Pentair ic40, surge board, intelliph and swg transformer.

Whoa there! Can't say I agree with @Flying Tivo completely. (Perhaps he meant red/black, not red/white.) You don't mess with the white and green wires. They must connect to the board, all four separately, to their respective original pins (or holes) as before. You only connect red to red and black to black. It's the red and black that carry the amps to the IntelliChlor. The green and white carry the buss "instructions." While signals in the green and white do make it to the SWG, the IpH board actually severs those temporarily, periodically. So that's why you don't join those pairs together before the board.

Also, the traces don't seem to be the problem. The problem is, in fact, the connectors, the pins inside the white connector. So, a couple things. While, so far, the traces seems to be able to handle the current, as I said before, I think it prudent to connect red to red and black to black before they get to the board. Unlike the green and white, the reds and blacks are permanently connected on the board (via traces), so connecting them before the board doesn't change the circuitry in any way. Just provides a more robust pathway for the current.

My [unproven] theory for this problem centers around the pin connectors inside the white connector (the female and male components). I think those are of inferior quality, probably cheap metal and/or coated with cheap metal, which is prone to corrosion over time. Once they start to corrode, that compromises their conductivity, which causes heat. Which exacerbates the corrosion, causing even more heat, until they get hot enough to melt the white plastic housing of the connector and then a set of pins.

To date, we have not seen the traces on the board melt, only the pins inside the white connector. Except... we have seen other components on the board get fried. We don't know if that is related to the overcurrent issue, or some other event (like a voltage spike of some sort). Regardless, that's why I will eventually connect my reds and blacks before my solder joints, just to play it safe.

Which brings me to my one warning about how you fixed your board. By leaving the four lower connections in place, you still run the risk of those cheap metal components causing the same problem again. The melting has not been confined to the upper row of pins. My theory is that the worst connection goes first, wherever it happens to be. We've seen this happen to either red and either black. Point being, if it's not too late, eliminating those four original pins, or at least getting some solder to pass through them, might be worth the effort.

@ogdento, please correct me if I have any of that wrong.

Dirk said:

(Perhaps he meant red/black, not red/white.)

Click to expand...

, sorry, corrected.