Troubleshooting Cell Circulation Systems


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Think and act in a safe manner. Always disconnect power and use a lockout before you work on the E-coat system, or any of the related subsystems. Observe any confined space conditions. Use the appropriate safety equipment and clothing for the task. Please carefully read all the instructions listed below to familiarize yourself with the project before attempting to perform any of the work.




This Trouble Shooting guide is for users of the UFS provided Standard Cell Circulation System (SCCS) or the original Cell Circulation System (CCS). Please use this listing by first focusing on the left hand column, then moving to the middle column to further define the possible problem. Consider each one of these causes carefully. At this point it is time to move to your SCCS, or CCS location and investigate each of the causes. Testing is sometimes necessary. It is good practice to try to isolate the most likely causes in order to reduce your testing. Finally, move to the right hand column to see the appropriate remedy.

Problem Possible Cause(s) Remedy
Leaking DI water solenoid valve

Inlet pressure is greater than 4.1 bar (60 psi)
Solenoid actuator is loose
Fittings are not tight

Reduce pressure at inlet to 2.6 - 4.1 bar (40 – 60 psi)
Tighten actuator
Use Teflon tape and re-tighten

Solenoid vibrates

Valve body is not opened up enough

Turn valve handle counter clockwise (CCW) to open as required

Solenoid valve not responding

Conductivity controller not calling for solenoid valve to open
Valve handle is fully closed
No DI water
Loose electrical connection
Manual override lever is in 12 O’clock, which is the ON position
No AC voltage to panel


Confirm contacts are closing inside the conductivity controller
Insure no fuse(s) are open
Open valve CCW fully
Confirm DI water is available
Tighten as required
Move lever to 9 or 3 O’clock position
Confirm proper voltage in panel

Low flow or low pressure

Motor is turning backwards
No suction to pump
Discharge valve is closed
Pressure gage has failed
Motor/pump malfunction

Re-wire as required
Open fully suction valve
Clean out strainer basket
Open fully
Order new gage with guard
See motor/pump manual

Malfunctioning Conductivity Controller

No AC power to panel
Fuse(s) are open
Sensor is dirty
Sensor is located in air pocket
Confirm set point is correct
Conductivity controller malfunction

Confirm AC power at panel
Change fuse(s) as required
Clean sensor as required
Change orientation of sensor to avoid any trapped air pockets
See conductivity controller manual
See conductivity controller manual

Low tank level

Look for leaks in tank
Looking for piping leaks
Look fodr Lleak in a ME Cells
Is Ddrain valve is partialypartially open
Blockage in return manifold

Tighten/repair as required
Fix/repair as required
Isolate Cell
Close drain valve completely.
Clear away as required






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