Troubleshooting Cell Circulation Systems

20 October 2016
Anode Service References

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Safety

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.

General

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

BULLETIN 990109