b Rtu Maintenanc1pgcile

ALSTOM PROJECTS INDIA LTD M&T / 1

RTU S900

MAINTENANCEAND

TROUBLE SHOOTING


INDEX• Maintenance Strategy & Planning• Maintenance Procedure• DOs & DON’Ts• Probable Problems &

Troubleshooting• Visual Indications• Operator Console - Operation• Replacement Procedures


MAINTENANCE PROCEDURE

PREVENTIVE

PERIODIC

BREAKDOWN

MAINTENANCE


PREVENTIVE

THE OPERATION OF DUMMY CKT. BREAKER WITH ASSOCIATED FEEDBACK TO RTU AS DIGITAL INPUT STATUS - ‘OPEN’ & ‘CLOSE’ ENABLES TO CHECK OVERALL FUNCTIONING OF

RTU - SIC COMM. CHANNEL MASTER & OPERATOR CONSOLE RC_SBO & DAU MODULES PRINTER

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D15D 25

S900 RTU

PLCCPLCC

PRINTERCONSOLE

RC

_SB

O

CFE

MODEM

DA

U

DB Relay

COM

SET & RESET latching relay


USING VT100 AS OP. CON. CHECK VARIOUS PARAMETERS.

CHECK & ANALYSE IF ANY FAULT LEDs ARE ‘ON’ IN RTU.

CHECK & ANALYSE IF ANY FAULT LEDs ARE ‘ON’ IN MODEM.

CHECK FUNCTIONING OF L/R SWITCH.

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PERIODIC

THE PROCEDURE SHALL BE ELABORATE & MAY NEED SPECIAL PERMIT FOR RTU DOWNTIME.

CHECKS ON POWER SUPPLIES. SECURE ALL MODULES INTO RACK (RTU ‘OFF’). CLEANING OF AIR FILTERS , USE VACCUM

CLEANER.

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CHECK WORKING OF VARIOUS SYSTEM UNITS.

CHECK , SECURE ALL EARTHING POINTS.

CHECK FUNCTIONING OF L/R SWITCH.

CHECK SAMPLE ANALOG INPUT.

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USING VT100 AS OP. CON. CHECK VARIOUS PARAMETERS.

CHECK & ANALYSE IF ANY FAULT LEDs ARE ‘ON’ IN RTU.

CHECK & ANALYSE IF ANY FAULT LEDs ‘ON’ IN MODEM.

CHECK OVERALL FUNCTIONING OF RTU-SIC.

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DOs AND DON’Ts

DOs ENSURE THAT ALL MODULES ARE PROPERLY

INSERTED & SECURED IN THE RACK . ALL TERMINAL WIRING IS SECURED & NO

LOOSE CONNECTION. ENSURE THAT SUITABLE EARTHING IS

PROVIDED & SECURED IN THE CUBICLE. ENSURE THAT PROPER POWER SUPPLY

VOLTAGES ARE PRESENT AT MCBs. ENSURE CORRECT CONNECTIONS FOR

PREFAB & MODEM CABLES.

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DOs AND DON’Ts

DOs ENSURE CORRECT CONNECTION MADE FOR

SAU900 / CPU900 FOR DESIGNATED OPERATIONS.

ENSURE BOARD CUSTOMISATION BEFORE REPLACING.

ENSURE PROPER CHANGE IN DB WHILE ADDING ANY ENTITIES / MODULES.

KEEP OUTSIDE / INSIDE OF CUBICLE NEAT & CLEAN. PROVIDE BETTER ENVIRONMENT FOR THE RTU-SIC FOR LONGER LIFE.

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DOs AND DON’TsDON’Ts

TO AVOID DAMAGES DUE TO STATIC CHARGE HANDLE MODULES WITH CARE & AFTER GROUNDING YOURSELF TO REMOVE THE STATIC CHARGE.

AVOID WEARING GARMENTS WHICH ARE KNOWN HIGH ABSORBERS OF STATIC ELECTRICITY.

AVOID UNNECESSARY INSERTION/REMOVAL OF COUPLER MODULES WITH SYSTEM POWERED ‘ON’.

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DOs AND DON’Ts

DON’Ts

HANDLE MODULES USING FRONT FACIA HANDLE. DO NOT TOUCH ELECTRONICS WITH BARE HANDS.

BEFORE REMOVING MODULES , ENSURE TWO FASTENING SCREWS LOCATED ON FRONT FACIA SECURING MODULE IN RACK ARE UNSCREWED FULLY.

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DOs AND DON’Ts

DON’Ts

PL. DO NOT INTERFERE WITH ANY JUMPER SETTING ON COUPLER MODULES.

DO NOT REMOVE THE CPU900 BATTERY BACKUP JUMPER. THIS SHALL DESTROY YOUR SITE DATABASE.

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DO NOT ATTEMPT TO REPAIR THE RTU MODULES , MODEM , TRANSDUCERS OR RELAYS. THIS CAN CAUSE SERIOUS DAMAGE.

DO NOT SUBJECT THE RTU COMPONENTS TO ABNORMAL INPUT CONDITIONS. THIS CAN CAUSE SERIOUS DAMAGE.

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DO NOT ATTEMPT TO INTERCHANGE THE RTU COMPONENTS BEFORE PROPER ANALYSIS.

DO NOT REPLACE ANY RTU COMPONENTS WITH THE INPUT SIGNAL / POWER PRESENT .

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DO NOT SUBJECT RTU-SIC TO OTHER THAN RECOMMENDED ENVIRONMENTAL CONDITIONS FOR WHICH IT IS SUPPLIED.

DO NOT BLOW OUT THE DUST FROM FILTER , USE ONLY VACCUM CLEANER AS THE DUST WILL ACCUMULATE IN THE RTU-SIC CUBICLE.

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PROBABLE PROBLEMS

LOSS OF COMMUNICATION / LINK COUPLER FAILURE / FAULTY CHANNEL CLOCK SYNC FAILURE FIP FAULT FAULTY FIELD DEVICE FAILURE OF TRANSDUCERS / RELAYS ETC. LOSS OF POWER SUPPLY REMOTE CONTROL NOT FUNCTIONING

MAINTENANCE


TROUBLESHOOTING

POWER SUPPLY

CHECK FOR PROPER VOLTAGES AT RESPECTIVE MCBs - 48VDC / 230VAC 50Hz NOMINAL

CHECK FOR GREEN LED ‘ON’ ON FRONT OF POWER SUPPLY MODULE WHEN SWITCHED ‘ON’

IF THE LED IS ‘OFF’ REPEAT AFTER SECURING THE MODULE IN THE RACK

IF LED IS STILL ‘OFF’ , REPLACE THE MODULE

MAINTENANCE


TROUBLESHOOTING COUPLER

IF COUPLER FAULT , RED LED DS2-B ON CPU900 WILL BE ‘ON’

THE COUPLER SHALL BE FAULTY IF GREEN LED ON THE COUPLER IS ‘OFF’ , MAY BE THE MODULE IS NOT PROPERLY INSERTED. SECURE THE MODULE IN THE RACK.

CHECK USING VT100 AS OP. CON. WHICH COUPLER IS ‘OFF’ ( FAULTY )

REPLACE THE COUPLER IF FAULTY

MAINTENANCE


TROUBLESHOOTING CLOCK SYNC FAILURE

IF CLOCK SYNC FAILURE , RED LED DS4-B ON CPU900 WILL BE ‘ON’.

REQUEST CONTROL CENTRE OPERATOR TO SEND SYNCHRONISING MESSAGE TO RTU.

IF THE LED IS NOT PUT ‘OFF’ AFTER FEW SECONDS , CHECK GREEN LED ON SAU900 FLASHING - IF NOT REPLACE SAU900.

MAINTENANCE


TROUBLESHOOTING CLOCK SYNC FAILURE

AFTER REPLACING SAU900 , IF CLOCK SYNC LED IS NOT PUT ‘OFF’ AFTER FEW SECONDS MAY BE COMMUNICATION PROBLEM.

CHECK THE MODEMs.

IF COMM. IS OK , REPLACE CPU900 , ASK FOR SYNC. MESSAGE FROM CONTROL CENTRE.

MAINTENANCE


TROUBLESHOOTING COMMUNICATION FAILURE- MODEM

IF MODEM MD50 IS OK , GREEN LED IS ‘OFF’ ON SAU900 , CHECK THE CONFIGURATION USING OP. CON.

SECURE THE SAU900 MODULE , IF GREEN LED IS STILL ‘OFF’ , REPLACE THE FAULTY SAU900 MODULE.

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TROUBLESHOOTING COMMUNICATION FAILURE

THE MODEM MD50 SHALL BE FAULTY IF THE YELLOW LED ON MODEM IS EITHER PERMANENTLY ‘ON’ OR FLASHING 2S / 2S.

THE MODEM MD50 IS FAULTY IF THE GREEN LED (RXD) IS FLASHING AND RED LED (INTERNAL FAULT) IS ‘ON’.

MAINTENANCE


TROUBLESHOOTING COMMUNICATION FAILURE

CONNECT VT100 TO MD50 MODEM & CONDUCT BUILTIN SELF DIAGNOSTICS & REPORT THE SPECIFIC FAILURE IN PROPER FORM.

COMM. FAILURE , RED LED DS3-A ON CPU900 IS NOT APPLICABLE.

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TROUBLESHOOTING FAULTY CHANNEL / ABNORMAL READING

CHECK THE CORRECTNESS OF ANALOG INPUT & DIGITAL INPUT SS / DS STATUS AS APPLICABLE.

USING VT100 AS OP. CONSOLE CHECK THE CORRECTNESS OF THE ANALOG READING OR SS/DS STATUS. IF NOT CORRECT REPLACE COUPLER WITH FAULTY CHANNEL.

MAINTENANCE


TROUBLESHOOTING FAULTY CHANNEL / ABNORMAL READING

TRANSDUCER SHALL BE FAULTY IF NOT RESPONDING OR READING THE DEFAULT VALUE WHEN THE INPUTS ARE ISOLATED FROM THE TRANSDUCERS.

THIS PROVIDES THE QUICK CHECK ON THE FUNCTIONING OF THE TRANSDUCERS.

MAINTENANCE


TROUBLESHOOTING L / R SWITCH

CHECK THE LAMP “RC POL OFF” IS OFF WHEN THE L/R SWITCH IS IN ‘R’ POSITION.

CHECK THE LAMP “RC POL OFF” IS ON WHEN THE L/R SWITCH IS IN ‘L’ POSITION.

IF NOT OK THEN CHECK WIRING , MCB Q5 & Q1 SHOULD BE ‘ON’.

SIMILARLY THE STATUS IS DISPLAYED ON OP. CON. AS ‘CLOSE’ - ‘R’ & ‘OPEN’ - ‘L’.

MAINTENANCE


VISUAL INDICATIONSALL S900 MODULESMAINTENANCE LED - ‘GREEN‘ ON FRONT FACIA.

THIS LED WHEN ‘ON’ & FLASHING INDICATES THE MODULE IS HEALTHY & THE RESPECTIVE I/O CHANNELS ARE BEING SCANNED.

THIS LED WHEN ‘OFF’ INDICATES THE RESPECTIVE MODULE IS FAULTY OR THE MODULE IS NOT SCANNED OR MODULE NOT ALLOCATED IN DB.

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VISUAL INDICATIONS

CPU S900 MODULE (FRONT FACIA LEDs)

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DS1

DS2-BDS2-A

DS3-A

DS4-A

DS5-A

DS3-B

DS4-B

DS5-B

WATCHDOG

EXPANSION RACK FAULT

COUPLER FAULT

COMM. FAULT(Not applicable in

IEC)PERIPHERAL FAULT

REMOTE RACK FAULT

FIP FAULT

CLOCK FAULT

DB DOWNLOADING


CPU S900 MODULE (FRONT FACIA LEDs)

DS1 GREEN LED , NORMALLY ‘ON’ , ‘OFF’ INDICATES WATCHDOG FAULT. IT SHALL DISABLE ANY RC O/P.

DS2B RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES ONE OF THE COUPLER IS OUT ie. EITHER FAULTY , NOT CONNECTED OR NOT DEFINED IN DB.

DS3B RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES FIP FAULT , CAN’T ESTABLISH FIP COMMUNICATIOS.

DS4B RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES CLOCK FAULT. THE BASE RACK IS OUT OF SYNC. FROM MASTER OR EXPN. RACK W.R.T. BASE RACK.

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VISUAL INDICATIONS

CPU S900 MODULE (FRONT FACIA LEDs)DS5B RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES DB

DOWNLOADING IS IN PROGRESS ON BASE RACK OR ONTO EXPN. RACK FROM BASE RACK.

DS5A RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES THE REMOTE RACK IS DISCONNECTED. THE BASE / EXPN. RACK DISCONNECTED.

THESE LEDS ARE APPLICABLE ON BOTH BASE AND EXPN. RACK.

MAINTENANCE


VISUAL INDICATIONS

CPU S900 MODULE (FRONT FACIA LEDs)DS2A RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES EXPN.

RACK FAULT , ONE / MORE EXPN. RACKS DISCONNECTED.

DS3A RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES THE COMM. FAULT , LOSS OF COMM. WITH MASTER.

DS4A RED LED , NORMALLY ‘OFF’ , ‘ON’ INDICATES THE PERIPHERAL FAULT , ONE OF THE PERIPHERALS DISCONNECTED FROM RTU.

THESE LEDS ARE APPLICABLE ONLY ON BASE RACK.

MAINTENANCE


OPERATOR CONSOLEOP. CON. (VT100) IS CONNECTED TO PORT J5 OF SAU900 MODULE. IT PROVIDES USER FRIENDLY MENU FOR MAINTENANCE / DIAGNOSTICS.NOTE ‘SELECT’ THE FUNCTION & ENTER ‘RETURN’ TO

ENDORSE THE FUNCTION.

THE FACELITY IS PROVIDED EITHER TO FOLLOW MENU OR ENTER DIRECT COMMAND AT THE COMMAND LINE WHICH IS ACCESSIBLE BY PRESSING ‘F4’ (= CHGWD). IN BOTH CASES ENTER ‘Y’ TO EXECUTE THE COMMAND.

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OPERATOR CONSOLE

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MAIN MENU REPORT

ACTION

DATE / TIME

VIEW


OPERATOR CONSOLE

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REPORT RSRMRCTTPSPRCBAYSTATION

STATE


OPERATOR CONSOLE

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REPORT RACKCOUPLERCOMMSPRINTERVERSION

SYSTEM


OPERATOR CONSOLE

MAINTENANCE

ASSIGN PRINTERSEND RCSEND SPSEND RCTCAPTURE ACTIVITYRESET RTU

ACTION


OPERATOR CONSOLE

MAINTENANCE

SET DATE *SET TIME *GET DATE / TIME

DATE / TIME

* These functions are used only at startup (or other emergencies) and then maintained through periodic synchronization from the Master station by means of SYNC command.


OPERATOR CONSOLE

MAINTENANCE

ARCHIVES W/SORT KEYS

ARCHIVES LAST_N_EVENTS

ARCHIVES FAULTS W/TIME/RANGE

ARCHIVES LAST N FAULTS

VIEW


+-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------+

LAST N FAULTS+-------------------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------+

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ARCHIVE REPORT *.* 28/10/99 16:12:45:240 TEMPLATE /…/

ARC*.*26/10/99 18:19:43:000 Resetting RTU… 0000 rack 00 STARTARC*.*28/10/99 12:38:26:000 Resetting RTU… 0000 rack 00 STARTARC*.*28/10/99 16:12:10:000 Resetting RTU… 0000 rack 00 START

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- Command or Message :FLN , ,

, conf (y/n) : y

F1=HELP F2=…….. F4=CHGWDF3=RETURN


+-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------+

ARCHIVES LAST_N_EVTS+-------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------+

MAINTENANCE

ARCHIVE REPORT *.* 28/10/99 16:37:25:740 TEMPLATE /…/

ARC*.*28/10/99 16:37:13:050 COUPLER RS 00 rack 00 OFF

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- Command or Message :ALN , , , , , ,

, conf (y/n) : y



+-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------+

COUPLER+-------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------+

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STATE REPORT COUPLER *.* 28/10/99 16:42:38:740 TEMPLATE /…/

COUPLER RS 00000000 rack 00 ONCOUPLER RS 00000001 rack 00 ONCOUPLER ADC 00000000 rack 00 ONCOUPLER ARM 00000000 rack 00 ONCOUPLER SAU 00000000 rack 00 ON

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- Command or Message :CPR , , , ,

, conf (y/n) : y



+-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------+

COUPLER+-------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------+

MAINTENANCE

STATE REPORT COUPLER *.* 28/10/99 16:42:38:740 TEMPLATE /…/

COUPLER RS 00000000 rack 00 ON COUPLER RS 00000001 rack 00 OFFCOUPLER ADC 00000000 rack 00 ONCOUPLER ARM 00000000 rack 00 ONCOUPLER SAU 00000000 rack 00 ON

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

- Command or Message :CPR , , , ,

, conf (y/n) : y



+-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------+

GET DATE / TIME+-------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------+

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DATE : 01 / 11 / 99TIME : 11 : 33 : 52 : 600

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- Command or Message :GDT ,

, conf (y/n) : y



REPLACEMENT PROCEDURE

MAINTENANCE

RTU S900 MODULES

To replace any module switch ‘OFF’ RTU power supply ( at power supply module).

Switch ‘OFF’ mcb Q2 (RTU power source). Unscrew fully two screws (securing the

module in the rack) located on front FACIA of module.

Pull out gently the module with help of module puller / module handle.



MAINTENANCE

RTU S900 MODULES Store the module in anti-static bag. Refer the O & M manual , check the correct

position of straps on the new module to be inserted in the rack.

Insert the module gently in the rack aligned in the module guides with Green health led on top.



MAINTENANCE

RTU S900 MODULES

Insert the module fully until it secures in the backplane euro connectors & secure fully the two screws to secure the module in the rack.

Switch ‘ON’ the MCB Q2 (RTU power). Switch ‘ON’ the RTU (power supply module)

and check the green health led on the module , shall be ‘ON’.



MAINTENANCE

Active / Reactive Transducers

The field inputs terminated at corresponding TB block located next to the transducers are to be isolated.

First the CT inputs at TB #3-4 & TB #7-8 are shorted by loosening the screw , flipping the shorting link & securing by tightening the screw fully. Next slide down the vertical shorting link after loosening screw provided on TB #3-4-7-8. This will isolate the field side.



MAINTENANCE


The PT inputs at TB #9-10-11 are isolated by loosening the screw (unsecuring the link) & sliding down the link provided on TB.

Switch ‘OFF’ MCB Q4. Disconnect the wires from the transducer &

keep isolated in safe manner.



MAINTENANCE


To remove transducer from DIN rail, pull down the lock tab at bottom-rear of transducer & swing forward from bottom to detach transducer from DIN rail.

Replace the transducer , secure the wiring respectively & switch ‘ON’ MCB Q4.

Displace the shorting links & secure to allow the CT / PT inputs to get connected to the transducers.



MAINTENANCE

Voltage / Frequency Transducers The field inputs terminated at corresponding

TB block located next to the transducer are to be isolated.

First the inputs at TB #1-2 are isolated by loosening the screw & sliding down the shorting link provided on TB #1-2.

Switch ‘OFF’ MCB Q4. Disconnect the wires from the transducer &

keep isolated in safe manner.



MAINTENANCE

Voltage / Frequency Transducers

To remove transducer from DIN rail, pull down the lock tab at bottom-rear of transducer & swing forward from bottom to detach transducer from DIN rail.

Replace the transducer , secure the wiring respectively & switch ‘ON’ MCB Q4.

Displace the shorting links & secure to allow the voltage input to get connected to the transducer.


DATABASE DOWNLOADING PROCEDURE

MAINTENANCE

1.Put the down Load cable(9pin to 9pin) on CPU-900 J-4 port to Laptop port.

2-Open console (HyperTerminal). To Configure Console Open file menu & select propertiesPress configure.Choose the setting Bits per second-38400 Data bits -8 Parity- -None Stop Bit- - 1 Flow Control -None



3-Reset the RTU. Message displays “ No FPU present Download data transfer rate 38400 bds. Do you to change(y/n)4. Press n Message displays” RT scope PROM: use esc to toggle”Press esc.A “RT>” prompt will appearGive command line “cmd”“RC>”prompt will appearGive command line “dlo.n”Message display“-------List File to be download-----“

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5 .Come out from console.6 .Change download cable on CPU-900 J3 port .7. Open Winload program. Choose Com-1 or Com-2 Press configure Set the bit per second-38400bps. Data bits -8 Parity -None Stop Bits -1 Flow Control -NoneAfter Configuring press Upload.System will ask to user the path of Hex file to be downloaded.Give path of ap-rtu hex file & press O.K.

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8-Downloading will complete within 10min approx for ap-rtu hex. Again repeat the whole procedure for downloading the particular Station hex file.9-After completing the downloading, close the Winload. Reset the RTU.

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