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Flo error, Sundance Maxxus 2001, have replaced circ motor and flo switch

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Mrs Solomon:
Hi everyone.  I am hoping I can get some help as I am about to go out of my mind.  I have one big problem and a smaller problem that has come from working on the big one.

I have a Sundance Maxxus, 2001, which has always been indoors, and I got a flashing flo error and the hot tub would not heat.  I had not had the benefit of this forum at the time and decided the issue was the circulation motor.  The previous circ motor would get very hot and make a whining noise with little water being pushed out the hole where the hot water enters the tub (sorry, I don't know the terminology).  The install went fine, the motor works, but still got a flashing flo error message and no heat. 

I tried running the tub without the filter in, just to make sure that the issue was not with a bad filter, but the flashing flo message was persistently there.

Reading more, including previous posts here, the flo switch seems to be the issue.  I ordered a new flo switch.  Just to give as much detail as possible, this switch did not seem to require any drilling for the bottom tube connection and so I did not do any.  I installed it, but still the same error (and still, of course, no heating).  And this is still without the filter installed.  When I look at the flow switch while the circulator is running, I can see water moving through the t-section, I can see the paddle moving, but it is not getting close to the stick.  It is, maybe, a 1/4 of a inch or so away from the stick.  That makes it seem as though there is not enough flow/strength to push it against the paddle and close the switch. 

Could there be something blocking the water flow, and if so, is it something I can fix myself?  Where should I look?  I read in a previous post about the potential presence of a nylon sock filter that could have gotten sucked into one of the therapy jets.  Is that a possibility for me?  How would I look for it/ remove it?  I have also read that aiming a hose into the hole the hot water comes out of could help with air bubbles.  Should I try that?

The small problem, however, is that I, before I sought the wisdom of this forum, decided to try and see if the flo error could be gotten rid of in a roundabout way, just to see if that helped to narrow down the possible problems.  I removed the two wires of the new flo switch from the sensor and put the two wires of the old flo switch in their place.  My idea was to turn the power back on and manually close the old flo switch just to see if the error would go away or change.  When I did this, before I got a chance to try to manually push the paddle against the stick, the fuse tripped.  I tried again, and again it tripped.  So, I thought, that is not going to work, and removed the old flow switch wires and tried to reinsert the new ones.  This is the problem - I can no longer raise the wire tines on the end of the wires, and therefore, the wires are not properly seated into the sensor.  I cannot see how to raise them at all so any help towards that end would be appreciated.

Thanks for reading this far!  Please, please, help me figure out what I have done wrong and how to right it.

SerjicalStrike:
It takes some time and usually a fine blade to get that tine up. 

When you replaced the flow switch, did you replace the whole switch, or did you unscrew the old one and screw in the new one?

A 2001 Sundance should have the circulation pump that pulls off the 2 speed pump.  If you turn on the 2 speed pump, does that push enough water through the flow switch?

How long has the water been in the spa?

Mrs Solomon:
Hi - thanks for the reply!

I replaced the entire flow switch.  I only unscrewed the old one just to see how it worked.  Before the breaker tripping, I was able to turn on the two speed pump, but the paddle did not hit the stick in the flow switch.  There are a few bubbles in the switch, on the left side, but I could clearly see water moving through it and the paddle being moved - just not enough to get it close to the paddle.

SerjicalStrike:
Is there any water coming out of the heat return when the circulation pump is supposed to be running? 

Were the plastic plugs on the inlet/outlet of the circulation pump removed prior to installation? 

Mrs Solomon:
The plastic plugs were removed before the circ pump was installed.  Your question made me second guess myself, so I just checked and I still have both plugs sitting on the bench near the tub.

There was also water coming out of the heat return when the circulation pump was running.  I cannot tell that the amount of water that comes out increases drastically, however, when the second pump was turned on.

I filled the tub last Thursday, after having replaced the circ pump.  I then drained it to replace the flow switch on Saturday as the clamps I have were not doing a good job of blocking the water on either side of the flow switch.  The water has now been in there since then.

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