I have a Viking Royale spa that's 1 yr old with a Cutler-Hammer 240volt 40 amp gfci in a seperate box. I have rewplaced the heate nad the gfci and am still having gfci tripping problems. Seems to be random as it might run ok for a week and then kick out for a couple of days off and on. the last couple times seem to be near the end of a filter cycle. Any ideas as to what is wrong or things to check?

could be something as simple as a loose connection somewhere, so you might want to double check all the connections from the GFI breaker to the tub's terminal strip. After that, could be a problem with ANY of the components connected to the circuit, assuming your new heater is indeed good. Lastly, a possible water leaking problem onto a component could cause this as well.

Thanks, All connections seem to be tight, I don't see any sign of water leaking. Haven't checked under the control panel on the top of the tub but I'm not sure if there is any electronics under there. As for components, other than the pump and heater are there any that draw the amount of power to cause this problem? I do have an ozonator.

a 240 spa should be able to run all the components at the same time without causing the breaker to trip. It is possible that the breaker could be defective. Cutler-Hammer doesn't make the best GFI breakers out there. I would try to disconnect the non-vital components(everything except pump/heater) and see if the breaker holds, and then start adding a device one at a time until it trips. Then suspect the last item added. If it is indeed truely random, I would suspect the breaker

Still an ongoing tripping. The pump, motor,heater and circuit board have been replaced as has the gfci. Still kicking out. After the diagnostics has run its course and the pump has run for a minute or so the heater will kick in showing the temp and with a solid red light indicating the heater is running after about 10 seconds the light will flicker and then the breaker trips. Tried disconnecting the copper leads to the heater and left the heater probes on each end plugged in and same result. Also if before the heater kicks in if I kick in the 2nd stage of the pump the heater will come on the light will flicker again but then go solid, but when the pump is shut down to the lower stage the breaker kicks out immediately. Does anyone have any ideas Please????
Thanks

First of all you havent mentioned if its the breaker or the GFCI thats tripping ?? GfCI brakers have 3 positions, ON - Tripped -- OFF. When this pops is it going all the way over to the OFF position like a normal breaker? Or is it going to the GFCI tripped position -- more towards the middle of the breakers throw.
If your tripping the breaker - you probably need to up the Amps -- 40 amp is not enough for most 240v dual pump systems.
If your tripping the GFCI part of the breaker than you have other issues all together.Sometimes its as simple as unplugging the Ozone unit.

No panel breaker goes all the way off when it's tripped, wether GFI or standard. They all go to a mid point, and need to be shut all the way off in order to reset. The only exception to this is a magnetic breaker, which you will never find in a spa, or house panel.

It is the Gfci that is tripping and it's tripping to the off position. Have never tried disconnecting the ozonator.

I disconnected the ozonator and it seems to run. Have replaced the ozonator and the heater and finally working (for now) Thanks for all the advice, much appreciated.