Fusion Soft 1400 - melted connectors

ladsjohn

Member
Mar 2, 2012
23
San Diego, CA
Pool system has been running fine.
Weekly check revealed no/low Cl levels.
No errors on the equipment (though I did briefly see a 'service' light during the week).

On inspection, my SWG electrodes have melted.
Am I looking at a grounding issue somewhere on the equipment?

I've shut everything off at the breaker for now.
At the very least, I'll need a new cell and the connector cable but before that I need to understand what caused this.
Any ideas?
 

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JamesW

TFP Expert
Mar 2, 2011
16,511
Probably had water leaking through the center pin around the edges.

Remove the cell assembly and then remove the two screws between the pins and remove the cover plate that slides over the pins.

The screws are in the two holes under the corrosion.

As salt water gets up in the connection, the connection generates chlorine gas on one polarity and hydrogen gas on the other polarity.

This causes corrosion and eventually complete failure.

Below the seal plate, there are O-rings on each pin that should seal the pins.

However, the seals can leak. The center pin seems to leak the most.
 

ladsjohn

Member
Mar 2, 2012
23
San Diego, CA
Thanks!
There certainly appears to be water trapped in the upper chamber. I can hear it sloshing in their now that I’ve removed the cell from the SWG unit. I removed the screws on top but the cap won’t budge due to the corrosion around the centre pin. Will try a little brute force next.

Best approach then would be to install a new cell, replace the cable with a new one and watch for any leaks going forward I suppose?
 

JamesW

TFP Expert
Mar 2, 2011
16,511
I think that the center pin had a leak. You need a new cell and cord.

Watch for leaks going forward.

You have some scale. The scale looks a little bit blue, which usually means copper in the water.

Periodically, check the cell for scale and clean if necessary.

Try to pop off the top to see what it shows inside.
 

ladsjohn

Member
Mar 2, 2012
23
San Diego, CA
Thanks James. Yes, had some Cu issues last year. Resolved with a partial drain/fill.
I'm going to reinstall the cell (disconnected) in order to run the pump until my replacement parts arrive. (already ordered).

Will dissemble it after that and report back here.
Thanks for the quick response!
 

mguzzy

Well-known member
Jul 8, 2015
758
OV, CA
If you don't know when it was purchased give us the serial numbers on the unit and we can decipher the date code. They really shouldn't fail like that.
 

ladsjohn

Member
Mar 2, 2012
23
San Diego, CA
There doesn't appear to be a serial# stamped on the cell anywhere. According to the zodiac website; it should be on the 'warranty registration card' that came with the cell. Needless to say, I threw that out after I installed it (lesson learned). Is the serial# stamped anywhere that I'm missing?
 

JamesW

TFP Expert
Mar 2, 2011
16,511
There should be a sticker somewhere on the equipment.

In any case, the builder who installed it has the records. File a claim with them.
 

ladsjohn

Member
Mar 2, 2012
23
San Diego, CA
Thanks James. The SWG has a serial number and that is already registered with Zodiac.
I've replaced the cell since the SWG was installed and that was what I was contacting them about.
I called their tech support, provided proof of purchase date etc via email and they have registered it in their system.
Just waiting on their contracted pool company to come out and inspect the cell to see if they'll honor a warranty claim.
I'll keep you posted here. Thanks again.

FYI - if you do replace your cell; the replacement should come with a warranty card that has the serial# printed on it.
Best to go to zodiac.com and register the new cell on install before throwing out the warranty card (as I did).