OK, wired the pump direct and it works fine, hooked up the controller again, tried to manualy increase the CAL, it was on 41, I increased to 60 then the fuse popped, tried a few more but kept popping the fuse instantly without even switching the controller on, is there a way to reset it? Ive attached a photo of the controller board, there are a few clear brown patches around some of the connections, not sure if its fried?
Thank you all for giving some good advice It may be the control, having said that if it worked fine last week before switching it to the new van that seems unlikely.
1.There is no manual reset on the control. In normal operation once the DE clears the control will restart the pump, There dose not appear to be any sign of the board be damaged.
2. The fuse is a 7.5amp - with a pump running at maximum we would expect the pump to draw between 5 and 6 amps.
So for the fuse to pop at a flow rate of 60, the pump is taking a high draw then we would expect to see. Check all your wiring and connectors ensure that there are no corroded or damaged connectors also any breaks in the cable.
As the fuse has blown the control was correctly wired otherwise the diode we put on the board to protect it from reverse polarity will have gone and you would spell burning.
Did the fuse blow before you turned the control on? If yes this suggests a higher ampage draw from the pump above 7.5amps or a cable fault.
Having connected the pump direct to the battery we can eliminate a possible restriction in the system or air lock.
We have two issues to look at.
1. stopping the fuse from blowing
2. Setting calibration so DE stops displaying
As above in the post check all wiring and connections from the battery through to the pump. How old is the Pump? Sometimes worn brushes in the motor mean the pump has to work harder and this will increase the amp draw. If you have a spare pump it is worth trying it on the system.
If you are confident the wiring and pump are ok. Check the water jets hose and brush for any signs of grit or a blockage.
I would also ask have you changed any fittings when you transferred the system?
Re connect the control Red = live Black = minus, connect these to the battery.
do not connect the control to the pump for a moment - Turn the control on if it is working normally it should display PS (Pressure Switch)
1.Now connect the controller to the pump if the fuse blows straight away there may be an issue with the pump.
2. If the display remains blank the control may be damaged (how Old is the control? )
3.If it now displays DE (Dead End) try to calibrate using the auto cal function on the controller. If the control still will not calibrate and stop displaying DE again it may be a fault with the unit.
I know there is a lot to go through here, It will help establish where the fault is and how we go about fixing it
Ian