IC60 Intermittment Red Flow Light

[DB-Cooper]

The battle with my IC60 continues. In late March the thermistor went out. I got a replacement flow sensor from Pentair and put it in and the unit has worked flawlessly until yesterday. Now the IC60 reports red flow (there's great flow, clean filter, extremely clean plates, great pressure on returns, etc.). Then without any real significant change it'll start working (green flow and cell) and then I'll come back and it'll be red again. I've tried running at max pump speed as well, so it's definitely not a real flow issue.

Initially I thought maybe all the rain was getting some connection wet, but given it goes in and out even when it hasn't rained in hours, I'm not thinking that's it. The flow sensor itself looks to be in great/new condition, it's installed in the right arrow config (I've verified the arrow is in the right direction). I did open a case with Pentair but they said there's like no warranty companies in Austin available. I'm also concerned that the warranty company will come by and it'll be magically working during that period as there's no specific formula to make it not work. Anyone got good troubleshooting ideas here? Even with no flow, it does report a relatively accurate salt level.

Once it's completely dry, I'm doing to wrap it in saran wrap to try and rule out water. If I remove the flow plastic cover, I can see a little moisture on the unit and water drops going into the hole that feeds power and the flow sensor.

Thanks for the help!

 

[Jimrahbe]

DB,

The very first place I would look would be the little crimp connectors that are used to install the replacement flow switch. They are flaky at best..

Worst case, I would install another new flow switch.

Thanks,

Jim R.

 

[DB-Cooper]

DB,

The very first place I would look would be the little crimp connectors that are used to install the replacement flow switch. They are flaky at best..

Worst case, I would install another new flow switch.

Thanks,

Jim R.

I looked and they definitely are in good (flush with the ends, very tight), and without movement it worked fine for exactly 2 months. I had my dad who's a EE look at it and he thought they looked good. No amount of wiggling/jostling the crimps made any difference. I opened a ticket with Pentair on Monday (they were open on Memorial Day) and their warranty contractor called me about an hour ago (after I posted) and said Pentair is sending them a new cell overnight and they were told to just replace the whole thing. Possibly because I'm on my second flow sensor in as many months. I'm not going to argue, but it's weird that it goes in and out. As it's under warranty and that I've had issues with two sensors, I'll take the new cell and restart the clock (13 months old).

I was going to cut the wires and wire red to black and see, but once I had the ticket open, I decided I didn't want to touch it for fear of warranty deny. I think the lady at Pentair I spoke with on Monday really took care of me, she was real friendly and we spent a lot of time as I needed to register all my equipment. Fingers crossed there's no surprises, but this morning it was off, then 30 minutes later it went on, 30 minutes later it went off, then an hour later back on. Does seem as once the sun hits it and it warms up (exterior not water), it performs better.

The new part is due in on Thursday so I'll report back on how things play out.

As always, Jim, thanks for the prompt response!