25 year old GFCI trips randomly, requires 3 or 4 attempts to reset every time.

[Romsk]

I have a 25 year old 50 Amp GFCI breaker (not an AFCI) in a basement breaker panel. The circuit runs only an outdoor hot tub that has been in service for just as long - but a new hot tub was installed just over 5 years ago. There was never any problem until receintly the GFCI started tripping randomly every week or so. There is a shut-off switch (breaker style) outside near the tub in a weather box. No water/moisture seems to be getting in anywhere and the circuit was fine for 25 years. The hot tub draws no more than 37 Amps at any instant including heater turn on in-rush. The tub is configuref for the 40 Amp option - so the heaters are off when all pumps are on. The heaters are delayed from turn-on at power up. I checked for proper neutral/grounds, touching neutral/grounds, and ground loops (I R an eng-a-neer but not an electrician so maybe I missed something).

After it trips (which I don't realize until I try to get into the tub days later - and notice the water is cooler), I reset the breaker (I am dry when I do this) and it buzzes and trips instantly before I can even let go of the lever. I have to try it 3 or 4 times for it to hold. Also, I have to push the Test button pretty hard (a bit wonky) for it to trip while testing. The pumps and heaters are delayed for about 30 seconds from power-up so there is less than 2 Amps of draw upon power-up (breaker reset).

My questions are:
Is this a typical failure mode for an older GFCI?
Is there a service life for GFCI reliability?

Before I replace a $100 GFCI, I just wanted to collaborate with some experts.

Thanks.

 

[Dennis Alwon]

If the gfci is tripping you need to find the issue with the tub. Unfortunately, we cannot assist you with this. You need to contact an electrician or a certified hot tub service contractor.


I am closing this thread, in accordance with the Forum rules. This Forum is intended to assist professional electricians, inspectors, engineers, and other members of the electrical industry in the performance of their job-related tasks. However, if you are not an electrician or an electrical contractor, then we are not permitted to help you perform your own electrical installation work.


If I have misjudged the situation, if for example this project is related to your work, then send me a Private Message. If you can show me that I am wrong, and that you are a licensed electrician (or at least a licensed apprentice), then I will reopen your post, and offer an apology for the delay and inconvenience.

A reminder to all members, if you see a questionable post, feel free to report it by clicking the

button at the bottom left corner of the post.