Standardized Middle Float Sensor Debugging Steps
The middle float level sensor is a vital element in the water level management system in the tank. If it is not representing the correct water level, or sending an incorrect signal to the controller, the machine will suffer from a water level management issue
Problems
The manifestation of the water level management issue could be one or more the following problems:
1. When water level is too low compared to cut bed:
Constant pause during cut, and UI screen displays “check drain filter and dump hose”
Constant pause during cut, and UI screen displays “add water to cut bed”
Water level more than 10mm or 1/2” below the cut bed.
Water level drops too quickly
Machine shuts off during cutting due to low water level, low kill switch triggered.
2. When water level is too high compared to cut bed:
Constant pause during cut, and UI screen displays “check drain filter and dump hose”
Constant pause during cut, and UI screen displays “add water to cut bed
Water level more than 5mm or 1/4” above the cut bed
Water level rises too quickly
Machine stops cutting and displays “cut failed, lower water level to cut bed”.
Machine shuts off during cutting due to high water level, high kill switch triggered.
If you witness any of these manifestation during an operation, please contact support@wazer.com, and conduct the checks below.
Procedure
If you observe a lowered water level
1. Preliminary checks
Refer to this page to conduct the preliminary checks. If we can confirm the root cause is with the middle float sensor, please proceed with the steps
2. Firmware Update
Root cause: Sometimes the firmware can be corrupted during shipping and messes up the water management logic. A firmware re-fresh will put the correct logic back in place.
Action: Please refer to to this page for a quick firmware update, the firmware and config file can be downloaded from the download page
3. Float Sensor Quick Check
Root cause: If the middle float sensor is broken, or the connection is not secured, changes in water level will not result in high/low signals, or the signals cannot be delivered to the controller.
Action: We need to confirm the controller can read the receive and read the signals. Please Navigate to Setup & Maintenance > Maintenance > Input Output Check > Input > Water Level Sensor. Check the UI screen display. Repeat the check for at least 3 times.
4. Water Level Setup
Root cause: sometimes the middle float sensor can function when manually actuated but cannot respond to real water level change. This check is to put the middle float sensor under real operation condition
Action: please navigate to Setup & Maintenance > Maintenance > Water Level Setup. Please measure the water level relative to the top level of cut bed after this. Taking a picture to share with support will help us get to the bottom of your issue.
5. Float Sensor Position Check
Root cause:
middle float sensor is a switch, its closing point and opening points are two different points. The closing point is when the circuit is completed, “high” signal generated, we usually refer to it as “high triggering point”. The opening point is when the circuit is broken, “low” signal is generated, we usually refer to this as “low triggering point”
WAZER have set very tight specifications for these two points.
However, if the two points on your switch is not within the specification, the middle float is presumed not representing the true water level
Thus we need to either confirm or eliminate this possibility
Action
Add water into the tank till the level reaches the top surface of the cutting bed
Turn on the main unit. Wait until the screen displays information. Go to "water level sensor" at "Input check". check if the UI screen displays "push right side float switch down"
Reach into the drain compartment, locate the middle float sensor
Without touching other float sensors, slowly push down the floater on the middle float sensor down. Keep an eye on the UI screen. Record the position of the floater when the screen displays "pull right side float switch up"
Slowly let the float come up. Record the position of the float when the screen displays "water level sensor detected"
Please share with us the recorded position.
Please share with us the recorded position
If you observe a abnormally high water level
1. Preliminary Checks
Refer to this page to conduct the preliminary checks. If we can confirm the root cause is with the middle float sensor, please proceed with the steps below
2. Firmware upgrade
Root cause: Sometimes the firmware can be corrupted during shipping and messes up the water management logic. A firmware re-fresh will put the correct logic back in place
Action: Please refer to this page for a quick firmware update. The firmware file and config file can be found in this download page
3. Float sensor quick check
Root cause: If the middle float sensor is broken, or the connection is not secured, changes in water level will not result in high/low signals, or the signals cannot be delivered to the controller
Action: We need to confirm the controller can read the receive and read the signals. Please Navigate to Setup & Maintenance > Maintenance > Input Output Check > Input > Water Level Sensor. Pay attention to the UI display. Repeat the check for at least 3 times
4. Water Level Setup
Root cause: sometimes the middle float sensor can function when manually fiddled but cannot respond to real water level change. This check is to put the middle float sensor under real operation condition
Action: please navigate to Setup & Maintenance > Maintenance > Water Level Setup. Please measure the water level relative to the top level of cut bed after this. Taking a picture and share with us will be greatly helpful
5. Float Sensor Potion Check
Root cause:
Middle float sensor is a switch, its closing point and opening point are two different points. The closing point is when the circuit is completed, “high” signal generated, we usually refer to it as “high triggering point”. The opening point is when the circuit is broken, “low” signal is generated, we usually refer to this as “low triggering point”
WAZER have set very tight specifications for these two points
However, if the two points on your switch is not within the specification, the middle float is presumed not representing the true water level
Thus we need to either confirm or eliminate this possibility
Action:
Add water into the tank till the level reaches the top surface of the cutting bed
Turn on the main unit. Wait until the screen displays information. Go to "water level sensor" at "Input check". check if the UI screen displays "push right side float switch down"
Reach into the drain compartment, locate the middle float sensor
Without touching other float sensors, slowly push down the float on the middle float sensor down. Keep an eye on the UI screen. Record the position of the float when the screen displays "pull right side float switch up"
Slowly let the float come up. Record the position of the float when the screen displays "water level sensor detected"
Please share with us the recorded position
Solutions
After the checks are completed, we can be certain of the condition of the float sensor. Then we have two solutions
1. Replace the middle float sensor:
This method is the most certain way to resolve the water level issue
This method has longer turn-around time. A new and tested middle float sensor needs to be provided by us. You will have to wait for the replacement part to arrive. Depending on the distances, the delivery time ranges from days to 2 weeks
After the parts arrives, please refer to this page to replace the middle float sensor
2. Swap the low kill and middle float sensor
The low kill and middle float sensor are same in construction.
This method assumes that the low kill’s high and low triggering point is within the specification. If so, swapping the placement and connection of these two switches will bring machine back to operation. Thus eliminating the need for replacement part, cutting down the turn-around time
Action:
Check the high and low triggering points of low kill switch
Add water into the tank till the level reaches the top surface of the cutting bed
Turn on the main unit. Wait until the screen displays information.
Reach into the drain compartment, locate the low
Without touching other float sensors, slowly push down the floater on the low kill down. Keep an eye on the UI screen. Record the position of the float when the screen goes dark
Slowly let the float comes up. Record the position of the float when the screen display back on
Swap the middle float sensor and low kill
Please read this page to familiarize with the float sensor replacement procedure. The swapping procedure is similar to this
Mark the low kill connection with “lo-k” and middle float connection with “lo” if there are not any existing marking.
Disconnect the sensors' harness from the female socket
Swap the two float switches' placements
Swap their connections. Connect the switch harness labeled “lo” to the “lo-k” female socket, and switch harness labeled “lo-k” to “lo” female socket
After that, make sure the floats do not interfere with each others' motion, and fill the tank to make sure no leaking.
Background
The water level manage system is controlled by 4 major parts:
Middle float sensor
Controller
Low pressure pumps
Drain valve.
The middle float sensor is a water level float switch that sits between the low kill and high kill switch.
The floater of the middle float sensor goes up with the varying water level, and a embedded magnet triggers a reed switch inside the stator of the sensor, completing a circuit, creates a “high” signal. When the water level drops, the floater goes down,. As a result the reed switch breaks the continuity of the circuit, creating a “low” signal. The “high” and “low” signals are sent to the controller.
In the meantime, the low-pressure pumps are constantly pushing water through the low pressure system.
After the controller gets the signals from the middle float sensor, it runs a water level management logic, and send a command to the drain valve. To briefly put it, after the controller senses a high signal from the middle float sensor, it opens the drain valve to discharge the water out from the tank. After the controller senses a low signal, it closes the drain valve to stop discharging