Common RTO Alarms Solutions & Aftermarket Service Options

Possible Solutions/ Corrective actions

• Loose thermocouple wire
• Damaged thermocouple
• Damaged thermocouple wire

• Check the thermocouple wires & connections.
•  Use the second thermocouple element
•  Use a new thermocouple

• High temperature from the process
• Inaccurate reading from the thermocouple
• Loose thermocouple wire
• Damaged thermocouple
• Damaged thermocouple wire

• Check the process for any possible changes
• Check the accuracy of the thermocouple
• Check the thermocouple wires & connections.
• Use the second thermocouple element
• Use a new thermocouple

• RTO chamber temperature is more than 1800F

• Check the process for any possible changes
• Check the thermocouple
• Check the air flows to the units
• Check the capacity of the unit. RTO may be overloaded.
• Check the status of the hot by pass ( if applicable)
• Check the alarm set point on the temperature limit controller
• Make sure that the alarm has been rest manually on the controller.

• RTO chamber temperature is less than 1425F when RTO  is online

• Check the process for any possible changes
• Check the RTO ready temperature set point on the HMI screen
• Check the RTO ready temperature  timer set point on the HMI screen
• Check the RTO differential temperature set point on the HMI screen
• Check the RTO burner PID loop

High hopper A temperature fault

High hopper B temperature fault

• Hopper temperature is more than 425F.

• Check  the thermocouples
• Check air flows to the unit
• Check RTO high hopper temperature set point on the HMI screen
• Check the poppet cycle time on the HMI screen
• Check the sealing on the unit
• Check VFD frequency

• Stack temperature is more than 450F.

• Check  the thermocouples
• Check air flows to the unit
• Check RTO high stack temperature set point on the HMI screen
• Check the poppet cycle time on the HMI screen
• Check the sealing on the unit
• Check VFD frequency

Poppet  extension proximity switch fault

Poppet retraction proximity switch fault

• PLC cannot confirm the position of the poppet

• Check the field wiring for any possible loose wire
• Check the proximity/reed switches for any possible damages
• Check the poppet fault timer set point on the HMI
• Check the poppet actuators
• Check the poppet  travel speed

•  Low compressed air pressure from the compressor
• Set point on the compressed air pressure switch on the RTO

• Adjust compressed air pressure switch
• Check air filter
• Check air line for possible debris
•  Check the wiring for any possible loose wire
•  Check the air compressor

•  High temperature on the hydraulic unit

• Check for any possible leaking on the unit
• Check the wiring for any possible loose wire

•  Low hydraulic fluid level

•  Low or high hydraulic fluid pressure

• Low combustion air pressure

• Check the combustion blower rotation.
• Check the combustion blower motor starter. If it is tripped, it should be reset manually.
• Check the combustion line for possible debris
• Check the combustion air pressure differential switch set point
• Check the wiring for any possible loose wire
• Check the combustion blower air flow fault timer set point on the HMI

•  Low air pressure to the unit

• Check the main blower rotation.
• Check the main blower motor starter, soft starter or VFD.
• Check the RTO inlet for any possible debris
• Check the main supply fan air pressure differential switch set point
•  Check the wiring for any possible loose wire
• Check the main supply fan  air flow fault timer set point on the HMI

• VFD fault signal from the VFD panel

•  Check the alarm history from the VFD panel.

Clear path damper fault

3-Way Damper Fault

Fresh air damper fault

Process isolation damper fault

Diverters fault

Puff damper fault

Hot by pass fault

Secondary fresh air damper fault

• PLC cannot confirm the position of the damper

• Check the wiring for any possible loose wire
• Check the proximity, reed  or auxiliary switches
• Check the dampers actuator
• Check the damper fault  timer set point on the HMI
• Check the 4-20ma signal on the actuator ( if applicable)

•  Not enough natural gas pressure

• Check the supplied gas
• Check the set point on the low gas pressure switch
• Check the wiring for any possible loose wire
• Make sure that the switch has been reset manually

• Excessive natural gas pressure

• Check the supplied gas
• Check the set point on the low gas pressure switch
• Check the wiring for any possible loose wire
• Make sure that the switch has been reset manually (Canada only)

• Burner monitoring system cannot confirm that flame exists

• Clean the UV scanner
• Check the wiring for any possible loose wire
• Check the ignitor
• Check the air/gas damper
• Check the ignition transformer
• Monitor the DC voltage at the burner monitoring system
• Consider burner fine tuning or tuning

• PLC cannot confirm that gas safety shut off valve is closed

• Check the safety shut off valve
• Check the indicator
• Check the wiring for any possible loose wire
• Check the gas POC (proof of closure) fault timer on the HMI

• Check the low fire switch on the burner or auxiliary switch on the burner actuator
• Check the burner actuator
• Check the 4-20ma signal on the burner actuator
• Check the mechanical linkage
• Check the wiring for any possible loose wire
• Check the burner low fire switch fault timer on the HMI

• Consider changing the PLC battery

•  N/A