Prodigy Pump Troubleshooting

Pump Controller Error Code Troubleshooting

Use the fault messages on the Alarm screen with this table to diagnose and correct pump controller problems.

Error Code	Message	Correction
571	System heartbeat lost	Check circuit board connections.
572	5/24 volt power	Check circuit board connections.
573	Error writing to internal EEPROM	Hardware error. Replace card
574	Error reading from internal EEPROM	Hardware error. Replace card
575	Node address changed from last power up	Saved address does not match current address. Address switches were changed. Informational message only.
576	Internal database version changed - resetting to defaults	An update to the database wea detected and the current data is no longer valid. Informational message only, operation should not be affected
577	Preset out of range	The preset sent to the remote device was out of range. Check preset settings and reset as required.
701	Pattern servo fault	The solenoid resistance was not detected or incorrect when the device was not triggered. When the solenoid is not energized, the resistance of the solenoid is checked by the system. These faults are generated if no resistance is detected, or the correct resistance is not detected. Check the proportional valve wiring connections. Check the solenoid operation. Replace the valve if the solenoid is bad.
702	Pump servo fault
705	Powder low PWM	Pump air flow less than commanded value. Check for obstruction in pump air flow control valve. Clean valve as described in pump manifold manual.
706	Pattern low PWM	Pattern air flow less than commanded value. Check for obstruction in pattern air flow control valve. Clean valve as described in pump manifold manual.
707	Powder high PWM	Powder air flow more than commanded value. Check output of flow regulator (center regulator in pump panel) - should be 85 psi. Check for kinked or blocked powder delivery tubing. Check for blocked pump flow air servo valve.
708	Pattern high PWM	Pattern air flow more than commanded value. Check output of flow regulator (center regulator in pump panel) - should be 85 psi. Check for kinked or blocked pattern air tubing. Check for blocked pattern air servo valve.

Air Flow Re-Zero Procedure

Perform this procedure if the iControl gun control screeens are indicating pattern air flow when a spray gun is off and no air is actually flowing. Before performing this procedure:

Make sure the air pressure supplied to the pump cabinet is higher than the minimum 5.86 bar (85 psi).
Make sure no air is flowing through the pumps, around the pump control manifold gaskets, or from or around any of the solenoid valves on the manifold, for the pumps supplying the guns indicating air flow. Re-zeroing a board when a leak is present will result in additional errors.

Disconnect the pattern air tubing controlled by the pump board from the output fittings on the rear panel of the pump cabinet.
Plug the output fittings.
Record the board number and address settings of SW1 for each pump board.
Set each address switch to zero.
Turn off the power to the pump cabinet, wait 5 seconds, then turn the power back on.
Press and hold the TEST button on each pump board being re-zeroed until the red fault LED turns on. Release the TEST button and wait for the fault LED to turn off.
Move the SW1 address switches back to their original positions.
Turn off the power to the pump cabinet, wait 5 seconds, then turn the power back on.
Remove the plugs from the pattern air output fittings and reconnect the pattern air tubing.
At the iControl console, check each gun control screen that was previously indicating air flow when the gun was off. No air flow should be indicated.