[Twc services]

My digital pump controller keeps flashing battery after a while of being used so i decided to buy i knew one, even though i have a smart charger and a split charge relay. Fitted new battery and it still does it ? it flashes then screen goes dim and goes of sometimes. When i wiggle the wires in the controller it comes back to life. Anybody else had this ?

Thanks

[Plankton]

My variestream would flash L when the current dropped as it was designed to safe the battery, also the connections started to go white which also caused it to flash L and then stop. If the connection has a bad contact this could be the problem.

[Ian Sheppard]

My digital pump controller keeps flashing battery after a while of being used so i decided to buy i knew one, even though i have a smart charger and a split charge relay. Fitted new battery and it still does it ? it flashes then screen goes dim and goes of sometimes. When i wiggle the wires in the controller it comes back to life. Anybody else had this ?

Thanks

I would agree with Alan that a poor connector or damaged cable are likely sources of the issue. I would also suggest checking the fuse holder and fuse if there is corrosion they will need replacing. You also mention a a split charge relay. The cable here will also need checking together with the second in line fuse between the battery and relay. As moving the cables has an impact a cable is a pointer to the issue. The connections at the controller PCB are Soldered and not likely to move.

Any damage to cables, connector, or fuses will cause volt drop. http://www.springltd.co/node/133
The controller is checking voltage regularly and even a momentary drop in volts will be detected by the control. I am working on the basis your new controller was recently and is a V11 The V11 has battery management software as well as the volt meter. Bat will flash at 11V with the control shutting down the pump at 10.5V or below.

Something not mentioned in your original post is the age and AH size of the battery plus the starting voltage of the battery at the beginning of the day. If you can provide that information as well it helps build up a picture. Also what calibration setting and flow rates are you running?

[Twc services]

Thanks for the input guys. The battery is 100Ah its only a week old. The voltage at the start of the day is 12.9 with no load and 12.5 at the end of the day with no load. It will show 11.9 when running but if you move the wires in the controller it will go back up to 12.2v. You can actually hear the pump speed up slightly whilst moving the wires.

Thanks

[Ian Sheppard]

Thank you for the additional info. the symptoms described certainly suggest loose or poor connections. The end of the tails on the controller PCB are soldered plus the cable runs through a rubber gland so its not likely to be that end. Are the bullet connectors firmly attached also check all the connectors.

A 1 volt drop is quite a lot with the pump under load. This may be due to a volt drop along the cable length, try keep cable runs as short as possible, you could also consider using 2mm cable as this will reduce the effect of volt drop.

[Twc services]

Thanks Ian  I will pull it all apart and check the connections and possibly use 2mm cable just to be safe. Hopefully this cures it.

Thanks again

[Ian Sheppard]

No problem let me know the outcome. It is a loose connection somewhere. Once you have located it the system should run with no issue.

Ian

[Twc services]

Hi Ian i found the problem !!! It was a loose earth connection onto the chassis. I fitted the black wire from the pump to the chassis instead of the battery earth. The nut had worked loose causing a earth problem.

Thanks again for your help

[Ian Sheppard]

Thank you for the feedback. Glad it is all sorted