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Pressure Control Repair
309674M 27
Motor Control Board Diagnostics
NOTE:
• Keep a new transducer on hand to use for test.
• No display does not mean the sprayer is not pres-
surized. Before repair, relieve pressure, page 7.
1. For sprayers with digital display, see Digital Display
Messages.
2. Remove screws (12) and cover (50).
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
* Ultra, Ultimate Nova, Super Nova and ST Max 395/495/595.
** Ultra Max II, Ultimate MX II and ST Max II 490/495/595.
CAUTION
Do not allow sprayer to develop fluid pressure without
transducer installed. Leave drain valve open if test
transducer is used.
DISPLAY LED BLINKS SPRAYER OPERATION INDICATES WHAT TO DO
No Display Never blinks Sprayer stops. Power is not
applied. Sprayer must be pres-
surized.
Loss of power. Check power source. Relieve pressure
before repair or disassembly.
psi/bar/MPa Once Sprayer is pressurized. Power is
applied. (Pressure varies with tip
size and pressure control set-
ting.)
Normal operation Do nothing
E=02 Two times
repeatedly
Sprayer may continue to run.
Power is applied.
Run away pressure. Pres-
sure greater than 4500 psi
(310 bar, 31 MPa) or dam-
aged pressure transducer
Replace motor control board or pressure
transducer
E=03 Three times
repeatedly
Sprayer shuts down and LED
continues to blink three times
repeatedly
Pressure transducer is
faulty or missing
Check transducer connection. Open drain
valve. Substitute new transducer for trans-
ducer in sprayer. If sprayer runs, replace
transducer
E=04* Four times
repeatedly
Sprayer shuts down and LED
continues to blink four times
repeatedly. Power is applied.
Line voltage is too high Check for voltage supply problems
E=05 Five times
repeatedly
Sprayer does not start or stops
and LED continues to blink five
times repeatedly. Power is
applied.
Motor fault Check for locked rotor, shorted wiring or
disconnected motor. Repair or replace
failed parts.
E=06 Six times
repeatedly
Sprayer stops and LED blinks six
times repeatedly. Power is
applied.
Motor is too hot or there is a
fault in motor thermal
device
Allow sprayer to cool. If sprayer runs cor-
rectly when cool, check motor fan function
and air flow. Keep sprayer in cool location.
If sprayer does not run when cool and con-
tinues to blink six times, replace motor.
- - - Power is applied. Pressure less than 200 psi
(14 bar, 1.4 MPa).
Increase pressure if desired. Drain valve
may be open.
EMPTY* Sprayer stops. Power is applied. Empty paint pail. Loss of
pressure.
Refill paint pail. Check for leaks or clogged
pump inlet. Repeat Startup procedure.
E=10** Blinks 10
times repeat-
edly
Sprayer does not start or stops
and LED continues to blink 10
times repeatedly. Power is
applied.
High control board temper-
ature.
• Make sure motor air intake in not
blocked.
• Make sure control board is properly con-
nected to the back plate and that con-
ductive thermal paste is used on the
power components.