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An AFR greater than the NFR and TOL suggests a leak large enough to find either visually, with a pressure tester, or by process of elimination.

 

Steps:

 

1. Locate the leak visually.

Run an inspection mist cycle and walk the nozzle circuit while it is misting. Look for a noticeable difference in mist intensity between adjacent nozzles, or sections misting poorly or not at all. This is the most direct indication of a leak being present.

2. Segment nozzle circuit branches if the leak still isn’t visible.

If there’s no obvious visual difference in performance between nozzles:

• • Choose a branch or section to temporarily remove for testing and block it off with a plug.
  • Adjust the controller’s nozzle count (NOZ) down by the number of nozzles on the plugged branch, so it matches the actively misting nozzle count, otherwise the test will be inaccurate.
  • Run a manual mist cycle and compare the AFR to the original baseline:
    • If AFR dropped, the leak is in the removed branch.
    • If the change is minimal (less than 5) or none, that branch is not the source. Re-add it and test the next branch.
  • Once a leaking branch is identified, re-add it, run an inspection mist, and fix the leak(s) found. Reset the controller’s nozzle count back to normal after this process is completed.

3. Replace underground tubing with above-ground tubing if the leak is in a buried section.

Buried tubing is hard to inspect visually and a common source of hidden leaks. Even when buried deep underground, root growth and other elements can cause to the destruction of buried tubing.

• • Choose a section of underground tubing and disconnect it from the circuit at each end that it is above ground.
  • Run a temporary line of above-ground tubing in its place.
  • Run a manual mist cycle and compare the AFR to baseline:
    • If AFR dropped, the leak is in that buried section.
    • If the change is minimal or none, a different buried section is the likely source, repeat with another buried run.
  • Once identified, either replace the underground tubing, or for a temporary fix, leave the above ground tubing in place until time can be made for the buried tubing replacement.
    • This approach works best when only a small amount of the circuit is underground; for extensively buried circuits, prioritize the pressure-tester and branch-segmentation steps first.

Break the loop and isolate one branch of the circuit. Adjust the NOZ count to match the new branch and test again.

 

4. Fix and confirm.

Repair any leaking tubing or fittings found, then run a manual mist cycle (hold Up + Down together) and compare the new AFR to baseline. There should be a noticeable drop in the AFR compared to the previous higher reading.

5. Repeat as needed.

If Error 3 occurs again after the fix, the circuit likely has more than one leak. Repeat the visual/pressure-tester check until Error 3 no longer appears and mist intensity looks normal across all nozzles.

 

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• Visible Leak
• Portion(s) of nozzle circuit not misting adequately
• Drum’s actual fluid level runs empty before the controller’s volume gauge

Troubleshooting Tests:

1.  Visually Inspect Nozzle Circuit To Find Leak

• Run an inspection mist cycle by going to the controller’s “Maintenance” menu, looking for “INS“, and holding down the “green” button. Take note of/record the pressure that is being read by the pressure gauge on the misting unit.
• Walk around and inspect nozzle circuit while unit is misting.
• Look for difference in mist intensity between adjacent nozzles or sections of nozzles that are misting poorly/not misting at all.
• Check for and fix any leaks in tubing or fittings around these areas.
• Run another inspection mist cycle.
• Compare the pressure at the misting unit and the mist intensity of the nozzles to the previous mist.
• Repeat Test 1 as necessary until pressure and mist intensity of nozzles meets expectation.

2.  Segment Nozzle Circuit Branches To Find Leak

• Run an inspection mist cycle and take note of/record the pressure that is being read by the pressure gauge on the misting unit.
• Stop the inspection mist cycle and choose the branch or section of the nozzle circuit that is not misting well to temporarily remove for testing purposes.
• Block off the chosen branch of the nozzle circuit using a metal plug.
• Run another inspection mist cycle and observe if pressure rises at the misting unit:
  • If pressure goes up to expected levels (230 psi – 250 psi), then your leak can be found at the branch that was blocked off for testing.
  • If pressure does not change, then the leak is in another area of the nozzle circuit and Test 3 will have to be repeated with a different branch.
  • If pressure only marginally goes up, the nozzle circuit may have leaks in multiple branches. Re-add the currently removed branch to the nozzle circuit, run an inspection cycle, and look closely for any potential leaks to fix.
• Repeat Test 2 as necessary until pressure and mist intensity of nozzles meets expectation.

3.  Replace Buried Tubing With New Tubing Above Ground

• This test is ideal for nozzle circuits that have a small amount of tubing that runs underground.
• Run an inspection mist cycle and take note of/record the pressure that is being read by the pressure gauge on the misting unit.
• Choose a section of tubing that is underground and disconnect it from the rest of the nozzle circuit at each end.
• Connect a new line of tubing in its place above the ground.
• Run another inspection mist cycle.
• Compare the pressure at the misting unit and the mist intensity of the nozzles to the previous mist.
  • If pressure or nozzle performance improves, that section of buried tubing has a leak.
  • If there is no improvement in either metric, then other sections of buried tubing must be tested.
• Fix any leaks or replace the chosen buried line with new tubing.
• Repeat Test 3 as necessary at other sections of the nozzle circuit that are buried until pressure and mist intensity of nozzles meets expectation.

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How it should work:

At the end of a mist cycle, when the controller stops the motor (and pump), the pressure in the line is relieved by a small amount of fluid flowing back through the auto-drain elbow into the tank. Because the fluid is incompressible, not much fluid has to leave the lines for the pressure to fall. The pressure should decay very quickly and minimize the time spent in the pressure range that causes nozzle dripping.

Scenarios that can induce dripping:

1. The check valve in the nozzle is working as it should, but the pressure in the nozzle circuit isn’t decaying quickly.  Something is restricting the fluid from traveling back into the misting unit through the auto-drain valve to relieve the pressure. The most common causes are:
   • There is a kink in the line between the unit and the dripping nozzles
   • The drum cover causes kink a in the nozzle circuit line that restricts flow
   • The agitation valve closed if HOLD time is too short
   • The agitation valve has failed and is only partially opening.  If this is the cause, the unit would mist while in agitation mode.
   • A check valve has been installed in the line (not necessary with our system).
2. The pressure in the nozzle circuit is decaying quickly, but there is something wrong with the internal check valve of the nozzle, causing it to stay open at a pressure that it is designed to close at.  Possible causes for this phenomenon are:

• • The valve is not aligned with the orifice and cannot seal it. This can be due to grit/dirt getting jammed internally or swelling/distortion of the check valve (caused by incompatibility between the insecticide and the seal material).
    • Cleaning and Rebuilding Nozzle Tips
    • What do I do about clogged nozzles?
  • The spring of the internal check valve is too light

The best way to test is to install an in-line pressure tester next to a dripping nozzle and mist the unit.  When the unit ends the mist cycle, observe the pressure decay on the gauge at the same time you watch the nozzle.  The pressure in the line should drop from an operating mist pressure (230 – 250 psi) to around 30 psi within 1 – 2 seconds.  Visibly, the nozzle should go from atomizing to off during that period.  From there, it should take a further 5 seconds for the pressure to decay to 5-10 psi.

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To function properly, the leak TOLerance should be calibrated to reflect the number of nozzles on the nozzle circuit.

To configure Leak Detection TOLerance for Nozzle Count

• DATA Menu, TOL.  Press and hold Green ► button for 5 seconds
• Use ▲ or ▼ buttons to adjust value based on nozzle count:

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• Enables Gen 1.3 to detect a leak in the nozzle circuit and suspend misting.
• Enables Gen 1.3 to accurately report the level of remaining solution in the drum  See Gen 1.3:  Level Display
• Required to enable full functionality of iMistAway.

To function properly, the leak TOLerance should be calibrated to reflect the number of nozzles on the nozzle circuit.  Leak Detection will not function on systems (or zones) with fewer than 12 nozzles because the flow meter is not reliable at very low flows.  And, it may not function reliably with mist durations shorter than 15 seconds.

To determine if Leak Detection is installed:

• Remove the controller from the unit and look for the flowmeter as pictured.

• The flowmeter is secured to the chassis with a zip-tie, and is installed on the discharge side of the pump, downstream of the agitation valve, on the tubing that feeds the nozzle circuit.

To determine if Leak Detection is operating:

• Go to the DATA Menu and cycle through the variables by pressing the Green ► button.
• Values labeled FL, TL, AFR, and TOL indicate that Leak Detection is operating.

To configure Leak Detection TOLerance for Nozzle Count

• DATA Menu, TOL.  Press and hold Green ► button for 5 seconds
• Use ▲ or ▼ buttons to adjust value based on nozzle count:

To disable Leak Detection:

• Unplug misting unit.
• Unplug the gray cable shown from the 6 pin connector on the back of controller as pictured below.
• Restore power to misting unit.

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