Symptom-first troubleshooting for the InteliHive: find what you are seeing, check the likely causes in order, and follow the link to the page that covers the fix.
Isolate before you touch. Many fixes below mean opening a panel, a sample line, or a chemical line. Lock out power and depressurize first — the relay devices and wireless outputs the controller drives are fed from their own circuits and stay live when the controller is off. See Isolating Equipment.
¶ Start here
Four questions narrow most problems down before you open anything:
- What do the three lights say? Read them left to right — Health, WiFi, Power. A Power light blinking red means fix the supply before anything else. See What the LEDs Mean.
- Which alarms are active? Every alarm has a code with its own page; the alarm title often names the device or input at fault. See Alarms and Error Codes.
- What dropped, and what still works? Everything wired at once points at power; one device points at that device. See Troubleshooting device connections.
- What changed? Recent panel work, a replaced cable, a new drive nearby, a changed setting. Controllers and probes rarely fail on their own.
Diagnose power first. A power fault cuts the Modbus bus supply and the IO-Link sensor supplies, so healthy sensors look disconnected and healthy control modes look broken. Fixing the supply often clears several alarms at once.
¶ Power and start-up
| Symptom | Likely cause | What to do |
|---|---|---|
| No lights, blank display | No 24 V DC at the controller | Measure at the input terminals. Check the supply’s own mains feed and breaker, the supply’s output, polarity, and the terminal connections. See Wiring. |
| Power light blinking red | Input below about 18 V DC — often an undersized supply sagging under load | See Power Fault (600). Measure the supply under load, not idle. |
| Power light blinking amber | A supply the controller provides has faulted — the Modbus bus supply or an IO-Link port’s sensor supply | See Modbus Supply Fault (620) or IO-Link Supply Short (610). Look for a short on device wiring. |
| Rainbow start-up never settles; Health light fast red | Start-up has stalled | Restart the controller. If it happens again, contact support. See Starting up. |
| Works on USB, nothing connected works | USB powers only the board, not the Modbus port or peripherals | Connect the 24 V DC supply. |
| Display frozen or not updating | Display fault | See Display Degraded (540). |
| Restarts on its own | Supply dropping out, or a loose supply connection | Check the supply and terminals; review the alarm history for 600. |
¶ An output does not run
A pump, valve, or outlet that should be on is off. Work down the list — the first match is usually the answer.
| Check | Likely cause | What to do |
|---|---|---|
| Is the output set to Auto? | It was left on Off  |
Set it back to Auto. See Hand, Off, Auto. |
| Is the mode enabled and complete? | Mode disabled, incomplete, or waiting for a role | See Setup Incomplete (500) and Profile Unset (501). |
| Is Policy Blocked (200) active? | An interlock — no flow, low tank, external stop — or a safety rule is holding it | The alarm title names the source. See Policy Blocked (200) and Interlocks. |
| Is Control Inoperable (230) active? | The sensor or output device the mode needs is offline | Fix the device first — see Device Disconnected (100). |
| Is Rate Limit Exhausted (211) active? | The output has used its actuation budget for this window | New actuations resume once earlier ones fall outside the window. Frequent hits mean the output is demanded too often — check the setpoint and differential. See 211. |
| Is a calendar program running? | A calendar lockout is holding the mode off | Normal during a biocide program. See Calendar — Lockouts. |
| Is the reading actually past the setpoint? | Direction set the wrong way (Rising vs Falling), or differential not yet cleared | See Setpoint Control. |
| Is the device itself switching? | Wireless output lost contact and its failsafe turned it off; relay or outlet failed | Check the output device’s status and supply. See Wireless Devices and Modbus RTU Devices. |
| Is the load getting power? | The relay switches, but the load’s own circuit is off | Check the load’s breaker or fuse. The controller only switches it. |
¶ The output runs, but nothing happens
| Symptom | Likely cause | What to do |
|---|---|---|
| Pump runs, no chemical fed | Lost prime, empty tank, closed valve, blocked injection quill | Check the tank, the suction line, and the injection point. On a NextStep pump, check its alarms — 330–337. |
| Bleed valve opens, conductivity keeps rising | Strainer, valve, or drain blocked; manual throttling valve closed | Clear the strainer and drain; check the valve actually opens. See Sample Line and Bleed Plumbing. |
| Actuation Limit (212) | One bleed or dose ran longer than its limit alarm | The same causes as above — something is stopping the output from bringing the reading back. See 212. |
| Dose Backlog Full (232) | Water is arriving faster than doses can be fed | See 232 — the on duration is too long for the flow, or gallons per dose too small. |
¶ An output runs when it should not
| Symptom | Likely cause | What to do |
|---|---|---|
| Output on, mode says off | Left in On (Hand)  — it returns to Auto at the end of its run time |
See Hand, Off, Auto. |
| Local Override (231) | Switched on at the device itself | Switch it back at the device. See 231. |
| Bleed opens during a biocide program | The program’s pre-bleed step | Normal. See Biocide Programs. |
| Output stays on, controller off | A relay welded or a valve stuck open; a load wired around the relay | Isolate the load and inspect the relay and valve. |
| Output chatters on and off | Differential too small for a noisy reading, or a bouncing contact | Widen the differential; check the probe is in steady flow. |
¶ Readings
| Symptom | Likely cause | What to do |
|---|---|---|
| Reading missing, shows unavailable | Device offline | See Device Disconnected (100) and the page for its connection type. |
| Reading erratic or noisy | Air bubbles or poor flow past the probe; electrical noise from drives; shields grounded at both ends | Check flow through the sample line; route probe cables away from drives; ground cable shields at the controller end only. |
| Reading steady but wrong against a handheld | Probe fouled, needs calibration, or the handheld is off | Clean the probe, check the handheld against a standard, then calibrate. See Calibration. |
| Reading flat, never changes | Probe in stagnant water — flow stopped, or a boiler line between samples | Check the flow switch and sample line. On a boiler, see Sampling and Blowdown Control. |
| Boiler conductivity reads low | Steam flashing around the probe | See Sampling and Blowdown Control — Troubleshooting. |
| Reading shown but flagged | The sensor’s own diagnostics — foam, interference, mounting too close, dirty optics | See the sensor’s page under Instrumentation. |
| Low, High, Low-Low, High-High (310–313) | The reading crossed an alarm limit | If the reading is real, the process needs attention; if not, treat it as a reading problem above. See Reading Limits. |
| Calibration refused — gain out of range | The correction is too large: wrong standard value, or a failing probe | Check the standard, clean the probe, retry. See Calibration. |
| PTSA reads low, ST-500 shows Fouled | Dirty optics — Probe Needs Cleaning (340) | Clean the probe, then calibrate it. A fouled ST-500 makes a PTSA mode overfeed. |
| Pyxis calibration: Clean first | The ST-500’s cleanliness check read fouled in the standard | Clean the probe and Retry. See Calibration — Pyxis ST-500. |
| Level probe shows No tank set | An LS-200/202 with no tank settings | Enter them under its Configure. See Tank settings. |
¶ Devices
| Symptom | Where to look |
|---|---|
| Every wired device dropped at once | Input power — 600 |
| Modbus devices dropped | Modbus RTU Devices — Troubleshooting |
| A probe will not move to a new address | Modbus RTU Devices — If a move fails |
| IO-Link sensor dropped or not detected | IO-Link Devices — Troubleshooting |
| Wireless device dropped, or will not pair | Wireless Devices — Troubleshooting |
| Device Conflict (102) | A different device at a saved location — 102 |
| Device won’t add | Wrong address or bus settings; unsupported model — Supported Devices |
¶ Network and cloud
| Symptom | Likely cause | What to do |
|---|---|---|
| WiFi light blinking red | Can’t join the site WiFi | Check the router and the password. See WiFi Lost (401). |
| WiFi light blinking amber | On WiFi, but can’t reach Inteliverse | Check the site’s internet and firewall; Settings → Networking → Network Info shows which step fails. See Cloud Failed (420). |
| Wireless devices unreachable after a network change | The site network overlaps the controller’s own | See AP Subnet Conflict (412). |
| Registration rejected | A device with the same name exists, or its record was deleted | See Cloud Conflict (422) and Cloud Credentials Invalid (423). |
| Never connected to Inteliverse | Cloud setup not finished, or offline not chosen | See Cloud Setup Pending (502) and Network and Cloud. |
A controller keeps controlling when the internet is down; only reporting stops.
¶ Time, schedules, and settings
| Symptom | Likely cause | What to do |
|---|---|---|
| Calendar program did not run | Clock not set; controller off at start time; start missed by more than a minute; interlock blocking | See Calendar — Timing rules and Time Not Set (521). |
| Clock wrong after power loss | Hardware clock missing or failed | See RTC Missing (520). |
| On (Hand) refused — time not set | Timed runs need a trusted clock | Wait for the time, or set it. See 521. |
| Settings lost, or a save refused | A settings file failed to load or failed validation | See Config Error (530). |
| Firmware update failed | Interrupted, or rolled back | See Firmware Update Failed (550) and Firmware Updates. |
¶ Before you call support
Have these ready — they turn a long call into a short one:
- The controller’s firmware version and its serial number.
- The active alarms and the alarm history, with times. See Alarms.
- What changed before the problem started, and when.
- A photo of the lights, and of the wiring if the problem is electrical.
- What you have already checked, from this page.