New Icon (Image/Weslo) spa - worked for 3 days - then the 120v side of the 240v contactor got smoked. If we physically hold the contactor in the spa powers up and seems to function properly, so hopefully a new contactor will correct the problem. Seems to be a coincidence that it happened maybe 3 minutes after I installed the Ozonator (supplied with the spa, amp style plug that fits the spa pack control box outlet) and turned the power back on. We did make a wiring error initially and popped the 50amp circuit breaker in the house panel twice (immediately on switching on) before realizing that we had improperly connected a white (neutral) wire from the http://www.connecticut-electric.com/spa.aspCT Electric disconnect to the spa. Once we capped both ends of the white and used only hot black, hot red, and ground wire from the disconnect to the spa all seemed to be ok. So did we weaken the contactor coil with the improper wiring initially or is my ozonator no good? Is there any way to test a CD 240v ozonator? Do I look for other problems? <br>(My electrician is an out of practice licensed electrician who did this as a personal favor, so don't tell me to get a new electrician!)

By the "120v side of the relay" do you mean the coil voltage? If so, just meter the coil voltage (if it's 110v coil, you should get 110v across the coil) If you're getting 110v at the coil, and the relay refuses to close, you're right, it needs replacement. But if you're not getting the proper coil voltage, the coil is likely fine, and you'll need to hunt for the problem elswhere in the coil loop...Oh wait a minute- stop the presses!

You disconencted the neutral?? Of course the 110v coil relay is not working. It needs that neutral to complete the circuit. Right now, it's getting 110v to one side, but there is no neutral on the other side for it to complete the circuit, the magnetic coil will not function. Your ozone generator isn't going to work either if it's 110v.

Double check the wiring instructions that came with the subpanel...

Yes I meant the coil voltage. And I am not 100% sure if that is supposed to be 120 or 240v.

We disconnected the white neutral from the disconnect to the spa as per the spa AND disconnect instructions. That is what made the unit WORK. We still have a neutral from the panel to the disconnect as needed.

Here is basic schematic: House panel - 50 amp breaker - 4 wires (hot red, hot black, white neutral, ground) - disconnect panel with GFCI and contactor - 3 wires to spa (hot red, hot black, ground) - spa

ahh- well, that's a kicker. Pretty tough to troublshhot if you don't know. Can you tell by looking at the wires, and the source of the wires that energize that relay? Do the wires eventually meet up with both phases of the hot wires, or do they use a neutral somewhere in the loop? Might be tough to track it down without a schematic.....

I'm a little surprised that you have a spa that does not require a neutral wire at all, it's quite rare, so I apologize if I headed in the wrong direction...

If the spa is 220v only, and was wired properly, and working properly and simply stopped working, it's probably safe to assume that relay uses a 220v coil. I doubt they would incorporate a "ground" to complete the circuit on a 110v coil, so lets assume it's 220v.

If that's the case, meter it out the coil, it should be getting 220v (Be sure to meter accros both ends of the coil at the same time, not one at a time) Chance are you're right on target.

Good luck!

I talked to Connecticut Electric about the situation and they admitted to a problem with the contactor contained in my model of disconnect that came from them. They needed numbers off the contactor to confirm that I had an old style - and said that it was not uncommon for those to work a week or less - just what happened to me. They have switched to a different brand contactor but it does not fit the layout of the box that I have - so they are shipping me a brand new box, next day air, no charge. If this does the trick I will be sold on Connecticut Electric as a source for anything they sell - I know they make generator hook-ups that I am going to need soon too.

So it looks like the Ozonator was just a coincidence we hope.