10-Pump, 80-Station Controller Chapter 7: Troubleshooting 70

Chapter 7: Troubleshooting

7-1 General Troubleshooting

Problem Possible cause Solution
The controller panel is not
connected to a power source. Plug in the controller panel.
Fuse/circuit breaker in the power
drop is blown/tripped. Replace/reset.
The controller panel doesn’t light
up at all.
Broken controller power switch. Replace.
The motor circuit breaker/
overload has tripped.
Reset the circuit breaker and
check the motor for the proper
amp draw on tag.
Main fuse in power drop circuit
breaker has blown. Replace the fuse/reset circuit
breaker.
A pump package doesn’t run,
even though it is on line and its
indicator is lit.
Motor contact is faulty. Repair or replace as required.
The bin below it is full if its
amber indicator light is off.
Normal operation. When the
level drops, material conveys to
the hopper.
The hopper is off line. Using the controller, place the
hopper on line.
The field-installed station bypass
switch is simulating a Bin Full
condition.
Normal operation. Set the switch
so the hopper is back in the
loading sequence.
A vacuum hopper is being
bypassed in the loading cycle.
The field-installed station bypass
switch is bad or mis-wired. Repair, replace, or rewire.
Conveying times are too long
(Time Fill mode only).
Time the hopper(s) during
loading, and set conveying times
to a few seconds less.
Vacuum hoppers are over-filling. Maximum conveying times are
too long and/or the controller
does not recognize the Hopper
Full proximity switch(es).
Check proximity sensors for
proper operation. Repair as
needed. Reset the conveying
times to a reasonable value, and
adjust as needed.
Power supply shorting out. Repair shorting circuit.
Controller blows fuses. Improper fuse installed. Replace fuse with one that has a
proper rating.