IELD TROUBLE SHOOTING GUIDE REMVue 500 PLC/media/resources/spartan controls... · The following...

– i –

SPARTAN CONTROLS LTD. FIELD TROUBLE SHOOTING GUIDE

RREEMMVVuuee®®–– 550000SS // PPLLCC

Version 1 August 06, 2009

REMVue®– 500 / PLC FFIIEELLDD TTRROOUUBBLLEE SSHHOOOOTTIINNGG GGUUIIDDEE

– ii –

RREEMMVVuuee®®–– 550000SS // PPLLCC FFIIEELLDD TTRROOUUBBLLEE SSHHOOOOTTIINNGG GGUUIIDDEE

TTAABBLLEE OOFF CCOONNTTEENNTTSS TABLE OF CONTENTS ................................................................................................................................ ii 1. Control System Electronics ................................................................................................................. 1-1

1.1 Controller..........................................................................................................................1-1 1.2 I/O Module Status.............................................................................................................1-1

2. Thermocouples ..................................................................................................................................... 2-2 3. HMI Problem .......................................................................................................................................... 3-3

3.1 PLC Message...................................................................................................................3-3 3.2 HMI Does Not Come On ..................................................................................................3-3

4. Operating Problems.............................................................................................................................. 4-4 4.1 Starting .............................................................................................................................4-4 4.2 Loading.............................................................................................................................4-5 4.3 Engine Speed...................................................................................................................4-6 4.4 Engine Exhaust Temperature(s) ......................................................................................4-7 4.5 Engine Can’t Take Load...................................................................................................4-7 4.6 Overspeed Shutdown.......................................................................................................4-7

5. FAQ’s...................................................................................................................................................... 5-8 6. HMI Navigation ...................................................................................................................................... 6-9

6.1 Navigation Chart...............................................................................................................6-9 6.2 HMI Screen Snapshots ..................................................................................................6-12

7. Appendix 1 — Grounding................................................................................................................... 7-42 8. Appendix 3 — Alarm Logs, Trends and Data Logs ......................................................................... 8-43 9. Appendix 4 — Shutdown/Alarm classes .......................................................................................... 9-43

This document is designed to provide information regarding the troubleshooting of the RRREEEMMMVVVuuueee®®®––– 555000000SSS /// PPPLLLCCC Control Systems. Before changing any setpoints or operating parameters consult a Spartan Service Representative or the packager of the unit. Passwords should not be given out without approval from the packager (warranty considerations) or approval from an end user supervisor.

DDIISSCCLLAAIIMMEERR


– 1-1 –

RREEMMVVuuee®®–– 550000SS // PPLLCC FFIIEELLDD TTRROOUUBBLLEE SSHHOOOOTTIINNGG GGUUIIDDEE

11.. CCoonnttrrooll SSyysstteemm EElleeccttrroonniiccss

The following covers the REMVue 500 hardware. For PLC consult the PLC hardware manual.

1.1 Controller

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Status LED OFF No power; check input voltage and fuse.

Status LED OFF after 20s initialization Hardware or software error; try cycling power.

Status LED Fast Blink Controller is being reset; firmware to be downloaded with I/O Toolkit software.

Status LED Slow or periodic blink (about 1/sec)

Internal watchdog has detected a problem

Clear memory and load project with the I/O Toolkit software.

Communications LEDs Send (TD) and Receive (RD) do not blink

Check wiring. Set other device correctly. To confirm COM Port operations, use notebook computer with the SIXNET I/O Toolkit set to Modbus; use a 422 or 232 converter (if required).

1.2 I/O Module Status

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Status LED OFF No power, check connections.

Wait until I/O Toolkit operation complete.

Status LED Long Blink (0.75s on; 0.25s Off)

Module has lost communication with controller for more than 10s.

Check ST BUS wiring. Expected start-up condition — wait a few seconds.

Status LED Short Blink (0.25s on; 0.75s Off)

Failure of module self-test on start; replace module.

Status LED Winking (10 blinks/s) Occurs during linking operation. If after linking, refer to I/O Toolkit for help.


– 2-2 –

22.. TThheerrmmooccoouupplleess PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Failure of thermocouple

Loose connection Broken Short — constant or intermittent

Check terminals. Disconnect thermocouple; ohmmeter should show < 20 ohms for thermocouple.

Disconnect thermocouple; meggar or ohmmeter at 10M ohm scale should show isolation from ground.

Use thermocouple calibrator (if available).

Wrong Temperature value Mechanical problem Wrong thermocouple type Wiring backwards Module needs calibrating Stake-on connectors present

Check for real engine/compressor problem. J type is White (+) and Red (-). K type is Yellow (+) and Red (-). Calibrate where possible from end device end. Remove stake-on connectors.

Temperature erratic Real engine/load problem Splice terminal problem

Determine if temperature behaviour is possible due to mechanical fault.

Redo splice if not correct. Tighten cold junction terminals.


– 3-3 –

33.. HHMMII PPrroobblleemm 3.1 PLC Message

Message appears in the bottom left-hand corner.

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) PLC Not Responding message

Communications cable loose or disconnected

Different baud rates Controller address has been changed (i.e.: by I/O Toolkit)

Put cable in place and secure fastening screws. Put in correct addressing between HMI and controller; common values are 1 and 17.

Controller settings must be 115.2kbaud, N, 8, 1

PLC Disconnected message Controller off or not running Cable problem

Make sure the controller is powered up. Check cable to make sure it did not come loose on the controller or HMI. Repair/replace cable

HMI locked-up Cycle power to HMI (can be done when engine is running) with fuse on switch.

3.2 HMI Does Not Come On

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Voltage out of range Voltage required is 19.2 to 28.8 VDC.

Fuse blown Check for cause and replace fuse.


– 4-4 –

44.. OOppeerraattiinngg PPrroobblleemmss

The following covers only the most commonly encountered problems. The REMVue will not directly control the crank, ignition and fuel on a Cat engine with an ADEM system or a Waukesha engine with an ESM. The REMVue may not control the lube pumps for these units. For more detailed information consult the operating philosophy for that particular panel.

4.1 Starting PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS))

Alarm/shutdown not cleared Check the first out banner to se what caused the initial shutdown. Fix the cause of the shutdown.

Acknowledge and clear. Make sure the panel is in LOCAL mode.

If there are class B, b or C shutdowns flagged the ARM CLASS BbC is enabled on the DISCRETE INPUT VERIFY PAGE, turn this off.

Prelube not clear. Check shutdown/alarm to see if the engine or compressor permissive is faulted

Check to make sure the prelube pumps are running. If pumps are not running check the signal from the panel to the solenoid (requires voltmeter). If the solenoid is not getting power check the wiring and fuses.

Check the supply pressure to the solenoid. If the pumps are running check the engine and compressor oil pressures and make sure they are above the permissive settings (settings in the SEQUENCE PARAMETER PAGES).

Fail to Crank shutdown

Faults when the panel does not see an RPM signal 10 seconds after the crank turns on.

If the engine is cranking over make sure the panel is displaying an RPM.

Check the manual start valve and make sure it is open.

Check the starter supply pressure, consult starter manufacturer manual for correct pressure.

Check the starter solenoid to make sure it is turning on. If possible check the supply to the starter solenoid and make sure it is opening the starter valve.

Fail to Start Faults when the engine speed

does not go over the RUN PERMIT SPEED before the ENGINE FAILED TO START TIMER expires.

Verify the engine crank speed is > PURGE PERMIT SPEED (found in SEQUENCE PARAMATER PAGES). If the speed is not over the PURGE PERMIT SPEED the fuel and ignition will not turn on.

Check the ignition to make sure it is firing. An MPI display will show if the ignition is firing. Other ignition systems may require test equipment to determine if the ignition is firing.

Verify the fuel shutoff valve is opening. Check the fuel supply pressure.


– 4-5 –

4.2 Loading

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) “Ready to Load” does not appear after engine running and warmed up

Engine Oil Temp permissive not met

Compressor Oil Temp permissive not met

Check oil temps; determine cause if not OK. Consider reducing engine oil temperature permissive. Warning: Consult the engine warranty provider or manufacturer before changing settings.

Consider lowering compressor oil temperature permissive. Warning: Consult the compressor warranty provider or manufacturer before changing settings.

Load started, does not load

Verify the engine speed is > Minimum Load Speed (found in SEQUENCE PARAMATER PAGES).

Check the Capacity Overview to make sure there are no override conditions.

Verify the suction pressure is > suction override setpoint (CAPACITY OVERVIEW or PROCESS CONTROL).

Verify the discharge pressure is < discharge override setpoint (CAPACITY OVERVIEW or PROCESS CONTROL).

Check the suction valve control. Make sure the suction valve setpoint is > suction override setpoint.

Suction Valve control problems Check to make sure the suction valve is in Auto (SUCTION VALVE CONTROL PAGE). Make sure the suction pressure is not within the deadband.

Make sure there are no overrides on the suction control that could be causing the suction valve not control (most common is discharge override).

Place the suction valve into Manual. Try making a small increase or decrease to the suction valve output. Remember to return the control back to Auto.

If the suction valve does not move in manual check the supply pressure to the I/P or positioner. If possible check the analog output signal from the panel. Check the wiring between the panel and the suction valve control.


– 4-6 –

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Bypass Valve control problems Check to make sure the bypass is in Auto

(CAPACITY CONTROL PAGE). Check the CAPACITY OVERVIEW PAGE to see what the Low Select PID output is at. The Low Select PID output has to be > lower split range value in order for the bypass output to increase. As an example: Bypass split range 20 – 80%. The bypass valve will start to close when the Low Select PID output is >20%. The bypass valve will be closed when the Low Select PID output is at 80%.

Place the bypass valve in Manual (CAPACITY CONTROL PAGE). Try increasing or decreasing the bypass control. Remember to return the control back to Auto.

If the bypass valve does not respond check the supply pressure to the I/P or positioner. If possible check the analog output signal from the panel. Check the wiring between the panel and the bypass valve control.

4.3 Engine Speed

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) RPM fluctuates

Check the load on the unit to make sure it is not fluctuating and causing the speed swings.

Check the fuel pressure to make sure it is not fluctuating.

Check the engine exhaust temperatures and ignition system to make sure a cylinder is not misfiring.

If the governor control is using an I/P, check the supply and output pressures.

If the governor control is electronic (i.e. Cat ADEM or Waukesha ESM) check the wiring and control devices.

Check the output on the GOV CONTROL screen or the CAPACITY OVERVIEW screen, verify the output from the panel is stable.

Cylinder performance erratic Watch cylinder exhaust temperatures (see Section 4.4 Engine Exhaust Temperature(s) on page 4-7).

Check ignition system (diagnostics if applicable).


– 4-7 –

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Speed not controlling to setpoint. Check the GOV CONTROL screen and make sure the

speed is not within the deadband. Check the GOV CONTROL screen to see if the output is at 0% or 100% limit.

If there is an I/P being used check the supply and output pressures.

If there is an electronic governor the problem may not be with the REMVue control. Verify the output signal is getting to the electronic governor. If the signal is okay the problem is with the electronic governor system.

Check the wiring and fuse for the output. 4.4 Engine Exhaust Temperature(s)

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Thermocouple problem See Section 2 Thermocouples on page 2-2.

Please use care — an exhaust thermocouple can be changed with engine running.

Ignition component problems Plug — shorted or gap too large Secondary lead Coil

View exhaust temperature differences; typically will affect individual cylinders.

Check ignition system diagnostics.

Exhaust valve leak If just one cylinder is high, it could be a mechanical problem.

Engine overload Check load. If overload, reduce load.

4.5 Engine Can’t Take Load

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Low fuel pressure The fuel pressure may have to be increased at the

regulator before fuel valve. Warning: Consult the unit warranty provider or manufacturer before changing settings.

Compressor bypass/suction changes too sudden

The loading parameters or PID parameters may have to be adjusted. Warning: Consult a Spartan Service Representative before changing values.

4.6 Overspeed Shutdown

PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS)) Load reduced too quickly Reduce rate of flow change with compressor

suction/ bypass valve(s).

Ignition system problems Check the ignition system to make sure all cylinders are firing. The exhaust temperatures may also help determine if there is an ignition problem.


– 5-8 –

55.. FFAAQQ’’ss PPRROOBBLLEEMM CCOORRRREECCTTIIVVEE AACCTTIIOONN((SS))

There is a shutdown/alarm that will not reset.

Make sure the panel is in LOCAL. Check to see if the shutdown/alarm condition is clear. If it is a discrete input make sure the switch is closed (or open if set to normally open), this can be checked on the VERIFY DI PAGE. For analogs or temperatures make sure the process variable is not within the shutdown/alarm limits, this can be checked on the ANALOG/THERMOCOUPLE INPUT READINGS PAGES.

Verify the ARM CLASS BbC is not enabled on the VERIFY DI PAGE.

The engine will not start Make sure the engine is cranking over and the panel is showing an RPM.

Verify the engine speed is > PURGE PERMIT SPEED, this setting is in the SEQUENCE PARAMATER PAGES.

Make sure the fuel shutoff valve is opening. Verify there is sufficient fuel pressure.

Check the ignition to make sure it is firing.

The unit will not load, panel shows loading initiated.

Make sure controls are in AUTO. Check the engine speed to make sure it is at the MINIMUM LOAD SPEED, this setting is found in the SEQUENCE PARAMTER PAGES.

Check the CAPACITY OVERVIEW PAGE to see if what control is active and make sure it is not in an override condition (typically suction or discharge).

The unit keeps going down on underspeed, low compressor oil pressure or low engine oil pressure.

Check to see if the load is changing and stalling the engine, the DATA LOG can be used to track pressures.

Check the fuel system to make sure it is not causing the engine to quit.

Check the ignition system.


– 6-9 –

66.. HHMMII NNaavviiggaattiioonn 6.1 Navigation Chart

The navigation chart references the standard program. Some sites may have custom screen layouts. Blocks highlighted in grey are password protected by the OPERATOR PASSWORD. Blocks highlighted in yellow are password protected by the OPERATOR PASSWORD but also allow a view only that does not require a password.

SD MAIN

LOCAL/REMOTE MODE SELECTOR

START/STOP AND LOAD/UNLOAD

SD OVERVIEW


– 6-10 –

SUCT PID TUNING

DISCH PID TUNING

PROCESS CONTROL

CAPACITY/ PROCESS CONTROL

PROCESS READINGS

SHUTDOWN BYPASS

VIEW/ENTER SETPOINT

SD OVERVIEW

ANALOG INPUT

TC/RTD INPUT

SEQUENCE PARAMATERS

DISCRETE INPUTS

AI/TEMP INPUTS

ANALOG INPUT READINGS

TC/RTD INPUT READINGS

PERFORMANCE

SUCTION VALVE CTRL

CAPACITY CONTROL

PROCESS CONTROL

CAPACITY OVERVIEW

ANALOG SETPOINTS

ANALOG CLASS

ANALOG RANGES

ANALOG INPUT

TC/RTD INPUT

TC/RTD SETPOINTS

TC/RTD CLASS

SETPOINT OVERVIEW

ANALOG SETPOINTS/CLASS/RANGE TC SETPOINTS/CLASS

DI CLASS CONFIG DIFFERENTIAL/SPEED SETPOINTS

EXHAUST CYLINDER TEMPERATURES

EXHAUST CYLINDER DELTA TEMPERATURES

PERFORMANCE

TUNING SCHEDULE ENABLE/DISABLE

TUNING SCHEDULE SETUP

DISCH OVRD ON SP ENABLE/DISABLE

SUCTION VALVE OVERRIDE

SUCTION VALVE CTRL

PID SETUP

CAPACITY CONTROL

GOVERNOR CONTROL


– 6-11 –

DISCRETES

SD OVERVIEW

FORCE DO

VERIFY DO

VERIFY DI

PANEL CONTROL

OPERATOR LOG

DATA LOGGING


– 6-12 –

6.2 HMI Screen Snapshots

The screen snapshots are for the standard REMVUE 500 program. Some panels may have customized screens. For PLC screens consult the PLC operation manual.

The SD MAIN screen gives a quick overview of some of the operating readings. This page allows the starting, stopping, loading and unloading of the unit. You can also select LOCAL or REMOTE mode for the panel. From this screen you can go to the SD OVERVIEW screen which allows access to all other pages for the shutdown portion of the panel. Number displays that are in yellow can be edited, numbers in white are read only.


– 6-13 –

The SD OVERVIEW screen is used to navigate to all other screens. Note that some screens have a number display under them, these screens have password protected settings in them. To edit password protected settings touch on the yellow numbers and the password screen will pop up and the correct password will have to be entered. If you want to just view screens without entering the password touch on the text portion.


– 6-14 –

The support screen shows the software versions as well as the panel number. The heartbeat monitor light is also on this page.


– 6-15 –

The analog input setpoints page shows the low and high alarm/shutdown settings. The values in yellow (alarms) can be edited without entering the password. The values in blue (shutdowns) can only be edited by entering the password. The input description numbers will actually show the text of the input on the HMI. You can go to the analog input class setup and ranges from the setpoints pages.


– 6-16 –

The analog input class shows what type the shutdown is. Go to the help page to view more information on the class types. The class can only be changed by entering the password.


– 6-17 –


– 6-18 –

The AI transmitter ranges, filtering and zero/span adjustments can be made from this page. Requires a password to allow editing. See the calibrate help for more information.


– 6-19 –


– 6-20 –

The TC/RTD input setpoints page shows the low and high alarm/shutdown settings. The values in yellow (alarms) can be edited without entering the password. The values in blue (shutdowns) can only be edited by entering the password. The input description numbers will actually show the text of the input on the HMI. You can go to the TC/RTD input class setup from the setpoints pages.


– 6-21 –

The TC/RTD input class shows what type the shutdown is. Go to the help page to view more information on the class types. The class can only be changed by entering the password.


– 6-22 –


– 6-23 –

The sequence parameter pages show various panel settings. The values in yellow can be edited without entering the password. The values in blue can only be edited by entering the password.


– 6-24 –


– 6-25 –


– 6-26 –


– 6-27 –

This screen allows access to the exhaust differential setup and pressure differential/RPM setpoints. All other setpoints can also be accessed from this page. To edit setpoint values you have to go into the edit password protected screen and enter the password.


– 6-28 –

The discrete inputs can be bypassed for a short period of time. This screen requires a password. To enable the bypass just touch the NOT BYPASSED button, it will then change to BYPASSED. The BYPASS TIMER will start counting down.


– 6-29 –

The analog/thermocouple inputs can be bypassed for a short period of time. This screen requires a password. To enable the bypass just touch the NOT BYPASSED button, it will then change to BYPASSED. The BYPASS TIMER will start counting down.


– 6-30 –

The analog input readings show the value as well as the high/low alarms and shutdowns. This is a view only screen.


– 6-31 –

The tc/rtd input readings show the value as well as the high/low alarms and shutdowns. This is a view only screen.


– 6-32 –

The performance page allows access to the engine exhaust temperatures and the trending. These are view only pages. The most commonly used screen is the exhaust cylinder temperatures.


– 6-33 –


– 6-34 –

Suction valve control page. This is where the suction valve can be changed between auto and manual control. The tuning schedule and discharge override can be enabled/disabled from this page. The user can access the tuning schedule setup, suction valve overrides and PID setup from this page.


– 6-35 –

The bypass valve and the speed control can be placed in AUTO/MANUAL on this page.


– 6-36 –

The GOV CONTROL screen is where the governor can be placed in manual. This shows the output to the interface device for the governor, typically an I/P.


– 6-37 –

The PROCESS CONTROL page allows the SUCTION OVERRIDE to be placed in manual. The user can also access the suction and discharge overrides PID pages for the capacity control.


– 6-38 –

The capacity overview shows the override outputs and the low select which is then passed into the speed and bypass control.


– 6-39 –

The discrete outputs can be forced on/off. The crank, fuel and ignition can not be turned on at the same time. The unit has to be stopped and no ESD shutdowns flagged. Put the control in MANUAL to toggle the outputs.


– 6-40 –

Verify DO page shows the state of the discrete outputs.


– 6-41 –

Verify DI screen is where you can access the ARM CLASS BbC button. If this is turned on all of the class B, b and C shutdowns will trip and not clear. Push the button to turn it off.


– 7-42 –

77.. AAppppeennddiixx 11 —— GGrroouunnddiinngg The diagram here shows the recommended grounding arrangement to avoid ground loops. Poor grounding or grounding loops can cause many strange electrical and operational problems.


– 9-43 –

88.. AAppppeennddiixx 33 —— AAllaarrmm LLooggss,, TTrreennddss aanndd DDaattaa LLooggss Alarm logs, trends and data logs are sometimes very useful in trouble-shooting a problem. The Alarm Log shows the nature of the alarm, when the alarm occurred and if the alarm has been acknowledged. This is supplemented by the historic Shutdown/Alarm Log. The Trend Display shows up to 12 parameters in a trend format. The time base of the trend can be set from 30 minutes and up to 999,999 min (> 1 year). There are 60 samples per trace so a new sample appears every 30 s for the minimum time base of 30 minutes. The engine exhaust temperatures are shown on a separate trend screen. There are two data logs in the REMVue® system:

HMI Data Log — This is accessible from the OVERVIEW screen and the other is in the controller. The HMI data log screen samples data in a circular buffer for 60 seconds after the engine stops; thus allowing a detailed review from before the engine stopped to after it stopped. Up to 1,000 samples 64 points each can be captured. The sampling frequency is set from a supervisor HMI screen. A review of this data can help determine any recent changes.

Controller Data Log — This data log exists in the controller and is accessible only with the I/O Toolkit software. Typically, the sampling period is 15 or 30 minutes allowing data capture for a longer period (1 to 3 months).

99.. AAppppeennddiixx 44 —— SShhuuttddoowwnn//AAllaarrmm ccllaasssseess All the input sensors and selected calculated parameters (e.g.: torque index) in both the REMVue®– 500 /A and /S versions can be scaled and have provision for upper and lower alarms and upper and lower shut down limits as appropriate. As well, the alarms and shutdowns can be classified as shown below. The digital, analog, thermocouple and RTD inputs can be configured for different alarm and shutdown classes.

Class A — Alarm/shutdown functions are always enabled. All Class A shutdowns must be cleared before the unit can be started. Examples: engine oil level, compressor cylinder discharge temperature.

Class B — Alarm/shutdown functions are disabled until the B Timer is started. Class B functions are bypassed until the B Timer expires. Examples: lubricator no flow, engine jacket water temperature, intake manifold temperature

Class b — Alarm/shutdown functions are disabled until the b Timer is started. Class b functions are bypassed until the b Timer expires. Examples: engine/compressor oil pressures.


– 9-44 –

Class C — Alarm/shutdown functions are disabled until the unit is running. Class C functions are then individually monitored. When a Class C function becomes healthy it is enabled, and will cause an alarm/shutdown if it then goes unhealthy.

Class Other — Custom logic as required. Indication — Alarms and shutdowns are disabled. A sensor failure will generate an

alarm. Disabled — No alarms, shutdowns or sensor failure alarm.

Date post:	17-Apr-2018
Category:	Documents
Upload:	duongminh
View:	219 times
Download:	3 times

IELD TROUBLE SHOOTING GUIDE REMVue 500 PLC/media/resources/spartan controls... · The following...

Documents