This is a little more complicated than the title suggests, but I went for most meaningful rather than exhaustive title or vague title.
I got a 2003 Sundance Optima 850 for free on craigslist. It was in great shape. I replaced the headrests and cleaned the filter, and got it started up. The pumps are all good, ozonator is working, heater is working. Everything looked great. The cover and cover lift are a little worse for wear, but everything else is pristine. Heats up to 104 and sustains the temperature like a champ. Had to replace one of the diverter valves, but now all the valves are in perfect working order and the jets are all fully functional.
Unfortunately there are some bugs that have shown up. 2 to be exact.
1 ) The tub will occassionally shut off for a short interval. When this happens, the jet pumps shut off, the air pump shuts off, and the control panel goes completely blank and unresponsive. The circulation motor, however, continues churning on as if nothing has happened. No faults in breaker at all, and the tub starts back up on its own. That is all I know about this one.
2 ) The tub get a FLO and FLO2 message. I have replaced the flow switch and the problem continues. This is where it gets strange though. When the tub is powered on, FLO2 shows, but if I turn the flow switch a quarter turn so that the switch is sideways, that message goes away and everything comes on as it should. The message FLO usually shows at this point, but I can turn the flow switch back about an eighth of a turn and everything works fine for a while. Usually I will come back to it a day later and be looking at a flow message again and tweaking the flow switch position a little will get it back to working fine. I thought maybe I had gotten a bad flow switch so I got another one and replaced it. The problem still exists. I have made absolutely certain that the switch I have installed is the correct switch for the tub. I can visually see that the switch works as intended when installed in the correct position (open when off, closed when on), but the tub doesnt work with it turned correctly. This problem is making my brain explode. I am assuming that the flow switch is actually a variable resistor using a magnetic field to vary the resistance based on the proximity of the tab to the pole. Turning the switch a quarter turn causes the tab to separate from the pole fully. Turning it back the eighth of a turn causes to to get closer, but not touch.
Does anyone have any experience with this crazy? Are there any good ways to resolve these? Or is this indicative of a failing board that needs to be replaced?
I refuse to give up on this tub. When its not having any of the above mentioned issues, man does it work great. Any help to fully revive this beast would be awesome.
Thanks in advance!