Filters Destroyed After 2 Months?

matthewsunshineflorida

Gold Supporter
Sep 28, 2018
238
Tampa, FL
Pool Size
13000
Surface
Plaster
Chlorine
Salt Water Generator
SWG Type
Pentair Intellichlor IC-40
FIRST A THANK YOU
First off, you guys are awesome. I have literally had perfect water from day one April 20th. It has been remarkably easy to maintain and the water is so comfortable. I grew up with parents who had no idea how any of this worked and would just shock the pool harshly on a regular basis, thinking algae was just something you fight all the time, getting random chemicals from the pool store only once a month or less. Looking back, I realize that a lot of the problems we had with the surface scaling and flaking were probably because of totally out of whack chemistry (and I bet their CYA is 1000 to this day). I also so often remember my skin and eyes hurting and I haven't had that one time in our pool. My neighbors pay $150/mo, rent their SWG, and still deal with occasional issues. But with intellicenter's Circuit Groups, an SWG, TFP forums, and TFP water guidelines, I honestly feel guilty this being so easy and honestly kinda fun. So $100 for a gold membership to a great non profit is a no brainer IMHO. I'm also using the full Pool Math which is great.

Problem TLDR:
The pump had enough power to circulate the spa overflow at 700 RPM when I got it and now it takes 1300 RPM - why!? Filters clean, only a couple added PSI even when dirty.

Background:
We got our pool filled April 20th. I measured the water as we filled it with Flume and confirmed with my meter so we have a 12,000 gallon pool (company said 16,000 lol) and a 12" raised 500 gallon spa with a 420sqft CC Plus (4 cartridge) filter. I have a 3hp intelliflo for the pool/spa and another one for the sheer descent/bubbler. Ic40 and MT 400k BTU on intellicenter firmware up to date.

Problem:
I initially ran the pool pump at 700 RPM 24/7 and at 1400 for 8 hours for the SWG, and then 2100 for a skim (40gpm) or for the gas heater. However, over time, I realized that the spa would no longer get any water at 700 RPM (i.e. there was too much resistance to push into it and cause a slow spillover), so I had to raise it to 800 RPM. I cleaned the filters that were full of tons of plaster dust and pebbles but it made no difference. Then it took 900 RPM to overflow the spa. Then a couple weeks ago 900 wasn't doing it the pump REFUSED to run at 1000 - it would run for 15 seconds then literally turn off, then restart and prime at 3450 RPM and then back to 1000 then restart in perpetuity. So I cleaned the filters again and it still needed to go up to 1100 RPM instead, which was stable without issue. Today I noticed 1100 won't cut it and neither will 1200 so I'm at 1300. I also have to run the IC40 at 1600 RPM to get enough flow when it was around 1300 initially.

GPM:
When I got the pool, 2100 RPM got us about 43 GPM flow at 500 watts. Now it's about 38 GPM at like 520 watts.

So clearly there's some added resistance that wasn't there when we started. I have tried:
1) Cleaning the filters. Although admittedly, I just sprayed them down thoroughly with the strongest nozzle setting until there was no apparent dirt or plaster dust but I didn't soak them in cleaner or anything. Keep in mind, the pressure rose hardly at all even when they were filthy (at 2100 PRM) because they are so large compared to the pool.
2) Opening up the main drain AND skimmer completely to see if it was suffocated by a restriction in the skimmer somewhere but this made no difference so I'm keeping it 100% skimmer 10% main drain.

The second pump (water feature pump) still runs at 700 RPM using 35 watts and pushes through 12" of water so much that it creates aeration so I'm having to run it through the bypass in the pool to slow down the bubbler. That one clearly has SO much less resistance, which has remained steady since the pool was filled.

My thought is that all this means it has to be (in order of likeliness)
1) Filters are still clogged with maybe plaster dust or phosophorus when I did no phos (though I cleaned it as above, maybe I need to soak them in trash cans of cleaner?).
2) Heater or SWG are constricted because of calcium or something. But my calcium levels were very low initially (as recommended by Wet Edge) then have been in the low 300s consistently - I'm actually planning to add a little to get it to 350-375ish. All my other metrics have been maintained from day one with TFP methods and I've always had crystal clear water and a proper CYA/FC ratio. I got rid of phosphorus only because I figured what's a $30 bottle for peace of mind but I don't remember if my issue started before or after doing this.
3) My intelliflo is defective which is why it won't run at 1000 RPM without constant restarts and also seems to be getting less efficient

Is there an option I'm missing? Am I a dummy and am missing something obvious? lol I don't know how to search for this in the forum so please feel free to link to a thread I may have missed here.

I'm considering
1) Putting in a filter/heater/SWG bypass and testing that to see how much that helps.
2) If it makes a big difference, maybe I'll do a heater/SWG bypass as well and see if it's the filter or the heater/SWG.
3) If it's the filter, do I get one of these cleaner solutions and soak it in the trash can even though they're not even 2 months old? Maybe the phosphorus and plaster dust just doesn't come out well with spraying?
4) Maybe get an extra set of 4 filters and try them, then rotate them in. But this seems like you're asking for more wear as I know getting wet then dry over and over isn't good for plastic/rubber, staying wet is better for sealants so I would think the same would be true here - use the same set until they're bad then swap em.

Thanks all - I'll be sure to post more pictures of the final pool when we get more done. I figure at this point I'll wait until our landscaping and other toys are in - have a LOT to do but I got a new job so I've been absolutely slammed.
 
Last edited:
I would do the following.. :)

1. get another set of filters to see if that is the cause of the restriction.. You can soak the ones you have in TSP..
2. add heater bypass as that is adding the most restriction.. No need to have the heater in the system if you are not using it all the time..
3. you could get a rebuild kit for your pump with a new salt or SCS seal and when you take it apart see if there is anything in the impeller...
 
Matt,

What specific IntelliFlo do you have?

If it won't run at 1000 RPM, but runs at other speeds something is wrong with the pump.. If this is a new build, I would file a warranty claim.

Thanks,

Jim R.
 
I am going to say with 90% certainty its your filters.

You have a newish pool, so plaster dust is still an issue. And you used a phosphate treatment that has a clarifier. I would do the TSP soak first and see if that helps. Sometimes this gets is all sometimes it doesnt. After the TSP treatment you might want a very dilute MA soak, but that can cause other issues.

I bet if you put a brand new set of filters in your problem would go away. Its not bad to have two sets of filters. One old and dirty one, for when you do things like a phosphate treatment. It also lets you soak your filters for a longer time without putting your pool out of commision.

+1 on putting in a heater bypass. That adds a fair amount of resistance. No need to bypass the SWG.
 
Thanks for all the insight - wanted to make sure I wasn't going crazy.

I would do the following.. :)

1. get another set of filters to see if that is the cause of the restriction.. You can soak the ones you have in TSP..
2. add heater bypass as that is adding the most restriction.. No need to have the heater in the system if you are not using it all the time..
3. you could get a rebuild kit for your pump with a new salt or SCS seal and when you take it apart see if there is anything in the impeller...
I will do 1 and 2 ASAP. Same pump runs the spa too so maybe I put a heater bypass on 1/2 open? Don't know anything about 3 but I kinda feel like I shouldn't have to do that given the pump isn't even 2 months old and is covered by my pool warranty.

Matt,

What specific IntelliFlo do you have?

If it won't run at 1000 RPM, but runs at other speeds something is wrong with the pump.. If this is a new build, I would file a warranty claim.

Thanks,

Jim R.
Model 350305. This makes me nervous. Should I try working the filters first and see if maybe 1000 RPM is just an intersection of resistance/power that causes excess restriction and the pump shuts down thinking it's pushing through a closed valve? Otherwise, yea my pool is warrantied for parts/labor for the first year so I definitely don't want to miss that window. This was making me pretty frustrated, then seeing 1000 RPM arbitrarily shut down over and over while 900 and 1100 work is so strange.

I am going to say with 90% certainty its your filters.

You have a newish pool, so plaster dust is still an issue. And you used a phosphate treatment that has a clarifier. I would do the TSP soak first and see if that helps. Sometimes this gets is all sometimes it doesnt. After the TSP treatment you might want a very dilute MA soak, but that can cause other issues.

I bet if you put a brand new set of filters in your problem would go away. Its not bad to have two sets of filters. One old and dirty one, for when you do things like a phosphate treatment. It also lets you soak your filters for a longer time without putting your pool out of commision.

+1 on putting in a heater bypass. That adds a fair amount of resistance. No need to bypass the SWG.
I didn't realize NoPhos had clarifiers, definitely my mistake. I'll do the TSP soak and look into MA soak. Also didn't know a heater introduces so much resistance. But the SWG doesn't? Any reason to ever bypass my filter or SWG? I'd rather redo the plumbing once and have every possible need done.
 
Matt,


That does not look like a valid P/N to me... Usually something like 011018, 011028, 011057, etc...

I just want to make sure you did not buy the IntelliFlo that has the SVRS option...

Thanks,

Jim R.
Thanks Jim, really appreciate your expertise - these are the photos of the stickers:
 
Matt,

That is a sticker, but it is not the sticker.. :mrgreen:

It is not a big deal.. Plain and simple, your pump should be able to run at a 1000 RPM.. period.. A clogged filter might restrict the water flow, but it is not going to shut the pump off. I would file a warranty claim on that problem alone.

So.. You don't see a sticker that says "IntelliFlo VS +SVRS" or "IntelliFlo XXX"??

Thanks,

Jim R.
 
Matt,

That is a sticker, but it is not the sticker.. :mrgreen:

It is not a big deal.. Plain and simple, your pump should be able to run at a 1000 RPM.. period.. A clogged filter might restrict the water flow, but it is not going to shut the pump off. I would file a warranty claim on that problem alone.

So.. You don't see a sticker that says "IntelliFlo VS +SVRS" or "IntelliFlo XXX"??

Thanks,

Jim R.
Well I figured "P#" meant "Product Number" i.e. "P/N" like you said. I'm not sure if I'm crazy or what but here's a photo of every sticker on these things - let me know if I missed something obvious or if this represents a new model. It does say Nov 2020 manufactured, which could easily mean these haven't actually started getting around until the spring of this year... or am I just not seeing it?
 

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Matt,

Turns out that is the P/N for the Motor..


What numbers do you see up at the pump (wet) end???

Thanks,

Jim R.
The sticker was under it and blended in! It's 011056 - quick search on the site seems to indicate that's a good one? Going to soak and wash the filters several times and then if it still refuses to start at 1000 RPM I'll call warranty. Still, makes me nervous regardless...
 
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I pulled the filters out and really looked at them closely this time and realized they really look surprisingly bad for being just two months old! This is after spray down (before TSP bath). The bands are non functional in several areas (they're not actually in contact) and the top looks chipped away - looks worse in person especially remembering how they looked at the first clean 1 week in.


They've been cleaned 3 times, a 520sqft filter with a 12,500 gallon pool. Yet they look years old. My chemistry has been in check from day 1 checked every 1 to 3 days max (have been trying to be better about the pool math logging so feel free to look). Obviously they're always filled with tons of plaster dust and each time less and less pebbles. I use a Dolphin Sigma robot and regularly clean that out which gets a surprising amount of dirt for a screened in pool.

I found a good Pleatco set to replace them (or at least serve as a second set) but I'm wondering if I put them in I'll just be subjecting them to whatever the exact same conditions are that wrecked these in just two months! My main thought is that a 3hp pump on max 3450 RPM is pushing too much water through and tearing them in spa mode. Should I install a bypass and partially open it to reduce the PSI in the filters to below a certain amount?

I'm thinking I'll measure the Pleatco PSI at various pump speeds, then when those are ready to be cleaned I'll put these old ones in and see if it's drastically more. Just don't want to destroy the new ones if plaster dust or something about my setup is dooming them to failure.
 
Matt,

Double check and make sure the pump's output is going to the filter's input.. We have seen other filters plumbed backwards..

Two months just does not sound right to me.. Did you use a floc or clarifier??

At full speed what is the filter pressure?

Thanks,

Jim R.
 
Matt,

Double check and make sure the pump's output is going to the filter's input.. We have seen other filters plumbed backwards..

Two months just does not sound right to me.. Did you use a floc or clarifier??

At full speed what is the filter pressure?

Thanks,

Jim R.
Double checked the inlet is the top outlet is bottom as the manual seems to indicate.
Filter pressure: 3450 RPM = 20 PSI, 2600 = 12 PSI, 2000 = 8 PSI, 1300 RPM = 4 PSI

I did use No Phos to bring my phosphorus from 1500 to 0. I ran the filter slow (1600) and cleaned it immediately after (didn't do NSP bath though). Didn't know it had a clarifier in it at the time.

Looks rough for 2 months right? Trying to figure out why so I don't put new ones into the same apparent torture.
 
Do you think it's worthwhile to put a bypass on the filter and either partially open it so water can get by in spa mode or use an intellivalve and tie it into the spa actuator?

I've heard some also suggest bypassing the heater. I wonder if I should get an intellivalve and partially bypass the filter and heater (and SWG?) whenever it's in spa mode? Might increase the flow in the spa allowing me to lower the RPM and reduce the pressure/wear through the pump/heater.

But I don't want to spend hundreds of dollars for no reason. Just trying to find the best long term solution for the decades to come.
 
So it sure does look like the flow is reversed. The have no strength in the outward direction.

Yet you confirmed it’s ok, so I’m gonna vote for a factory dud. I’m going to guess the glue didn’t hold at the top and the pleats walked/vibrated at a high RPM breaking the plastic rim. There have been tons of defective products since everybody started rushing to keep up with Covid demands. And then Texas froze and they are all racing 10X as hard to put stuff out now. Quality control goes out the window and my own brand new filters have 2 issues that won’t affect performance but still show real sloppy work. One is the glue is extra thick at spots at the top edge taking away the uniformity of those pleats and one of the 3 bottom support legs is glued on in the wrong spot. It still hold the filter up but it points to lazy. Maybe it was 5 minutes into lunchtime that day when they were finishing it.

Nothing you could do to your pool would do that. We have boatloads of members with 3HP pumps (many even retrofits on smaller old plumbing) and have yet to see somebody blow a filter. The same with your chemistry, nothing could possibly crack that filter. Melt it maybe with MA, but not blow it apart into plastic chunks.

Did you file a warranty claim ?
 
So it sure does look like the flow is reversed. The have no strength in the outward direction.

Yet you confirmed it’s ok, so I’m gonna vote for a factory dud. I’m going to guess the glue didn’t hold at the top and the pleats walked/vibrated at a high RPM breaking the plastic rim. There have been tons of defective products since everybody started rushing to keep up with Covid demands. And then Texas froze and they are all racing 10X as hard to put stuff out now. Quality control goes out the window and my own brand new filters have 2 issues that won’t affect performance but still show real sloppy work. One is the glue is extra thick at spots at the top edge taking away the uniformity of those pleats and one of the 3 bottom support legs is glued on in the wrong spot. It still hold the filter up but it points to lazy. Maybe it was 5 minutes into lunchtime that day when they were finishing it.

Nothing you could do to your pool would do that. We have boatloads of members with 3HP pumps (many even retrofits on smaller old plumbing) and have yet to see somebody blow a filter. The same with your chemistry, nothing could possibly crack that filter. Melt it maybe with MA, but not blow it apart into plastic chunks.

Did you file a warranty claim ?
Take a look at the plumbing below and let me know if you see any issues.

Yes, the PB has 1 year bumper to bumper but no I haven't filed for filters - I have a feeling they'd say it's "wear and tear" (literally, in this case). I'm having a hard enough time getting them to respond to the other issues (collapsed sheer descent, broken intellivalve, insufficient gutter downspouts despite paying extra for the 7" super gutter). I'm nearing the point where I have my 50 closest friends leave one star reviews while asking my big wig downtown corporate attorney friend to send them a letter. Old college roommate works for a firm whose name would make them immediately jump. Hate to do it because I'm friends with someone who is married into family with the owner and nobody likes lawyers or bad press... but the communication has been terrible and I've been given no timeline on fixes for nearly two months while they've entirely ghosted me via email for two weeks.

So I'm sending one last email on Tuesday directly to the owner and his manager wife both saying I understand the company is slammed busy but you cannot ignore existing customers to chase new money so I need a timeline for timely resolution or I'll escalate this. Think I should include the filters in my list as well? I can prove my water chemistry to them from the Pool Store a few times a month (and I test Taylor 2006C myself 2-4 times per week). It's coming on one year since we signed and I love the pool but I have no more patience for these companies.

A 520 sq-ft cartridge filter should be able to handle 150 GPM easily. Low quality filters?
Right? I read that it should have no problem with 150 GPM so I'm not sure but they're labeled Pentair filters and look the same as photos I've seen online. I was actually contracted for 420sqft but just discovered it's 520 when looking for replacement filters. Even at 3450 RPM it's nowhere near 150 GPM, the pump says it's outputting something like 90 in pool mode and 60 in spa mode if I remember right (which I know isn't totally accurate based on a guy on TFP who put in a flo meter and tested it).

Post a pic of your equipmemt pad and also of the pump to filter piping.

I have intellivalves on now and the temperature sensor was installed but otherwise nothing has changed.
 

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