5.0 ALARMS & TROUBLESHOOTING

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1 5.0 ALARMS & TROUBLESHOOTING INTRODUCTION: Included in this section is a general guide for determining the possible causes of a failure and possible solutions. This guide is not intended to be all-inclusive. Always consult the troubleshooting guide of vendor supplied equipment, such as, flame scanners, burner controls and temperature controls in addition to the instructions given here. Do not alter the original settings established during startup without recording and consulting Ship & Shore Environmental. Follow all safety precautions listed in the safety sections of this manual. DANGER: CHANGING SETTINGS IN THE CONTROL SETUP SCREEN COULD RESULT IN DEATH OR INJURY AND/OR COSTLY DAMAGE TO THE OXIDIZER. 5.2 SERVICE HELP: At Ship & Shore Environmental, Inc., we are always committed to provide our customers with our best services available, either in troubleshooting or in new designs to increase the capacity of the unit to adapt to new production environments. Our service number is (562) , 8:30-4:30 Pacific Time Zone. After hours call (562) or (562) Our is Service@ShipandShore.com As you become more familiar with this system, you will be able to use the information contained in the troubleshooting section of this manual to solve many of the problems yourself. Most of the time, just by monitoring the indicator lights, the alarms, and the operator interface, the operator will be able to identify the problem.

2 5.3 ALARMS LIST RTO communicates with operator through the HMI. There are several messages that may appear on the HMI. There are three types of messages which required operator attention. The following is a brief description on these categories: : In case of critical alarms, the PLC will generate visual and audio alarms. Additionally, the RTO will be shutdown. The alarm can be silent by alarm acknowledge push button on control panel or alarm silence button on HMI. However, the alarm needs to be cleared before running the RTO again. In certain cases, it is required to reset the safety devices manually. Warning: In case of warning, a message will be displayed on HMI. The issue should be cleared and after that the warning message will be cleared automatically. Based on the type of warning alarm, RTO may to fresh air until warning alarm is cleared. The following is a list of possible alarms: Message Type Possible Cause Corrective Action Check the combustion blower & wiring Combustion Blower Air Combustion blower air Check the combustion Flow Fault proving is not made line for possible debris build up Check the inlet filter & clean the filter regularly Poppet Extension Fault Poppet Retraction Fault Problem with proximity Problem with poppet cylinder Problem with internal shafts Problem with shaft & cylinder moving too slow, not meeting timing set point on PLC Check proximity & wiring closest to Chamber B Check/hear poppet cylinder internal air leakage or hose leak Check speed control mufflers for debris build up & clean as required

3 VFD Fault (Manual Reset) VFD is not running Check VFD panel Write the error code on the VFD LCD screen. Reset the VFD manually by pressing the reset button Look up error code on VFD manual Main Fan Air Pressure Switch Fault Main fan air proving is not made Check the main fan, wiring & set point Check for condensation/water in the Main Fan/Combustion Air Pressure Switch Short Fault Main Fan/Combustion Air Pressure Switch is shorted Check the air pressure not to be jammed Check the air pressure wiring & set point Low Compressed Air Fault Problem with the supplied compressed air from plant Check air pressure indicator on air cylinder tank meeting above 60 PSI Check compressed air pressure on air line Check air filters & air line for possible debris build up Check air compressor inside plant High Temperature Limit Controller Fault (Manual Reset) Problem with the center thermocouple Problem with burner control and/or mechanical linkage Poppet cycle time is not correct Check the center thermocouple & wiring Verify the RTO set points Check that the burner modulates on low & high fire Please note: You will need to reset the temperature controller manually located on the top left corner of the control panel

4 Clear Path Damper Fault Problem with proximity Problem with clear path damper air cylinder VFD error Not enough pressure or air being delivered to cylinder Check the proximity Check the air cylinder for leakage through hoses or mufflers being clogged up Check the VFD for possible error codes Check the wiring on the proximity /solenoid Gas POC Switch Fault Thermocouple Broken Wire Fault Low Gas Pressure Switch Fault (Manual Reset) Warning Slow open SSOV is not close Check gas safety shut off valves Check the wiring wiring loose or broken Low gas pressure is not made Supplied gas pressure is not adequate Check the thermocouples on the RTO & look for a disconnect or broken wire Check the gas pressure & flow being supplied by utility company Check setting on the low gas pressure Check wiring on the Check for condensation/water in the Please note: Operator may need to reset low gas pressure manually on gas train High Gas Pressure Switch Fault High gas pressure is not made Supplied gas pressure is not adequate Check the gas pressure & flow being supplied by utility company Check setting on the high gas pressure Check wiring on the Check for condensation/water in the

5 No Flame Detected or Veri-Flame Fault Problem with self-check UV scanner Problem with burner pilot Problem with ignition transformer Problem with flame safeguard relay Problem with ignitor Problem with gas/air ratio to burner and/or butterfly valve (internal mechanism on burner) Check the UV scanner for carbon build up or moisture and clean lens with dry cloth Check pilot solenoid valve Check safety shut off valve Check/test the burner actuator Check the wiring on the actuator, UV scanner, transformer, safety shut off valve Check/replace ignitor Low Fire Switch Fault Mechanical linkage is not meeting the low fire Problem with low fire Problem with burner actuator not moving/working Problem with Natural Gas Pressure Check/test the burner actuator Check the low fire Check/adjust the linkage to meet the low fire Check the wiring of & actuator Check Natural Gas Pressure Air/Gas Actuator Fault Damper position change speed is not met Problem with Low/High fire Check the mechanical status of damper and joint to actuator Check the Low/High fire 3-Way Damper Fault Damper is not at the right position. Damper is moving too slow Problem with proximity/auxiliary Check the damper actuator Check the proximity/auxiliary Check the wiring

6 High Stack Temperature Fault Poppet cycle time is not correct Problem with unbalanced chamber temperature Check the thermocouple on the stack & wiring Verify RTO set points High Hopper (A or B) Temperature Fault Poppet cycle time is not correct Problem with unbalanced chamber temperature Check the thermocouple on the stack & wiring Verify RTO set points VFD Time Out Fault VFD delay time is passed and VFD permission is not met. Check the requirements for VFD permission Thermocouple (High Temp) Check the thermocouple on the RTO inlet & wiring Verify RTO set points Low Temperature Warning Warning Burner is off and RTO is online Problem with low fire Problem with burner actuator Verify that burner is on and PLC is controlling it Check burner actuator Diverter Fault Warning Problem with the process T-damper electric actuator Problem with proximity or actuator internal Problem with mechanical linkage meeting proximity sensor range Check the electric actuator Check the proximity Check the wiring Check the mechanical linkage Grease the bearings on the dampers