You got 5 years out of an Intellichlor? I am AMAZED!
Pentair started out with a 3-year warranty on those dogs, and almost immediately reduced it to 1. Unfortunately, I'd installed 6 of them in a large commercial pool, before I found out.
Don't think you "over did it" with the IC-60. All SWCG's live and die by "on-time"; the bigger the unit, the smaller the "on-time", and the longer it will last. The fact you got an 'oversized' IC60 is almost certainly the REASON yours lasted so long.
You could do some testing, but with 5 years, you are at the end of life no matter what.
I looked around and Amazon has them for a good price, comparatively ($800!): Pentair 521105 IntelliChlor IC60. If you DO buy from Amazon, pick the one SOLD BY Amazon. Amazon ships better than the 3rd party sellers, and will handle a DOA return MUCH better. (Not that I've ever had a DOA IC-##; that's not how they fail).
If you want a better unit, a complete Hayward Goldline AQR15 is not much more ($880). But you'll have to replumb and you STILL can't EXPECT more than 3 years of life.
Honestly, I'd probably go with the IC-60. It's bigger than the AQR15, and so might last longer, again. (Do you have problems with the power unit overheating? I had to install fans on mine!)
Here are a few tips that will help maximize the life of ANY SWCG:
- Low water temps kill SWCGs.
Turn them OFF when the water temp gets below 65 degrees!- Never, ever use "Boost". It is the OTHER SWCG 'killer'.
Pour a gallon of Walmart Pool Bleach in, instead.- Don't use an SWCG to deal with algae.
They do well with ROUTINE chlorine demand. If you have an SWCG and have algae problems, consider going low phosphate . . . which is now a practical option.- Keep your alkalinity low-ish (< 100) and let your pH be a bit high-ish (> 7.4) to minimize pH issues.
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