Pool and Spa
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1) What type of GFCI? A GFCI circuit breaker or a GFCI receptacle?
2) Burn't wires suggest that the branch circuit wire size may be too small or a loose wire connection. A GFCI will only trip upon a current imbalance and not because of improper wire sizes.
3) If the GFCI can successfully trip using the test button under a "no load" condition, then the GFCI is working correctly.
OK, Thank you for the replies.
1) Since the spa is a 50 amp GFCI disconnect, the branch circuit conductors need to be sized as 6 AWG Copper. Branch circuit conductors that are sized smaller than 6 AWG Copper can overload and the insulation can burn due to overheating.
2) The only way to test a GFCI is to intentionally trip it via the test button. If the GFCI can successfully trip under a "no-load" condition then it is working OK.
3) When wires start to overheat and burn, this is due to either an incorrect wire size (overloaded conductors) or a loose wire termination that will cause arcing on the wire insulation. Loose wire terminations can cause unstable voltages and a sudden spike in the branch circuit voltage therefore compromising the wire rated insulation value.
4) Since the control box wires show signs of burnt marks, this may suggest an internal problem with the spa control box and not the branch circuit conductors or GFCI disco switch.
1) Corrosion/rust on wire connections can easily lead to a poor or a loose connection which in return, can contribute to a voltage drop or a spike in voltage. All wire terminations should be free and clear of any rust or corrosion deposits in order to make a proper connection.
Flip the spa branch circuit breaker in the main electrical panel to the OFF position as well as turn the GFCI breaker to the OFF position. Remove the wire connections and clean them using some steel wool pads or a wire brush and make sure they are clean and no more rust deposits. Then re-activate power by turning the breakers back to the ON position.
2) The GFCI breaker needs to have power and voltage connected to it in order to test the GFCI by using the test button. A "no load" condition means to temporarily remove the "LOAD" side connection (spa side wiring). If the GFCI can successfully trip via the test button when the spa wires are not connected to it, then the GFCI is working correctly.
Thank you for the replies.......I understand on the new heater.
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