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Vantage

Troubleshooting Guide

Quality from Cooper


Turbocompressor

Overview
This guide describes basic troubleshooting procedures that should be used to
assist solving problems encountered with the Vantage compressor control
system.
This guide does not provide information on every possible installation or
operational issue that may be encountered with specific installations and
applications, and therefore will not answer every question that may arise while
troubleshooting your particular system. Consult with a factory trained service
representative if there is any question of how to proceed with solving a problem.
Safety Precautions
Centrifugal compressors are powerful industrial machines that utilize high-speed
rotating elements and high voltages to produce high gas pressures. Therefore, it
is very important to use extra safety precautions whenever the compressor is in
operation as well as when performing maintenance or making repairs.

WARNING:
Read, be sure to clearly understand, and then carefully follow all
of the directions and procedures included in this guide.
Failure to adhere to the guidelines and specific instructions
provided could cause equipment damage and serious
personal injury or death.

WARNING:
Personnel who will be troubleshooting the Vantage control
system must be trained and qualified to work on electrical
equipment. Personnel must be familiar with the applicable local,
state, and national electrical codes and procedures to be used
with this type of equipment.

WARNING:
Personnel must be trained and aware of the safety and lockout
procedures of the compressor that they will be working on.
Because of the nature of the troubleshooting procedures, it is
possible that the control system will produce unintended actions.
Caution must be used to insure a safe working environment
regardless of what the control system might do at any point.

Troubleshooting Procedures
The Vantage compressor control system utilizes hardware and software to
provide the functionality to control the compressor for a wide variety of
applications. Because of the flexibility and capabilities offered by the control
system, it can appear to be complex when trying to solve a particular problem.
The key to effective troubleshooting is to use a methodical approach, breaking
the problem solving process down into small steps.
The primary issue to be determined when troubleshooting a problem is to
determine if the problem is caused by software or hardware. Software problems
are typically more difficult to solve because you must understand how the
software was designed to operate to determine if the problem is truly an error in
the software, or it is the result of how the software is configured.
Hardware troubleshooting is relatively straight forward and uses measurable
values and procedures to determine if there is a hardware problem.
Consequently, it is strongly recommended that you go through the hardware
troubleshooting procedures first when working to resolve any problem. If the
hardware is determined to be functioning properly, then the problem lies with the
software, or with devices outside of the control system.
Equipment and Materials Required
The following equipment and materials are required to troubleshoot and service
the Vantage control system:
Personal computer running Microsoft Windows 95 or later, 800 x 600
display resolution, with an available serial port.
An RS-485 to RS-232 converter and cable to connect the PC to the
Vantage controller.
Vantage Desktop software version 5.00.040 or later. This includes the
vantage controller software.
The Vantage connector test kit. The kit includes plug-in connectors wired
with precision resistors, one connector wired with a test jumper, and
several empty connectors. This test kit can be ordered directly from Bay
Controls 419-891-4390, Part Number CN-MLM2-KIT.
An industrial use multi-meter capable of AC and DC voltage and current
measurement, resistance measurement, and a clamp on high current
probe to measure main motor current.
Spare Vantage User Interface Module (P/N: CN-UIM2).
Spare Vantage Main Logic Module (P/N: CN-MLM2).
Spare UIM to MLM cable (P/N: CN-UIM2MLM).
Power cable. This cable is a standard line cord wired to the three pole
plug connector used on the Vantage MLM.

Contact your factory service representative to obtain or answer questions


regarding the test materials and equipment.
Hardware Troubleshooting
The Vantage controller uses three types of hardware components, the User
Interface module (UIM) and Main Logic Module (MLM) and an interconnecting
cable. The first step in troubleshooting a hardware problem is identifying which
component has the problem.
If the problem is related to use of the keypad, display quality, or garbled
information on the display, the problem may be with the UIM hardware. If the
display does not function at all, the problem may be in the UIM, MLM, or cable.
If the problem is related to measured inputs to the controller, or outputs from the
controller, the problem is likely to be in the MLM.
User Interface Module (UIM)
The User Interface Module (UIM) contains the display, keypad, and associated
electronic components. There are no user serviceable parts inside the module.
Opening the module will void the warranty.
The simplest method of confirming a UIM problem is to disconnect the suspect
module, connect a spare module, press the Home key to restore the display, and
see if the problem still exists with the spare module. You can safely change UIMs
with the power on and the compressor running if necessary.
If the problem appears to be solved by using the spare module, reinstall the
suspect module and confirm the problem reoccurs with the suspect module. If it
does not reoccur, the problem may be with the cable, or with how the module
was mounted.
If the same problem occurs on the spare module, the problem is likely with the
cable or MLM. Try changing the cable with the spare, if that does not solve the
problem; try replacing the MLM with the spare.
The following table can be used to identify which components may be causing
user interface related problems:
Symptom
User interface inoperative, blank
display.
Poor display quality.

Possible Causes
UIM to MLM cable defective.
UIM defective.
MLM defective.
Improper contrast setting.
Operating temperature outside
maximum specification.
UIM defective.

Symptom
One or more keys inoperative.
Garbled or missing information on
display,

Possible Causes
UIM to MLM cable defective.
UIM defective.
UIM to MLM cable defective.
Incorrect alternate language
selected.
UIM defective.
MLM defective.

Main Logic Modules (MLM)


The Main Logic Module (MLM) contains the input and output circuitry, memory,
microprocessor, and associated logic components. There are no user
serviceable parts inside the module. Opening the module will void the warranty.
While it may seem that you can swap the MLM with the spare to troubleshoot the
problem, this is not recommended for the following reasons: 1. if the problem is
caused by field wiring or devices, you may damage the spare module when
installing it. 2. Swapping the module is relatively time consuming, if you seem to
solve the problem, you really need to swap it back to confirm you have really
solved the problem and have not inadvertently treated the symptom. 3. To
receive warranty credit, you must identify the specific problem with the MLM.
Because a problem with one area of the controller may be caused by something
interrelated in another area, you should test all functions of the MLM using the
following procedures. Be sure to document the results of each test.
Analog Input Channels
The analog inputs are tested as follows:
Disconnect the field devices and wiring by unplugging connectors J5 and
J6. Do not disconnect the wiring from the connectors.
Insert the input test connectors from the connector test kit into connectors
J5 and J6. These connectors can also be fabricated by wiring a 1.80 kiloohm, 0.1%, precision resistor between the thirteen plus and minus
terminals of each input channel.
Select the View Input Channels Page on the Vantage controller. This is
accessed by pressing the Set Points key, from the Tools menu. Note that
an access code may be required depending on the configuration.
Analog Inputs 1 through 13 should all indicate between 10.0 to 12.0 mA. If
one or more channels indicate outside of this range, or Open, Short, or
Fail, the respective channel is defective.
If the input channels indicate an acceptable value, the input channel
hardware is functioning correctly. Problems with inputs are due to
improper configuration, or with the field devices.

The input channels of the optional second MLM are tested using the
procedure above, and pressing the down arrow key on the Vantage to
view the channels on the second module.
Temperature Input Channels
The temperature inputs are tested as follows:
Disconnect the field devices and wiring by unplugging connectors J7 and
J8. Do not disconnect the wiring from the connectors.
Insert the input test connectors from the connector test kit into connectors
J7 and J8. These connectors can also be fabricated by wiring a 100 ohm,
0.1%, precision resistor between the ten plus and minus terminals of each
input channel. The two minus terminals of each channel must also be
connected together.
Select the View Input Channels Page on the Vantage controller. This is
accessed by pressing the Set Points key, from the Tools menu. Note that
an access code may be required depending on the configuration.
RTD Inputs 1 through 10 should all indicate between 13.0 to 34.0 DegF. If
one or more channels indicate outside of this range, or Open, Short, or
Fail, the respective channel is defective.
If the input channels indicate an acceptable value, the input channel
hardware is functioning correctly. Problems with temperature inputs are
due to improper configuration, or with the field RTDs.
The temperature input channels of the optional second MLM are tested
using the procedure above, and pressing the down arrow key on the
Vantage to view the channels on the second module.
Digital Input Channels
The digital input channels are tested as follows:
Disconnect the field devices and wiring by unplugging connector J10. Do
not disconnect the wiring from the connectors.
Insert the input test connector from the connector test kit into connector
J10. This connector can also be fabricated by wiring a small jumper wire
to one of the plus terminals of the connector, the unconnected end of the
wire should have the insulation removed.
Select the View Input Channels Page on the Vantage controller. This is
accessed by pressing the Set Points key, from the Tools menu. Note that
an access code may be required depending on the configuration.
All of the Digital Inputs should indicate OFF. Connect the free end of the
jumper wire on connector J10 to each of the numbered input terminals one
at a time, and check the indication on the Vantage. The channel should
indicate ON when the jumper is attached. If any of the digital input

channels do not indicate correctly, or show Fail, the respective channel


is defective.
If the input channels indicate properly, the input channel hardware is
functioning correctly. Problems with digital inputs are due to improper
configuration, or with the field devices.
The digital input channels of the optional second MLM are tested using the
procedure above, and pressing the down arrow key on the Vantage to
view the channels on the second module.
Analog Output Channels
The analog output channels of the MLM are tested using the following procedure:
Disconnect the field wiring by unplugging connector J4 from the MLM.
Insert the blank connector from the test kit into connector J4.
Select the Set Output Channels page on the Vantage controller. This is
located on the Tools menu via the Set Points key. An access code may be
required depending on the configuration. Note: the emergency stop switch
must be engaged before you can access this page.
Connect the multi-meter to channel 1 of connector J4 to measure the DC
current of the channel.
Use the Increase and Decrease keys on the Vantage keypad to set the
output between 4 and 20 milliamps. Verify that the current measurement
on the multi-meter matches the current shown on the Vantage within +/- 2
%.
Use the Up and Down arrow keys on the Vantage to select the next
analog output channel. Connect the multi-meter to the next channel and
repeat the current measurement test described in the previous step.
Test all four channels on connector J4.
Digital Output Channels
The digital output channels of the MLM (connectors J13, J14) are tested using
the following procedure:

CAUTION:
The solid state relays normally leak up to 2 milliamps when in the
off state. Do not assume a digital output is safe to touch when
it is off.

Select the Set Output Channels page on the Vantage controller. This is
located on the Tools menu via the Set Points key. An access code may be
required depending on the configuration. Note: the emergency stop switch
must be engaged before you can access this page.

Use the Up and Down arrow keys on the Vantage to select each digital
output channel in order.
Use the Increase and Decrease keys on the Vantage to turn the output
ON and OFF. Confirm that the LED indicator on the associated relay turns
ON and OFF with the indication on the Vantage page.
If the relay LED indicator can be turned ON and OFF using the Vantage,
the hardware is functioning correctly up to the relay module, the MLM is
functioning correctly. If the device wired to the output channel does not
also turn ON and OFF, check the fuse in the relay (by measuring the
resistance with the multi-meter) to insure it is intact. If the fuse is good but
the field device still does not function, try replacing the relay with a known
working one. You can temporarily use one from another output channel. If
the relay is determined to be inoperative, only the relay should be
replaced, do not replace the MLM.
Current Input Channel
Typically the current input channel functions properly or fails by indicating zero
with the compressor running.
It is possible but unlikely that the calibration or range of this input will drift. If the
measurement appears to be inaccurate but providing a value that moves in the
correct direction it is likely that the scaling is set incorrectly in the configuration. If
you suspect that the channel is inaccurate, compare the displayed value on the
View Input Channels Page (Set Points key, Tools Menu) to that measured using
your multi-meter with a clamp on current probe on the wires going to connector
J11.
If the measured current is relatively close to that displayed on the Vantage (within
2%) and the scaling is correctly configured, then it is likely that the CT ratio is
different than planned / configured.
If the current reading indicates zero when the compressor is running, the internal
fuse on this input may be blown. Disconnect the CT wiring on connector J11. Use
the multi-meter to measure the resistance between the two pins on connector
J11. If no connection or a high resistance (mega ohms) is measured, the fuse is
blown and the module will need to be replaced. CAUTION: If the CT input fuse is
blown the current transformer is not sized correctly for the application. Typically
the CT is sized so that the CT Ratio divided by the motor full load amps (FLA) is
2 or greater. Do not replace the module without changing the current transformer;
it will simply blow the fuse on the spare module.
Motor Control Output
The Vantage motor control output is implemented using a dedicated digital output
channel. It is not possible to use the general purpose outputs to control the
motor. An emergency stop switch is required to be wired to connector J12 as
shown in the installation drawings.

Due to safety concerns, it is not possible to manually control the motor control
output as done with the general purpose outputs. The compressor, motor, and
related systems and equipment must be ready to start to test and troubleshoot
the Vantage motor control output.
The motor control output is activated by pressing the Start key on the Vantage,
initiating the configurable start sequence.
Note that the emergency stop is hard wired; if the emergency stop is activated,
the motor control output can not be activated regardless of what the Vantage
MLM does.
If the LED indicator on the MTR relay turns ON when the Vantage indicates the
start output is being activated, the MLM output circuitry is functioning correctly. If
the motor output does not activate the motor starter, check the function of the
emergency stop switch and fuse in the MTR relay.
If the MTR relay fuse is good and the emergency stop is not activated, try
replacing the MTR relay with a known good one. You can temporarily use one
from one of the general use output channels.
MLM Buss
The MLM buss is used to connect the optional secondary MLM to the primary
MLM via connector J3.
The input and output test procedures described above also test the MLM buss
when testing I/O on the secondary module. Additionally the following test
procedure can be used to test the port of the individual modules:
Disconnect the field wiring by unplugging connector J3 of the MLM.
Insert the blank connector from the test kit into connector J3 of the MLM.
Insure that the MLM is powered up.
Using the multi-meter measure the DC voltage between the plus and
common terminal of connector J3. The positive lead from the meter
connects to the plus terminal. The voltage should be between 0.0 and 1.5
volts.
Using the multi-meter measure the DC voltage between the minus and
common terminal of connector J3. The positive lead from the meter
connects to the minus terminal. The voltage should be between 3.5 and
5.0 volts.
Remove power from the MLM. Wait 60 seconds for the internal circuitry to
discharge.

Using the multi-meter measure the resistance between the plus and
common terminal of connector J3. The resistance should be between 10
and 20 kilo-ohms.
Using the multi-meter measure the resistance between the minus and
common terminal of connector J9. The resistance should be between 10
and 20 kilo-ohms.
C-Link Network Interface
The C-Link interface is used to connect a PC to the MLM for loading software
and configurations via connector J2.
If you are able to retrieve a configuration using the Vantage Desktop software,
the C-Link interface hardware is working correctly. Additionally the following test
procedure can be used to test the C-Link interface port:
Disconnect the field wiring by unplugging connector J2 of the MLM.
Insert the blank connector from the test kit into connector J2 of the MLM.
Insure that the MLM is powered up.
Using the multi-meter measure the DC voltage between the plus and
common terminal of connector J2. The positive lead from the meter
connects to the plus terminal. The voltage should be between 0.0 and 1.5
volts.
Using the multi-meter measure the DC voltage between the minus and
common terminal of connector J2. The positive lead from the meter
connects to the minus terminal. The voltage should be between 3.5 and
5.0 volts.
Remove power from the MLM. Wait 60 seconds for the internal circuitry to
discharge.
Using the multi-meter measure the resistance between the plus and
common terminal of connector J2. The resistance should be between 10
and 20 kilo-ohms.
Using the multi-meter measure the resistance between the minus and
common terminal of connector J2. The resistance should be between 10
and 20 kilo-ohms.
Modbus Network Interface
The Modbus interface port hardware test procedure is as follows:
Disconnect the field wiring by unplugging connector J9 of the MLM.
Insert the blank connector from the test kit into connector J9 of the MLM.
Insure that the MLM is powered up.
Using the multi-meter measure the DC voltage between the plus and
common terminal of connector J9. The positive lead from the meter

connects to the plus terminal. The voltage should be between 0 and 0.5
volts.
Using the multi-meter measure the DC voltage between the minus and
common terminal of connector J9. The positive lead from the meter
connects to the minus terminal. The voltage should be between 4.0 and
5.0 volts.
Remove power from the MLM. Wait 60 seconds for the internal circuitry to
discharge.
Using the multi-meter measure the resistance between the plus and
common terminal of connector J9. The resistance should be between 17
and 18 kilo-ohms.
Using the multi-meter measure the resistance between the minus and
common terminal of connector J9. The resistance should be between 17
and 18 kilo-ohms.
Software Troubleshooting
Resolving problems with the Vantage software will likely require the involvement
of a factory service representative.
Should a problem be identified with the Vantage software, a software update will
be issued to correct the problem. The update will need to be applied to the
software license and loaded into the controller.
Use the following steps to identify a software problem:
1. Run diagnostic tests on the hardware described later in this guide to
insure that the problem is not related to a hardware issue.
2. Check if you are using the latest version of software. The online support
area at vantage-solution.com provides access to the latest releases of the
controller and desktop software, as well as release notes on what has
been modified with each version.
3. Download and install the latest software if an update is available. This is
recommended even if the problem being experienced is not listed in the
release notes.
4. Review the release notes and problem report history on the online support
area of the vantage-solution.com web site. It is possible that the problem
experienced has already been resolved.
5. Review the operating and configuration instructions of the area of the
software you are having problems with.
6. Attempt to repeat or duplicate the problem, identifying the steps used to
demonstrate the problem occurring.
7. Contact your factory service representative and communicate the
information you obtained from steps 1-3. Send the software package you

are using to your service representative. Alternatively, report the problem


on the vantage-solution.com web site.

Returning Modules for Service


A return request form must be completed, and a return goods authorization
(RGA) number must be obtained before returning a module for service or
replacement.
The return request form is completed online on the vantage-solution.com web
site. Point your browser to http://vantage-solution.com and click on the online
support link. Click on the Vantage Troubleshooting link and follow the instructions
to complete the return request form. An RGA number will be e-mailed to you after
the return request has been evaluated.