Spartan Controls Ltd. Field Trouble Shooting Guide

SPARTAN CONTROLS LTD.
FIELD TROUBLE SHOOTING GUIDE

REMVue®– 500S / PLC
Version 1
August 06, 2009
–i–
REMVue®– 500 / PLC FIELD TROUBLE SHOOTING GUIDE
DISCLAIMER
This document® is designed to provide information regarding the troubleshooting
Vuuee®–– 550000SS // PPLLCC Control Systems. Before changing any setpoints or
®
MV
REEM
of the R
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.
REM Vue®– 5 00 S / P LC
FIELD TROUBLE S HOOTI NG G UIDE
TABLE OF CONTENTS
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
– ii –
REM Vue® – 5 0 0S / PLC

FIELD TROUBLE S HOOTI NG G UIDE
1. Control Sy st e m El e ct roni cs
The following covers the REMVue 500 hardware. For PLC consult the PLC
hardware manual.
1.1 Controller
PROBLEM CORRECTIVE ACTION(S)
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 Clear memory and load project with the I/O Toolkit
(about 1/sec) software.
¾ Internal watchdog has detected a
problem
Communications LEDs Check wiring.
¾ Send (TD) and Receive (RD) do not Set other device correctly.
blink
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

Status LED OFF No power, check connections.
Wait until I/O Toolkit operation complete.
Status LED Long Blink (0.75s on; 0.25s Module has lost communication with controller for
Off) more than 10s.
Check ST BUS wiring.
Expected start-up condition — wait a few seconds.
Status LED Short Blink (0.25s on; 0.75s Failure of module self-test on start; replace module.
Off)
Status LED Winking (10 blinks/s) Occurs during linking operation.

If after linking, refer to I/O Toolkit for help.
– 1-1 –
2. Ther mo coup le s
Failure of thermocouple Check terminals.
¾ Loose connection Disconnect thermocouple; ohmmeter should show <
¾ Broken 20 ohms for thermocouple.
¾ Short — constant or intermittent
Disconnect thermocouple; meggar or ohmmeter at
10M ohm scale should show isolation from ground.
Use thermocouple calibrator (if available).
Wrong Temperature value Check for real engine/compressor problem.
¾ Mechanical problem J type is White (+) and Red (-).
¾ Wrong thermocouple type
K type is Yellow (+) and Red (-).
¾ Wiring backwards
¾ Module needs calibrating Calibrate where possible from end device end.
¾ Stake-on connectors present Remove stake-on connectors.
Temperature erratic
¾ Real engine/load problem Determine if temperature behaviour is possible due
¾ Splice terminal problem to mechanical fault.
Redo splice if not correct.
Tighten cold junction terminals.
– 2-2 –
3. HMI Pr oble m
3.1 PLC Message
Message appears in the bottom left-hand corner.

PLC Not Responding message Put cable in place and secure fastening screws.
¾ Communications cable loose or Put in correct addressing between HMI and controller;
disconnected common values are 1 and 17.
¾ Different baud rates
Controller settings must be 115.2kbaud, N, 8, 1
¾ Controller address has been
changed (i.e.: by I/O Toolkit)
PLC Disconnected message Make sure the controller is powered up.
¾ Controller off or not running Check cable to make sure it did not come loose on
¾ Cable problem 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

Voltage out of range Voltage required is 19.2 to 28.8 VDC.
Fuse blown Check for cause and replace fuse.
– 3-3 –
4. Operat i ng Pro ble ms
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
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 to make sure the prelube pumps are running.
¾ Check shutdown/alarm to see if the If pumps are not running check the signal from the
engine or compressor permissive is panel to the solenoid (requires voltmeter). If the
faulted 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 If the engine is cranking over make sure the panel is
¾ Faults when the panel does not displaying an RPM.
see an RPM signal 10 seconds Check the manual start valve and make sure it is
after the crank turns on. 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 Verify the engine crank speed is > PURGE PERMIT
¾ Faults when the engine speed SPEED (found in SEQUENCE PARAMATER
does not go over the RUN PAGES). If the speed is not over the PURGE
PERMIT SPEED before the PERMIT SPEED the fuel and ignition will not turn
ENGINE FAILED TO START on.
TIMER expires. 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.
– 4-4 –
4.2 Loading
“Ready to Load” does not appear after Check oil temps; determine cause if not OK.
engine running and warmed up Consider reducing engine oil temperature
¾ Engine Oil Temp permissive not permissive. Warning: Consult the engine warranty
met provider or manufacturer before changing settings.
Compressor Oil Temp permissive not
Consider lowering compressor oil temperature
met
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.
– 4-5 –

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

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).
– 4-6 –

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)

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 View exhaust temperature differences; typically will
¾ Plug — shorted or gap too large affect individual cylinders.
¾ Secondary lead Check ignition system diagnostics.
¾ Coil
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

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

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.
– 4-7 –
5. FAQ’s
¾ There is a shutdown/alarm that Make sure the panel is in LOCAL.
will not reset. 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.
¾ 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.
¾ The unit will not load, panel shows Make sure controls are in AUTO.
loading initiated. 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).
¾ The unit keeps going down on Check to see if the load is changing and stalling the
underspeed, low compressor oil engine, the DATA LOG can be used to track
pressure or low engine oil pressures.
pressure. Check the fuel system to make sure it is not causing
the engine to quit.
Check the ignition system.
– 5-8 –
6. HMI N a vig ati o n

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.
LOCAL/REMOTE MODE SELECTOR
SD MAIN START/STOP AND LOAD/UNLOAD
SD OVERVIEW
– 6-9 –
ANALOG SETPOINTS
ANALOG INPUT ANALOG CLASS
ANALOG RANGES
VIEW/ENTER
ANALOG INPUT
SETPOINT TC/RTD SETPOINTS
TC/RTD INPUT
TC/RTD INPUT TC/RTD CLASS
SEQUENCE PARAMATERS ANALOG SETPOINTS/CLASS/RANGE

SETPOINT TC SETPOINTS/CLASS
OVERVIEW DI CLASS CONFIG
DIFFERENTIAL/SPEED SETPOINTS
SHUTDOWN
DISCRETE INPUTS
BYPASS
EXHAUST CYLINDER
TEMPERATURES
AI/TEMP INPUTS PERFORMANCE
EXHAUST CYLINDER
DELTA TEMPERATURES
PROCESS
ANALOG INPUT READINGS
SD OVERVIEW READINGS
TUNING SCHEDULE
ENABLE/DISABLE
TC/RTD INPUT READINGS
TUNING SCHEDULE
SETUP
PERFORMANCE SUCTION VALVE
CTRL
DISCH OVRD ON SP
ENABLE/DISABLE
CAPACITY/
SUCTION VALVE CTRL PROCESS
CONTROL SUCTION VALVE
OVERRIDE
CAPACITY CONTROL
PID
SETUP
PROCESS CONTROL
CAPACITY OVERVIEW CAPACITY GOVERNOR CONTROL

CONTROL
SUCT PID TUNING
PROCESS CONTROL
DISCH PID TUNING
– 6-10 –
DISCRETES
FORCE DO
VERIFY DO
VERIFY DI
SD OVERVIEW
PANEL CONTROL
OPERATOR LOG
DATA LOGGING
– 6-11 –
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.
– 6-12 –
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.
– 6-13 –
The support screen shows the software versions as well as the panel number. The heartbeat monitor
light is also on this page.
– 6-14 –
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.
– 6-15 –
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.
– 6-16 –
– 6-17 –
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.
– 6-18 –
– 6-19 –
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.
– 6-20 –
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.
– 6-21 –
– 6-22 –
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.
– 6-23 –
– 6-24 –
– 6-25 –
– 6-26 –
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.
– 6-27 –
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.
– 6-28 –
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.
– 6-29 –
The analog input readings show the value as well as the high/low alarms and shutdowns. This is a
view only screen.
– 6-30 –
The tc/rtd input readings show the value as well as the high/low alarms and shutdowns. This is a view
only screen.
– 6-31 –
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.
– 6-32 –
– 6-33 –
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.
– 6-34 –
The bypass valve and the speed control can be placed in AUTO/MANUAL on this page.
– 6-35 –
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.
– 6-36 –
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.
– 6-37 –
The capacity overview shows the override outputs and the low select which is then passed into the
speed and bypass control.
– 6-38 –
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.
– 6-39 –
Verify DO page shows the state of the discrete outputs.
– 6-40 –
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.
– 6-41 –
7. Append ix 1 — Ground ing

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.
– 7-42 –
8. Appendix 3 — Alarm Logs, Trends and Data Logs

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).
9. Appendix 4 — Shutdown/Alarm classes

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.
– 9-43 –
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.
– 9-44 –

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SPARTAN CONTROLS LTD.

FIELD TROUBLE SHOOTING GUIDE

REM Vue® – 5 0 0S / PLC

1.2 I/O Module Status

Status LED Winking (10 blinks/s) Occurs during linking operation.

Message appears in the bottom left-hand corner.

PROBLEM CORRECTIVE ACTION(S)

HMI locked-up Cycle power to HMI (can be done when engine is

3.2 HMI Does Not Come On

4. Operat i ng Pro ble ms

The following covers only the most commonly encountered problems.

PROBLEM CORRECTIVE ACTION(S)

4.3 Engine Speed

PROBLEM CORRECTIVE ACTION(S)

4.4 Engine Exhaust Temperature(s)

4.5 Engine Can’t Take Load

4.6 Overspeed Shutdown

6. HMI N a vig ati o n

Blocks highlighted in grey are password protected by the OPERATOR PASSWORD.

LOCAL/REMOTE MODE SELECTOR

SD MAIN START/STOP AND LOAD/UNLOAD

ANALOG INPUT ANALOG CLASS

SEQUENCE PARAMATERS ANALOG SETPOINTS/CLASS/RANGE

CAPACITY OVERVIEW CAPACITY GOVERNOR CONTROL

SUCT PID TUNING

DISCH PID TUNING

6.2 HMI Screen Snapshots

Verify DO page shows the state of the discrete outputs.

7. Append ix 1 — Ground ing

8. Appendix 3 — Alarm Logs, Trends and Data Logs

There are two data logs in the REMVue® system:

9. Appendix 4 — Shutdown/Alarm classes

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