Cal Spa Oh - Heats Up, Pumps Work, Breaker Not Tripped

[maverick23]

I have a Cal Spa of unknown origin - after letting it sit and neglecting the filter for about 2 - 3 months, came out to see OH code flashing and water was ambient temp. Nothing tripped - pressed the temp button to adjust temp and it started heating, low pumps activated. It would eventually heat back up to specified heat, but a day or two later OH would flash again and the system shuts down. Deep cleaned the filter, Oh came on again about 2 hours after reaching temp (90F).

Running now without filter. Any ideas? The temp readings have always been accurate.

[brettnolan]

If it runs without getting the error, and heats to full set temp, when the filter is not in, you should replace your filter.

[maverick23]

Update - I replaced the filter, then reset the circuit breaker. It ran normally for 5 days, but then went 'OH' again.

Still not tripping the breaker.

This makes little sense - anyone experience something similar? Only guess is the high limit temp sensor, but 5 days of no issues seems much too long. I am not sure of the filter frequency setting but it is every 12 hours at the least, maybe more often.

[brettnolan]

Is the temp of the spa going considerably OVER your set temp? If so, that might indicate too much filtration.

How long does it take to get OH?

Obviously you probably didn't run it for 5 days without the filter, so you might try that again.

Other things you can do:

Make sure there are no obstructions in the pump

Make sure the impeller (in the pump) is not broken and it moves water properly (you should notice plenty of water movement on low speed)

It could possibly be the hi-limit sensor

You could check voltage to the heater when the heater is supposed to be OFF - there should be none.

[maverick23]

 

Is the temp of the spa going considerably OVER your set temp? If so, that might indicate too much filtration. < No, the actual water temp has always been correct and has never overheated. I check the temp readout against a baking thermometer, it is correct

How long does it take to get OH? < usually at least 24 hours (5 days this past time). Maybe 12 hours once

Obviously you probably didn't run it for 5 days without the filter, so you might try that again. <correct, will consider trying

Other things you can do:

Make sure there are no obstructions in the pump <none, water flow is normal at hi/lo pump speed

Make sure the impeller (in the pump) is not broken and it moves water properly (you should notice plenty of water movement on low speed) <no signs of malfunction here

It could possibly be the hi-limit sensor

You could check voltage to the heater when the heater is supposed to be OFF - there should be none.

  <if there is voltage in this case, what would that indicate? faulty circuit board?

[brettnolan]

If the heat light is off on the topside control, or the circulation pump is not running, there should be no voltage to the heater. That means that either the heater relay on the board is stuck closed, or something else is wrong with the board causing it send voltage to the heater.

If there is voltage to the heater when the pump is not running, that would be the cause of the OH.

I can't seem to post pictures and it doesn't appear that I have access to some features, so use the link below...If your board looks like the one in this link, relays with the yellow coils, you can probably find which relay is the heater relay. Look at the relay closely when the heater is on, then shut off the power to the spa...the switch in the relay should move to the other side. If it doesn't, it's stuck. You can, very carefully, with a small flat screwdriver, try and open the switch...WITH THE POWER OFF. Even if it works, there's no guarantee it won't get stuck again.

Newer boards, usually have a black plastic cover over the relays. I have been told you can break those covers to get to the actual relay, but I've had no luck.

http://www.hottubworks.com/part-2-51429-item-hottub-circuit-board.php?utm_source=GoogleProducts&utm_medium=CSE&utm_term=2-51429&utm_campaign=GoogleProducts&zmam=8865791&zmas=9&zmac=97&zmap=2-51429&gclid=CNeEysqh9bsCFUtgMgod4y4AEA

[maverick23]

Good tips - I will test for that when/if the rain and wind stop.

FYI I believe my spa is at least 15 years old. I purchased it used from a local refurbisher with a pretty good reputation who offers a 30 day warranty on all of their units. I am at about 150 days.

If the relay is getting stuck - I am looking at a new board, right? IMO that is something the refurbisher should have caught. Is that a realistic point of view?

Thanks for the help!

[brettnolan]

If it's that old, it's likely that you can "unstuck" it yourself manually as I described. As I also noted, though, there's not guarantee that it won't stick again. Otherwise, if you can't get it released, you MAY BE able to find someone that can replace the relay, but most likely, yes, new board.

I would say that you can try and talk your way into he should have caught it, but realistically, electronics are finicky and you can never really predict when and how they might malfunction. I could be totally wrong about that, but I think manufacturers offer warranties only for goodwill. They probably have crunched the numbers and have a pretty good idea that a certain number will go bad within given time frames and based the length of their warranty on that. But my experience tells me that you can never tell. Could last nearly a 15-20 years, could last 15-20 months.

[maverick23]

I think you are right about being able to unstuck the relay. I turned the heat down by about 20 degrees, so in theory, the heater will not have to activate. If it doesn't fault until it falls below the set temp then this pinpoints the relay or the temp sensor, I believe.

If it is the relay that is getting stuck, and it 'stuck' mechanically, I'm not sure I understand how either resetting the breaker or simply pressing the temp button to clear the OH code will fix a mechanically 'stuck' part. If it responded to the button, that would suggest that it works pretty well? Although, I have not been listening for a 'click' sound. And, one time (out of 10 or so), pressing the temp button did not clear the OH code immediately, so that may suggest it was stuck in that instance.

Thanks for all your help!

[maverick23]

And my board is a Cal Spa/Balboa 52934 - http://www.spacare.com/calspaliteleadercircuitboard52935.aspx

[Spa Board Doctor]

Most common "OH" error code causes:

1. Dirty filter or other obstruction in plumbing causes low flow across heater i.e. water in heater hotter than 110F. Pressing any button on spaside will reset as long as the high limit has cooled to 108F or lower.

2. Sticking/stuck heater relay causes overheat. With stuck relay, common to hear "sizzle" of water boiling in heater housing at power-on (before pump turns on). If many occurrences, can also damage high limit sensor. This is a repairable failure.

3. High limit thermistor failure.

4. Bad diode on PC board causing loss of power to comparator circuit for high limit protection. (constant "OH") This is a repairable failure.

brandon@spokanespas.com

[maverick23]

Following this up - although I don;t believe in problems simply disappearing, my spa hasn;t faulted in probably 6 weeks now. I suspect it may have something to do with a stuck relay in cold ambient temps, as we had a bit of a freeze at the time. I say this simply because I can't think of anything more sensible.

[maverick23]

Picking this up, the problem returned this morning for the first time since January. It has hit OH 3 times today alone now. It is in the 70s F where I am.

Does the 6 month code-free period indicate anything? Thanks in advance

[maverick23]

This time, the unit won't stop heating. I have the temperature set to 99, though the deckside display shows the temp above 99, and the low speed pumps are still on even though I have them off, as though it was attempting to heat itself above the set temp of 99. The heating indicator light is NOT on when this is occuring. Since it is actually overheating I presume, I just switched it off.

Any ideas?

[luke s]

did you ever resolve this?

I have exact same issue that has occurred over a span of a year or so.

had the OH errors for a while in early-mid 2014 but then they went away. it would occur randomly every once in a while but not too often.

now the error is back. the temperatures have been low lately. I believe it is a stuck relay because it just heats until it reaches 110 or until the pump shuts down, and then you can hear the "sizzle" as per post #11 (heat lamp not on, but power is presumably going to the element because water keeps getting warmer, etc)

so if it is the relay like I suspect, is it as simple as moving the contact back down. is there anything I can apply to it to make sure it doesnt get stuck again?

&;

This time, the unit won't stop heating. I have the temperature set to 99, though the deckside display shows the temp above 99, and the low speed pumps are still on even though I have them off, as though it was attempting to heat itself above the set temp of 99. The heating indicator light is NOT on when this is occuring. Since it is actually overheating I presume, I just switched it off.Any ideas?

&

[Hot-N-Wet]

Your filter duration time is set to run for too long. Your spa is getting hot due to the friction generated by the excessive run time of the pump. press temp then jets to get into the filter program mode set it for F2 or lower.

[luke s]

please read above........ no this is not related to my issue in any way whatsoever. filter is set 2x a day for 2 hours (min)

pump would not raise the temp 12 degrees in 2 hours only and there would be no fizzling sound at the heater once the pump turned off

Your filter duration time is set to run for too long. Your spa is getting hot due to the friction generated by the excessive run time of the pump. press temp then jets to get into the filter program mode set it for F2 or lower.

[luke s]

well the issue has "fixed itself" a few weeks ago and then returned again. Now it has "fixed itself" again. pretty annoying as it is unpredictable