We have a ThermoSpa Hot Tub outside on our deck that came with the house (in MA). It requires 2 - 240v circuits, both 30 amps. It is currently wired with the following:

Main (house) Panel:
1 - 30 Amp 240V GFCI
1 - 20 Amp 120V GFCI (incorrect, need a 240v)

Sub-Panel near Hot Tub, outside:
-Hard wired with a "big handle" type switch on the side, no additional GFCI, controls ONLY the 240V line.

They originally hijacked the 240v supply for the Range, and added a GFCI breaker, but they did NOT connect the White load-wire to the GFCI and left it connected to the neutral\ground bar in the box (which I fixed). They did the same thing for the 120v GFCI breaker, so I moved the white wire to the breaker for that one as well. The white pigtails were connected to the ground strip on both GFCI breakers. (I hope all that makes sense!)

My questions are:
1) Is it OK that the GFCI breakers are in the main box?
2) is it OK that there are no breakers in the Sub-Panel and just a large lever-type switch?
3) Am I correct that all load-wires should be connected to the GFCI breaker (red, black, white), except for the ground wire?
4) Is there any way to test the GFCI breaker other than hitting the "TEST" button (ie, short out the line at the Hot Tub)

Thanks for your help!

Yes
Yes (as long as it breaks every hot wire)
Yes
Yes (though this is a rather expensive piece of test equipment)

Thanks for your help!

One last question: They used aluminum wire (appears to be very heavy gauge) on the 30 Amp 240V line to the Hot Tub. Will that be OK? The hot tub does say "copper only." Should we look to replace this when possible?

Thanks!