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GFI Tripping

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Botswana:
My 2016 Vanto is still randomly tripping the GFCI every week/other week.  Pump 1 was replaced.  I pulled the board and there are no signs of any problems. Tighten all connections. Tub is wired correctly. Tried replacing the breaker itself.  Thought it was pump 2 so disconnected it and it still happened.  What else could it be!?  If it was the heater I would think it would happen more often.  Only other things are the control thermistor, LEDs, and pressure switch.  All connections for them looked good.  Losing my mind.  Been more than a year of this happening.

SerjicalStrike:
Are there any junction boxes between the breaker and the tub?
Are the wires run underground?

You can put a meter on the tub and see if there is any amperage leaking to ground. 

You may need to check the wire from the breaker to the spa.

Botswana:
No junction boxes that I know of. We had the house pre-wired for a hot tub when we built it in 2011 so the wires run through the firs floor walls of the house to the backside.  They used 6 gauge from our main panel to a spa box on the back of the house. We ran 6 huge from that spa panel to the tub. The wire from the spa panel to the tub ( underground in PVC for a few feet) has already been replaced, as has the breaker. My multimeter tests of amperage indicated no leaks to ground..that I remember. Is there a certain test you have in mind?

bud16415:
The last time you posted I suggested a test using a special tester called a megger tester to test the insulation value on the heater pass thru. I have read slight intermitting weeping or any moisture can cause an intermitting GFCI fault and could be no place close to what would progress to a melt thru if the GFCI wouldn’t be in place doing its job. The GFCI will shut it down so quickly there would be no evidence of shorting. As it is right on the boarder line to trip it would go back to working fine. A multi meter doesn’t have the current potential to see a break in the insulation.

It is the only helpful thought I have as you have run down all the other potential problems.

Sometimes romex is run thru the house but then per code if where the feed exits the house and runs to the GFCI panel outside it has to switch to conduit and romex is not allowed in conduit. So there is a J-box at that place. If the romex stays in the house and passes straight into the GFCI panel thru the back there wouldn’t be a junction point.   

Botswana:
Oddly enough I just found out one of my neighbors is a master electrician so I was going to contact him and see if he had the tool and could help. There may be a junction box in the house though I doubt it based on the wiring I see in the main house panel and what exits the house in the back. Just so I'm clear, you think the guy should test the connectors to the heater with the megger? I'm assuming he'd know how to do it, but if not, how does one do this test? I'm guessing all components (pumps) and lines into the tub panel can be tested with the megger too?

I'll report back when I have the electrician come over. Absent of that, I have no clue where to go from here.

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