2000 Bahia by Sundance spa wires getting hot!

[mdezeeuw]

I recently been having a problem with my spa. I just replaced my circuit board (6600-288). Also have a rev 5.56 chip in it. I now have a problem with my wires from my circuit board to the heater getting hot and almost melting. They turn black but do not smell like a short. I have had to replace the ends on them twice already. The same for the wires going into the board for the power. All 4 get very hot and turn black. The hot tub still works, heats up, but i do not think this should happen. let me know what you guys think.

Mike

 

[Bama Rambler]

Wiring getting hot and melting insulation is due to bad connections and/or high current. How are you making the connections?
What size heater is in the spa?
What size wire is it?
Are you sure that the voltage to the heater didn't get changed?

 

[mdezeeuw]

Well it is all factory parts so dont think that the wire size would be a problem. here is a pic

 

[Bama Rambler]

Where are the wires that are melting the insulation?

 

[mdezeeuw]

Here is one i replaced

 

[Melt In The Sun]

looks like the two at the bottom left of the board, as well as the bunch of wires looping up over the fuse mount in the bottom middle of the photo?

 

[mdezeeuw]

Yes, thats my old board and it had a melt down. but i am seeing my wires do the same thing. I am working on the vibration i have. when the pump kicks on it has a bad vibration.