Hi, I've got a problem similiar to one listed on the board, but I'd like to pose my question anyway.

I've got an hq-1001e series control box. I noticed my water was no longer heating, and when I opened my box to check, my heater relay on the right (I have two heater relays, I think) had been burnt as well as the wires connecting to it (on the top right terminal of this particular heater relay).
I replaced the heater relay, wire which was burnt and checked for other burnt wires.

When I turned the spa back on, both my relays got extremely hot, as well as the wires connecting to the heating element, and to top it off, my water did not even warm up. I then replaced my other heater relay, replaced my heating element and made sure all my existing wires were ok, as near as I could. Still the same problem, my heater relays heat up along with the wires going to my heating element.

I tried to turn my psi up and down, but I left it on one psi, just not knowing what to do with it.

The only picture I have of my box will show the new relays and wiring. I donot have a before picture.

I did have the wiring diagram for my control box, and I checked my wiring as best I could, and it all looked ok. (I've since lost my wiring diagram and need to get another one from somewhere.

If you could provide any help or advice I would be greatful.

I would say those relays aren't strong enough for the current load on the heater element, and what is happening is that your contacts on the relays are burning up and heating up your wires. Your heater will be drawing up to 27 amps when on, and those relays may only be rated for 10. Check that and perhaps consider going with a contactor instead of a relay. A contactor is designed for much higher loads.

Well, I ended up replacing all my wires/connectors and it works just fine now. My guess was the larger wires were getting worn, since they were getting hot, before my relays got hot. After replacing them, every thing went back to normal.

Just a note, for your refrence in the future and anyone else viewing this forum:

Any time you have a loose or coroded connection, especially on the heater circuit, you can experiance hot wires, poor heater performance, even melted wires/relays. The reason for this is that the loose or coroded connection acts as a resistor, which is just like a heater, just in the wrong spot!