DC4000/DC4500 Conductivity Controller Troubleshooting

1. Verify the current software revision being used for the controller (DC4000 Rev. 1.13, DC4500 Rev. 1.53). If earlier version of software STOP! Get latest revision and troubleshoot from there.

2. Scroll down to "Advanced Menu" to access "Load Defaults". Reload factory defaults to clear all previous programming parameters. Any programming that has been entered in the controller will need to be re-entered after all tests are performed. (This will return the controller settings to a "ground zero" where we can determine that all programming has been cleared.) Enter the Manual Output mode and test all outputs to verify correct operation and that no relays on the I/O Board are faulty.

3. Remove the lower cover from the controller to access the I/O Board. In the upper right hand corner you will locate an internal test switch, (the test switch for the DC4000 will be found in the center of the I/O Board). Flip the test switch to the down position, this will enter the test mode. In the test mode, the test switch will by-pass the probe input and put a resistor across the conductivity input and simulate a conductivity reading of 3000 microseimens. Press "Enter" on the keypad to access the "Calibration" mode and use the Up/Down arrows to change the reading to 3000. (Remember: The value that is being displayed may not be at 3000. This controller may have been calibrated to the probe or system water for this application.) After scrolling the value to 3000, press the "Enter" key to hold the value then flip the test switch back to the up or Run position. Wait for 20 – 30 seconds for the programming change to be held in non-volatile memory then put the test switch back into test mode. The conductivity value that is being displayed should stable be at 3000 +/- 10 uS. This will confirm that the controller can hold calibration and continue to next test. If the value displayed is not what it was left at, follow instructions one more time from beginning as a second verification. If after second test and unit does not hold calibration, a replacement CPU or Front Panel will be needed. Contact your local distributor for part number, pricing or warranty information.

4. Using a paper clip, short out pins 1 and 2 of the 4-pin connector for the probe input. This will simulate a full scale reading on the controller of 20,000 uS. If this test works correctly, then you can determine that the controller is working fine and any problems that you may be having are located outside the controller, (i.e.- The cause of the problem lies in the probe or in the system and not in the controller itself).

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