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Hey jbiker1950, thanks for input, , ,I think you found my problem!! Makes sense that runs OK in free mode, , did not try placing load on pump (yet). Will try the smaller impeller first. By the way, I ride a tricked out 05 Triumph America if you are that type of biker. Thanks again - - -

Thanks Peteyboy, , will keep plugging away and advise if I find someone who has had same issue with resolution.

Thanks for input Peteyboy, , dropped off pump with GFCI and cable at spa shop, ,they will test with GFCI tomorrow. Removed heater sub board and main board looking for burnt areas, found none. All wiring and connections look good. Found the IQ2000 housing to be very brittle plastic after seven years of use. Top two mounting points for main board broke when removing board, but board went back in with lower and center screws OK. I've had that problem with some control boxes - be very careful with it - one of them fell apart completely. Took pump with GFCI plug and spare cable to Electric Motor Repair Shop and he found no problem of anything shorting to ground. Hooked motor up through my GFCI to his 50 amp feed and motor ran perfect. He suggested I check pedestal female plug and underground cable from GFCI to tub. Today removed and used multi-meter on female plug and found no shorts or issues. Replaced underground cable from GFCI to tub and will reinstall pump, ,fill with water and start all over again now knowing I do not have a motor shorting to ground. If I could get my hands on a Soverign circuit diagram I could find the problem ! I'm unsure what else (like relays) are brought 'on-line' when I hit the jets button. Still shooting in the dark and all obvious attempts have failed to date. NEED HELP or Schematic

Thanks for input Peteyboy, , dropped off pump with GFCI and cable at spa shop, ,they will test with GFCI tomorrow. Removed heater sub board and main board looking for burnt areas, found none. All wiring and connections look good. Found the IQ2000 housing to be very brittle plastic after seven years of use. Top two mounting points for main board broke when removing board, but board went back in with lower and center screws OK. I've had that problem with some control boxes - be very careful with it - one of them fell apart completely.

Thanks for input Peteyboy, , dropped off pump with GFCI and cable at spa shop, ,they will test with GFCI tomorrow. Removed heater sub board and main board looking for burnt areas, found none. All wiring and connections look good. Found the IQ2000 housing to be very brittle plastic after seven years of use. Top two mounting points for main board broke when removing board, but board went back in with lower and center screws OK. I've had that problem with some control boxes - be very careful with it - one of them fell apart completely. Dropped pump motor and GFCI unit off at electrical repair shop and advised probable short to ground. He stated maybe a week, possible more before he could get to it. Will advise of results.

Thanks for input Peteyboy, , dropped off pump with GFCI and cable at spa shop, ,they will test with GFCI tomorrow. Removed heater sub board and main board looking for burnt areas, found none. All wiring and connections look good. Found the IQ2000 housing to be very brittle plastic after seven years of use. Top two mounting points for main board broke when removing board, but board went back in with lower and center screws OK.

Have removed filters, checked for obstruction to pump, took pump to spa shop, replaced 20amp GFCI plug. One at a time unplugged from circuit board: ozonator, heater, heater circulation pump and same issue of main pump kicking breaker. Note main pump works just fine when plugged in at spa shop. Unknown amperage of wall outlet he used. No signs of burnt component on either heater or main circuit board. ANY SUGGESTIONS? ? ?HELP ? ? ? My Hot Springs dealers charges $75 just to show up then about $100 an hour plus parts !!!!!!!!!!

Thanks to all for input, , ,,,Last night had visitors from the NE who were in my tub (too cold for us FL people), and one of them turned the underwater light on and zap 20amp kicked off. Since light and motor are two different circuits I am now a believer I have a weak breaker assembly. Will replace breaker and share results.

Have heard the spa GFCI units will weaken with time. My situation is my 20amp GFCI for my Hot Springs Soverign has been working fine for seven years. All of sudden the GFCI trips when the pump tries to start. Works fine to keep tub at 103, but either Jets or Clean selection kicks the 20amp breaker. Pump has been checked and found to be operable when plugged into non GFCI feed. Has anyone experienced a GFCI gets weak with age problem???

Thanks for input, , ,at this point I had removed my pump , took it to my local pool and spa supply shop. He plugged the pump into his test outlet and motor ran fine, , ,no noise or hesitation. However the pump was on his test bench and case was not monitored for a short. If all else fails, will pull it out again and test for case short/ground etc. Currently, I am attempting to replace the damn Watkins 20amp GFCI plug. I ordered a 'new' one off of ebay, but when I got it, I plugged it in and the plug's LED would not even come on. Tried with and without cable attached, same issue. My original plug does have LED lite when plugged in, , keeps heat at 103, but kicks off when pump is engaged in either Jets or Clean cycles. Have ordered a security torx bit set so as to open the GFCI portion of the plugs for a look see. Local Hot Springs dealer wants $103 for a plug over the counter!! $$!! Will probably replace outlet with a TRUE 20amp GFCI breaker and eliminate the damn Watkins plug. Until then any other suggestions would be appreciated.

Yes, removed all three filters and had same issue. I then removed motor and pump looking for any restrictions. No such luck, , had hoped the filters or something in the impeller was blocking pump rotation.

Have a 2000 Sovereign that is maintaining heat at 104 degrees, BUT soon as I turn jets on, it trips the 20amp (110v) GFCI breaker. Took pump motor out and plugged into outlet (without GFCI) and motor ran fine. I then ordered an new Watkins GFCI 20 amp plug on Ebay. When I replaced my GFCI plug with the new one, the LED would not ever light. Pushed test, reset several times and nada. Then unwired tub from plug, still no LED. Installed old GFCI plug and LED lights, tub panel comes on, have red and green lights on stating water is at temp selected on panel, BUT soon as I hit either jets or clean button, , ,GFCI kicks off. Any suggestions please??????