Hello Everyone,

I have an older hot tub with a HydroQuip D2S control panel. Recently the jets stopped working, but heater and circulation still worked. I had a friend who's an electrician come over to take a look. I told him a smelled a "burnt electronic" smell prior to the jets not working. He checked it out and suggested that I probably need a to replace the control panel. So I made the mistake of continuing to use the tub. Without the jets of course. Only one night to loose all power. Discovering that the wire plugs for the pump and blower, that connect into the panel, had melted. So my questions are what caused this? Would this be the control panel that needs replaced? And if so. Where am I able to find a replacement control panel and plugs? As I believe they're not made anymore. I've also attached some photos. Thanks for any help. CK

I may not be of much help but since I don't have one but I can help answer your question of what caused it.
Connectors are the bain of almost every application where large currents are involved. Over time the contacts begin to corrode and the resistance between the contact points increases.
As this resistance increases the contact interface will start to get hotter. As it gets hotter it begins to corrode more. Ultimately you end up with whats in your pictures.

I suspect that all you need to do is replace the connectors on the wire and on the controller board. Unless the controller board was burned as well nothing else should have suffered any damage.

Thanks for your input and help. Does anybody have an idea where I can get new connectors for this unit? As I've searched and have come up with nothing. Thanks, CK

Yes that's probably what happened. Those Amphenol connectors under the wrong conditions can create a rather bad connection and overheat with age - it never gets better.

It looks like what appears to be your blower plug, (I'm guessing that's what it is - the violet one), didn't overheat it just got hot from the pump connector melting down next to it.

If it were me and I wanted this thing up now, instead looking for some dollar two ninety eight connector - I wire it straight into the controller wiring and dump the connection.

Otherwise we have these pump cords you just need to call us in the office. What you need is a pump cord, 'amp' style 4 pin.

PS: Your pump could be fried too.... If you put a new plug in there or wire it direct and the wires want to start getting hot or start burning... Then your pump is on the way out and it's time to stop using the spa and get the pump fixed or replaced.

If your looking for something that's new and cheap to replace this system with...

http://spapartsnet.com/p_Spa-Packs_SPAS ... 9_1_1.html

If you feel daring and want to just change the connectors, you can try http://www.newark.com. It may take a while searching, but if I remember right, they are in there. They will be plain white, not colored, but color is only for ease of identification. Unless they were discontinued, Newark should have them.