Why was the electronics modified if only 381 hours ? How old is it ? What was wrong with the wand?
The machine will be about 7 years old now
There’s nothing wrong with the wand sir
As regards to the electronics
The modified electronics is the wiring on the float switches in the mixer tank
The mixer tank pump draws 5 amps and the magnetic float switches that switch the pump have a maximum switching capacity of ½ Amp and will take a maximum load of 1 amp
On the original Hydramaster spitfire 3.2 schematic there is a relay in circuit that should reduce the current
However when the pump has a circuit as explained before it draws 5 amps
Live is drawn from ever the ignition switch or the lower mixer tank stop relay (dose not rely mater)
It then goes to port 30 on the mixer tank relay then through the switch and out of com 87 on the MT relay it then goes straight off to the pump which is drawing 5 amps
Also on that circuit there is a wire that goes from post 87 to bought mixer tank switches
The problem now is that the float switches are not designed for such a heavy load
The upper float switch is fine as on the other end/wire of the float switch it is wired into com 86 of the relay which is a magnetic coil and will reduce the current to mille amps
However on the lower float switch the other end/wire goes straight back to com 30 on the relay and when there is a circuit you have a full 5amp load passing through the lower float switch
This will cause the float switch to weld/ arch together and damage it
As can be seen on the original wiring schematic there is a Diode in place between com 87 of the relay and the two float switches
A diode is designed to allow electricity to pass in one direction and block it in the other or to stop any back loads
It is not decided to reduce the current
Having a diode in circuit may protect the float switches for a short time but this dose not work for very long
As from previous experience the upper float switch soon goes
The original Hydramaster wiring schematic is a very poor unworkable design
On my circuit I have added another relay to work in parallel with each other
Live goes to both the float switch relay and the pump relay on com 30 of the relays and to the lower float switch
Instead of having com 87 going to both switches com 86 goes to both switches so we have a reduction of current there
On the other side/wire of the upper float switch, that goes to com 87 of the float switch relay
But this time as we have 2 relays we do not have a wire going from that same relay port to the pump thus drawing 5 amps
On the pump relay on port 87 goes direct to the pump
And com 86 is still the same both relays go to earth
So by having the 2 relays one for the switches and one for the pump we have reduced our current on the pump relay as the current is being drawn from live and through port 86 on the float switch relay
There is still a Diode in circuit between both float switches and the float switch relay as it not rely needed but is there to stop any back loads in case of a short circuit
Hope this helps