iFlow Module Troubleshooting

Only Faults F1 and F2 will activate the alarm relay.

Error Code	Error Message	Fault Code	Correction
401	Flow valve not detected or bad	F1	See the module illustration. 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.
402	Atomize valve not detected or bad	F2
403	Auxiliary solenoid valve not detected or bad	F3
404	Flow airflow low	F4	Air flow is less than commanded value. Air flow setting may be too high for the system to achieve. Do not set above 3.5 SCFM. Check the tubing from the iFlow module to the powder pump for kinks or blockage. Make sure the check valves are not blocked. Disconnect the air tubing at the pump. If the fault goes away, clean or replace the pump venturi nozzle or throat. Disconnect the air tubing from the iControl console. If the fault goes away, then the air tubing is too long or the tubing diameter is too large. If more than one module reports the same fault, check the console air supply pressure. The pressure must be above 85 psi. Check the tubing supplying air to the iFlow module for blockage.
405	Atomize airflow low	F5
406	Flow airflow high	F6	Air flow more than the commanded value. If the spray gun is triggered off, disconnect the air tubing from the output fitting and plug the fitting. Reset the fault. If the fault does not reoccur then the proportional valve is stuck open. Refer to the iControl Hardware manual 1044158J for cleaning instructions. If the spray gun is triggered on, disconnect the air tubing from the output fitting and set the flow to zero. If air is still flowing from the fitting then plug the fitting and then reset the fault. If the fault does not reoccur then the proportional valve is stuck open. Refer to the iControl Hardware manual 1044158J for cleaning instructions. If the fault reoccurs and the screen is showing air flow, then check for leaks around the proportional valves or transducers. Re-zero the airflow module as described below.
407	Atomize airflow high	F7
541	System heartbeat lost	-	Check circuit board connections.
542	5/24 volt power	-	Check circuit board connections.
543	Error writing to internal EEPROM	-	Hardware error. Replace card.
544	Error reading from internal EEPROM	-	Hardware error. Replace card.
545	Node address changed from last power up	-	Saved address does not match current address. Address switches were changed. Informational message only.
546	Internal database version changed - resetting to defaults	-	An update to the database was detected and the current data is no longer valid. Informational message only, operation should not be affected.
547	Preset out of range	-	The preset sent to the remote device was out of range. Check preset settings and reset as required.
548	Trigger ON message received - controller in lockout	-	The card was commanded to trigger but the system is locked out. Trigger ON commands will be ignored until the system is returned to the Run state.

iFlow Module Re-Zero Procedure

Perform this procedure if a gun control screen indicates air flow when the gun is off, or if a Flow Air or Atomizing Air Flow High Fault (F6 or F7) appears.

Before performing a re-zero procedure:

Make sure the air pressure to the iControl console is higher than the minimum 5.86 bar (85 psi).
If the regulator supplying the module being re-zeroed is new, make sure it have been calibrated for the correct pressure output. Use an iFlow air flow verification kit to calibrate the regulator according to the instructions included with the kit.
Make sure no air is leaking through the module output fittings or from around the solenoid or proportional valves. Re-zeroing leaking modules will result in additional errors.

Disconnect the atomizing and flow air tubing from all four of the 8-mm output ports and plug the ports with tube plugs.
Note the setting of address switch SW3 on the module circuit board, then set SW3 to zero.
Press the pushbutton switch SW1 to reset the module. The red LED should be off.
Press and hold pushbutton switch SW2 for about 2 seconds, until the red LED comes back on, then release the button. The LED will turn off again in about seven seconds. The module is now re-zeroed.
Move address switch SW3 back to its original position.
Press pushbutton switch SW1 again. The red LED should shut off.
Remove the tube plugs from the output ports.
Check the Gun Control screen. With the spray gun off, the display should show no air flow.