, like many these days, I don't have the cash to throw into the spa this year, especially with summer approaching.

I see the replacement GFCI online, but I'm obviously worried about the main issues, the burned wire, but I've seen "power cables" online that look similar, and wonder if they can be replaced along with the GFCI? Based on the pictures and my info, does it seem feasible to replace the GFCI switch and the burned out power cable? Can anyone offer any advice about this situation. As you can see from the pictures, the interior of the controller is fine and isn't corroded, and I think this burned wire/power cord assembly and old GFCI are the issue and can be replaced (at least until next season when I can hopefully just replace the whole controller.)

Thanks for any info you guys can provide. I appreciate the assistance and knowledge.

Pics should be attached.

Your GFCI might be just fine and only tripping because of the wire damage. I'd remove the plug altogether, strip the wires back to where the insulation is good and the conductor isn't worn out, and then wire nut a new line in directly to the heater removing the plug altogether. The plug is just a convenience. That will be a quick way to get it back up and running to test the GFCI.

Thanks for the quick info, Spishex.

Pardon my ignorance.... so basically the wires leading to that plug are all connected to matching wires underneath the plug? Would I just be connecting all of these wires to their matching counterparts? Or would you recommend just replacing the two damaged wires and leaving the other wires connected with the plug? I guess I need a wiring diagram of some sort to make this easier? I will say my electrical experience isn't extensive, but I'm certainly comfortable installing new outlets, switches, and other fixtures like ceiling fans in my home.

Thanks again for the advice! I'd really like to get her running for at least the remainder of our short season here.

You've got it right. That plug just goes directly through to the other side.