Hot tub has a Len Gordon FF 32 Altco controller. Don't know the last time it worked right. 2 speed pump and blower work. Has a Vulcan 220V 6KW heater. The contactor for the heater won't engage, no power to the coil, maybe need to replace flow switch? Is there a way to check the flow switch? When I manually close the contacts and read the amps at the heater I get only 8 to 10 amps with 220 volts. The other thing is that something smells like it's overheating and the stepper relay gets hot to the touch. I'm not ready to replace the control unit yet! Thanks for any help and suggestions!

Hi Tomwila,

Your FF32 ALTCO controller is from 1988, or 89. The PRD contactor operates off of the Harwill flow switch that is probably flooded, or locked up. The Four Stepper ( Named our cat after that part ) operates off af a momentary air switch. If the airswitch has been replaced with a latching, or is stuck, then the stepper solenoid stays engaged, and burns up. I can't find an orriginal style Harwill flow switch, or a readily available PRD. If your PRD, I'm sorry, When your PRD finally sticks, it will burn up your $300.00 or so Vulcan heater. I know you don't want to hear this, but you need to re-furbish the equipment. I don't touch these in the field, and eat a trip charge to quote a "Retro"

OK, I'm still not convinced on replacing the whole spa pack and I'm wondering shouldn't I be reading more than 8 amps at the heater? I might go with a blue cam air trol to replace the 4 Stepper ( good name for a cat), and I can get a flow switch. I'll listen to anyone who can talk me into replacing the spa pack with something like Brett Aqualine CP-104.

Hi Tomwila,

You should be reading 20+ amp draw from a 6 KW heater. The controller is convertable, so make sure you are set up for 220V. Look at the top row of terminal, and you will see a configuration for a single phase, and double phase connection option. Check voltage on line side of PRD (220). After Flow Switch makes, it completes coil to heater PRD. Simple and scary. If the PRD sticks, it will dry fire the vulcan heater, melt the fittings, drain the spa etc.
Check the smaller terminal strip for signs of the flow switch wire "wicking"
water from a failed diaghram. (rusted terminal). Check inside the Vulcan heater for breached drywells, and melted wire nuts. You will probably need a fresh High limit, and Spa side if the unit has been in-op for a while.

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