Water wizard boom counts are not consistent during boom tests. When machine is running if counts are to low it skips the bug pass. If counts are not the same up and down it will set a code that top prox was on when boom was not home. This happened about a year ago and both counting prox wires and sensors along with the communication wire being changed to no avail. Shut off the red lion for the night and turned it on in the morning and everything has worked until now. Same symptoms as before, shut it off for the night and all is well in the morning. Ran for a day this time then quit. Shut it down again for the night but this time it did not come back to normal. Tech is starting to think a software problem but cannot get assistance or a call back from Coleman. Any ideas would be greatly appreciated. I saw a post on here about someone setting up a site for help with Water Wizards due to lack of help from the manufacturer but I can't find the information. If someone has the information that would be helpful. My first time using this site, hopefully I did it correctly.
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Water Wizard 2.0 boom counts
- Thread starter mud puppy
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Hope this is OK, but Jackson can delete if not. We're a small group but it's an easy way to get relatively quick input on water wizard problems
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Sounds like a 2.0. I don't think it's a software problem.
First, make sure there is no hose leaking in the area of the sensors. Make sure all wires connections are good. re-strip and re-land all wires to both boom prox switches and even the boom home prox and boom bottom prox. Aftermarket wires and switches are so cheap that I just replace at the slightest hint of a problem.
by the way make sure the switch spacing is correct. You can get a switch too close as well as too far away.
If this is only happening during a wash and not during boom test it could be slack in the boom bearings allowing excessive boom play and the high pressure pushing the boom away from the sensors. You will probably see an error pop up and it will be consistently at one end of the vehicle and probably around the same height when the error occurs. The easiest and cheapest option there is to order the conversion kit that moves the boom count prox switches off the boom and up to a count wheel up high on the gantry. It's only around $100 if I recall. This conversion kit is a good idea regardless and if you plan to keep this machine a long time I recommend it as it will virtually eliminate any boom count errors related to prox switch spacing. It also gets the prox switch wires out of the moving echain that the boom hose is in so that increases reliability
If all else failed you can throw the parts cannon at it and replace all switches and wires involved, the two counting prox switches and associated cables. You can even replace the boom home prox and bottom boom prox. Cables are sensors are all only around $25 each from automation direct.
The final step is to replace the input card. But I would only consider that after all other options have been explored
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Sounds like a 2.0. I don't think it's a software problem.
First, make sure there is no hose leaking in the area of the sensors. Make sure all wires connections are good. re-strip and re-land all wires to both boom prox switches and even the boom home prox and boom bottom prox. Aftermarket wires and switches are so cheap that I just replace at the slightest hint of a problem.
by the way make sure the switch spacing is correct. You can get a switch too close as well as too far away.
If this is only happening during a wash and not during boom test it could be slack in the boom bearings allowing excessive boom play and the high pressure pushing the boom away from the sensors. You will probably see an error pop up and it will be consistently at one end of the vehicle and probably around the same height when the error occurs. The easiest and cheapest option there is to order the conversion kit that moves the boom count prox switches off the boom and up to a count wheel up high on the gantry. It's only around $100 if I recall. This conversion kit is a good idea regardless and if you plan to keep this machine a long time I recommend it as it will virtually eliminate any boom count errors related to prox switch spacing. It also gets the prox switch wires out of the moving echain that the boom hose is in so that increases reliability
If all else failed you can throw the parts cannon at it and replace all switches and wires involved, the two counting prox switches and associated cables. You can even replace the boom home prox and bottom boom prox. Cables are sensors are all only around $25 each from automation direct.
The final step is to replace the input card. But I would only consider that after all other options have been explored
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I have been having same issues for several weeks I finally got it to a point that it sometimes works, and sometimes it doesn’t I will order the conversion kit in the morning Greg I did check on automation direct website can you post us a picture or part number for both the cable and the sensor? I have been getting my cables from Kleen-Rite or Coleman or my local distributor when they had to come up and send a tech to work on it. Thanks for all your help Greg.
Will warn you these switches don't seem quite as sensitive as the turk, but they otherwise work well and are of good quality. The cables are awesome.
Thanks for your reply. I have the conversion kit on this machine. I replaced both counting proxs and both wires. When problem first occurred I also ran a new communications cable. Nothing seemed to change the issue so i shut it off an went home. Next day everything worked and continued to work for almost a year. Problem has returned and the shut off go home idea did not fix it this time. Problem is there when running a boom test on the red lion. Counts are sometimes the same up and down and sometimes they are not. Sometimes counts are in the seventies sometimes the sixties and once in a while the fifties. Sometime the do not match up and down. I ran a test and counts were 77 both ways so I washed a pickup and when the boom went up for the last time at the rear the wash shut off and returned home with code that boom top prox was on when boom was below the sensor. I believe it does this because the count going up is wrong and the wizard thinks the boom is still down a ways because the counts are not matching.
