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TROUBLE SHOOTING GUIDE
Manu
Flo
®
TM
FOR BATCH CONTROLLER / ROTA PULSE FLOW METER SYSTEMS
PROBLEM
POSSIBLE CAUSE
SUGGESTED SOLUTION
No power to batch controller
Blown fuse or holder not tightened
Check fuse, tighten fuse holder (at rear of controller)
or displays not on
+12vdc and O.V. shorted
Check pulse cable from DCD to RPFS meter
No main power supply
Check power supply, check wiring
Pulse fails at start of batch
•Check calibration (K-factor) setting
•000 calibration -pulsefails. Make sure a calibration value is set,
(1.5 seconds after)
three switch shafts -H,T,U- located at rear top left of controller
Seized paddlewheel
Remove RPFS, inspect; if calcium buildup clean with diluted acid,
check axle/bushes, make sure paddlewheel spins freely.
Solenoid valve not opening
Check and service solenoid valve, check output control voltage is
240vac(N & C, pins 7&9) when pushing start button. Or other
voltage as per specification output
Restriction or service gate valve closed
Open gate valve
Empty water tank,
Check water level
Pump not turning
Check and service pump
•Pump foot valve failed
•Empty pipe, Install non-return valve
Signal cable cut, bad joint at JB,
Check signal cable for 12VDC at junction box near RPFS meter
oxidized cable- leakage
If no power, cable cut or oxidized- repair/replace.
Unwire RPFS, take up to batchroom, remove extension cable &
hardwire RPFS direct into the Batch controller (P,+,-), spin wheel
should count on display, if so, then extension cable or connections
at JB faulty, if no counts & 12vdc present then RPFS faulty
•RPFS not positioned in pipe
•Check RPFS slots are in keyway position, lock cap secured
Paddlewheel not inserted into flow stream
RPFS Flowmeter faulty
Replace with new RPFS
Pulse fails during batch cycle
Flowrate too slow
Open restriction gate valve, or increase flowrate pulse fail
timing capacitor (see service guide). Pipe diameter too big for flow
Pipe buildup restricting flow
Cleanout pipelines, calcium buildup on pipe walls -recycle systems
Paddlewheel problem
Calcium buildup on wheel, soak in diluted acid. Warn bushes.
Display digits count slowly
Non return valve faulty (jammed open)
Clean, service or replace
after batch complete
•Solenoid valve not properly closed
•damaged seal, faulty solenoid
Batch target display counter
Flowrate too fast excessive overflow
Turn down gate valve to restrict flowrate
counts past batch selection
or set pre-act (overflow deduct) function to compensate
Reduce delivery pipe diameter
•Intermittent overflow past batch select •Faulty solenoid valve not closing
•service solenoid valve, check air pressure
or water does not stop
properly, insufficient air pressure
Wet loads, more water
Paddlewheel bushes worn
Check paddlewheel
collected than indicated
Wheel dirty, flowing over range
Replace with new paddlewheel, recalibrate
Dry loads, less water
Requires recalibration test
Set new calibration figure, rear switches
collected than indicated
(See calibration guide for details -ME995-7 brochure)
Controller starts counting
Active and contact power
Contactor fused due to excessive current draw from pump
when power switched on
drive short circuited
Relay fused due to excessive current draw on solenoid coil
- install higher current rated contactor or install contactor.
Controller- FL(flow), LM(limit),
Controller malfunction, IC failure
Replace controller or call for service and advise
and or CD(contact drive) LEDs on
Diagnostic warning
Sequential fault finding and rectification
1.
If another ManuFlo controller (any model) is available, simply unplug doubtful unit and plug in exchange unit. If the new unit is also not
operating correctly, then the problem is isolated to the pulse flowmeter or wiring.
2.
When checking flowmeter, reset the ManuFlo controller. Remove the flow sensor and spin the paddlewheel. Check that the ManuFlo
controller has registered a number of counts on its display. If so, the electrical connections are probably OK. If no counts are registered,
check that 12VDC is supplied to the flow sensor. If supplied, then switch off the ManuFlo controller and replace the RPFS flow sensor.
3.
The flow sensor paddlewheel is jammed, damaged etc. (For servicing, refer to the flow sensor brochure).
System over batch problem
1.
Selector knob batch dials on ManuFlo Batch Controller may not be positioned correctly, and therefore not correspond to rotary switch
numeric values.
2.
To test, set all numbered dials to the zero position 0000. Then press the RESET toggle. The alarm should beep momentarily - this will
indicate correct alignment of dials. If alarm does not beep, this indicates incorrect alignment of number dials. To rectify, remove the grey
colored cap from dial, unscrew knob and pull knob off. Check that the exposed switch shaft’s flat (black) side is horizontal. If not, then turn to
horizontal and refit the numbered dial knob to the zero number setting. Also check the calibration and pre-act knob settings which are located
at the rear of the controller
3.
If the Batch Controller is found to be operating correctly, then proceed to checking and testing the flowmeter components.
If in further doubt, contact your local representative, or ManuFlo on ph +61 2 9938 1425 or 9905 4324.
