Cell connecting terminals too hot to touch

[poolaris]

I have a Zodiac Clearwater SWCG system. At approx. 80% generating I could let the cell go a couple of days between cleanings but lately I am having to clean it daily to prevent the plates from bridging completely. If the system has just been running the negative electrode terminals is too hot to touch. It may always have been that way, but is that normal?

I am thinking of turning it off and simply adding Cl as the SWCG necessitates adding about 1 gall. of acid every week. Also the cells themselves do not seem to last more than 2 years. I replaced it about a year ago with a generic one from Australia which seals a lot easier than the OEM. In general I have found the whole system a lot more work and expense than manually adding chlorine as I did on my previous pool. Is there anything I can do to stop the rapid build up of (presumably) calcium between the cell plates, and is the terminal heat normal with this type of system?

[BigTallGuy]

How big is your pool? AG or IG? Can you post your test readings, specifically pH and Salt?

[poolaris]

Pool size approx 12000 gallons. PH 7.8 salt 4200ppm.

[BigDave]

Is that salt level normal for your SWCG? How's your CYA level? What CYA does your SWCG mfg. recommend?

[poolaris]

Is that salt level normal for your SWCG? How's your CYA level? What CYA does your SWCG mfg. recommend?

Owners manual recommends salt level close to 4000ppm but not less than 3500. Mine is 4100. CYA level is 62 which is within the 40-80 rec. range. FC is 4.5 and CC is 0. The only thing that is out of recommendations is calcium hardness level wich should be 150-200, whereas mine is 450.

[BigDave]

Is there corrosion on the terminals?
Sounds like with your CH and having to clean the cell so often that dosing chlorine manually may be eaiser.

[BigTallGuy]

Hot wires and terminals usually means high resistance which could easily be poor/dirty connections. You could try cleaning the terminals and make sure they're good and tight. Loose terminals are just as bad as dirty ones for high resistance.