FIELD TEST OF WATER LEVEL CONTROL

Fill Unit (WLC-F)

This procedure will require the following items:

1. A digital multimeter will make testing faster.
2. Short pieces of stranded insulated 22awg wire to use as jumpers.
3. Small needle nose pliers.
4. Small slot screwdriver.

General:

The devices in the water level sensor assembly and the freeze guard sensor change resistance with the temperature. The colder the temperature-the higher the resistance.

INITIAL CONDITIONS:

1. Power off to the unit. Verify fuses are good with the multimeter.
2. Power Selector in the 230 VAC position (top 4 pins connected) if the power input voltage is 230 volts. Power Selector in the 115 VAC position (bottom 4 pins connected) if the power input voltage is 115 volts.
3. The sensor should be immersed in the water so that the bottom sensor is in the water and the middle sensor is above the water.
4. Temperature selector in the 40 degree setting (middle position) or a wire jumper is installed.
5. A valve should be connected to terminal TB2-6 and TB2-8.

INPUT POWER:

1. Turn on power to the unit.
2. With the multimeter set to measure up to 300 volts AC, put one lead on TB1-1 and TB1-2.
3. The voltage should be about 115vac or 230vac.
4. Verify the input voltage programming jumper (JP1) is set properly for the measured input power. (Top 4 pins for 230vac or bottom 4 pins for 115vac. )

CIRCUIT VOLTAGES (may be tested):

1. Set multimeter to measure 50 volts AC. Put one lead of the meter on TB1-3 (ground).
2. Put the other lead of the meter on TP1 and verify 24vac or greater is present.
3. Set multimeter to measure 25volts DC.
4. Put the common lead on TB1-3 put the second lead of the meter on TP2, the voltage should be about +5volts DC.
5. Put the second lead on TP8 the voltage should be about +12 volts DC.

FREEZE SENSOR:

The freeze sensor if defective or not connected will prevent the controller from working.

1. Make sure one lead of the wire from the sensor is connected to TB2-10. (Give a slight tug on the wire to insure proper connection.)
2. Verify the other lead of the wire from the freeze sensor and the water level sensor green wire are both making good connection in TB2-4. (Twist the two wires together before installing them in TB2.)
3. Set the meter to measure 25 volts DC.
4. Put the common lead on TB1-3, put the second lead of the meter on TP9.
5. The voltage should be about +5vdc. If the voltage is about 0vdc, the unit will not fill because it thinks that freezing conditions exist. (See above)
6. If a bad freeze sensor is suspected, remove the wires from the freeze sensor and install a jumper between TB2-10 and TB2-4. If the unit now operates correctly and the temperature is above 55 degrees, the freeze sensor or the connections to TB2 are bad.

SENSOR VOLTAGES AND OPERATIONAL CHECK:

Sensor Warm-up Verification

Set the meter to measure 25 volts DC.

Put the common lead on TB2-4, put the second lead of the meter on TB2-2. Wait until the voltage is below 3.7 vdc.

Put the second lead of the meter on TB2-3, the voltage should be greater than 3.95 vdc (usually it is greater than 4.5 vdc).

The led DS1 should be on and colored green.

Operational Test

Put the test jumper on JP2 (test mode selector). DS1 should remain green.

Move the sensor assembly so that it is completely out of the water (and still in a vertical position). Allow the water to drain out of the sensor.

Put the common lead of the meter on TB2-4, put the second lead of the meter on TB2-2. The voltage should still be below 3.7 vdc.

2. Put the second lead of the meter on TB2-3, wait for the voltage to go below about 3.8 vdc (depending on air temperature and water temperature this could take between 5 and 25 minutes).

4. When the sensor voltage drops below about 3.8vdc or sooner the unit will go into the fill mode. DS1 will turn yellow or orange. The valve will operate (if there is adequate water pressure).

5. The unit will alternate between the normal mode and the fill mode. The valve will alternate between on and off. With a good valve installed, when DS1 is orange 28vac can be measured between TB-2 pins 7 and 8.

6. The led DS1 will alternate between green and orange.

7. Reinsert the sensor assembly in the water so that both the lower and middle sensors are in the water.

8. Measure the sensor voltage between TB2-4 and TB2-2, it should be above 3.9vdc. Measure the sensor voltage between TB2-4 and TB2-3, it should be above 3.9vdc.

9. DS1 led will be green.

10. Move the test mode jumper back to the normal position - JP3.

This completes the field test of the Water Level Controller.

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