Quick Reference General Troubleshooting Guide
We are currently restructuring our database system. Detailed online troubleshooting guides will be available in the future.
Refer to your Operation & Maintenance manual for additional troubleshooting details
...or call customer service if you need assistance.
To efficiently troubleshoot your I-CON system, we recommend troubleshooting in the following order:
Sensor 
Controller Solenoid Valve
General Instructions for Troubleshooting I-CON Sensors
IF AN I-CON SENSOR IS NOT WORKING:
1) First verify that the controller is properly operating other touch sensors connected to the same controller as the sensor in question.
2) If sensor will not activate and if other sensors are working on the same controller and on the same port of the controller, then replace the sensor.
General Instructions for Troubleshooting I-CON Controllers
FIRST - Check all electrical connections, making sure they are free of corrosion and well connected.
IF AN A/C CONTROLLER IS NOT FUNCTIONING:
1) Verify amber light is on. If light is not lit then verify the power switch is in the ON position and there is power to transformer. Using a voltmeter, check to see if there is between 24 and 32 VAC power coming from secondary side of transformer.
2) If power is not coming out of the transformer, check the associated power outlet. If the outlet is good, then replace the transformer.
IF A BATTERY CONTROLLER IS NOT FUNCTIONING:
1) Verify the board is getting power, unplug the battery and wait up to 10 seconds. While plugging the battery back in, verify the LED blinks green and red.
2) If LED does not light, verify the battery has enough voltage by carefully removing the small cap on top of the white plug. Using a voltmeter, check to see if there is 4-6VDC and 7-9VDC coming from the two power lines (Black wire is GROUND; White is 6VDC; Red is 9VDC). If the voltages are too low replace battery.
IF CONTROLLER IS POWERED BUT INPUTS (SENSORS) ARE NOT FUNCTIONING:
1) Verify that all sensors have been plugged into their correct receptacle by referring to the controller’s lid.
2) Verify that the modular plug on each sensor is clean and has been fully inserted and locked into its receptacle.
3) Unplug one of the sensors that isn’t working, and in its place plug in a spare or test sensor. While activating the input verify the green LED, located near the sensor socket, turns on. If the green LED lights, replace the defective sensor. If the green LED does not light, contact I-Con Technical Support for further instructions.
IF INPUTS ARE FUNCTIONING BUT OUTPUTS (SOLENOID VALVES) ARE NOT ACTIVATING:
1) Verify that water has been turned on.
2) Verify that all solenoid valves have been plugged into their correct receptacle by referring to the controller’s lid.
3) Verify that the modular plug on each solenoid valve is clean and has been fully inserted and locked into its receptacle.
4) Turn off power to the controller, wait 15 seconds and then turn power back on. Retest solenoid operation. Turn off water supply to valve before replacing any solenoids on valves. Unplug one of the solenoid valves that isn’t working, and in its place plug in a solenoid valve that you know is working. Turn off water supply to valve on. Activate the input controlling the solenoid valve being tested and verify the output green LED, located near the solenoid receptacle, turns on. If green LED lights, replace defective solenoid (solenoid can be replaced without having to remove valve from the pipeline by simply unscrewing it from the valve assembly) . If green LED does not light, call I-Con Technical Support for further instructions.
General Instructions for Troubleshooting I-CON Solenoids
IF SENSOR IS ACTIVATED AT ONE FIXTURE BUT DIFFERENT FIXTURE RESPONDS:
1) Inputs and outputs are not properly matched. Refer to the controller’s lid for specific wiring. Sensor (Input) should be directly across from the corresponding solenoid (output).
CHECKING A BATTERY OR 24 VAC SOLENOID FOR OPERATION:
1) When the solenoid is energized, you should be able to hear a “click”. This is the sound of the plunger contacting the backing of the plunger guide tube when the magnet field intensifies.
DISASSEMBLY/INSPECTION OF THE BATTERY SOLENOID/BLEED PLUG ASSEMBLY:
1) Remove the nut from the top of the battery solenoid.
2) Carefully pull the bleed plug and plunger guide tube through the coil assembly. When this is removed, there are loose pieces (coil with lead attached, bracket, magnet, plate and white plastic ring) that need to stay in place for when the solenoid is reassembled.
3) The bleed plug/plunger guide tube assembly needs to be disassembled. Hold the bleed plug with pliers and use a pair of needle nose pliers to loosen the spanner ring holding the bleed plug to the plunger guide tube assembly.
4) Remove the bleed plug. Inside this assembly is the plunger with spring and o-ring that seals bleed plug to the plunger guide tube. Make sure that the center hole of the bleed plug is clear of debris. Also check the ridge around center hole to make sure it is not nicked or worn. If nicked or worn and the valve the solenoid was removed from was leaking through, replace the bleed plug.
5) Remove the plunger from the plunger guide tube. Make sure there is no debris in the guide tube.
6) Inspect the plunger to make sure it is free from rust or flake that may clog the bleed plug. Inspect the spring and the insert in the plunger. This insert should be perfectly flat. If not, it won’t seal against the bleed plug and the water will leak through.
7) Reassemble bleed plug, plunger, o-ring, spanner ring and plunger guide tube. Insert assembly through the other parts (coil, bracket, magnet, plate and white plastic ring).
8) When you put the nut back on to hold the assembly together it is very important that you DO NOT TIGHTEN THE NUT DOWN. It only needs to be snugged up. Over-tightening this nut can stop the solenoid from operating.
DISASSEMBLY/INSPECTION OF THE 24 VAC SOLENOID/BLEED PLUG ASSEMBLY:
1) Remove the nut from the top of the 24 VAC solenoid.
2) Pull the bleed plug and plunger guide tube through the coil assembly. When this is removed, there are two pieces (coil with lead and bracket) left.
3) The bleed plug/plunger guide tube assembly needs to be disassembled. Hold the bleed plug with the plastic latch and use an Allen Wrench to remove the plunger guide tube from the bleed plug.
4) Remove the bleed plug. Inside this assembly is the plunger with spring and o-ring that seals bleed plug to the plunger guide tube. Make sure that the center hole of the bleed plug is clear of debris. Also check the ridge around center hole to make sure it is not nicked or worn. If nicked or worn and the valve the solenoid was removed from was leaking through, replace the bleed plug.
5) Remove the plunger from the plunger guide tube. Make sure there is no debris in the guide tube.
6) Inspect the plunger to make sure it is free from rust or flake that may clog the bleed plug. Inspect the spring and the insert in the plunger. This insert should be perfectly flat. If not, it won’t seal against the bleed plug and the water will leak through.
7) Reassemble bleed plug, plunger, o-ring and plunger guide tube. Insert this assembly back through the bracket and coil with lead. Screw nut back on top to hold assembly together. DO NOT TIGHTEN THE NUT DOWN. It only needs to be snugged up. Over-tightening this nut can stop the solenoid from operating.
General Instructions for Troubleshooting I-CON Valves
IF TOILET DOES NOT FLUSH:
1) Verify water is turned on.
2) Please refer to the section in your operations manual on controllers before proceeding.
3) Activate the input controlling the flushing device that is not working. If core assembly of solenoid valve is functioning properly you should hear a metallic clicking sound. If clicking sound is heard then check to see if flush activation control knob is open. If clicking sound is not heard, replace solenoid.
4) To replace solenoid on flushing device, turn water supply to valve off, unscrew solenoid from flushing device, and unplug solenoid from controller. Install new solenoid onto flushing device, plug solenoid into controller, turn water to flushing device back on, and then check for proper operation.
IF TOILET FLUSHES CONTINUOUSLY:
1) Make sure bypass lever on solenoid valve is in OFF position. Turn clockwise until snug.
2) Unplug solenoid from controller. If water flow stops, the problem is with the controller (call I-Con Technical Support for assistance). If water flow continues, solenoid valve parts may need cleaning or replacement.
3) Turn water supply to valve off.
4) Remove solenoid valve core assembly and clean. Replace solenoid core assembly and turn water supply back on.
5) If toilet is still flushing, turn water supply back off.
6) Remove flush valve sealing gasket and seat seal assembly. Check for foreign material and/or defects. If parts are worn or damaged, install a complete rebuild kit. Turn water supply back on.
IF TOILET DOES NOT FLUSH LONG ENOUGH:
1) Verify factory preset on flushing device has been set properly. The toilet may have a blockage or calcium build-up at the flush jets. If flush action adjustment is needed, rotate knob 1/4 turn at a time: clockwise to decrease, counterclockwise to increase. After each adjustment check to see if flush action is reset properly.
NOTE: To return the flushing device to the 1.6 GPF setting, turn the knob clockwise until the valve seat touches the seal area and then rotate the knob counterclockwise 1-1/2 turns.