I have a 1995 hotspring sovereign with a relay problem.My hotub is wired 115V-works fine except for this noisy solenoid.Inside the cotrol box are three relays side by side-numbered "3" "4" "5". Relay "5" is the problem relay-which I replaced with no help.I have no wiring diagram.The relay does stop clicking when I turn on the hotub(jets) and imedidiately starts clicking when I turn it off.This relay is connected to the flow switch among other things.Thanks for any advise

Well if you're sure that it's connected to the flow switch, I would suspect that your heater is probably intermittent as well. The output of that relay, I'm guessing is a safety cut-out for the heater. The reason why it stops clicking is because the system shuts down the heater when you turn on the jets (because of the 20 amp circuit limitation).

So, if what you told me was true, I would immediately suspect that your circulation pump output is marginal, on it's way to being dead, or just clogged. If it were mine, I would unplug it, then remove the suction fitting on the small circulation pump and see what kind of gunk comes out of it. If nothing but just plain water, then I might so some more in-depth investigation like disassembling the face of the circulation pump and checking the discharge vanes and the suction area of the impeller for debris. That's where you normally start with a problem like this, that is if all other things are normal, like your filters are ok and not clogged up etc..

Hope this helps.

I Fixed your email address so you would receive a response to this post.

Thanks for the help.I removed/disassembled/replaced the circ pump.It was totally clean.I also found that the relay stops clicking when I - turn the thermostat all the way down -or- unplug the heater -or- unplug the circ pump.

I am still having the same problem with my relay constantly "clicking". I just replaced my heater (due to a pinhole leak/which was covered under warranty).After installing the heater I turned on power/ran the hottub/turned off the hottub and it imediately started clicking again.

The noise that you are suggesting sounds like it is a flow switch making noise. The flow switch controls a contactor. on the 1995 and 1996 hotspring, they equipped models with a circ pump that is 2 speed w/ the flow switch & No heater hi limit. (basically if the flow switch was no activated then the heater will not work without the flow). The circ pump would then flow at a higher speed when the heater was on. They have now changed w/ NO flow switch but they went back to having the TCO (Thermal Cut Off) and/or High Limit (HL). For the Engineering...This was a great idea if you want to save $2 a month (of the $15 a month average operational cost) of a yearly adverage) in electrical cost. But the negitive is that if the filters are slowing the flow of water (because they are dirty)which is having a direct result in the flow switch turning on and off.

This is what I would do it is was mine...
1.. I would eliminate the flow switch. I would bypass the circut by taping the two wires together. MAKE SURE THE SPA IS OFF!
2.. I would get a new Unicel filters (Qty3 - 35square filters)
3.. I would wire my circulation pump to run on high speed 24hrs a day.
(If I told you my spa is the same year, different model, but same componets, and I have done the above.)

That should now solve your problem. If you are still having problems with the spa heating, and you getting a red LED flashing light on your spa. Then a new Circulation Pump Part # 70813 is needed. Cost should range for a brand new one $150 - $225 at a local dealer. The reason that the pump is in need of replacement is because the filters have been neglected from being cleaned once a week, and that circulation pump has been pulling from a restricted sorce, which now has slowed and ruined the circ pump. Which, proper cleaning of the spa filters on a weekly bases I have seen these circulation pumps last 15 years.

Instead of having your circ pump run 24 hours a day, you could still eliminate the flow switch but install a pressure switch in its place.
Is there power still getting to the relay? Would this make it chatter like you are saying. If so then something else is staying on partialy to make the relay make noise.
I don't know alot about Hot Spring so I am curiuos about this.

First, my thought process would say the DC Relay making the noise. In 1995 these model used the Relays that physically look like a Contactor that slam down to send the power. These are making the humming noise and ultimatly the chatter. More commonly I see the Heater relay wear out and make noise and become annoying. If that is not it, there are Rectifiers... 2 of them that control the AC and DC voltage through it. Quite possibly they are not sending the proper voltage from the Bridge into the PWA Timer Board. I have seen where these inexpensive inexpensive bridge rectifiers have caused intermitant issues with the spa after the spa was hit by lighting or a power surge go out.

Second, HotSprings spa are different... To explain and understand, Look at it this way. Eliminate any flow switch/pressure switch. There is no need to have one. If the circulation pump should be running at high speed (remember high speed is only drawing like 0.8amps) 24hour 7 days a week pulling from the filter. Thous giving you 24 hour 7days a week filtering. And also if the heater needs to heat or not (that being controlled if the t-stat is telling it to turn on or off at the time) Is that a better concept on the subject? You see you would not need to really have a physical check to see if there is flow going through. The only thing that you would really need as a safety device on the spa, which would be a high limit. The hi limits are what commonly home owner trip out (overheat there heater cause of the slow flow going through it) and cause their spa not to heat. The concept is simple. It is rather different then most spas on the market. Some similarities. Let me know if I can be of any help on the HotSpring questions.

I am having this same issue with my 96' Soveregn. The second I hit the button on the GFI, I hear a couple of clicks from some relays and it shuts down.
I have replaced the circ pump and I can use the circ pump or the heater but not both. I did have a failed circ pump for a few days. Could that have wiped my heater out? I was also wondering if it was the GFI on the plug that was going.

I can try your advice about the bypass of the relay but I dont even see how to get inside the panel. Please explain exactly what wires to connect..

Thanks for your help!!

Mark