Pentair IntelliChlor Plus40 vs IC40 Salt Cell: Worth The Upgrade?

Are you looking at your IC40 salt cell and wondering if upgrading to the newer Plus40 is actually worth it? You're definitely not the only pool owner asking this question. The Pentair IntelliChlor IC40 has been the go-to choice for pools up to 40,000 gallons for years. It does its job—converts salt in your water into chlorine automatically—and most pool owners have been perfectly happy with it. But now Pentair has released the Plus40 as a drop-in replacement, and suddenly everyone's second-guessing their current setup.

Here's what we know from our decades of experience at Shasta Pool Supply: the Plus40 isn't just a marketing gimmick. Both units handle the same basic job of automatic chlorine generation, but the Plus40 brings some genuinely useful improvements while still working with your existing Pentair automation systems like IntelliCenter, IntelliConnect, and IntellipH. These new salt chlorine generators still operate best at 3,600 ppm salt levels and include the same safety features, like automatically shutting down when water temperatures drop below 52°F.

Do those improvements actually matter for your pool? We've helped countless lots of Arizona pool owners make this exact decision since the decide between these two salt cells since the Plus40 hit the market. Some upgrades are genuinely worth it. Others? Well, they're just expensive ways to get the same result you're already getting.

Let's break down what's actually different between these two Pentair salt cells, figure out where the Plus40 earns its keep, and help you decide whether upgrading makes sense for your specific situation—or if you're better off sticking with what's already working. 

Pick up both salt cells side by side, and you'll immediately notice Pentair didn't just slap a new label on the same old design. We handle both models daily at Shasta Pool Supply, and the differences go well beyond surface-level changes.

Why Does the Pluse40 Last Longer in Harsh Conditions?

The IC40 has served pool owners well, but Arizona's brutal sun exposure has always been its weakness. After a few seasons, you've probably noticed your IC40 starting to look a bit weathered—maybe some fading, possibly some cracking around the seals.

Pentair addressed this head-on with the Plus40. They upgraded to more robust, UV-resistant materials and seals that actually hold up to our desert conditions. The exterior gets a high-gloss polyurethane coating specifically engineered for UV resistance, which means your salt cell will still look presentable years down the road instead of like it's been through a sandstorm.

Is this just cosmetic? Not really. When seals fail and housings crack, you're looking at water infiltration and premature equipment failure. 

Here's where the age difference really shows. The IC40's display works fine, but it looks like something from the early 2000s. You get basic information, but good luck figuring out what's actually happening inside your salt cell when problems arise.

The Plus40 features an LCD/LED interface with over 20 built-in diagnostics and warnings. This isn't just fancy tech for the sake of it—you can actually see your salt levels, chlorine output, cell cleanliness, and remaining cell life without playing guessing games. When something goes wrong, the display tells you exactly what needs attention instead of leaving you to troubleshoot blindly.

Durability in Harsh Pool Environments

Both units handle daily pool operation just fine, but the Plus40 takes durability seriously. The modular design lets you replace electronics and sensors individually when they fail, rather than tossing the entire unit. That's a practical advantage that could save you hundreds down the line.

The Plus40 also features enhanced surge protection—crucial during Arizona's monsoon season when power surges can fry pool equipment. The titanium cell plates still deliver reliable chlorine production, but now they're backed by smarter electronics that actually protect your investment.

After serving Phoenix Valley pool owners since 1966, we can tell you these aren't just marketing improvements. They solve real problems we've seen with the IC40 over the years.

When it comes to actual pool sanitation, the performance differences between these two Pentair salt cells tell a more interesting story than their looks might suggest.

Is There a Difference in How Much Chlorine Each Cell Produces?

Both the Pentair IntelliChlor IC40 and Plus40 pump out identical chlorine production—1.4 pounds per day at 100% output. Your 40,000-gallon pool gets the same sanitizing power from either unit. That's not where the Plus40 earns its keep.

The difference lies in how the Plus40 uses that capacity. The improved electronics make the unit more energy-efficient, which means lower electricity bills over time. Not earth-shattering savings, but they add up. 

This is where the Plus40 actually gets interesting. The IC40 doesn't have SmartSense technology—it just runs whenever you tell it to run.

The Plus40's SmartSense automatically dials back chlorine production when your pump shuts off or when it detects a pool cover. Why does this matter? Your salt cell lives longer because it's not working unnecessarily, and you're not wasting chlorine when your pool doesn't need it.
We've seen this feature extend cell life by months in real-world conditions. That's money back in your pocket.

Salinity Accuracy: Basic vs Enhanced Sensors

The IC40's salt sensors work fine most of the time. But "most of the time" isn't always good enough, especially when water temperatures fluctuate.

The Plus40 uses a redesigned conductivity sensor that's about 98% as accurate as professional testing equipment. Translation: fewer false alarms and more reliable readings. The Plus40 shows "ADD SALT" at 3,000 ppm and shuts down at 2,600 ppm with "SYS OFF LOW SALT"—clear warnings that actually mean something.

False salt readings are one of the biggest frustrations we hear about. The Pentair Plus40 calls is built to stop those from happening in the first place. The Plus40 virtually eliminates this headache.

Temperature Handling: Auto Shutoff Below 52°F

Both models shut down below 52°F (±3°F) to protect their cell blades. The Plus40 just gives you better warnings about what's happening.

You'll see "LOW TEMP" at 60°F, then "SYS OFF LOW TEMP" when it hits the critical 52°F threshold. The IC40 shuts down too, but doesn't tell you why as clearly.

For Arizona pool owners, this temperature protection matters during our occasional cold snaps. At least with the Plus40, you know exactly what's going on. 

Worried about having to rewire your entire pool system just to upgrade your salt cell? Here's some good news: Pentair designed the Plus40 to make your life easier, not more complicated.

Plumbing Fit: Drop-in Replacement for IC40

The Plus40 uses the exact same plumbing dimensions as your current IC40. Same 2" union inlet and outlet connections. Same mounting setup.

What does this mean for you? Zero plumbing modifications required. You can literally unscrew your old IC40 and screw in the new Plus40 without touching a single pipe or calling a plumber.

Power Center Compatibility: PC100 Support

Your existing IntelliChlor Power Center PC100 works perfectly with the Plus40. The connector is identical to what your IC40 uses, so there's no need to buy additional equipment or worry about compatibility issues.

This is where Pentair got it right—they could have forced you to upgrade your entire system, but they didn't.

Automation Integration: IntelliCenter, IntelliConnect, IntelliSync

Got a newer IntelliCenter or IntelliConnect system? The Plus40 plays nice with both. Still running an older setup like IntelliSync, SunTouch, EasyTouch, or IntelliTouch? No problem there either.

The connection process is straightforward: connect the RS-485 communication cable from your power center to your automation system. Most pool owners can handle this themselves, though you can always have your pool service tech take care of it during regular maintenance.

No Electrical Rewiring Needed

Perhaps the best news of all: your existing electrical connections work as-is. The Plus40 uses the same power requirements and wiring setup as your current IC40.
This truly is a plug-and-play upgrade. Remove the old unit, install the new one, and you're back in business.

We've walked countless Shasta Pool Supply customers through this upgrade process since 1966, and the simplicity consistently surprises people. Most expect installation headaches that just don't exist with this particular upgrade.

Nobody enjoys maintaining their Pentair salt cell. It's messy, time-consuming, and half the time you're not even sure if you're doing it right.

The Plus40 actually tries to fix some of these headaches.

Acid Cleaning Kit Included in Plus40

Right out of the box, the Plus40 comes with its own dedicated acid cleaning stand. This isn't just a nice-to-have—it's genuinely useful. Instead of trying to balance your cell precariously while pouring muriatic acid, you've got a proper stand that keeps everything stable and safe.
Your IC40? You're on your own figuring out how to clean it properly.

Boost Mode: 24-Hour 100% Output

Had a pool party last weekend? Kids had friends over and your pool looks like a swamp?

Just hit the "BOOST" button on the Plus40 and it cranks up to 100% chlorine output for 24 hours. Need to cancel it early? Hold the button down again. Done.

The IC40 doesn't have this feature. You're stuck manually adjusting settings and trying to remember to change them back.

Cell Cleaning Alerts and Blade Wear Warnings

Here's where the Plus40 actually saves you money. When it flashes "SYS OFF CHK CELL," you know exactly what to do. Clean the cell first. If the warning sticks around after cleaning, your blades are worn out and need replacing.

No guesswork. No wondering if that strange behavior means your cell is dying or just needs a cleaning.

Polarity Reversal to Reduce Scale Build-Up
Both units flip polarity every three hours to prevent calcium buildup. But the Plus40's electronics handle this more smoothly, which means less stress on the cell plates over time.

Winterization Options: Spacer Cells for Off-Season

Arizona pool owners who shut down for winter have a smart option: spacer cells (part #520588 for Plus40). These bypass cells let you remove your expensive salt cell during off-season without leaving your plumbing open.

It's a small thing, but it protects your investment when you're not using the pool. 

You want the facts without the fluff. Here's exactly how these two Pentair salt cells stack up against each other:

Both units will keep your pool sanitized. The Plus40 just does it with fewer headaches and more convenience features that actually matter in day-to-day use. 

Here's the bottom line after everything we've covered: the Plus40 is a solid upgrade, but it's not necessarily the right choice for everyone.

If your IC40 is still working fine and you're not dealing with constant false salt alerts or faded housing, you might want to hold off. Why spend money on something that's solving problems you don't actually have?
But if you're tired of guessing whether your salt levels are accurate, or you're frustrated with that ancient-looking display that tells you almost nothing useful, the Plus40 addresses those exact pain points. The SmartSense technology alone saves you from running the cell when your pump is off—something that'll extend its life and save you money in the long run.

What really sold us on recommending the Plus40 to our customers? It's the fact that Pentair didn't make this upgrade complicated. No rewiring. No plumbing changes. No buying extra equipment. You literally unscrew the old one and screw in the new one.

The boost mode is surprisingly handy too. Pool party last weekend and your water looks a little cloudy? Hit the button and let it run at 100% for 24 hours. It's one of those features that seems simple until you actually need it.

Here's how we'd break down the decision:

Upgrade to the Plus40 if you're dealing with:

• False salt alerts from your IC40
• Faded or cracked housing from Arizona sun
• Wanting better diagnostics and warnings
• Needing more accurate salt readings

Stick with your IC40 if:

• It's working perfectly and still looks good
• You're planning to replace your entire system soon anyway
• The cost difference matters more than the convenience features

At Shasta Pool Supply, we've been helping Arizona pool owners make these decisions since 1966. Our team can look at your specific setup and give you honest advice about whether the upgrade makes sense for your situation.

Whether you choose the IC40 or Plus40, both will keep your pool properly chlorinated. The Plus40 just does it with less guesswork and fewer headaches along the way. 

Visit the Pentair website for details about each salt cell