I just replaced my heater element in an old Hercules 5000. This a 5,500 Watt unit. Instead of the longer length element, I put in the shorter version ( 8". Powered it back up and started heating, all seemed well. Started to notice smoke coming out of the control box, and when I checked it out found the power wires that go into the contactor to be cooking pretty heavily. Nothing else changed and need to know if the shorter length element is causing this. Thanx.

If the KW are the same, length isn't a factor.

Replace the wires, and be sure they're tight. Loose wires probably causedf the issue. If the relay or contactor is damaged, replace it as well.

Thanks..I didn't think the length would matter. Cut back the wires going into the contactor and made sure all was tight. Now the situation has progressed to the point where the low speed on the pump functions but flow is definitley reduced ( heat is working) and the high speed does not kick in at all. Time for a new pump?

That's a different kind of problem-and likely unrelated. Unless the voltage drop is too great (increases amp draw)

What the distance of the electrical run, the size of the wire, the requirements of the spa?

Thanks for the response. The wiring should not be an issue. It has working without issue for over two years. The pump is a two speed 3/4 HP. basic unit. 6 guage wire going into the contactor. I am going to pull out the filter and recheck to see if that changes the flow at all. It is confusing because after replacing the heater element both speeds on the pump were working and then the incoming wires started overheating. Maybe something got in and blocked the pump...can't see anything geting in there other than maybe ice.......

Also pump is form about 1989 so it is quite feasible that it has ran out its' useful life........ " title="Sad" />

Don't worry about the age, pumps motors are are pretty much either good or bad, not a whole lot of inbetween.

If your spa is equiped with "slice valves," be sure they are in the open position-they may have gotten closed during the heater repair.
It's very likely an obstruction- or even ice. Don't spend too much time going over wiring issues on this one-
Cleaning the filter is a great first step.
Good luck!