Osmolator 3155 / Water Level Controller 5017 malfunction

holder45

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For Roger (or any Tunze experts):

Last night I unplugged the power supply from my Osmolator (specifically, from the controller unit) to perform routine maintenance. I always unplug the unit to avoid the alarm when I'm working in the sump. Afterwards, I plugged the power back into the controller and all 4 lights come on as well as the muffled sound of the alarm. As long as the power remains plugged in, all light stay on and a strange buzzing (not that of the full alarm) persists.

I disconnected all pieces of the unit (power supply from controller, pump, sensors) and cleaned/checked each. Using a 9V battery direct to the pump leads, the pump powers on and works just fine. With the pump disconnected from the controller, the same lights and noise occur. Reading the other Osmolator posts here, I've isolated each wire (sensors, pump leads, power to controller) to try and avoid EMF interference. No change.

When I plug the power unit into an isolated circuit (not near the aquarium or anything else), the unit does power on and give a 1 second alarm with all 4 lights lit, then the lights go out and the green level light stays on. That cycle repeats until power is removed. The pump never comes on though, and there is no response when manually activating the float switch.

The unit is normally powered through a ReefKeeper Lite PC4 power bar. The unit was purchased from Bulk Reef Supply in December 2011, but never removed from the box until January 2013.

Any ideas on what the problem is or how to fix it? Will Tunze replace the controller?

Thanks for any insight.
 
You have about 8 months left under warranty, so long as it did not get wet it would be repaired under warranty if you send it in. Since it works more normally away from the tank, I suspect two issues, magnetic interference and a possibly faulty optic sensor, though it could also just be hazed over by salt crust and calcium. On controllers from this time period they were more prone to EMF interference because the float wire made a long bend over the board and served as an antenna, specifically it passes over the processor. Rerouting this wire internally may solve the EMF issue. I would just send it in, however, please note, no repairs will be done next week, I will be out of town on vacation, Craig will be here to answer questions and he can do more basic repairs. If this is urgent, please send it so it arrives before Friday, send the controller, pump, power supply and a copy of the receipt, make sure a current return address and phone number are included.

Tunze USA
305 Victor St
Austin, TX 78753
 
So I was just getting ready to box up my items and send back to you, but thought I would reassemble and test one more time before going through the process of packaging. It worked!

Nothing changed other than the controller was disconnected from power for a day and laid flat (horizontally) as opposed to its normal vertical mounting position. I plugged it in and it starts up as expected, and responds accurately if I change the sensor levels. So I have a new question--
Should I go ahead and return it given the strange behavior? I'll be on vacation next week as well and won't be home to get the replacement. What do you recommend?

Thanks again for the outstanding service,

Drew
 
Actually, strike my last.

The thing just went haywire again. I'm shipping from Florida, so you should have it by Thursday. It would be great if you could get it out Friday, if possible. Thanks.
 
Two issues, a faulty optic sensor and a weak power supply. They have been replaced and shipping back today.
 
Thanks, Roger, for the speedy fix!!!

Any advice on how to avoid these issues in the future? Or was this just some anomalous occurrence? Seems strange this would happen after only 3 months operating.

At any rate, kudos for fantastic service and fast turnaround. It's the number one reason Tunze is worth the money.
 
This unit was made 02/11, at this time we just redesigned the optic sensor and some of the first of the new design could develop a pinhole where water entered and shorted them into a perpetually "water level" condition. The power supply has to put out at least 9V to give the controller enough power, occasionally one is just a dud, but it is rare, the one you sent in put out 8.2V and it should be 11V.
 
Appreciate the extra info. Looking forward to getting the Osmolator back in uninterrupted service for many years. Forgot what a PITA it is to do manual top offs!
 
Received the repaired unit, reinstalled and everything is working perfectly. Major kudos again to the Tunze USA team for outstanding customer support, warranty work and fast turnaround. Couldn't be happier with their level of service.
 
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