Troubleshooting Guide

System Components

Fig. 1

1. Control Box

1. Remote Control Antenna
2. Program Clock (Analog or Digital)
3. Spray Time Adjustment
4. Enclosure Latch
5. Auto / Off / Test Switch
6. Tank Empty Light
7. Circuit Breaker
8. Float Switch Connector
9. Power cord

2. Motor

3. Pump

1. Intake From Tank

4. Manifold

1. Pressure Gauge
2. Needle Valve
3. Output to Nozzles

5. Agitator (optional)

6. Mounting plate

7. Remote Control transmitter

General Troubleshooting Guide

The system will not operate.

• Tank is empty: The float switch will shut off the system when liquid level is low so that the pump will not run dry. Add new misting concentrate and water.
• No power. Confirm power to electric outlet, check circuit breakers and GFCI’s.
• Control box circuit breaker has tripped: toggle off power to control box, push in the circuit breaker to reset, then toggle on power back to “Auto.”
  • Check the intake filter: a clogged filter will overwork the pump and motor causing the breaker to trip.
  • Extension cords and power strips should not be used to supply power to the system.
  • Most common circuit breaker trip issues are caused by overworked/bad motors or pumps. For more information, see “The system continually trips a breaker” below.
• Bad Float Switch connection: Check to ensure wires from both the float switch and the control box are properly seated in the lever wire connector.  These are critical wire connections: For systems purchased after February 2021 (Serial Number 13120 and greater), float switch and the control box connector wires must be paired black to black, red to red, and white to white. Configurations in older systems vary. Please contact Fly Control U.S. for assistance.  
• Bad Float Switch: wiring in the float has shorted. Replace the float switch.
• For Digital Program Clock systems (see below ‘Programming the Digital Clocks’ for details):
  • Check that programmed spray cycles have been properly set with both ON and OFF times.
  • Check that the Clock is in AUTO mode. Press the MANUAL button and toggle to OFF. Press the MANUAL button once again to AUTO mode. System must be in AUTO mode for programmed spray cycles to activate.

The system continually trips a breaker.

• Ensure the tank filter is clean and not clogged, damaged, or corroded. Flow restricted from a dirty filter can cause the pump and motor to overheat in turn tripping the system breaker, the house breaker or both.  Clean tank filters regularly and replace them annually.
• Check for pressure loss along the nozzle circuit: Overcompensating for a lack of output line pressure will cause the motor to overheat and fail. Look for drips/spray coming from any connection other than nozzle tips. Inspect buried and close to ground tubing for cuts and punctures due to rodents or lawn and garden tools. Note that breaks/cuts in tubing must be removed and properly spliced or lines will not pressurize. 
• Verify that the pump output pressure is 180 – 200 PSI.  Adjust the pump manifold needle valve (Fig. 1, 4.b.) to reduce pressure if needed.
• Eliminate resistance on electrical circuit:
  • Avoid plugging the system into circuits powering other high amperage appliances (e.g. Pool Pumps, Dryers).
  • Do not supply power to the system via an extension cord.
  • Test circuit by powering with a different circuit to see if the breaker continues to trip.

• If the filter is clean and the system pressure is 180 – 200 PSI, remove the pump from the motor and switch the system to test. If the system runs without issue, then the pump needs to be replaced. If the breaker still trips, disconnect the motor leads from the back of the motor. Switch the system to test, if the breaker does not trip, the motor will need to be replaced. If a breaker still trips there is a short in the control box. Please contact Fly Control U.S. for support.
• It is very important to perform the above steps in order when troubleshooting; 99% of the time breakers trip due to issues with the Filter/Pump/Motor.

The system does not spray at the correct times.

• Check the Program Clock and see that the clock is set with the correct time. To set analog clocks: Turn the minute hand clockwise until the time of day on the outer dial is aligned with the triangular marker on the inner dial.  See ‘Program Clocks’ for more information. If the analog clock is not keeping time it will need to be replaced.
• For digital clocks see ‘PROGRAMMING THE DIGITAL CLOCK’ below.

The system will not build pressure.

• Verify the tank level and check that the filter is fully submerged in the solution.
• Ensure the in-take filter is clean. Tank filters should be cleaned regularly and replaced annually.
• Check that the in-take tube is firmly seated to the pump. (See Fig. 1, 3.a.)
• Make sure all tubing is seated firmly in fittings and that all nozzles are screwed in tightly using O-rings or Teflon tape if required. Note: if tubing is properly seated in fittings it will take an R-tool, or similar device, to remove.
• Check for pressure loss along nozzle circuit; look for any drips/mists coming from any connection other than nozzle tips. Inspect buried and close to ground tubing for cuts and punctures due to rodents or lawn and garden tools. Note that breaks/cuts in tubing must be removed and properly spliced or lines will not pressurize.
• Check the pump manifold needle valve (Fig. 1, 4.b.). Adjust output pressure to 180 – 200 PSI.  Turn needle valve adjustment clockwise to increase pressure.
• Bad pump: if all the above has been checked and tested and there is still no output spray pressure the pump will need to be replaced.

The system builds pressure, but the nozzles do not spray.

• Spray nozzles are clogged: Old nozzles or nozzles that have been sitting without use for an extended period can accumulate deposits near the nozzle orifice. A razorblade makes a good tool for scraping the build-up from the nozzle tip. Clean nozzle by disassembling and blowing out the housing with compressed air. Many users find soaking the parts in a liquid lime and calcium remover (CLR) helps to loosen impurities and hard water deposits. Replace the nozzle if cleaning does not solve the problem.
• Tubing is restricted: Remove any kinks and avoid bends of 45 degrees or more.

Spray nozzles drip.

• Ensure all nozzle tips are screwed in tightly using O-rings or Teflon tape if required.
• Low system pressure (less than 150 PSI) can cause nozzle drip.  Use the manifold needle valve (Fig. 1, 4.b.) to adjust the pump output pressure to optimal 180 – 200 PSI.
• Check that all nozzles are spraying uniformly.  Non-uniform spraying indicates that some nozzles are clogged which can cause dripping.
• Big height differences between nozzles throughout a system may cause dripping. Installation of strategically placed inline check valves can eliminate dripping.
• If your pump manifold has a check valve, the supply line may be under excessive pressure. In extreme cases, the check valve may need to be removed.

Program Clocks

The Program Clock tells the system when to initiate a spray cycle. All systems contain either an Analog or Digital clock. Described below are commonly observed issues associated with clocks grouped by clock type. NOTE: the clock only tells the system when to initiate a spray cycle; it does not govern how long the spray cycle will last. The length of a spray cycle is determined by the Spray Time Adjustment knob (see Fig. 1, 1.c. above).

General Troubleshooting Analog Clocks

Analog clocks initiate spraying by pins along the clock face set to desired spray times. The example in Fig. 2 below shows the time at 7AM with a pin pulled to initiate a spray cycle at 8AM. The four pins per hour on the clock face make it possible to set spray times quarter hourly. Due to mechanics of the clock, a 15-minute reset is necessary before another spray cycle can be activated. Therefore, spray cycles can only be set 30 min. apart from one another. Pulling two pins in a row holds the trigger switch ‘on’ not allowing reset for 30 minutes.

NOTE: during the 15-minute interval in which a pin is holding down the switch, remote control and “Mist Now” button features are not useable. 

Fig. 2

Analog clocks are mechanical devices. They have moving parts and a switch. Exposure to dirt and excessive moisture dramatically shortens the lifespan of an analog clock and voids its warranty. The clock in Fig. 3 (below) stopped working within 6 months.

Fig. 3

It is critical that clocks be kept clean from dust, debris and moisture. Enclosure doors must be kept closed (Fig. 1, 1.d.).  It is highly recommended that Protective Covers be placed over systems in dusty environments. Covers can be found in SHOP > ACCESSORIES on the Mosquito Control Equipment WEB site. Alternatively, search for Cover-Black.

In some cases, the mechanical components of an Analog clock can break down internally. If a system with an Analog clock is not keeping time or initiates spray cycles randomly; the clock could be sticking at the pins. In Fig. 4 (image below), the clock face shows the time for when a pulled pin should initiate a spray cycle at 8AM. 

Fig. 4

If a clock is stuck at a pin, it will not progress further to initiate spray cycles. If you notice a cycle has been skipped; check to see if the clock is stuck. Note that clocks move slowly; it can take an hour or so to know if a clock is truly stuck.

Program Clocks that stick at pins will need to be replaced. Please contact Mosquito Control Equipment for assistance. 

PROGRAMMING THE DIGITAL CLOCK

Setting the Clock:

• While pressing and holding down the CLOCK button, press the MIN button until the correct minute is displayed. (Pressing and holding down the MIN button allows for quick scroll.)
• While pressing and holding the CLOCK button, press the HOUR button. Select the correct time.
• While pressing and holding the CLOCK button, press the DAY button. Select the correct day.

Programming the Timer:

1. Press the TIMER button once.
2. Press the DAY button once. The display will show daily program option 1: Mon – Sun, 7 days a week. Pressing the DAY button to toggle through the remaining 14 program options.
3. Press the HOUR and MIN buttons to set the desired spray cycle ON time. (Ex 7:00AM)
4. Next press the TIMER button once to proceed to the OFF setting.
5. Press the DAY button to match the same day(s) used for the ON time setting.
6. Next press the HOUR and MIN buttons to set the corresponding OFF time one minute later than programmed ON time. (Ex 7:01am).
7. Repeat steps 1. – 6. to program all desired spray cycles. The clock allows 16 unique programs.
8. Press the CLOCK button to exit programing.
9. Important: Review programmed times. Stepwise pressing the TIMER button allows you to scroll through program settings to ensure that ON and OFF times have been programmed one minute apart from one-another. 
10. Press the CLOCK button to exit programming.

NOTE: Programmed times only start spray events and do not affect the duration of these spray events. Spray event duration is set by the Control Box Spray Time Adjustment Knob (Fig. 1, 1.c.).  Spray time duration can be set between 5 – 180 sec.

Clock Timer Modes:

Pressing the MANUAL button changes the clock mode. The mode active is identified by the display indicator bar appearing over ON/AUTO/OFF printed on the clock face. See Fig. 5 below: the indicator bar shows the clock in AUTO mode. Below in Fig. 7 the indicator bar shows the clock in ON mode.

• AUTO mode: The clock must be in AUTO mode with the power LED off for routine spray programming to perform. Toggle to AUTO by repeatedly pressing the MANUAL button passing from ON to AUTO to OFF and back to AUTO so that when in AUTO the power LED is off.
• ON mode: Manually turning the system ON can be useful for troubleshooting. However, leaving the clock in ON will override the system functions (i.e. suspends spray cycles, disables the remote and renders the MIST NOW feature inoperable). From the ON mode, return to AUTO by toggling from ON to AUTO to OFF and again back to AUTO mode.
• OFF mode: The OFF mode turns off the TIMER programs and suspends spray cycles. However, the system remote and the MIST NOW feature, where applicable, remain operable.

Quick Guide:

Press: TIMER; HOUR (Ex. 7:00AM when HOUR is pressed 7 times).

Press: TIMER; HOUR; MIN (Ex 7:01AM when HOUR is pressed 7 times and MIN pressed once).

Press: CLOCK to exit programming.

Press: TIMER; TIMER (to verify set ON is 7:00AM and that set OFF is 7:01AM.)

Press: CLOCK to exit programming.

Fig. 5

General Troubleshooting Digital Clocks

Digital clocks do not have mechanical components and, on average, last longer than Analog clocks. Most problems reported with digital clocks relate to programing issues, errors made when switching ON/AUTO/OFF modes, or when the clock back-up battery depletes.

OVERVIEW:

Digital clocks initiate spray cycles according to TIMER programming. A programmed event requires both an ON and an OFF time. The ON time initiates a spray cycle and the OFF time resets the clock timer relay.  The clock timer relay does not govern the length of a spray cycle; it only triggers the system to initiate a spray cycle. The length of a spray cycle is determined by setting the Control Box Spray Time Adjustment Knob (See Fig. 1, 1.c.). Because the clock relay only triggers a spray cycle and has no control on the spray cycle duration, the ON and OFF times are separated by only one minute in set programs.

Clock Modes

Programmed TIMER spray cycles only activate when the digital clock is in AUTO mode with the power LED off. A bar on the display indicates which of the three modes (ON/AUTO/OFF) the timer is in. For reference see Fig. 5 above showing the clock in AUTO mode. Note that the power LED is off and no program is activated.

Pressing the MANUAL button changes the clock mode.  Manually turning the system ON can be a feature useful for troubleshooting. Note that the power LED illuminates when the system is ON. Leaving the clock in ON, however, overrides routine system function (i.e. suspends spray cycles, disables the remote and when applicable renders the MIST NOW feature inoperable). Therefore, for routine system operation, the clock must be returned to AUTO mode with the power LED off. This is done by pressing the MANUAL button repeatedly toggling from ON to AUTO to OFF and back to AUTO. Note that the power LED stays on when toggling from ON to AUTO but that it is off when toggling to AUTO from OFF mode.

• When programming the TIMER, ensure that both ON/OFF times have been entered for each spray cycle. ON times with no corresponding OFF times suspend activation of further spray cycles and override system functionality (i.e. remote and/or “Mist Now” button function) until the clock reaches an “Off” time. 
• Be sure “On” and corresponding “Off” times are set only one minute apart. (Ex On 7:00AM, Off 7:01AM) 
• If the LED stays on for longer than one minute during a spray, check programing to ensure all set spray cycle ON times have a corresponding set OFF times.

Digital Clock Battery

Digital clocks rely on a lithium CR2032 battery to retain programming during system power loss. Over time this battery will drain and will need to be replaced. The battery drains more rapidly when there is no power to the system. Therefore, when winterizing, leave the system plugged to the outlet and switch modes on the clock from AUTO to OFF to conserve the battery. Replace the CR2032 battery if the clock display dims, does not show, or if programmed spray times are not staying saved. 

To replace a battery:

• Disconnect power to the system.
• Unscrew the face plate from the inclosure.
• Carefully orient the plate to allow access to the back of the clock.
• Using a coin or broad screwdriver, remove the screw cap to the battery compartment by turning clockwise.
• Remove the old battery replacing it with a new one.
• Replace the battery compartment screw cap.
• Reattach the face plate and reconnect system power.

Fig. 6

Fig. 7

In the OFF mode, the Digital clock will not initiate spray cycles. Use the MANUAL button to toggle to AUTO mode.