08/08/2023
Inspection Report Public Advisory
On Friday, August 4th, 2023 a service call was done for a Swim Spa Synergy FX19. On inspection, we found a significant amount of damage inside the main control panel for the spa. As you can see from the pictures a lot of the wiring has been melted and charred from what appears to be a large flashover. We found a 12 gauge wire jumper with a melted bolt still attached to it, that mounts to the right side of the large power relay on the circuit board. The location where this bolt was mounted to the board, has a large 1 1/2” hole burned right through the circuit board. I used a multi-meter to test the fusing and water heater. All tested fine. So nothing was overloaded to the point that the fuse protection was blown.
On further inspection of the circuit board, we have found that the black 12 gauge wire jumper and the copper tracing on the circuit board were inadequate to withstand the large amount of current that a 5500 Watt heater would draw. We also found that the problem originated on the large relay right beside the hole due to inadequate solder attaching the relay to the board. This with the inadequate gauge of wire led to over time the significant amount of damage which you can see from the photos
Timeline would have been something like this: After installation of the Spa 2 or 3 months in the solder would have started to break down on this relay. At the same time, the small 12 gauge wire was overheating as the solder became weaker, not only on the relay but also the mounting post for the 12 gauge wire the solder joint would have become less efficient. As the solder joints are becoming less and less efficient, more heat is building up. Finally the solder joints break down to the point where they start arcing. When this happens, carbon builds up (carbon is conductive and flammable). As more and more carbon builds up, a flashover happens.
In conclusion, we have deemed this to be a manufacturers defect. Due to the inadequate amount of solder used, in high current components and inadequate gauge of wire used in high current circuits. The manufacturers typology of this design, led to catastrophic failure of the spa.