I'll try to provide as much info as possible. I recently purchased a 2001 vintage Cal Spa. It has two different 5.0 HP T145 pumps and no "stand-alone" circulation pump. What I am calling pump #1 is attached to the heater element. The tub WILL heat up to the proper temperature that I select just fine...Problem is that the low speed on pump #1 will NEVER shut off (even though the heater does...like it's suppose to). The manual says "The low speed pump will automatically turn itself off after 4-hours if not turned off manually" this doesn't happen. Also, pressing of the "jets" button each time is met with usually a "click" from pump #1 if it is suppose to be doing something. Pump #2 works great.

BTW, I replaced the pressure switch.
Now, on the "spa pack" I guess you'd call it I found that I could switch the plugs between the two motors, so...I moved the wires going to pump #1 (which DOES have one additional wire than the wiring to pump #2) and plugged pump #1 into the pump #2 position and plugged pump #2 into the pump #1 position. Doing this JUST ABOUT fixed my problem. BOTH pumps seem to be working great (at least the HIGH speed portion) but I AM missing the ability to heat the tub using regular methods (like simply setting the temp and the low speed pump/heat turns on---the tub will heat when I have actuated the Jets button as it would normally if you were in it using it, but after pressing the button a fifth time everything SHOULD turn off and it would normally turn on a low speed pump and heat up. I suspect this is a product of me moving the wires around. But this is the only function that doesn't work after the "swap"
So, there are a few things at work here it seems, Pump #1 could have a "low speed" portion that is bad or there is some sort of logic/relay that is bad? I realize that each motor is wired differently and that my change my results when I moved around the wires, I was just trying to troubleshoot each motor. Any ideas???? Thanks in advance.
Bob

bobnkathy,

While I know you're hoping that this response will be the solution, it isn't. It's more of a "I know where you're coming from" message. My hot tub (a 1993 Emerald Cygnus series) is suffering from the exact same problem, and I am also trying to determine whether or not it's a pump motor problem or a switch/relay issue in the electronics.

Thus far, I replaced the pressure switch. I have had the motor in to an electric motor repair place where it worked fine on his workbench when he applied power to it. I don't know if he tried getting it to work on both speeds though. I even replaced the circuit board for the spa control (believe it or not, the previous owners of this house and hot tub had an extra one which the left in the cabinet next to the hot tub).

Anyway, I have a friend who owns an electronics repair shop and he plans on making a trip to my house on some Saturday in October (I'm hoping 10/6) and we're going to run some tests on some components to try to isolate the problem. I will keep you posted as to what we discover because it seems to me our problems are very similar, if not identical.

Good luck in the meantime.

Sincerely,

RB Asplund

Well, I was kind of at wits end so I pulled the trigger and ordered a new pump (waiting for its arrival). I'm really leaning towards the pump because when I switched plugs (plugged #2 into #1 spot and vice versa) I had totally different indications. It's hard to explain, but instead of just hearing a "click" the pump (#2---plugged into the #1 spot) fired up and circulated water great! So because my indications were different when I switched plugs I have kind of ruled out the circuit board. I DID change the pressure switch. SOOOO, if nothing else I'll have a new pump in there and I'll continue to troubleshoot, got my fingers crossed.

New pump fixed my problem!