6212 wavebox losing sync

[psykokid]

I've got a 6212 wavebox that is being run off a 6091 controller. The box will work for a minute and the wave will begin to build then the pump will seem to stall out and only pump for just a minute fraction of a second before it goes into the next rext phase of the cycle. In doing this it wrecks the wave that had began to build and it has to start all over again. here's a quick video i made of the 6091 when this happens: http://picasaweb.google.com/lh/photo/EUSxlniFqZeQ8E5i-k6wUQ?feat=directlink The video is only 1 min long. the stall in the sync or the pulse happens at :02, :27, :33, and :43 respectively.

I have a 6206 running in the tank currently which works fine, but is on loan from a friend until he gets his tank back up and running. I opened up the 6091 and made sure that the board and everything were kosher. No signs of water ingress or loose solder joints. I swapped the 6091's between the 6212 and 6206 wave boxes with no change in behaviour in the 6212. It does this regardless whether the power is dialed all the way down to the min, somewhere in the middle or at full power. I opened the 7240.27 driver for the 6100.10 pump in the wave box and all was good there as well. No signs of water ingress, all connectors appeared to be solid.

I may try and borrow a 6100.10 with driver and power supply over the weekend to see of that changes anything. I just picked up the wavebox from a friend yesterday. The 6100.10 has the later style impeller. I cleaned everything out really well. The center hole was all crudded up with calcium so i cleaned that out and made sure everything else was kosher as well. The pump seems to be a little loud though. Im not sure if that is something inherent in the nature of the pump or what or if the impeller is worn too much. In the how to clean your pump thread the one piece impeller seemed to have a bit of a shoulder on it, mine is smooth with no such shoulder present, only a bit of a taper.

 

[rvitko]

Later drive units were tapered instead of shouldered, this reduced noise. I don't know of any electrical problems from these older pumps that can cause this issue. My guess would be the drive unit has some unnoticed problem, a common issue is an incomplete replacement, if you leave the older bush bearing and upper bearing from a 6100.600 type drive unit and install only the rotor and prop of 6200.700 this mismatch can cause a stall, the old bearings were tighter fitting. I could also imagine some salt creep or moisture damage to the driver or damaged cable from the controller to the driver could cause intermittent failure to turn on. The other possibility is that the pump is turned down to a really low power setting on the driver potentiometer and with a bit of calcium build up or wear, is struggling to start. You might check that this is turned up to full power.

 

[psykokid]

Roger,

I opened the driver box when I was troubleshooting as well ant there was no noticeable creep or anything that looked awry. I tried checking with the power pot cranked all the way up to all the way down to several points in between with no change. I cleaned the entire pump when I first brought it home. Ther was some calcium buildup in the
shaft but a vinegar bath sorted everything. I tested two different 6091's and it had the same problem. It does have the later single piece prop/rotor assembly. Is there any physical differences between the early and late upper and bush bearings?

 

[rvitko]

Yes, there are physical differences but they are not easily described. These parts all slowly evolved over the years to increase energy efficiency and reduce noise and lime build up. A new drive unit always includes all needed parts and all must be replaced to ensure a proper fit. The critical thing is that the fit is not tight and the parts can freely spin. I would suggest sending the pump in, I will figure out what is wrong.

Tunze USA
305 Victor St
Austin, TX 78753

 

[psykokid]

Roger - sounds good, i'll remove the 6100 from the wavebox housing and send it in this week. Thanks in advance

 

[psykokid]

Roger - Just getting around to sending out this today. I'm kind of glad i waited due to a 6045 that i had was acting up and not re-starting after being turned off and then back on. It would restart if it was given a little shake. That not being right I took the 6045 apart and found that the impeller shaft had decided it didnt like being whole anymore. It appears that there is a bit of the shaft left in the impeller but doesnt want to seem to come out. The lower bearing that goes between the impeller and the motor block is also MIA. I serviced it about 9 months ago and all parts were present and accounted for. Im going to include it in the package so you can take a look at it along with the drive unit for the wave box.

I'll put my contact info in the box and everything should be to you by mid week.

Also, i need to buy a replacement 6025.510 for the 6045. I dropped the magnet while i had the pump apart to check what was going on and it landed on the clamp and cracked. Can I order the 6025.510 online and have you include it in the package when you send the drive unit for the wave box and the 6045 back? Is there a notes section in the order form where i can state such?

Thanks in advance,

Jake

 

[rvitko]

The easiest, provided you are not to difficult to reach by phone, would be to just include a number and a list of what you need and I will call to get your cc info. The other option would be to order the parts on tunze.com and immediately PM me the order number and to ship it with your repair.

 

[psykokid]

I put all of my contact info and a description of what i needed (as i didn't have the part number off hand) when i was writing the note i included in the package. Just give me a ring when you're ready. Thanks again, look forward to hearing from you.

 

[psykokid]

Roger,

Just checking in and making sure everything got there OK.

 

[rvitko]

Yes, I just left you a message, not much I can do for the wavebox pump, please check your message.

 

[psykokid]

Got your message, I'll ring you tomorrow morning so we can get it sorted. Thanks!!

 

[psykokid]

Roger - Sent you a PM