IC40 no lights off and fire in the easytouch panel

[okam99]

Hello all - hoping you can help me

I have a 3 year old pool with all pentair equipment (IC40 and easytouch panel) - I noticed a few days ago that the chlorine was very high but lights were on the IC40 and everything looked good - I reduced the output and a few days later, I noticed that the lights on the IC40 were off and the breaker was tripped. Every time I tried to reset the breaker, it would trip.
I shut off the main breaker of the panel and reset the breaker, when I turned the main breaker back on the red wire caught fire and I shut everything down immediately.
I opened up the IC40 to see if there's build up and it doesn't look like it (see photos). I have ordered a new board and a new breaker but was hoping you guys could help me to understand why there was a power surge in the first place - hoping I don't have to replace the IC40 as it is costly. I am planning to do an acid wash this weekend.

 

[ajw22]

Welcome to TFP.

I see lots of red wires. Which red wire caught fire?

Trying to reset a breaker multiple times without correcting the underlying problem is never good.

 

[okam99]

Yes definitely agree with you and lesson learned (on the breaker part) - I circled the wire - I did the multimeter test for the transformer as per the 12mins video online and everything works on the transformer side -

 

[ajw22]

Was the cell connected to the surge board when you got that fire surge?

@Jimrahbe may have thoughts.

 

[okam99]

Was the cell connected to the surge board when you got that fire surge?

@Jimrahbe may have thoughts.

Yes it was - The lights were off and the 12amp breaker was off - So I switched off the main breaker - reset the 12amp breaker and when I switched the main breaker on it started the fire surge - I shut everything down. I read online that it could be the board so ordered that but when I spoke with an electrician friend he said something is causing the surge and it could be the chlorinator but this is where I am stuck - The pool store said that I most likely need a new salt chlorinator but it is 3 years old which is also a lot of money but wanted to check first here before I committed to a new salt cell.

 

[JamesW]

Maybe the rectifier on the back of the surge board.

 

[ajw22]

We would have advised you to disconnect the cell before resetting the breaker.

If the breaker trips with the cell disconnected, then it is the surge board.

If the breaker trips with the cell connected, it is the cell.

 

[JamesW]

You can load test the board by connecting a 150 watt load to the red and black wires.

 

[okam99]

Thanks for the advice guys - in hindsight, I should have asked first before doing these things - lesson learned. Do you think that if I replace the surge board, breaker and do an acid wash - that should either fix everything or end up being a bad salt cell?

 

[ajw22]

If the cell is bad and you are lucky it will just trip the breaker.

Do NOT give the cell an acid bath until you have tried other cleaning methods. Read SWG How It Works - Further Reading

 

[Jimrahbe]

99,

Step 1.. Disconnect the cell at the plug at the bottom of the EasyTouch.
Step 2.. Turn on the power and see if the breaker pops or not..
Step 3.. If the breaker pops, replace the surge card.
Step 4.. If the breaker does not pop... Test the output of the Surge card.. Test between the larger Red and Black wires that go to the cell... Should be about 35 to 40 Volts DC.
Step 5.. If the Surge card output is not 35 to 40 Volts DC, replace the surge card.
Step 6.. If you have 35 to 40 VDC out of the Surge card, shut off power and connect the cell, turn on the power.
Step 7. If the breaker pops now, replace the cell.

Thanks,

Jim R.

 

[okam99]

Thanks for all the help everyone - much appreciated. Based on these photos, does it require a clean?

 

[ajw22]

Thanks for all the help everyone - much appreciated. Based on these photos, does it require a clean?

Nope.

 

[okam99]

99,

Step 1.. Disconnect the cell at the plug at the bottom of the EasyTouch.
Step 2.. Turn on the power and see if the breaker pops or not..
Step 3.. If the breaker pops, replace the surge card.
Step 4.. If the breaker does not pop... Test the output of the Surge card.. Test between the larger Red and Black wires that go to the cell... Should be about 35 to 40 Volts DC.
Step 5.. If the Surge card output is not 35 to 40 Volts DC, replace the surge card.
Step 6.. If you have 35 to 40 VDC out of the Surge card, shut off power and connect the cell, turn on the power.
Step 7. If the breaker pops now, replace the cell.

Thanks,

Jim R.

But because of the fire the breaker is stuck on on, so I have ordered a replacement breaker so I will have to replace the breaker and surge card (given the fire on the red wire)

 

[okam99]

I forgot to mention that before I did anything it said comm error in the diagnostic setting for the easytouch if that helps at all

 

[Jimrahbe]

99,
How do you know the breaker is stuck 'on'???

Your breaker may well be bad, but they do not go bad often...

Thanks,

Jim R.