TABLE OF CONTENTS
1.0 1.1 1.2 2.0 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 5.5 126.96.36.199 188.8.131.52 184.108.40.206.1 220.127.116.11.2 18.104.22.168.3 22.214.171.124.6 126.96.36.199.0 188.8.131.52.1 184.108.40.206.2 220.127.116.11.0. 18.104.22.168.1 Introduction Organization of the Manual Who will get the best out of this manual Overview of Traction Power Distribution Overview of the Scada System Remote Control Centre Location of RCC equipment Remote Terminal Unit ( RTU ) Functional Description of the SCADA System General Remote Control Centre Remote Terminal Unit Technical description of Remote Terminal Unit General RTU at Traction Sub-station RTU at sectioning and paralleling post RTU at sub-sectioning and paralleling post Functional description of Remote terminal Unit Logic chassis CPU module Watch dog Timer Interrupt Logic Address Latch Memory Digital Output Module ( DOM ) Functional Description of DOM Select Before Operation and Description Digital Input Module ( DIM ) Interface Connection and Functional Description
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22.214.171.124.0 126.96.36.199.1 188.8.131.52 184.108.40.206 220.127.116.11 18.104.22.168 22.214.171.124 126.96.36.199 188.8.131.52 184.108.40.206.1 220.127.116.11.2 18.104.22.168 22.214.171.124 126.96.36.199 188.8.131.52 184.108.40.206 220.127.116.11 18.104.22.168 5.6.0 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 5.6.8 5.6.9 5.6.10 Analog Input Module ( POWER METER ) Functional Description of POWER METER Interface Card Enclosure Catanery Interface ( CIC ) Modem Overview of Modem Power Supply Unit Principle of Operation Protection Features Mains Supervision Battery Supervision Functional Description of LDA75F Functional Description of LDC30F Overcurrent Protection Overvoltage Protection FoldBack Characteristics Contactors / Relays Terminal Block Description of Telemetry at TSS Under Voltage Tripping of Bridging Interruptors Scheme of Telemetry at SP Scheme of Catenary Indication at SP Closing of Bridging Interruptors Under Voltage Tripping of Interruptors Sequence of Operations of Under Voltage Tripping Catenary Voltage Sensing at TSS Scheme of Telemetry at TSS Auto Re-closing Scheme at TSS Field Wiring
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6.0 6.1 6.2 6.4 6.5 6.6 6.7 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 8.0 9.0 9.1 Maintenance of SCADA System Maintenance philosophy RTU Power Supply Unit Table of Periodic Inspection and Maintenance Fault Finding and Rectification Testing Equipment Requirement Test Equipment RTU Trouble Shooting Procedure TeleSignal Telemetry Telecommand Power supply Unit Trouble Shooting Chart for UPS Trouble Shooting Procedure for Modem TeleSignal Fault Finding Chart TeleMetry Fault Finding Chart TeleCommand Fault finding Chart Downloading Program To Rtu Micro controller Download Parameters to RTU Testing the various parameters using MERITDIAG:
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The details contained in this manual are highly technical in nature and hence the reader is expected to have a basic understanding of electronics circuits and exposure to the latest state of art technology. Finally.1
1. The manual only covers basic trouble-shooting procedures and techniques.
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. It contains the technical description. 1. it deals with the maintenance aspects.2 Who will get the best out of this manual ? This manual is prepared for the use of the technical persons who are involved in using the system and those who have the responsibility for maintaining it. before embarking on component changes. manufactured and supplied by M/s MERIT. This manual helps the user to correctly install the system .merit
CHAPTER . use it effectively and maintain properly. Chennai.1 INTRODUCTION ORGANISATION OF THIS MANUAL This document is the hardware manual of Remote Terminal Unit for Supervisory Control and Data Acquisition (SCADA) System designed. The manual starts with an overview of traction distribution network and briefly introduces the user to the SCADA system. Then the manual gives the technical description of the system and the associated sub-systems.0 1. The reader is advised to contact the technically trained engineers of SCADA system. user procedures and maintenance aspects of the system.
CHAPTER - 2
2.0 OVERVIEW OF TRACTION POWER DISTRIBUTION 25KV AC, 50 Hz Single phase electric traction system is adopted for the electrified tracks. Power is obtained from State Electricity Boards (SEBs) from their network at 220/132/110/66 KV at traction substations (TSS) and stepped down to 25 KV. The high voltage winding of the single phase transformer is connected across two phases and one terminal of the 25KV winding is connected to the rail and the other terminal to the catenary system (Over Head Equipment (OHE)). The TSSs are spaced at a distance of 40 to 60 km. The supply to the OHE from TSS is fed through interrupters located at feeding post (FP). Adjacent TSSs normally supply power to the OHE on different phases to reduce unbalance in the supply authorities grid. To avoid the pantograph of a locomotive or electric multiple unit from bridging the supply from different phases when it passes from one zone to another, a neutral section is provided to separate the OHEs fed from different phases. The switching station provided at neutral section is called "Sectioning and Paralleling post" (SP). At the SP in multi track sections, the OHEs are also paralleled independently on either side of the neutral section to reduce voltage drop. In an emergency, when a TSS is out of commission, feed from adjacent TSSs on either side is extended up to the failed TSS by closing interrupters at SP. The pantograph(s) of locomotive(s) or electric multiple unit is (are) lowered at the failed TSS to avoid short circuiting the phases at the insulated overlap. Between a TSS and adjacent neutral section, the OHE is divided into sub-sections for isolating the faulty section for the purpose of maintenance and repairs. The switching stations provided at such points are called "Sub-sectioning and paralleling posts (SSP)”. The OHE of various tracks, in multiple track sections, are also paralleled at the SSP to reduce voltage drop in OHE. The sub-sectors are further divided into elementary sections by the use of manually operated isolators.
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At TSS, SP and SSP, equipment like power transformers, circuit breakers, interrupters, single and double pole isolators, potential and current transformers, lightning arrestors, LT supply transformers etc., are installed in a fenced enclosure which is locked up. A masonry building is provided for housing the control panels, SCADA equipment, battery and battery chargers, telephones and others. All traction substations are manned and switching stations are normally unmanned. The devices that are controlled from RCC through the SCADA equipment are circuit breakers, interrupters and transformer tap changers. The tap changer of the transformer, circuit breakers and interrupters can also be operated locally at the TSS, SP and SSP as the case may be.
At the TSS, a local / remote changeover switch is provided on the control panel, as well as in the mechanism box of the circuit breaker, interrupter and motor operated isolators. No control panel exists for the interrupters at the SP and SSP and therefore the local / remote changeover switch is provided on the mechanism box of the interrupter.
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CHAPTER – 3
3.0 OVERVIEW OF THE SCADA SYSTEM The SCADA system is designed to monitor the status and control of the 25KV electrified traction system. It is a fully integrated hardware and software system with a central control to monitor and control the field devices located at remote sites. The SCADA system can be classified into two broad categories: 1. 2. 3.1 Remote Control Centre (RCC) Remote Terminal Unit (RTU)
Remote Control Centre RCC is designed for monitoring different types of data like catenary indication, device status and telemetry from various control stations. It also controls the field equipment like circuit breakers, bridging interrupters, transformer tap position changing etc., RCC stores the data regarding alarms, events, and telemetry to help the user to analyse the status of the overhead equipment and switching stations. This data can be used for maintenance purposes also. For example, RCC helps the user to easily identify the fault in OHE located in various sections, for immediate rectification. RCC consists of the following equipment: a) b) c) d) e) f)UPS g) Battery Main and standby Computer Operator Workstation computer Communication Processors with Modems Printer and Print Sharer Switch Modem
Location of RCC equipment These equipments are located in Traction Power Control (TPC) room. The UPS and batteries are located in the UPS room and batteries room respectively. Main and Standby Computers, Communication Processors, Modems Workstation Computers and Printers are installed in the TPC Room. Supervisory console is installed at CTPC Room.
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coupled with firmware programming allows the RTU to perform sophisticated control and data acquisition functions.merit
3. modular and reliable making it easy to maintain and expand. RTU can be divided into the following four parts: a) b) c) d) Logic Chassis Interface Unit Energy Meter Modem
RTU accepts digital and analog input signals from the remote locations (TSS/SP/SSP) and receives the control command from the RCC to perform the following tasks : * Status input monitoring and change of status * Control output operation * Analog input monitoring * Communication with RCC
RTU is designed to be flexible. A highly integrated microprocessor based system. RTU system can be configured for a wide variety of I/O mix. This provides a convenient means to alter and / or extend the capabilities of the RTU without significant hardware modification. The RTU provides the following basic data acquisition functions: * * * Data acquisition for status input and analog input Control outputs RTU / Master station communications
Implementation of the RTU capabilities is a combination of hardware logic and firmware logic that is stored in Read Only Memory (ROM).
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. which can be configured and expanded as required in the field. The configuration of an RTU is stored in non-volatile memory and may be edited or expanded without hardware changes. It receives the control commands from the RCC.3 Remote Terminal Unit (RTU) – DESIGN AND MANUFACTURE BY M/S SANMAR RTU is designed to control and monitor field equipment. It accepts digital and analog input signals from the remote field equipment.
* * * up to ninety six (96 ) Digital Input points up to Fourty Eight (48 ) Digital Output Points up to sixty four (8 ) analog input Points
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Each TSS RTU will support.
which enables the user to understand the field conditions. The RCC Computers communicate with each RTU in a predefined sequence over the WAN to acquire information regarding.1
FUNCTIONAL DESCRIPTION OF SCADA SYSTEM
General The SCADA System. relays etc. The Main computer also responds to the requests of the OWS computer. The RCC and RTUs are connected in Wide Area Network (WAN).2
Remote Control Centre The Main and Standby Computers are Server Grade – Pentium IV with 15" color monitor. which receives commands from Traction power controller.0
4. which should have the same information. Whenever the Main computer fails. Work station computers. * Status of CB. then the Slave will become Main with updated information. The Workstation Computers are Server Grade – Pentium IIV with 21" color monitor
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. * Alarm condition in the controlled station • Measurand values
4. this information will be formatted and sent to the communication processor. It also monitors and operates various equipments at traction sub stations located enroute. Communication processors are connected in the LAN set up and Powered through UPS with battery back up at RCC b) Remote Terminal Units (RTU) for acquisition of field parameters from the unmanned control stations along the traction network. The Main computer also updates available information with the slave computer. Then. The Communication Processors (CP) are Server Grade – Pentium IV Computers.merit
4. from RCC enables the Traction Power Controller (TPC) to control the 25 KV traction power supply to OHE. The Main computer interacts between the Communication processor and Workstation computers. It collects the formatted RTU information from Communication processor and sends the processed information to the Operating Workstation (OWS) computers. interrupter. The SCADA System for Traction Power Control consists of two major parts: a) Main and Standby Computers.
Termination Section is used to interconnect the field cables and RTU internal cables to perform the control and supervisory operation at the field. * Power Supply Unit * Logic Chassis * Interface Unit * Modem * Termination Section
Power Supply unit Consists of two Parts. It performs the following tasks: * Input status monitoring and recording the change of status * Control output operation * Analog input monitoring * Communication with RCC RTU consists of the following five parts. -12v) for Modem and Interface card reference supply. and is based on microprocessor. 48 digital output signals.
CHAPTER . one for main 24V dc supply and the other is (5v.merit
4. 12v. It receives the control signals from the RCC. TSS. Energy Meter that is part of the Interface Unit is used to convert the field analog signals like voltage and current.3 Remote Terminal Unit (RTU) RTU accepts digital and analog input signals. SP and SSP. The Logic Chassis is the main part of RTU. The Interface Unit receives and controls the field signal devices. It is used to control and process all field signals. 8 analog input signals.5
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. from the remote locations. namely (not shown in the block diagram). Each Logic Chassis supports 96 digital input. Modem is used to convert the digital information to analog information suitable to for four wire based communication cable and vice-versa in the FSK & PSK mode.
highly integrated microprocessor based The Remote Terminal Unit is designed logic system.1 TECHNICAL DESCRIPTION OF REMOTE TERMINAL UNIT GENERAL The Remote Terminal Unit (RTU) acts as the common interface between the field devices and the Remote Control Centre of the system. which allows the Remote Terminal Unit to perform sophisticated control and data acquisition functions.TSS This RTU is designed for the following capacity: * 24 Telecommands * 48 Telesignals * 06 Telemetries The term Tele command is used in railways to give output and sense the status feedback for the particular device. It is programming. coupled with firmware to be flexible. making it easy to maintain and easy to expand. modular and reliable.0 5. RTU accepts digital and analog input signals from the Remote locations (TSS / SP / SSP) and receives the Control command from the RCC to perform the following tasks: * Status input monitoring and change of status * Control Output operation * Analog Input monitoring * Communication with RCC 5.
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. Generally each Telecommand represents two digital outputs and corresponding two digital inputs.2 RTU AT TRACTION SUB-STATION .merit
132 KV Circuit Breakers 02
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RTU Block Diagram
The following are the Telecommands available in the TSS RTU: 1.
25 KV Interrupters 4. The RTU is to sense the locked out signal and command is to be given to release / reset the lock out.R / O. This TAP POSITION may be raised or lowered by giving RAISE or LOWER commands and status of TAP POSITION (any one out of six) is to be monitored.no.P. This requires close and open operations from the RTU and monitoring the status. which is stepping down 132 KV to 30 KV. Tap Changer 6.
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.P.R relay (FCB – I) (FCB – II) 2 nos 2 nos 12 nos 2 nos 1 no 3 nos 3 nos
Using 110V DC from the field senses the above alarms. 25 KV Circuit Breakers 3. Alarm * W.1.C / D. Tr.C / D. Trip * 110V DC Fail for Tr. is having six steps of tapping position. 2 & 3 is shown in the figure. TSS control panel to close the feeder CB automatically once whenever the CB trips and the scheme will become locked out condition. Auto reclosure is the facility available in the field. The following are the Telesignals to be sensed at TSS: TYPE I Telesignals * Transformer alarm * Transformer fault * Transformer Tap position * 110V DC Fail for Tr.C.merit
2. Auto Re-closure 5.R / O. Interlock release 05 05 02 02 01
The scheme of operating the sl.C.P.R relay * W. Transformer.P.
Block diagram of tss
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General scheme of TSS wiring
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Tss wiring 2 of 2
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Line Pt Fuse fail * 25 KV Shunt Cap. TYPE III Telesignals * 110V DC Low 1 no
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. PT fuse fail 2 no 1 no 1 no 1 no
In the above alarms are sensed by using availability of 240V AC and 110V AC from the field.A DIAGRAM OF TSS
TYPE II Telesignals * 240V AC failure / PSU on DC * 25 KV feeder PT Fuse fail * Tr.merit
Current is measured from the CTs whose ratings are given below The Accuracy of the Voltage. • • • Voltage Current Maximum demand
Voltage is measured from the 25 KV / 110 V Pts and Voltage changeover scheme connects the higher side of the PT voltage to the Transducer. Current.merit
In the above alarms are sensed by using availability of 110V DC from field batteries. Dead Band Resolution : 0 to 255 ( 1 byte) : 10 Bit
Normal value : 1000 Units.5%). TYPE IV Telesignals * Catenary indication 4 nos. PF and MD is Class A Type (ie.
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In the above alarms are sensed by the availability of 120V AC from PTs connected to the Overhead equipment. voltage and Maximum demand from the field. Value of the LSB bit : 10 mv (Resolution ) For 25 KV side Primary side 1000A or 500A 1500A or 750A For 132 KV side Primary side 100A or 200A Secondary side 5A 5A 5A Secondary side
The secondary side will be connected to the Energy Meter through Shorting terminals. Each Telemetry will have one analog input from the field. 0. The term Telemetry is used in railways to measure the current.
TYPE II Telesignals * 240V AC failure / PSU on DC * Spare 1 no 1 no
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.SP will have two nos of parallel interrupters which could be operated by issuing open and close commands and another two nos of bridging interrupters which have to meet the following Under voltage trip conditions : Under-voltage Tripping Under voltage tripping is the facility provided for bridging interrupters of SP. then RTU is able to close the Bridging interrupters to extend the feed from one side to another side.
5. This will be done in the software at the Remote Control Center.3
RTU AT SECTIONING AND PARALLELING POST . if both side voltages are going low.SP The following is the design capacity of SP RTU : Telecommands Telesignals Telemetry 8 nos 12 nos 4 nos
The following are the Telecommands available in the SP RTU 25 KV interrupter Spare 4 nos 4 nos
In general .merit
Maximum demand is the parameter calculated from the measured Voltage and Current. The following are the Telesignals to be sensed at SP : TYPE I Telesignals * Spare 4 nos The above alarms are sensed by the availability of 110V DC from the field. The two different phases of 25 KV voltage are fed from the adjacent TSS to the Bridging interrupter and it should not be closed when both sides of the voltages are high. Whenever one side TSS fails. then RTU should trip the bridging interrupters. After extending the feed.
In the above alarms are sensed by the availability of 240V AC.
Block diagram of sp & ssp
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. TYPE III Telesignals * 110V DC Low * Spare 1 no 1 no
In the above alarms are sensed by the availability of 110V DC from field batteries.
TYPE IV Telesignals * Catenary Indication 4 nos (Inclusive of Under voltage tripping facility) In the above alarms are sensed by the availability of 120V AC from PTs connected to the Overhead equipment.
General scheme of sp/ssp wiring
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General scheme of sp / ssp wiring 2 of 2
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G.A DIAGRAM OF SP /SSP
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SSP The following is the design capacity of SSP RTU : Telecommands Telesignals Telemeter RTU) The following are the Telecommands available in the SSP RTU : 25 KV interrupter Spare 5 nos 3 nos 8 nos 12 nos 4 nos *
( * The above 4no Telemeters are spare.merit
TELEMETRY In SP. Hence Transducers will not be provided in the
The following are the Telesignals are to be sensed at SSP : TYPE I Telesignals * Spare 8 nos The above alarms are sensed by using availability of 110V DC from the field.4
RTU AT SUB-SECTIONING AND PARALLELING POST .
TYPE II Telesignals * 240V AC failure / PSU on DC * Spare 1 no 1 no
The above alarms are sensed by using availability of 240V AC.
TYPE III Telesignals
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5. voltage is measured from the up and down line 30 KV / 120V PTs where the secondary voltage of the PT is connected to the Energy Meter.
TYPE IV Telesignals ( Subject to the requirement ) * Catenary indication overhead equipment. 4 nos.merit
* 110V DC Low * Spare 1 no 1 no The above alarms are sensed by using availability of 110V DC from the field batteries.5
Functional Description of Remote Terminal Unit Remote Terminal Unit is comprised of the following modular blocks a) Logic Chassis b) Interface Unit c) Modem d) Power Supply Unit e) Transducer f) Contactors / Relays g) Terminal Block
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. The above alarms are sensed by using availability of 120V AC from PTs connected to the
allows Logic Chassis to perform sophisticated control and data acquisition functions.1.0 Logic Chassis A highly integrated microprocessor – based logic system.5. coupled with firmware programming. The Logic Chassis can be configured for a wide variety of I/O mix which can be configured and expanded as required in the field. The configuration of an Logic Chassis is stored in non-volatile memory and may be edited or expanded without hardware changes
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Signal flow diagram
acts to integrate efficiently with the Rut’s other assemblies such as Interface unit. Modem and Power supply unit etc. The Logic Chassis consists of the following modules • • • CPU module (CPU) Digital Output Module (DOT) Digital Input Module (DIT)
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. Pulse and Control points Up to 8 Analog Inputs Asynchronous communication Channel
The Logic Chassis which is shown in figure.merit
The Logic Chassis provides the following data acquisition * * * Data Acquisition for status input and analog input Control Outputs Logic Chassis/Master station communications
Each Logic Chassis can contain * * * Expandable to meet the maximum requirement of Status.
5.1. It is based on the microcontroller Technology Philips micro-controller 80C669.1 CPU Module CPU Module acts as the backbone to Logic Chassis.merit
Block diagram of logic chasis
5. The 80C669 is a highly integrated 16 bit device with 33MHz speed which implements the following on-chip features
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DO and AI can handle by a single CPU: Digital Input and Digital Output: Analog input: * * * Up to 16 Mbytes linear address space Five programmable chip selects Maximum of 56 interrupts Maximum 1536 Maximum 8
Block diagram of CPU
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In build in CPU and can support up to two serial ports on the designed baud rate * Number of DI.
Functional block diagram of CPU
These features combined with 33 MHz processor clock to perform many sophisticated
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data acquisition and control functions as software tasks. It contains the following function blocks * * * * * * * Watchdog timer Interrupt Logic Address Latch Modules Select Logic Module Address Data Bus Flash EPROM and RAM Dip Switches to set the address of Node
LED Indications To display the operating status. the CPU module have four LED indications INDICATION PWR RUN TXI RXI TX2 RX2 Red ON FUNCTION Supply Voltage Monitor CPU status and error display TX Status OF COM1 RX Status OF COM1 TX Status OF COM2 RX Status OF COM2 Supply Voltage < 17V dc and Low Battery
Details of RUN LED
LED STATUS OFF
MEANING Controller stopped / Fault
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if the strobe input is not driven low before the chips internal 500 ms timer has timed out. a strobe pulse is not generated and the reset line is forced to the active state.1. i.1. First.1. The watchdog timer continuously monitors the process of Microprocessor. a precision temperature compensated reference and comparator circuit is used to monitor the status of +5V (VCC) power supply.5.65V. the Chip forces reset to the active state. The reset is held momentarily and then released. Status input modules contain the logic which generate a signal any time their input values are changed. these signals are then sent to CPU and are input at data latches. When VCC returns to normal.1. When VCC falls below 4. The first is initiated when a change occurs at a status input.e.5. It should be noted that only odd numbered COS lines are input to data latch this is because the even numbered modules pass their interrupts along to the odd numbered
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Green blinking Controller Running
5. It has also additional feature of write protection for CMOS RAM or EPROM.2 Interrupt Logic The Logic Chassis is a real time device and therefore fully utilizes interrupts. which causes the RTU to reinitialize and start execution from the restart vector. The Watchdog accomplishes this by activating the reset line.
5. There are two external hardware sources from which an interrupt can originate. power supply and external reset. then the reset signal is kept active for a minimum of 250ms to allow the power supply and processor to stabilize.1 Watchdog Timer The inbuilt function of the Micro controller monitors three vital conditions for the Microcontroller. greater than 4. The strobe input is derived from the microprocessor timer / counter output (TCO) which must be set from the software.65 V. If the software does not reset the timer counter within the allotted time.
1.1. These devices also word are byte accessed using the select logic provided by the processor control lines. An active COS signal at the inputs to data latch acts to generate an active state at its output and in turn at the 80C167C interrupt input. The ram may be accessed through 16bit word or Byte segments. which have changed. RAM (256KB) is used as a general-purpose area for the microcontroller to store data.merit
modules using the dedicated COS and COMPEN lines on the MOD bus and the odds in turn pass the COS to data latch. Flash RAM (128 KB) is used by the RTU to store configuration variables and system data.5. the processor reads the indicated module pair to determine the specific input or inputs. which reads latch to determine which pair of Status inputs signals (COS). When the processor receives an interrupt.1.6 Memory The Memory is divided into 3 types Processor RAM External RAM Processor RAM of 2KB is made available to the processor module to store the nonalterable storage of program code.5. yet alterable without hardware changes or replacement.0 Digital output Module (DOM) The Control output system for the RTU comprised of two basic types of components. therefore it is necessary to de multiplex or latch the address information. variables and operating information that are temporary in nature.
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.1.2. it immediately enters service routine. Once the pair has been determined. which require memory to be non-volatile.1. 5. 5.3 Address Latch The 89C669 utilizes a multiplexed Address data bus. caused the interrupt.5. The Address latch is comprised of D type latches whose outputs are always enabled and clocked by the ALE (Address Latch Enable) signal 5. Information stored in this section area is volatile and will be lost in the event that power is removed from the Logic Chassis.
Respective LED’s of Orange color indicates present state of output signal. operate the contactors.1 A and the Module requires the power supply is from +18V to +30V dc with the power consumption of 200mW.merit
control function modules (DOM) that are added in the Din rail and attached with the CPU module to interface with the field equipments through potential free contactors. verifies it by strobing the data and reads back to latch.isolator
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.5. The Digital output module (DOM) contains the logic and CPU interfaces hardware. Next the CPU reads back the data.2. Each Digital output Module (DOT) has sixteen outputs and is designed to drive the Contactors of 10A rate. All control output operations are initiated and monitored by CPU module. If the read data and already sent data are same then the CPU issues an execute pulse to drive the Each module provides 8 digital outputs at the rate of 24Vdc / 0. The Output from the Opto . which in turn activate the field equipments. A control operation begins when CPU places a bit pattern and simultaneously strobe the new value into the data latch of the Digital output module. which act together write-read-execute sequence logic to provide secure control operations.1. These modules could be plugged into the Din rail as and when required.1 Functional Description of DOM The Digital output function module (DOM) is comprised of group of data latches.
Connection details of dot
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the selected digital output point read by the CPU and simultaneously strobe the new data output point into the data latch of the Digital output module. Request: Selection Command Whenever activation is enabled in Select Command packet. If
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. the CPU module reads back the data from data latch of DOT and compare the bit pattern of the digital output value.1.2. Response: Select Confirmation Once receiving the Select Command from RCC.
2.5.2 SBO ( Select Before Operation) Operation and Description : 1.merit
Block Diagram of DOT
bit pattern are matching and CPU sends the “Selection Confirmation” to RCC and If RCC decides to cancel the selection, then the Select command is sent with a “deactivation” and the CPU will disable the data latch value.
3. Request: Execute Command Once RCC gets the Selection confirmation then it transmits the command message with Execution packet. After getting the execution command, the CPU enables the output channel in DOT that was already selected by the selection command. The digital output channel enable time duration depend upon qualifier bit (10 ms to 2.55 Seconds (in single command record. The default enable time is one second.
4. Request: Execute Confirmation Once the CPU executes the command and enable the selected digital output channel, then the RTU responds with an “ activation termination” to RCC to indicate that the command has been successfully issued.
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Connection details of DIT
BLOCK DIAGRAM OF DIT
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22.214.171.124.0 Digital Input Module (DIM) Each Digital input module has eight inputs and is designed to provide input points of status information to the CPU module from the Input interface cards. 126.96.36.199.1 Interface Connection and Function Description The Digital input Module (DIM) accepts the inputs from the field (110v DC) , the 16 Inputs and the which are multiplexed and Transferred to CPU. block for input with reference to common 0V connection. Basic circuit of Digital input module is shown. It describes the process of the input signal with isolation and the LEDs connected to show the status of each signal. The modules are designed for signal voltages up to 110V dc and used to collect the binary control signals from the system and transmit them to the CPU. It may be easily exchanged in the working condition without disconnecting the individual wire. Individual Green LEDs are used to show the status of the system and the maximum power consumption is 100mW. All the four inputs are electrically isolated from the logic circuitry of the module and connected through terminal
188.8.131.52.0 Analog Input module (AIT) – POWER METER The system comprises of a single 8 channel Analog input module with necessary Inbuilt
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Transducers. The channels are read sequentially starting with channel 1 and proceeding to the last channel configured in the system.
CONNECTION DETAILS OF AIT
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. The Analog input module fixed in the Din rail and the system uses multiplexing method which selects a specific termination channel read by the A to D converter.
BLOCK DIAGRAM OF AIT
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reference. All the input channels are led to a common multiplexer and are galvanically isolated. ground or multiplexed field inputs.5.merit
The Analog input module accepts PT Voltage and Feeder Current and converts them to proportional digital values.4 Catnery Interface Module ( CIC )
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.1 Functional Description of Power Meter The Analog input values are received from the field in the form of PT voltage and Feeder current.0 INTERFACE CARD ENCLOSURE
Interface card enclosure consists CIC INTERFACE to Monitor the Status Of Catenary Input Signals
5.4. Analog source select switch is used to select between the +reference. .2.
.5.1. signal conditioning and multiplexing hardware required to select the correct signals from the field.2.5. The time-multiplexed voltage is fed to the instrumentation amplifier where the signal is converted from a differential mode to single ended signal.
5. The module contains A to D converter. reference sources. In this module we have the features to select the type of input is voltage or current is based on the DIPswitch present at the backside of the module. The output of the power meter is been transmitted to the CPU module through serial data bus.
from the field (25KV / 100V AC PT) is sensed using this circuit. The stepped down output from the Transformer is rectified through bridge rectifier and filtered of transients with capacitance filter C. which is available in the range of 0-120V AC. Two numbers of 8 way dip switches SW1 and SW2 are provided for pick up (high level) and drop off (low level) voltage for catenary indication. The respective setting range will be as follows : Drop off Pickup : : 48% to 70% (12 kV to 17. This catenary indication is sensed with various ranges to eliminate the effect of induced voltage from the adjacent OHE when the sensing OHE is dead. The comparator circuits have been provided with potentiometer to adjust the drop-off and pickup of the relay as described below: The 0-100V AC from PT is fed as an input to the Transformer.5 kV = 48V to 70V)
60% to 80% (15 kV to 20 kV = 60V to 80V)
The Dip switch settings will be in steps of 1 kV. The interface supply (12V DC) is connected to this circuit for functioning of ICs and Relays and same voltage is adjusted for comparator input reference voltage.
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The catenary indication. An MOV is provided across this input to act as a surge arrestor.
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Both of these comparator outputs ( U1-U3 ) are to be connected to input of the AND gate.3. The output from this card goes to Digital Input Function Module of Logic Chassis through Euro connector. This will be fed to the input of Drop Off comparator and the respective trimpot is to be adjusted to make output high. Then the AC OFF input voltage is to be set using suitable resistor path selected by DIP switch.0 Modem
The word MODEM is an acronym for MOdulator and DEModulator. This energizes the output relay through driver transistor. This will be fed to the input of Drop Off comparator and the respective trim pot is to be adjusted to make the output high.5.
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. This will be fed to input of the pick up comparator and the trimpot is to be adjusted to make output high. The field signal input is connected through 32 pin Half Euro connector. Modem is used to transfer data between two computers located at a distant place by using a normal telephone line. Then the AC OFF input voltage is to be set using suitable resistor path selected by DIP switch. 5.merit
The DC signal corresponding to AC ON input voltage would be stepped down using suitable resistor path selected by DIP switch.
5. and AC Fail Status also be provided by this module to Digital Input Module
5.5.4. Multi-drop Modem configuration can be either 2 wire or 4 wire SCADA Multi-drop modem configuration is 4-wire configuration.
The Supervisory module monitors the input voltage to check the High/Low value.3.0
POWER SUPPLY UNIT
5.2. Supervisory Module The function of this card is to monitor the presence of the input AC voltage and change over to battery whenever the input AC voltage crosses beyond the specified limits which is less than 155 V or greater than 290 V. 12v.5.1 Overview of SCADA Modem The basic configuration consists of one master modem and one or slave modems connected.4.5.1 Principle of Operation The RTU Power supply consists of two parts .-12v) for Modem and interface card reference supply.
5. The relay circuitry is used to control the AC/DC Supply switch over.merit
5. The transmit output of master modem is connected to transmit output of all slave modems. one for main 24 v dc Supply and the other is (5v. At any given time either master modem will be transmitting data to slave modem will be transmitting data to the master modem.4. Our Railway
configuration The mode of communication between master and slave modem is always half duplex mode. The receive input of master modem is connected to transmit output of all slave modems.5.1 Mains supervision : When AC Mains voltage is between 155V AC to 290V AC as specified in the RDSO document then AC Mains will be connected to the DC-DC
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. The DC LOW.2 PROTECTION FEATURES
2. Protection of electronics from surges and noises are taken care by using transient voltage suppressors and line filters.2 Battery supervision : When battery voltage is between 99V DC to 140V DC as specified in the RDSO document then Battery voltage will be connected to the DC-DC converter. Transient voltage suppressor will prevent the abnormal rise of AC input voltage.5. Line filters will provide filtering of electrical noises of DC supply given to the SMPS.
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. 5. otherwise 110V DC battery voltage will be connected.merit
Block diagram of Power supply
PWER SUPPLY WIRING DIAGRAM
Page No : 50
Block diagram of psu of LDA75f
Page No : 51
component layout of LDA
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Ckt of psu LDC 30F
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component layout of lLDC 30f
This power supply unit is to work with 240V AC from MAINS. Whenever AC is cut off due to high or low level. then the 110V DC input voltage from Battery is to be connected. If the AC input goes above 290V AC. If this
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. then the input will be cut off and it has to reach 175V AC to become normal. then it will be cut off. If this voltage goes below 155V AC.
The Negative output is AC Grounded to flame grounded before feeding through inrush limiting thermistor to tank capacitors.5. The Positive/Negative terminals of output are floating with respect to ground. A LC filter combination will filter the rectified output to feed a steady current into primary of transformer. The leakage and mutually inductive coupled input is fed to the rectifier bridge. 5. The voltage control is affected by programmable IC. A damper discharge resistance bleeder for this capacitor is formed by resistor network. which is filtered by spike noise suppression capacitor C11. A LC filter combination will filter the rectified output to feed a steady current into primary of transformer. which is filtered by spike noise suppression capacitor C11. which has comparator resistors network for output setting. If it goes to 140V DC and above it will be cut off. then it has to reach 95V DC to become normal. Any over/under shoots are damped by bleeder resistor network.4
Functional Description of LDC30F
The DC input voltage is provided through Molex connector at the line and neutral points. A damper discharge resistance bleeder for this capacitor is formed by resistor network.2 Amps). The PWM (Pulse Width Modulation) control has pulse modulated between primary winding of the transformer. The leakage and mutually inductive coupled input is fed to the rectifier bridge.4.
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. The output voltage is crowbar clamped with zener diode and optically coupled.
5.4. The Negative output is AC Grounded to flame grounded before feeding through inrush limiting thermistor to tank capacitors. A 3Amps fuse isolates the power. A 3Amps fuse isolates the power.merit
voltage goes below 80V DC. Auxiliary winding pin provide for soft start control with capacitor.5.3 Amps at 200v AC.3
Functional Description of LDA75F
The DC input voltage is provided through Molex connector at the line and neutral points. The primary winding of transformer are current switched by MOSFET TR31 at 140 KHz to generate an average input current of 3. The Output Voltage of LDA75F is +24 V DC (3. The output is RC damped and LC filtered. The output terminals of the transformer operate a common cathode dual diode in the feed forward mode through inductances.
The output is RC damped and LC filtered. The PWM (Pulse Width Modulation) control has pulse modulated between primary winding of the transformer.5. when cause of activation of over current protection is removed.3 Amps). The voltage control is affected by programmable IC. This function works to protect against short circuit and over current condition. Auxiliary winding pin provide for soft start control with capacitor.3 Amps at 200v AC.2Amps) and 12V(0. Any over/under shoots are damped by bleeder resistor network. The Positive/Negative terminals of output are floating with respect to ground.
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. the output will be automatically recovered. The output terminals of the transformer operate a common cathode dual diode in the feed forward mode through inductances. which is less than 20 seconds. which has comparator resistors network for output setting.merit
The primary winding of transformer are current switched by MOSFET TR31 at 140 KHz to generate an average input current of 1.5 Over current Protection Over current protection circuit is built-in to be operated over 120% of the rated current. +12V(1.4. The output Voltage of LDC30F is +5V (3. The output voltage is crowbar clamped with zener diode and optically coupled. 5.0 Amps).
Supervisory 1 OF 2
Supervisory 2 OF 2
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PCB LAYOUT OF SUPERVISORY
5. When this function operates. Output Voltage will be recovered
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.6 Over Voltage Protection Over Voltage Protection is built–in and will be operated at 290 of the rated input Voltage.5. input should be shut off.
C Input Voltage (Lower range) Hysterisis: 20 V AC for both Higher and Lower range.5. Transformer TAP positions and Autoreclosure lockouts.6. 5.7 Fold Back Characteristics INPUT A.0
Contactors / Relays The Contactors are used to activate the field devices such as Circuit breakers.merit
whenever the input supply becomes Normal.4. The rating of these contactors is as follows Make C&S
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. Contactors 24V DC with respect to GND 4.5.C Input Voltage (High Range) A. Logic Chassis +24 v DC with respect to GND 2. The output voltages are as follows: 1. Modem +12V DC -12V DC +5V DC with respect to GND 3. Interface Cards +12V DC with respect to GND 155V AC 135V AC Pick up 270V AC Drop off 290V AC
Enclosed contacts and shrouded terminals ensure protection against accidental touch.merit
Coil voltage Contactor rating No. Of contacts for CB / BM No. replacement of coil is very easy without disturbing the power connections. Mounting space is saved due to its compact design. Make : OEN / 4R Series Type : 4R Series No. Accessibility for change of coil is from the front. Due to modular design. These are made of flame retardant thermoplastic material. These are very strong. The Relays are used in the Interlocking circuit and under voltage circuit. compact and light in weight. bounce free contact system and high contact pressure makes the contactor suitable for high making and breaking currents. DIN rail mounting offers ease of assembly in the panels. of contacts : 3 Changeover Coil voltage : 24V DC Contact rating : 2A
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. The terminals have self propelling washers for easy connections. Of contacts for Auto reclosure 24V DC 10A 3 NO + I NC 2 NO + 2 NC -
These contactors are suitable for DIN rail mounting as well as screw mounting.
Schematic for tele command
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Schematic for hv cb tele command
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Terminal Block Terminal Block is used to interconnect the field cables and RTU internal cables to perform the control and supervisory operation at the field.merit
5. Interconnection between RTU and field terminal block is done in the switching stations to collect the Status / Alarms and control the Field equipment. The RTU terminal block section is designed in such a way that separate terminal sections are arranged for Tele commands.
Note : Please Refer Annexure I & II for Terminal Block Connection Details.5.7.1
DESCRIPTION OF TELEMETRY SYSTEM AT TSS Under-voltage Tripping of Bridging Interrupters
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. Tele signals and Telemetry.
the Power Meter will be connected to the other line through the PT changeover circuitry.2
Scheme of Telemetry at SP The arrangement is such that a Power Meter is used to measure the voltage of either up line or down line. even after section has actually been de-energised. The pick up voltage selection range is available from 60% to 80% of PT voltage and drop off voltage is available from 50% to 70% of PT voltage.
5. The arrangement of these settings programmed in the CPU card. In case of failure of any one line.6.3
Scheme of Catenary Indication at SP The arrangement is such that the catenary indication is available at the pick up voltage and will go off at the drop off voltage selected and set by the user.merit
This scheme is applicable only under extended feed condition. The arrangement is such that the bridging interrupters at SP can be closed only when OHE is dead on one side of neutral section. The pick up and drop off settings have been provided to take effect of induced voltage in adjacent OHE which otherwise may give false indication of OHE live. then the bridging interrupter will be tripped by the under voltage circuit.6.
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. The logic program is designed such that if both the catenaries are low as per the set value then the respective Bridging BM open command will be executed at RTU level. When the undervoltage scheme is in active condition and if OHE voltage goes below the set level. The changeover will be effective based on the settings on catenary indication circuit. The under voltage scheme becomes operative only after the bridging interrupter is closed.
SCHEME OF TELEMETRY AT TSS
5. then the bridging interrupter can be closed.4
Closing of Bridging Interrupter When OHE is dead on one side of SP. This is
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When OHE voltage is available on both sides of SP. To achieve this function. then the bridging interrupter is to be tripped. the operator will be able to close the bridging interrupter by energizing NT coil.6.5
Under voltage Tripping of Interrupter When under voltage circuit is in active condition. Whenever both the adjacent catenaries are going low then the respective Digital output channel will enable the FT coil to trip the Bridging BM. 3.
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. then the respective Digital output module will initiate the command to trip the Bridging BM without Operator’s action.
5.e. PT1 or PT2). then the close command should not be executed.6
Sequence of operations of under voltage Tripping 1. One end to close command contactor (NT) coil is permanently connected with +24V and the other end is controlled by a command driven by a Digital output module.merit
achieved for BM1 as given below. and the other end is connected to the Digital output module. 2. The respective output of the Digital output module is programmed to give command when any one of the catenary values becomes low which is sensed from the respective Transducer connected to the Analog input module. When both the PT fails under the feed extended condition. Note : The Software is designed such a way that the bridging interruptors can be
closed only when the section on one side of neutral section is dead and the under voltage circuit become operative only after the bridging interrupter is closed. one end of the trip command contactor (FT) coil is connected +24V DC. When OHE is dead in any one side of the SP (i. if OHE voltage becomes low below the set level due to any fault.6.
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6. 2 nos of 8 way dip switches SW1 and SW2 are provided for
rectifier and filtered of
transients with capacitance
filter C. under voltage tripping and telemetry circuit.
For catenary indication.merit
5. This voltage is stepped down by the Transformer. rectified through a bridge surge arrestor. An MOV (Metal Oxide varistor) is provided across the input to act as
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Catenary Voltage Sensing at TSS
The secondary of 25 KV / 100V PT is fed to the catenary indicator.
The locked out condition is telesignalled to RCC.6. a single shot auto-reclosing scheme re-closes that breaker automatically only once after a pre-set time delay.9
Auto Re-Closing scheme at TSS In case of tripping of the feeder circuit breaker on fault at TSS. In the event of any fault on OHE presisting the feeder circiut breaker trips again and and autoreclosing scheme gets automatically locked out to prevent reclosing of the breaker a second time.merit
selecting pick-up (high level) and drop off (low level) voltage.
5. The changeover will be effective based on the settings on catenary indication circuit. the Transducer will be connected to the other line through the PT changeover circuitry.10 Field Wiring
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. The operator releases the locked-out condition when a telecommand is initiated through the keyboard console.6. The respective setting range will be as follows : Drop off Pick up : : 48% to 70% (12 KV to 17.5 KV = 48V to 70V) 60% to 80% (15 KV to 20 KV = 60V to 80V)
The Dip switch settings will be in steps of 1 KV.
IT IS TO BE ENSURED THAT THE DROP OFF VOLTAGE SETTING IS ALWAYS LESSER THAN PICK-UP VOLTAGE SETTING FOR PROPER OPERATION OF SCHEME
5.6. In case of failure of any one line.
Scheme of Telemetry at TSS
The arrangement is such that a POWER METER is used to measure the voltage of either up line or down line.
Power cables and Communication cables are routed in different PVC pipes from RTU to field terminal block.
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. Different color cables are used for easy identification of Cable terminations are numbered using the ferrules for the
traceability of the signals. the signals in the field. Field termination cables are used with different thickness to meet the current carrying capacity of the field equipment.merit
Interconnection between RTU and field terminal block is done in the switching stations to collect the Status / Alarms and control the Field equipment. Tele signals and Telemetry. The RTU terminal block section is designed in such a way that separates terminal sections are arranged for Tele commands. Signal cables.
These tools are generally used only in a production centre. The recommendation is based on the complexity of trouble shooting and technology used for mounting of component as explained below: 1. Switch off the RTU and check the Power Supply Gently for any loose contact if so tight the same. The components are soldered to the Printed circuit card with surface
mounting technology. 4.merit
6. Therefore. During Changeover observe any disturbance in CPU Module. Check AC to DC Changeover during the violation of set limit for input voltage. 2. it is recommended to identify the faulty printed circuit card and replace the card with a working card. component level troubleshooting needs a specialist with special tools. Removal of faulty components from the card and soldering of a new component on to it also needs a skilled person with special and expensive tools. the component has to be tested for all its intended functions to conclude whether it is faulty. The system is based on the microcontroller technology where almost every
component has a very high level of integration. To Measure the Ripple Voltage in D. Also Check DC to AC Changeover and observe the AC Fail & DC low indication on RTU.1 MAINTENANCE OF SCADA SYSTEM Maintenance philosophy
In the event of failure of the system. 2.C
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. as the level of integration is high.
6. The testing engineer should know each and every function of the component under test and the testing methods.0 6.2
RTU Power Supply Unit
1. Preventive maintenance is to reduce the number of failures and corrective maintenance to put back the failed system into operation. Hence. 3. Switch On Both AC & DC Supply. The components perform multiple functions. Maintenance of SCADA system may be classified into two as preventive and corrective maintenance.
Input 240V AC 110 V DC +24V DC +5 V DC +12 V DC -12 V DC
Limit ( 155 to 290 V) ( 100 to 130 V) (+/.1 VDC)
6. However a regular periodic maintenance program should be followed.2 VDC) (+ 1 V / . It is completely static with all advanced digital circuits. Measure the Output Voltage of RTU power Supply of MCB and ensure that the deviation is with in the limit as indicated in the below.3
The UPS System is conservatively designed.merit
5. This system will provide many years of trouble-free service with minimum maintenance.1 VDC) (+/ . If any voltage falls beyond its limit then replace the related Module. HENCE EXTREME CARE SHOULD BE TAKEN WHEN PERFORMING MAINTENANCE TASK OF TROUBLE SHOOTING THIS SYSTEM. Table given below provides the schedule maintenance procedure in detail.0.
HIGH VOLTAGE IS USED IN THE OPERATION OF THE SYSTEM. TO PREVENT ACCIDENTAL ELECTRIC SHOCK
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clean electrical contacts with a cloth dampened with carbon tetrachloride.1 6. Controls 3 Months Check all indicator lamps Check all the controls for operability. chokes for evidence of heating. Do not use cleaning solvent on electrical contacts. Check the components for
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. loose mounting of screws. Replace if any damage or mal6 Controls 12 Months functioning is observed. damaged insulation. keep the 3 Cabinet 3 Months 3 Months battery terminals clean. Replace as 7 12 Months indicated. Tighten any loose screws or nuts. 12 Months Check the cable for input and output power and internal wiring to components.4 Sl No 1 2 TABLE OF PERIODIC INSPECTION AND MAINTENANCE ITEMS Ventilation & opening Chassis Assemblies INSPECTION Daily Weekly PERIOD Daily Weekly PROCEDURE Check that intake and exhaust air openings are not obstructed. Remove dust & foreign particles within & Battery the chassis & battery bank using compressed air or blower. tighten them. 4 5 Controls Controls 3 Months 6 Months 3 Months 6 Months Replace if found defective. Check the operation of meters. 12 Months Inspect the general conditions of PCBs.merit
TABLE . Check for cracks or broken insulation. Correct any malfunctioning before operating the unit. Check mounting bolts and terminals for looseness. Inspect the transformers.
Use carbon tetrachloride in well ventilated areas. if 8 12 Months necessary. 12 Months Inspect PCB. 12 Months Inspect diodes and silicon Controlled rectifiers and their heat dissipators for loose mounting or defective electrical 9 12 Months connections.5
FAULT FINDING AND RECTIFICATION When replacing the components. Repair or replace wiring. Tighten the mounting screws & replace 10 12 Months defective sockets.merit
evidence of over heating. Repair or replace board.
FUSE REPLACEMENT MUST BE MADE ONLY WITH TYPES SPECIFIED IN THE PARTS LIST
6. observe the following :
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. Tighten mounting screws 11 if necessary. Do not breathe fumes. cracks orpeeling. Tighten screws and nuts. 12 Months Inspect terminal boards for breakage or dry joints. if any. sockets for loose components electrical connections. Inspect the electric wiring for broken solder connections or peeled insulation and general deterioration. Replace if necessary the defective TB.
make it possible to reverse the procedure or to facilitate the communications regarding repair procedure. Comprehensive notes and an components. which component effect readjustment. 6. as a poorly soldered joint can Do not drop drips of solder or hardware into the chassis. cause further trouble and is one of the most difficult faults to locate. When detaching wires from components. Do not damage leads of other components by pushing or them aside. Mfr APLAB
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. Maintain a log of all repairs and adjustments. Familiarity with the Systems and judgement must be exercised when determining. testing and correct re-wiring.
readjustment of appropriate circuit is necessary.6
TESTING EQUIPMENT REQUIREMENT
Whenever it becomes necessary to replace any of the components in the UPS. Whenever one or more components have been replaced. readjustment of the appropriate circuits may be necessary.
accurate log. 8. 3. 5.7
TEST EQUIPMENT EQUIPMENT WITH MODEL / TYPE Oscilloscope with Dual Channel QTY 1 no.
6. mark the wire with tape to ensure Always place the component in the exact position occupied original.merit
1. Following Table lists the test equipment required for reforming adjustment servicing :
6. 2. 7. 4. When soldering avoid excessive heat which may damage associated Be careful while making all soldering joints.
1 no. 1 no. 1 no. APLAB NIL APLAB APLAB Numeric
Voltage Probes into 10 Model Digital Multimeter Type Distortion Meter Decade Resistance Card Servicing Unit 2 nos 1 no. Telecommand (BM/CB) not operating
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.0 7.1 RTU TROUBLE SHOOTING PROCEDURE TELESIGNAL The problems in the field equipment can be classified into three types a).
Check the respective PT/CT secondary at RTU terminal block as per the wiring diagram
or the Field Termination Chart.
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b). Telesignal (BM/CB status and Alarms) not coming c). Telemetry (Voltage/Current) not received from the post δ
1. If the voltage is available then follow the next step. 2. If there is no required minimum Voltage or Current then the problem is not in the RTU side. 2.
. Check the field equipment side and the cable continuity.
Check the 110 V DC at respective RTU terminal block as per the Field
Termination Chart or the Wiring Diagram where this voltage comes from the field devices. If there is no voltage at RTU terminal block then the problem is not with RTU. Replace the respective DIM d as per the wiring diagram or Field termination Chart and check respective LED indication at DIM card. Check the field devices and the interconnecting cables.
3. 5. if there is no serial output with respect to input voltage or current then replace the Power meter check the value at RCC. Replace the flat cable and check the value at RCC. If there is no Voltage or Current then check the cable between the RTU terminal block and Power Meter input.
7. 4. Check the power Meyer output.3
Page No : 78
. Check the POWER METER input Voltage or Current.
b. then replace the contactor. c. then check the contactor operates.4
Power Supply Unit :
( If output voltages are not coming)
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. the problem may be resolved by changing the following items one after another. If channel does not glow. then check the NO contact for input and output voltages. If the problem is not resolved. If the channel glows. then change the cable termination.
7. then check the 24 V DC Supply at terminal block TB1. If the coil voltage is not available. if voltage is available. e.merit
HARDWARE MANUAL 1. If the 110 V DC is not available on the input side then the problem is again on the railway terminal board. a. Change the DOM card. if available. Check the Selected channel enable and indication is proper. If voltage is available on the input side but not available on the output side then change the contactor. d. If the contactor operates. Otherwise check for 24 V DC across coil. then problem is in the Field devices side.
7.Check the output voltage at Molex Connector JP4. Check the Output voltage at Connector (JP5) for 24v/DC. Then check the module fuse (F1). If the D/C Input voltage is not present then check the fuse (F3) and MCB-2 Input and Output.( The Voltage must be less than 140v and greater than 90v DC) 6. 3. If the Input Voltage is not present .merit
1. ( The Voltage Must be less than 290v and greater than 155v ) 5. then replace the 2A fuse (20mm) If the the LDA /LDC input voltage is present at connector CN1 . ( Check the Molex pin connection and crimping ) Supervisory Module
7. If the Fuse (F3) blown up. (if the Voltage is available go to step-7 2. Check the input voltage of the LDA (OR) LDC Module at Molex connector CN1.
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. Check the Output voltage at connector (JP3) for +5v/+12v/-12v.5
TROUBLESHOOTING CHART FOR UPS FAULT SYSTEM System working on mains but not working on battery REASON Battery fuse blown REMARKS Check the battery polarity and replace the fuse. ( Check the Molex pin connection and crimping ) 9. If the A/c Input voltage is not present then check the MCB-1 input & Output. then check the A/C input voltage at connector JP1. 8. If the supervisory card input voltage is not present . 4.
Check the battery polarity and connection.B. Provide rated input voltage. Replace the fuse Check the input supply. Replace the fuse
Mains Input Fuse Failure
Very low input voltage Input cable capacity is less Loose contact in the input wiring Inverter Fuse blown
DC Under Voltage indica tion comes on even when DC voltage is nominal and the Inverter Trips. DC under Voltage comes immediately after the Inverter is switched on (NO LOAD) and Inverter Trips DC under voltage indication comes on while working on Battery (in the absence of mains) and Inverter trips. Keep the battery in charged condition Replace the cable with a correctly rated cable. check the wiring of Contactor & rectify it. Tighten the connections. replace with proper fuse.
7. Switch on the loads one by one . Check the coil.If it is of lower rating. with correctly rated capacity.6
Trouble Shooting Procedure for Modem :
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. Correct if it is wrong. Overload Indication comes on while the load is switched ON
Mains input cable is less than rated capacity Battery is discharged Battery cable of lesser capacity less than rated Load surge. If present. Replace the wiring with correctly rated cable. Voltage reaches 230V
Replace the cable from D. Replace if faulty.merit
Charger not coming ON when switched ON
Mains input fuse failed or mains MCB tripped Input fuse of the charger blown Contactor not coming ON
Check the rating of the fuse.
Make sure that the power card is kept correctly. 1. In case the polling operation does not take place the following points will facilitate the first line maintenance of the card. B) Ensure that the modem to RTU /MTU connections are proper. MTU .
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C) Ensure that the Modem to Modem connection are proper. Check for correct ness of the jumper setting. Verify that the modem is powered on by observing the MR led glowing on the front panel. 230v. Verify that the RTU/ MTU signals are coming properly at the RS-232C cable coming from RTU/ MTU. A) Ensure all the modems involved are powered on. 2 of RS-232C cable coming from RTU/
with corresponding Connector of the modem end. 1. 2. AC in case of master modem. DC voltage in case of Slave modem. If the signals are present ensure that the RS-232 Cable is mating properly Request to send (RTS) at Pin No.merit
Team link SCADA modem is designed in such a way that it requires just plug in the modem for normal operation. Verify the following signals are in the range of –3v to –15v at the RS232 C Cable coming from RTU/ MTU. MTU If the voltages are not present then check for the continuity of the cable. 4 of RS-232C cable coming from RTU/ Transmit Data (TXD) at Pin No.
if MR is glowing put the Analog loop back switch in to On position and send data and check. check for correctness. If data is correct then connect the modem with any one of the Remote modems and ask them to put in to Digital Loop back switch in to ON position. 2. send data and receive. Ensure that the Modems are operating properly Check for MR led on the modem.
If still the problem persists then replace the modem . Ensure that the connection from the Master modem are properly connected to Slave modems.merit
1. if data is not correct modem could be faulty. if not check for the communication cable.7
TELESIGNAL FAULT FINDING CHART
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. Check whether RTU is responding for the polling. Master Modem: CTS led should always be glowing. if not check the following Check the RS-232 cable from RTU. If the data is correct then. Check the continuity of the Communication Line. Start the polling cycle and observe the following 1. RD led should blink.
D). TD and RD led should blink
2) Slave Modem: DCD led should glow. If the data is not correct check for communication cable.
CHECK THE RTU TERMINAL BLOCK FOR 110V FOR FIELD INPUT
NO 110V AT TB
YES REPLACE DIM YES NO
NOT A RC PROBLEM
DIM LED IS GLOWIN G
REPLACE DIM MODULE
YES PROBLEM SOLVED NO
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8 TELEMETRY FAULT FINDIING CHART
CHECK THE RTU TERMINAL BLOCK FOR FIELD INPUT
NO FIELD INPUT YES NOT A RC PROBLEM
CHECK POWER Meter INPUT & Supply YES
CHECK FUSE & CABLE FOUND FAULTY REPLACE IT.
CHECK POWER METER OUTPUT YES PROBLEM SOLVED
NO REPLACE THE Power Meter
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HARDWARE MANUAL 7.
9 TELECOMMAND FAULT FINDING CHART
CHECK THE RESPECTIVE CHANNEL LED IS ENABLED
LED ENABLE D YES
NO REPLACE DOT MODULE
CONTACTO R IS OPERATING
REPLACE THE CONTACTOR
CHECK VOLTAGE ACROSS COIL
REPLACE THE CABLE
CHECK THE O/P VOLTAGE AT TB
NO CHECK THE WIRING FOR LOSSE CONNECTION.merit
HARDWARE MANUAL 7.0
DOWNLOADING PROGRAM TO RTU MICROCONTROLLER: Procedure:
Page No : 86
. ANY DAMAGE REPLACE IT
YES PROBLEM SOLVED
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4. Set the parameters as shown below.EXE
The preloaded SPJTERM.
5.EXE is the programming tool of the micro controller used in the RTU.merit
1. Connect the serial-port-1 of CPU to system serial port. After opening the program click Settings to set the communication Settings. Set the jumper J2 of CPU to download mode. 2. Software used for Download Program: C:\SCSI\BIN\SPJTERM. After setting the port parameters click port open to initialize the serial port.
Set all the parameters as shown below.
RTU is now ready for download and the communication is now initialized with the Controller.
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The window will appear as shown below.
6. Click the In System Programming in File menu.
9. Click Browse and select the . Click Program to start the downloading.merit
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.HEX file of RTU download file. The path and name of the file will be appearing on the band HEX file to download.
10.Click Full Chip Erase to clear the buffers of Micro controller.
The above shown window will disappear after download is completed.EXE is the downloading tool of the Merit RTU. Default-600. RTU is now ready for normal working.EXE
The preloaded MERITDIAG. 2.
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. Switch off the RTU and set the jumper J2 of CPU to normal position and Switch ON. Click Baud Rate and set the speed of serial communication.
Download Parameters to RTU
Procedure : 1. Software used for Download Program: C:\ADRA\MERITDIAG.
Page No : 91
. Click Comm Port and set the serial port to witch the RTU is connected. Default-Comm 1.
4.Click Setup and set the parameters to download to the RTU.
5. If a mismatch occurs while download. the modules will gets damaged and may cause serious damages to the whole unit. After setting the parameters click Download & Update button to set the RTU parameters. Setting of Analog Input Channels: SSP SP 0 2
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. Note: Before Clicking Download & Update make sure that the Digital Input Modules and the Digital Output Modules selected must match the actual modules inserted in the RTU. While setting the slot for Digital Output modules the RTU will start from the number of digital input modules and the slots will be allocated automatically after the Digital Input modules.
The window will appear as shown below. Click Scan Digital Inputs. The RTU running memory buffers can be cleared by clicking Reset RTU Database.1
Testing the various parameters using MERITDIAG: 1.merit
TSS/FP 8 Now the RTU is ready for communication and operation.
7. DO and AI channels can be checked through MERITDIAG. All the DI.
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. All the DI channels can be tested and viewed. The RTU real time clock can be set by clicking Set RTU Time. 6.
The window will appear as shown below.merit
2. “On” will appear.
Click Scan Output Status. • Press space bar once.
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. All the DO
channels can be tested and viewed
Testing Procedure: Click on the channel to be tested.
• • • •
Press space bar again. The window will appear as shown below. Analog count . The particular channel will be made On and Off by RTU. “On” will get disappeared.
Click Scan Analog Inputs. Click on Set Outputs.
3. The particular channel will be made On by RTU. Click on Set Outputs.merit
• Click on Set Outputs. The particular channel will be made off by RTU.
percentage and unit against all the AI channels can be viewed here.
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. Press space bar twice. “Timd” will appear.
LIST OF ABBREVIATIONS
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A AC AIT BM CAN CB CD CP CPU CT CTA DDC DC DIFM DIT DIP DMA DOT DRAM EMF EPROM FP FSK Hz IBM PC IC IDE IRQ LAN LC Amperes Alternating Current Analog Input Termination Bridging interrupter Controller Area Network Circuit Breaker Carrier Detect Communication Processor Central Processor Unit Current Transformer Cable Termination Module Bus Coupler Module Direct Current Digital Input Functional Module Digital Input Termination Dual-In-line Package Direct Memory Access Digital Output Termination Dynamic Random Access Memory Electro Motive Force Electrically Programmable Read Only Memory Feeding Post Frequency Shift Keying Hertz International Business Machines Personal Computer Integrated Circuit Integrated Drive Electronics Interrupt Request Local Area Network Logic Chassis
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LED MB MOBI MODEM MOSFET MOV NC NO NVRAM OHE PC PCB PCS POST PWM RCC RD RF RLA ROM RTS RTU SCADA SCR SEB SH SIMM SP SSP SVGA SW Light Emitting Diode Mega Byte Mod Bus Interface Modulator Demodulator Metal Oxide Semiconductor Field Effect Transistor Metal Oxide Varistor Normally Closed Normally Open Non-volatile Read Only Memory Overhead Equipment Personal Computer Printed Circuit Board Peripheral Chip Select Power ON Self Test Pulse Width Modulation Remote Control Centre Receive Data Radio Frequency Relay Read Only Memory Request to Send Remote Terminal Unit Supervisory Control and Data Acquisition Silicon Controlled Rectifier State Electricity Board Shunt Single-in-line Memory Module Sectioning and Paralleling Post Sub-sectioning and Paralleling Post Super Video Graphic Accelerator Switch
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TB TCO TD TPC TSS UPS V VGA WAN Terminal Block Timer Counter Output Transmit Data Traction Power Control Traction Sub-station Uninterrupted Power Supply Volts Video Graphic Accelerator Wide Area Network
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