Honeywell's Spyder platform represents one of the most widely deployed LON/BACnet controllers in mid-sized commercial buildings, while the WEBs-N4 (Niagara-based) platform offers advanced web connectivity and integrated analytics. This reference covers fault diagnostics specific to Spyder controllers, WEBs-N4 platform errors beyond generic Niagara issues, and the communication protocols that link them. Understanding LED patterns and log messages is essential for field-level troubleshooting before escalation.
The Spyder controller uses a three-LED indicator system (Power, LON, and Status/BACnet) to communicate operational state. Reading these patterns is the first step in field diagnosis.
| LED State | Power (Green) | LON (Yellow) | Status (Red) | Meaning | Action |
|---|---|---|---|---|---|
| Normal | Solid ON | Flashing (1/sec) | OFF | Controller operational, LON online | No action needed |
| LON Offline | Solid ON | OFF (dark) | OFF | Controller running, LON segment offline | Check LON transceiver, verify termination resistors (120Ω at each end) |
| Startup | Slow flash (1/2 sec) | OFF | OFF | Controller initializing (30-60 sec) | Wait for stabilization; if persists >2min, check power/configuration |
| Configuration Mode | Solid ON | Flashing (2/sec fast) | OFF | Controller in configuration or commissioning mode | Verify programmer is connected; exit mode when complete |
| Critical Fault | Solid ON | OFF | Solid ON | Hardware or firmware fault detected | Check error logs via LON interface; may require firmware reload |
| Power Loss/Reset | OFF | OFF | OFF | No power or performing reset | Verify power supply and circuit breaker; check 24V DC at controller terminals |
| BACnet Active | Solid ON | Flashing | Flashing (slow) | BACnet traffic detected | Normal for BACnet-only networks; verify IP connectivity if LON is intentionally offline |
Flashing LON LED at 1/sec (Normal): The LON network is healthy and the controller is receiving heartbeat messages from the LON router or repeater. If this LED goes dark, immediately check the LON transceiver connection at the back of the controller. LON uses twisted-pair cabling; verify:
Solid Red Status LED: This indicates a fault condition stored in the controller's non-volatile memory. Even after restart, the fault will remain until cleared. Access the controller via LON commissioning tool and review the Fault History object to identify the root cause. Common triggers include:
Fast-Flashing LON at 2/sec: The controller has entered a service or configuration mode, usually because:
In all cases, do not power-cycle the unit. Wait for the tool to complete its operation.
| Error | Code/Indicator | Cause | Solution |
|---|---|---|---|
| Watchdog Timer Exceeded | Solid Red LED + Event Log entry | Firmware loop or system overload | Power-cycle controller; if recurs, reload firmware from commissioning tool. Check for excessive traps (trend buffer full). |
| Stack Overflow | FID=0xED in error logs | Too many concurrent operations | Reduce number of active alarms/trends. Recompile application if using Spyder Tool. |
| EEPROM Checksum Mismatch | FID=0xC5 | Corrupted configuration store | Use Honeywell Commissioning Tool to restore from backup or reload baseline configuration. |
| Flash Memory Corruption | Critical Fault LED + boot fail | Interrupted firmware upload or power loss during update | Reload firmware via PROM programmer if available; otherwise contact Honeywell support for flash recovery. |
Spyder controllers communicate with I/O modules (AI/AO/DI/DO) via internal backplane or remote LON I/O modules. When communication is lost:
| Fault Indicator | Module Type | Probable Cause | Verification |
|---|---|---|---|
| I/O Module Offline | Remote LON I/O (e.g., XL-50, XL-211) | LON network offline or module powered down | Check LON LED pattern; verify I/O module power and LON termination. Run LON network diagnostic. |
| Point Forced/Stuck | Any analog input | Sensor disconnected or shorted | Check wiring at terminal block. Measure signal with multimeter (should be within 0-10V for standard 4-20mA converted signals). |
| Output Not Responding | AO or DO module | Firmware not responding to writes | Cycle power to I/O module (not controller). If persistent, verify module's LON address is not conflicting with another device. |
| Backplane Error | Onboard I/O | Internal backplane fault | Extremely rare; indicates controller needs replacement. Do not attempt repair in field. |
| Fault Type | Log Message | Root Cause | Field Solution |
|---|---|---|---|
| Node Offline | "Node XXXX offline" | LON transceiver loss or power | Reseat LON connector. Check 24V power at I/O module. Verify termination at network ends (should read 60Ω when LON network is dead, 120Ω when powered). |
| Duplicate Node ID | "Duplicate LON Node ID XXXX" | Two devices configured with same address | Use LON network tool to scan and identify duplicate. Reconfigure one device with new ID. |
| LON Router Failure | "Router XXXX not responding" | Router/repeater powered off or failed | Power-cycle router. If LED shows no life, check 24V supply and network cable. |
| Authentication Failure | "Domain mismatch" in logs | Commissioning tool not on same LON domain | Verify domain configuration. Use Honeywell tool to join/rejoin device to correct domain. |
| Service Pin Timeout | Device not responding to commissioning | Service pin expired or config mode locked | Hold Service button on controller for 2 seconds to activate. Re-run commissioning tool. |
Errors that occur when compiling or downloading applications via the Spyder Tool (Honeywell's graphical programming environment):
| Error Message | Cause | Resolution |
|---|---|---|
| "Type mismatch in block connection" | Data type incompatible between function blocks | Check block output/input types match. Convert data types (e.g., INT to REAL) using explicit conversion blocks. |
| "Undefined network variable" | NV not published or subscribed correctly | Verify NV direction (input vs output). Check NV type and array size. Re-export network list from tool. |
| "Checksum error during download" | Communication error or corrupted file | Retry download. If persistent, reload commissioning tool or try different USB/serial cable. |
| "Application too large" | Memory overflow | Remove unused blocks or split application into multiple controllers. Check for recursive loops consuming stack. |
| "Service pin disabled" | Security lockout after failed attempts | Wait 24 hours or use Honeywell tool to reset via backdoor method (requires supervisor credentials). |
The WEBs-N4 is built on the Niagara framework but includes Honeywell-specific modules and enhancements. Platform-agnostic Niagara errors are covered elsewhere; these are WEBs-specific issues.
| Error | Symptom | Cause | Fix |
|---|---|---|---|
| CIPer Controller Unreachable | "Device offline" in workstation | WEBs station lost IP connectivity to CIPer-enabled Spyder | Check network switch and IP routing. Ping controller IP from workstation. Verify CIPer license is active (Administration > Licensing). |
| CIPer Handshake Timeout | "Authentication failed" in driver logs | TCP connection established but application-layer CIPer protocol failed | Verify WEBs and Spyder have same CIPer encryption key in driver config. Restart CIPer driver in WEBs workstation. |
| SSL Certificate Expired | HTTPS connections fail with cert warning | WEBs HTTPS certificate past expiration date | Generate new certificate in WEBs Administration panel. Redeploy to controller if using secure LON gateway. |
| Proxy Authentication Needed | Web services calls fail from controller to external APIs | HTTP proxy requires authentication | Enter proxy credentials in WEBs Network Settings > Proxy Configuration. Test with curl command from workstation. |
Common error messages found in /logs/supervisor.txt or /logs/bql.txt on WEBs stations:
[ERROR] BQL Link Down: Communication lost with remote Spyder controller at 192.168.1.50:47808
→ Check network path. Run 'ping 192.168.1.50' from workstation console. Verify firewall allows port 47808 (BQL).
[WARN] DataPoint Conversion Error: Cannot convert 'REAL' to 'STRING' in expression
→ Logic error in extension or custom script. Review BQL/Sax code for type mismatch. Correct and reload driver.
[ERROR] Driver License Expired: WEBs-N4/SpaceLogic extension past license date
→ Contact Honeywell support for license renewal. Workstation will operate in degraded mode (some features disabled).
[ERROR] Memory Heap Exhaustion: Java heap 85% full after 14 days uptime
→ Memory leak in driver or extension. Restart workstation to reclaim memory. Check logs for repeated object creation patterns.
[ERROR] Database Connection Failed: Cannot connect to trend DB at pgsql.local:5432
→ Verify PostgreSQL service running on database server. Check network connectivity. Verify username/password in WEBs database config.
When upgrading from older WEBs-AX (Apollo-based) to WEBs-N4:
| Issue | Manifestation | Resolution |
|---|---|---|
| Network Variable References Broken | Points show "Unknown" in graphics | WEBs-N4 uses different NV namespace. Re-export NV list from Spyder. Update all NV subscriptions in WEBs configuration. |
| Custom Extensions Not Compatible | Extensions fail to load during startup | WEBs-N4 uses Java-based engine; old extensions must be recompiled. Contact vendor for updated JAR files. |
| Trend Database Format Changed | Historical trends inaccessible | Use WEBs migration tool to convert old .db files to PostgreSQL format. May lose some historical resolution. |
| User Accounts Lost | Login fails for existing users | WEBs-N4 LDAP integration different. Re-add users in Administration > Security > User Management. |
When a WEBs-N4 station cannot connect to distributed controllers running Comfort Point Open or older proprietary protocols:
| Problem | Check | Action |
|---|---|---|
| Comfort Point module offline in WEBs | Check driver status in Framework > Devices | Verify controller IP, port, and slave ID. Ping the controller. Reload driver in WEBs workstation. |
| Point values stuck (not updating) | Check timestamp in Properties panel | Driver connected but not subscribing. Re-run discovery wizard in WEBs to refresh point list. Verify read permissions. |
| Alarms not flowing to WEBs | Check if controller has alarms but WEBs shows none | Verify alarm mapping in WEBs driver config. Check controller's COV (Change of Value) settings; may be disabled. |
| Write operations blocked | Attempt to change setpoint; change doesn't stick | Verify write access in WEBs security group. Check controller's output priorities (may be locked at higher priority level). |
When a Honeywell Spyder or WEBs-N4 system fails, follow this diagnostic sequence: