CompuPool CPSC36 salt cell melted or burned

I have a CompuPool CPSC36 operating with my 25,000 inground vinyl pool. It was installed about August 30 of last summer, and we closed the pool in early October. We reopened around June 1 this year. Since installation, we've been getting wacky temperature readings (like 32 degrees Fahrenheit), and our digital salt readings on the Power Pack have been widely erratic (3100 ppm one day, 4200 ppm the next), but at least the unit seems to be producing chlorine, and our water chemistry this year has been very balanced (about 3800 ppm salt according to AquaChek strips; 2.5 free chlorine; 7.6 ph; 110 TA; 280 CH; 55 CYA while running the unit at 40%). Until now, all I was worried about was having too much salt in the pool due to me adding salt based on an inaccurate "add salt" indicator light, thus causing undue wear on my salt cell and perhaps damage to my gas heater.

A couple of weeks ago, we started noticing an odd burning smell near our pool equipment, but couldn't pinpoint it. About four days ago, the LCD screen on the Power Pack read "OVER CURRENT," which was not addressed anywhere in my manual. When I saw this message, I leaned over to get a closer look at my cell to see if anything revealed itself to me, and what do you know! That's where the burning smell was coming from! The rubber plug/cap was showing signs of melting, and there was brown discoloration all throughout the plastic housing. I'm posting links to photos of what the cell looks like when removed from the housing. I think you'll be shocked (no pun intended). What could be causing this? What kind of concern does this warrant? I have since turned off the unit and have been manually chlorinating the pool with liquid chlorine as a precaution.

Here are links to the photos:
https://lh4.googleusercontent.com/-q...0/P1060584.jpg
https://lh6.googleusercontent.com/-l...0/P1060585.jpg


-- Jody

Uh-m. Yikes?

For what it's worth, I've found that Pentair's power center - the same one is used for the IC20, IC40, and IC60 - is not quite big enough for the IC-60, and we have to replace fuses with some regularity. I've also had to hang a box fan right on top of my array of 4 power centers to keep them cool. But, replacing fuses is small potatoes compared to what you've got.

I hope your warranty is still good. The Pentair IC40 I put in the kiddie pool several years ago had a 3 year warranty, but the new units this year on the main pool only have a 1 year warranty . . . which means Pentair was finding too many units didn't last 3 years.

Ben

(BTW, I moved the photos to the PF Picasa album. I'll be doing that for ALL photos on the forum over the winter. Personal album links tend not to last as long as these threads do, leaving thread that make no sense when the picture is gone.)

Fortunately, according to our manual, there is a 2-year warranty plus a third year "pro rata" (whatever that means) or 8000 hours of operation "on the power unit and on the cell from the date of purchase." We are trying to get our pool company to respond to the problem, but it's a holiday weekend. I did email the owner, who poo-pooed it and said he doesn't believe anything dangerous is going on. He said if we have clear water then there is no problem.

Quote:

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Originally Posted by Jodester

Fortunately, according to our manual, there is a 2-year warranty plus a third year "pro rata" (whatever that means) or 8000 hours of operation "on the power unit and on the cell from the date of purchase." We are trying to get our pool company to respond to the problem, but it's a holiday weekend. I did email the owner, who poo-pooed it and said he doesn't believe anything dangerous is going on. He said if we have clear water then there is no problem.

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He said that after seeing that photo? I think I'd probably try and avoid those guys for future purchases!

It's weird -- while very prompt in responding to my emails about this and the other issues we're having with the salt and temperature readings, the guy has not acknowledged the photos. The last message he sent me said, "I do not believe there is anything dangerous going on, the unit worked fine last year, if something was wrong it would be a manufactorer's issue, but I am not saying anything is wrong... I hope you can relax and not worry too much about this... did you call the manufactorer?... I have never heard of a dangerous situation with a salt generator... the office will certainly help you, but just installing a new unit is not the answer, that might not change anything even if it happened... " Notice the repeated disclaimers avoiding responsibility -- "I am not saying anything is wrong" and "even if it happened". When I point-blank asked him after this message if he had viewed the photos, that's when I never got a response.

Does anyone out there have any experience with this?? Can anyone offer any explanation for why this is happening?

-- Jody

I'd call the manufacturer right away and unplug the cell until it's been replaced. Just use bleach to manually chlorinate in the meantime. Maybe there is some pool chemicals that could cause that kind of discoloration; but the thing definitely looks like it's been burned to me.

Good news! Our pool company sent my photos to the manufacturer, and they have agreed to replace the whole kit and caboodle under the warranty. I expressed a theory I have that this was possibly caused by the fact that the cell unit was installed vertically, when the manual says, "The cell is to be mounted horizontal with the inlets and outlets facing down. If required the cell can be mounted vertically." When vertical, I see there are two tiny (intentional) holes on the black rubber plug cap that I bet water can get into, especially if it rains hard enough -- which it did, both a week before Hurricane Irene and then during Irene itself. I bet there's a chance water got into the circuitry over time and when we had that tremendous rain around mid-August, that's when things got really heated in there. So we requested that they make every effort to install the cell horizontally this time, as I see no real reason why it couldn't have been horizontal in the first place.

-- Jody

At least somebody has some sense, even if your builder is a bit lacking! That's good news.

Ben

For future reference, here is Compu-pool's toll free number (888) 798-7665 then press 4. I have found them to be pretty responsive and helpful when I called. You may have better luck dealing with them direct. In Phoenix, there is a Factory Rep.