TKT-CM-01-OM-1060-I-R1-O&M Manual - Control & Monitoring System PDF

O&M Manual –Control & Monitoring system
TABLE OF CONTENTS
PAGE
S.NO DESCRIPTION
NO.
1 Introduction 3
1.1 About This Manual 3
1.2 Intended Use 3
1.3 Notice Of Claims 4
1.4 Copyright 4
2 Safety 4
2.1 Safety Devices 4
2.2 Basic safety instructions 5
3 Technical data 11
3.1 Control Boards 11
This drawing/document is the INTELLECTUAL PROPERTY of
ANDRITZ HYDRO GmbH, Vienna, Austria
3.2 Computer and Monitors 11

3.3 Touch Panels 12
3.4 Printer 12
3.5 LAN Components 13
3.6 NTP Server with GPS receiver 13
3.7 Process Control System 13
3.8 Automatic Synchronizer SYN3000 15
4 Description 16
4.1 General 16
4.2 Location and Components 16
4.3 Communication 17
4.4 General Real-time Concept 17
4.5 Remote Maintenance 17
4.6 SCADA System and Operator Stations 17
4.7 Process control System 18
5 Operation 20
5.1 SCADA System and HMI 20
5.2 Control Boards 86
6 Maintenance 97
6.1 Control Boards & Control System SICAM 1703 97
6.2 Handling of SICAM 1703 Hardware 102
6.3 Software for AK 1703 111
6.4 SCADA system SCALA 250 130
7 Spare parts and assembly devices 144
7.1 Specified Spare Parts 144
7.2 Recommended Spare Parts 144

REGISTERED
Client VSH Prep. ST Contract Nº.

Plant TKT HPP (2X110 MW) Chk. TD 817/2012/HD-VSH-AH
Project Nº C.388/C.389 / V-0322 Appr. HJ = +
Index R1 DOC Nº TKT-CM-01-OM-1060-I
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Date 31.01.2014
Page 2 of page 144 Internal Nº 2801060
1. Introduction
This manual is part of the project documentation for a machine/plant supplied by ANDRITZ HYDRO. The
manual is particularly adapted and refers to the stipulated scope of supply solely.
The manual contains essential information about the correct, safe and purposeful operation of the ma-
chine/plant. The adherence to these instructions helps to avoid so far well-known dangerous situations, to
minimize repair- and standstill costs and to optimize the availability and life cycle of the plant.
But the manual cannot cover all precautions, safety instructions and operating instructions of hydro power
plants. It contains only the most important information (in compressed form), which have to be taken into ac-
count and cannot compensate technical competence and training of operating personnel.
1.1 About this manual
(i) Target Group
The manual is exclusively addressed to the operator and his personnel, operating and maintaining the ma-
chine/plant (maintenance, inspection and repair).

The personnel assigned to work on the machine/plant have to read the manual before commencing work.
During work, it is too late. This applies particularly to people, who work only here and there, e.g. during
maintenance or repair of the machine/plant. In particular the following is to be considered:
 The entire chapter Safety and

 The safety instructions stated in the individual chapters.
(ii) Supplementing Instructions
Existing national instructions regarding health & safety and environmental protection have to be added to this
manual by the operator. Such instructions can regard e.g. handling with hazardous substances or availability /
wear of personal protective equipment, too.
Instructions, which consider the operational characteristics regarding labour organisation, operational se-
quences and employed personnel have to be added to this manual by the operator, too. This includes instruc-
tions regarding obligatory supervision and notification requirements.
The manual is to be kept always at place of installation within reach.
1.2 Intended use
The machine/power plant must be operated in accordance with the specifications acc. contract solely. Any
operation exceeding the stipulated performance limits or contrary to the intended company regulations, is
considered as unintended and can lead to damages. ANDRITZ HYDRO does not assume liability for these
damages.
The intended use contains also the compliance with this manual as well as the adherence to operating and
maintenance conditions and the adherence to cleaning and maintenance instructions.
The correct and safe operation of the machine/plant requires proper transport and storage, installation and
assembly as well as careful operation and maintenance.

REGISTERED

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Date 31.01.2014
1.3 Notice of claims
Lacks and damages, detected by the customer or operating personnel, serious accidents or other detected de-
viations from the normal operating condition have to be announced immediately to ANDRTIZ HYDRO regard-
less of the occurrence during or after expiration of the warranty period.
This notification should contain in particular the following information:
 Description of lack or damage (symptoms, detected by and when)

 Identification of systems or components concerned (identification number)
 Already taken measures
 Recordings of status-, error- and alarm messages
 Entries in operating log
 All recordings and prints of the electronic data logging
 Maintenance data
1.4 Copyright
This manual is the intellectual property of ANDRITZ HYDRO GmbH and must neither be copied nor handed
over to third parties without prior express agreement of ANDRITZ HYDRO GmbH. Violation will cause indem-
nities and can lead to prosecution. We reserve the right to make changes of technical details in relation to the
details stated in the manual.
2. Safety
The chapter Safety contains general safety instructions, which have to be considered when working on the
machine/plant.
Supplementary additional safety instructions to the individual activities are provided in the chapters of the
manual. These are set apart from the text by special warning notices.
Safety instructions for components, which were not made by ANDRITZ HYDRO, are included in the descrip-
tions of the component suppliers and have to be considered, too.
Non-adherence to the safety instructions can lead to personal injuries, environmental damages and/or materi-
al damages.
ANDRITZ HYDRO assumes that the operator guarantees the following:
 The operator prepared a comprehensive general safety program.

 Each person, working on or in the surrounding of the machine/plant was sufficiently trained (regarding
operation of machine/plant and its running procedures).

2.1 Safety devices
REGISTERED
The access to all safety devices must be ensured at any time.
The machine/plant can be put from operation to a safe operating condition at any time by pressing the
EMERGENCY STOP BUTTON (possible designs see illustrations below).

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Date 31.01.2014
The operating and maintaining personnel of the operator must be informed about the location and function
of the EMERGENCY STOP BUTTONS.
The location and number of EMERGENCY STOP BUTTONS is shown on the wiring diagrams.
Voltages and hydraulic pressures can still be present after pressing the EMERGENCY STOP
BUTTON.
2.2 Basic safety instructions

2.2.1 Duties of operator
(i) Intended Use

The operator of the machine/plant is responsible for the intended use of the machine/plant.
(ii) Work Instructions

In addition to the manual observe and use the relevant national legislation and other regulations
regarding health & safety and environmental protection.
(iii) Qualification of assigned personnel

 Operation, set-up and maintenance of machine/plant by qualified, reliable and authorized personnel
only.
 Qualified personnel are persons, who were authorized by the responsible safety person due to their
education, experience as well as knowledge of relevant standards and regulations, rules for the pre-
vention of accidents and operating conditions to perform the necessary works and to recognize and
avoid possible dangers.
 Ensure that only authorized personnel works on the machine.
 Personnel in education may only work on the machine/plant after theoretical training and only under
supervision of a qualified person.
 Take the legal age into account.
 Only an electricity specialist or person instructed by him is entitled to work on electrical systems of the
machine/plant under his direction or supervision.
 Only competent personnel are entitled to work on gas equipment (gas consumption equipment).
 Only personnel with special knowledge and experience are entitled to work on hydraulic equipment.
(iv) Instruction
 The operating and maintaining personnel of the operator must be introduced by qualified persons af-
ter completing the installation work.
 The operator is obliged to introduce new operating and maintaining personnel in the same extent and
with the same care under consideration of all safety instructions.

Plant TKT HPP (2X110 MW) Chk. TD 817/2012/HD-VSH-AH REGISTERED
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Date 31.01.2014
 Persons, who are involved with the transport, assembly, commissioning, operation and maintenance
of the machine/plant must have read and understood this manual as well as the descriptions of the
component suppliers before commencing work.
 Safety instructions for components, which were not made by ANDRITZ HYDRO, are included in the
descriptions of the component suppliers and have to be considered, too.
(v) Definition of Areas and Responsibilities

The operator is responsible for:
 the definition of the machine operator responsibility and the directive authority,
 the definition of the content (record of the function and malfunction of monitoring equipment) and the
responsibility for maintaining the shift handover log,
 The duties of the operating and maintaining personnel.
(vi) Inspections and Tests

The operator is obliged to:

 check regularly whether the safety instructions are kept in accordance with the manual when working
on the machine,
 Train the operating and maintaining personnel regularly and to confirm their knowledge.
(vii) Attachment of Safety Devices

The operator ensures that all safety-relevant instructions are kept and all necessary symbols and notices
are attached in the production area in accordance with the local instructions.
Beyond that ANDRITZ HYDRO recommends attaching of the following devices, symbols and notices as
far as these are not already contained in the local instructions:
 Emergency lighting
 Information sign – fire prevention equipment
 Information sign – emergency call
 Direction sign – exits
 Direction sign – escape routes
 Information sign – first aid
 Observe the national fire protection regulations.
All safety- and warning notices on the machine/plant shall be complete and readable.
The operating and maintaining personnel must be informed about the location and handling of fire extin-
guishers.
2.2.2 General duties of personnel
In order to avoid personnel injuries and material damages the following safety instructions apply to all per
sons, working on the machine/plant:
 Observe the safety instructions mentioned in the manual and attached on the machine.
 In case of safety-relevant malfunctions stop or secure the concerned part of the machine immediately.
Announce and repair the malfunctions immediately.
 Any safety-precarious mode of operation is not allowed. REGISTERED
 Use only the provided entries, routes and aisles.
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 Keep the machine/plant and work place clean and tidy. Do not put down tools and other items on the
machine.
 Do not wear clothes or pieces of jewelry, which enable getting caught by mobile machine parts. Ties,
neckerchiefs, rings and chains belong thereto.
 Do not wear long hair loose.
 Inform the personnel about the function and malfunction of monitoring instruments before commenc-
ing work.
 If necessary, place temporary barriers and limit the entrance when working on the machine/plant.
 Entering of danger zones is only allowed after the power supply is safely disconnected and the me-
chanical safety devices are mounted. Protective equipment must not be blocked or bridged.
 Avoid contact with switched-on circuits or rotating parts.
 Use or take along the personal protective equipment in accordance
 With the national instructions or instructions of the operator when working on the machine.
 The wear of protective footwear in all the factory premises is mandatory.

 Re-establish the original condition after maintaining.
 If the operating person cannot survey the entire zone of danger, nevertheless make precautions to
ensure that no persons are in the zone of danger when issuing control commands.
 Set the operating mode to AUTO before leaving the power house in order to ensure that the ma-
chine/plant can be stopped in case of danger.
2.2.3 Work on/in electrical systems
High voltage can lead to heavy or fatal injuries. Therefore it is essential to observe the following:
 Work on/in electrical systems must not be carried out unless a permit has been issued by the senior
authorized person.
 Operation and maintenance of the machine/plant only by qualified personnel.
 A second person must be present when working on live parts. In case of emergency this person can
press the EMERGENCY STOP BUTTON or the main switch with shunt trip. Demarcate the working
area with a red-white safety chain and a warning sign.
 Use proper insulated tools, protection devices and personal protective equipment and check them be-
fore each use.
 It is recommended to make oneself familiar with the safety standards, guidelines and electrical regula-
tions as well as the usual national and proven operating modes for plants (e.g. EN 50110, VDE0104
or IEC-standards). The following steps have to be met as minimum requirement before commencing
work on electrical machines/plants:
 Disconnect completely
 Secure against re-connecting
 Verify that the installation is dead (de-energized).
 Carry out earthing and short-circuiting REGISTERED
 Provide protection against adjacent live parts
 After finishing the work, carry out the above 5 steps in reverse order.

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Date 31.01.2014
 Regular inspection of electrical equipment of machine/plant. Lacks

 Such as loose connections or scorched cables have to be repaired immediately.
 Use only original locking devices with stipulated amperage.
 In addition to the general safety instructions observe and comply with the local safety instructions and
specifications.
 Remove covers and safety devices only after the appropriate ranges are de-energized and secured.
Before energizing mount the covers and safety devices again
2.2.4 Hydraulic, pneumatic
 Only personnel with special knowledge and experience are entitled to work on hydraulic equipment.
 Regular inspection of pipes, hoses and bolted connections for leakage and externally visible damages
(leaking-out oil can lead to injuries and fire). Damages have to be repaired immediately.
 System sections and pressure pipes (hydraulic, compressed air) have to be depressurised before
commencing repair work in accordance with the module descriptions.
 Hydraulic and compressed-air pipes have to be laid professionally (connections must not be mistak-
en).
 Armatures, length and quality of hose lines must correspond to the requirements.
 The operating space of the actuators must not be blocked and the access to this space must be
properly secured. This applies in particular to closing weights, servo motors and the guide apparatus.
2.2.5 Lifting and transport of components
The notices, stated in the following, have to be kept when lifting and transporting components in order to
avoid injuries and material damages.
 Do not stay or work below floating loads. Further it is not allowed to ride on floating loads.
 Adhere to the general and also local safety instructions as well as specifications or manuals of the lift-
ing tool or load lifting attachment manufacturer.
 The used lifting tool or transport vehicle must be suitable for the loads to be transported. If a mobile
crane is used, take additionally into ac-count that this crane is mounted in accordance with the manu-
facturer’s instructions.
 Usage permission for the crane must be available. Operation of remote controlled cranes only by per-
sonnel with proper written driving license.
 The results of the regular lifting tool inspection (inspection log book) must be available.
 All used slinging means (ropes, chains, shackles, eyebolts, lifting eye nuts, S-hooks) must be used
only in accordance with the manufacturer's data.
 Secure the loading properly before lifting and transport operations.
 Determine the required space in the power plant or on other provided (temporary) storage areas be-
fore commencing with lifting and transport operations. Further make sure that the floor loading is ade-
quate by granting access to the as-built drawings.
Client VSH Prep. ST Contract Nº. REGISTERED
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Date 31.01.2014
 During lifting observe the signs and other written instructions attached on the packing or components;
special customer requirements are to be considered, too.
 A "test brake" of the lifting unit is necessary when lifting heavy loads. Lift the load approx. 10 cm and
lower it in small steps. After each switch-off, the brakes have to stop the lowering process.
 Use 3D-lifting rings or eyebolts, if provided.
 Direction of crane operation by show of hands or wireless only by responsible specialist.
2.2.6 Mobile usable machines and components
 Secure the machines/components with appropriate fixings against un-intended positional changes be-
fore or immediately after finishing the loading process.
 Attach appropriate warning signs.
 Disconnect the machines/components from any external power supply; also in case of slight reloca-
tions.
 Remove transport and slinging means duly before re-commissioning.
 Mount and fasten the parts, which were removed for transportation purposes, again before re-
commissioning.
 Connect the machines/components again with the system before re-commissioning.
 Re-commissioning only in accordance with the manual.
2.2.7 Gas, dust, steam, smoke
 Welding, burning and grinding operations on the machine/plant are only allowed if expressly ap-
proved.
 Remove dust and inflammable materials from the machine/plant and its surrounding before welding,
burning and grinding operations. Further proper ventilation is to be ensured (danger of explosion)!
 If necessary take available national instructions for work in close rooms into account.
2.2.8 Noise
 Noise protection devices of the machine/plant must be in safe position during operation.

 When required, use hearing protection.
REGISTERED
2.2.9 Operating supplies
Before operating supplies can be used, read the safety data sheets of the machine and the instructions of
the manufacturer. Based on these data sheets prepare a proper protection concept and observe it.
Apart from that take the following measures in order to avoid damages and injuries of the personnel:

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Date 31.01.2014
 Wear protective goggles

 Avoid excessive skin contact with the product
 Proper ventilation of surrounding
 Use protective equipment
 Do not work near naked flame
Ignoring of these precautionary measures can lead to injuries by inhalation of poisonous steams or lead to
suffocation.
Be careful when dealing with hot operating supplies. Danger of burns and scalds!
Swarf of coatings, arising during repair work, must be disposed as hazardous waste.
2.2.10 Radio equipment
Only EMC-conform radio equipment must be used within the plant.

2.2.11 Gas extinguishing system
The entire operating and maintenance personnel of the operator must be familiar with the operating mode
of the gas extinguishing system, when using such a system. Further it must also be familiar with the
resulting special safety precautions in case of emergency.
Ignoring of these safety precautions can lead to injuries or death of persons by inhalation or quenching
gas.
If the gas extinguishing system is part of the scope of supply of ANDRITZ HYDRO, the description of the
operating mode and special safety precautions is contained in the project documentation of ANDRITZ
HYDRO.

REGISTERED

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3. Technical data
This chapter defines the main technical data of the Control system components. Details about Technical da-
ta’s of Hardware will be found in document TKT-CM-01-DS-1034-I Datasheets – Control & Monitoring System
3.1 Control Boards
Each Control Board consists of one or more standard cubicles as specified below:
Manufacturer: Rittal, Type TS 8 or equal

Dimensions per cubicle: 1000 x 800 x 2200 mm (WxDxH)
Doors : Front & Back
Painting: Priming + Textured powder
coating
Material : Self-supporting profiled steel

frame with 1.5 mm
sheet steel covers and 2 mm
Sheet steel doors.
Wiring : Black PVC insulated wires, led in
PVC ducts
Cross section:
Control circuits 1 mm²
VT circuits 1.5 mm²
CT circuits 2.5 mm²
Internal power supply min. 1.5 mm²
Cable connection : From below.
Terminals: Manufacturer: Phoenix
Types:
Current Terminal: URTK 6
Voltage Terminal: URTK 6
Signal Terminal: UT 4
Power Terminal: UT 4 – UT 10
Interface: Interface modules type TM for
standard rail mounting with inte-
grated terminals, designed for
connection of external cables as
well as internal cubicle wiring.
External cables are connected directly to the interface modules.

Cables from Voltage and Current Transformers will be connected to terminals.
For interface Amount please refer to document-
TKT-CM-01-1029-I- Topology diagram - control & monitoring system
3.2 Computer and Monitors
3.2.1 SCADA Server A & B,

Type: DELL Precision T5810
Processor: Intel Xeon- E5-1650 v3
Memory: 8GB (2x4GB) 2133MHz
Hard disk: 500GB SAS 10k RPM Enterprise HDD

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Mouse: Dell
Keyboard: English
3.2.2 Monitor Server A & B,
Type: DELL -U2412M 24” U2412M 24”

Maximum resolution: 1920 x 1200 at 60 Hz
Contrast: 1:1000
Brightness: 300 cd/m²
3.2.3 Engineering Station
Same specifications as SCADA Server A & B

3.3 Touch panels

Type: TOUCH PANEL–LIZARD LINE , 19" Touch Panel
Processor: Intel ® ATOM™ N2600 / N2800
Memory: 2GB DDR2 SD-RAM
Disk: 4 GB Compact Flash Card
Graphic Card: Intel 915 GME
Ports: 3 serial, 4 USB
Ethernet: 2 x 10/100/1000 Base-T
Screen 19 "
Resolution: 1280x1024
Contrast: 800:1
Brightness: 300 cd/m²
3.4 Printers
Type HP Color Laser jet CP5225N
Print speed: 20 ppm black/color
Resolution: 600 x 600 dpi,
Tray: 1x 100 sheet input tray,
Processor, memory: 540 MHz processor, 192 MB memory,
Print language: PCL 5C, PCL 6 & PS-3 emulation,
Interface: Ethernet 10/100Base-TX, USB 2.0,
Dimension: w x d x h = 545 x 598 x 338 [mm], 40,9kg,

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3.5 LAN Components

3.5.1 Ethernet Switch
Type Cisco IE3000-8TC

Interface: 8 Ethernet 10/100 ports and 2 Dual-Purpose
one 10/100/1000 Ethernet Port and one SFP based
Gigabit Ethernet port, one port active)
3.6 NTP Server with GPS Antenna

Type Meinberg, LANTIME M300 GPS
Interface: Ethernet, USB, SNMP, serial
3.7 Process Control
For detailed technical data of modules pls. refer to document TKT-CM-01-DS-1034-I Datasheet Control
and Monitoring System Components.
3.7.1 Processor Modules
3.7.1.1 Controller Main Processor
Type CP-2016
Function Main processor of each AK 3 system
main function: administration of the whole controller (Automation Unit),
I/O hardware connection, serial/LAN communication and logic function
3.7.1.2 Controller Processor
Type CP-2019
Function processor of AK 3 system
Main function: I/O hardware connection, serial/LAN communication and
logic function.
3.7.2 I/O Modules
3.7.2.1 Digital Input Module
Type DI-6103
Function 16x2 110/220V DC
3.7.2.2 Digital Output Module
Type DO-6212
Function 8 x2 Relay 24-220V DC / 230V AC

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3.7.2.3 Analog Input Module
Type AI-6300
Function 4 x2 ± 4-20mA / ±10V
3.7.2.4 Analog Input Module (Temperature Sensing)
Type AI-6310
Function 4 x2 PT100
3.7.2.5 Analog Input Card

Type AI-6303
Function 3 CT-inputs, 4 VT-inputs
3.7.3 Power Supply Modules
3.7.3.1 Power Supply for I/O Module
Type PS-6632
Input 110…220V DC
3.7.3.2 Power Supply for Controller AK-3
Type PS-2632
Input 110…220V DC
3.7.3.3 DC/DC Converter 100V/24V DC
Input voltage 100-240VAC or 110-300VDC

Output voltage 24VDC
Output power 240W
Monitoring DC-OK Relay contact
Operational -25°C … +70°C
Temp
Dimension w x d x h = 60x117x124mm
mounting on 35mm DIN-rail

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3.7.4 Converter Modules
3.7.4.1 AX-Bus Star coupler
Type CM -0843
Interface RJ-45 connector for the AX-Bus (I/O Bus) to the CPU USB-connector for
the AX-Bus (I/O Bus) from max. 4 Line Selectors (electrical RS485 star
coupler, proprietary protocol)
3.7.4.2 Optical Star coupler
Type CM-0821
Interface 1x RJ 45 RS485, 3x Optical Fiber Multi Mode connector ST
3.7.4.3 Optical Star coupler

Type CM-0822
Interface 4x Optical Fiber Multi Mode connector ST
3.8 Automatic Synchronizer SYN 3000

Voltage Transformer: Rated Voltage: 100 VAC
Operating Range: 0 - 150 VAC
Rated Frequency: 50 Hz
Burden: 1 VA
Selection Inputs: 2
Auxiliary Supply: 90-260 V AC or DC
Power Consumption: 8 W / 18 VA
Parameter Setting Ranges
Minimum Frequency Difference 0,01 Hz
df:
Maximum Frequency Differ- 0,25 Hz
ence df:
Minimum Voltage Difference 1V
dV:
Maximum Voltage Difference 30 V
dV:
Maximum Synchronizing Volt- 150 V
age,
Adjustable for Each System,
Vmax:
Minimum Synchronizing Volt- 30 V
age,
Adjustable for Each System
Vmin:
Maximum Permissible Phase 15 Degree Electrical

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Angle PHImax:
Maximum Permissible Residual 20 V
Voltage of a Dead System :
Maximum Adjustable CB Clos- 500 ms
ing Time:
4. Description
4.1 General
The detailed configuration of the Control & SCADA System is shown in DOC- TKT-CM-01-DM-1028-A
Design Memorandum Control and Monitoring System.
4.2 Location and Components

The Control & SCADA System for TKT HEPP provides components in following locations:
4.2.1 SCADA System and LAN

SCADA System consisting of:
 2 (two) Operator Stations in Power House Control Room
 1 (one) Mobile Engineering Notebook
 1 (one) Fixed Engineering Station
 2 (two) Printers
 1 (one) set LAN equipment
4.2.2 Power House

 2 (two) Unit Control Boards
 1 (one) Common Control Board (CCB)
 1 (one) Air Cushion Chamber Control Board
4.2.3 Switchyard
 1 (one) Switchyard Control Board (SCB)
4.2.4 Dam Site

 1 (one) Intake Gate Control Board (ICB)
 1 (one) NTP Server with GPS Antenna

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4.3 Communication
The communication between the components of Control & SCADA System is based on optic fibers.
To ensure a high reliability of the communication between the Automation Units Hirschman Industrial
Ethernet Switches are used. These switches use the proprietary Hyper ring protocol which ensures a
quick switching (less than 500ms) if one of the fiber optic cable is damaged.
Communication Protocols:
Local Area Network (LAN): IEC 60870-5-104
Control System with Generator Protection: IEC 60870-5-103
Control System with Unit and line Protection: IEC 60870-5-103
Control System with Excitation: IEC 60870-5-104
Control System with Digital Turbine Controller: IEC 60870-5-104
Communication with Dispatch Centre:
For communication with a Dispatch Centre two serial communication ports are provided in Switchyard
Control Board. Communication will be based on RS232/V.28 interface with protocol IEC 60870-5-101.
Transmission media and facilities are not included in scope of Control & SCADA System.
4.4 General Real-time Concept
The time and date information usually is entered in the automation system at a central point by a GPS
time signal receiver and distributed by the Network Time Server to all other components, using the
Standardized Network Time Protocol.
This real-time concept facilitates time-tagging of process data throughout the system with a resolution of
10ms. This time tagging is carried out directly at the input peripheral or at the data source. In the SCADA-
System data (events, values, counter, commands, set point values etc.) are stored in logs or archives
chronologically according to their time tags.
4.5 Remote Maintenance

The Control System allows remote maintenance of all components on the LAN either via Internet or via
telephone lines.
4.6 SCADA System and Operator Station

The SCADA System comprises
 2 redundant Operator Station with integrated data server
 1 Engineering Station
 1 Portable Station
 Periphery devices
4.6.1 Operator Station (OS)

2 (two) PC's (details pls. refer to item 3, Technical Data)
4.6.1.1 Standard Software

 1 (one) Operating Systems Windows 7 Ultimate
 1 (one) Excel 2010 (for reports)
 1 (one) License for redundant SCADA System
 1 (one) License for Data- and archive interface

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4.6.1.2 Application Software

For functions please refer to chapter 5, Operation
4.6.2 Engineering Station

1 (one) PC (details pls. refer to item 3, Technical Data)

 1 (one) SCALA 250 Client
 1 (one) Toolbox License (for Engineering of 1703 System)
 1 (one) Excel 2010
4.6.3 Mobile Engineering Station

1 (one) notebook (details pls. refer to item 3, Technical Data)

 1 (one) SCALA 250 Client
 1 (one) Toolbox License (for Engineering of 1703 System)

 1 (one) Excel 2010
4.6.4 Periphery devices

4.6.4.1 Printer
 1 (one) Color laser printer A4
 2 (two) Black and white laser printer A4
(Details please refer to item 3, Technical Data)
4.6.4.2 Clock
 1 (one) GPS receiver with integrated NTP time Server for time synchronization of Control System via
LAN.
(Details pls. refer to item 3, Technical Data)
4.7 Process control System

4.7.1 Unit Control Board
(Two) Unit Control Boards (UCB)
Each board consists of 3 cubicles with
1 (one) Unit Controller as described below
1 (one) Mechanical Protection System (as part of Unit Controller)
1 (one) Local MMI: 19” TFT color Touch Panel (TP), 1280 x 1024
1 (one) Automatic synchronizer SYN 3000
1 (one) One instrument for manual synchronizing (VV, ff, Synchronoscope)
1 (one) LAN Node: Two Ethernet Rail Switch with 8 ports for communication to LAN, to Electrical Protec
tion Relays and to Excitation
1 (one) Save Shut down System carried out by relays
1 (one) Set of switches and pushbuttons
1 (one) Emergency pushbutton with cover
1 (one) Set of auxiliary devices (MCB's, relays, terminals etc.) as necessary
Controller function:-
Automatic unit control and sequencing
 Mechanic Protection and alarm system
 Communication

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For detailed software functions of Controller (mechanic protection and automatic control) please refer to
chapter 5, Operation.
4.7.2 Common Control Board

(One) Common Control Board (CCB)
The board consists of 3 cubicles, equipped with:
1 (one) Controller as described below
1 (one) Local MMI: 19” TFT color Touch Panel (TP), 1280x1024
1 (one) LAN Node: Two Ethernet Rail Switch with 8 ports for communication to LAN
 Control and supervision of LT and MV system
 Control and supervision of common auxiliaries like LP Compressor, Drainage and dewatering, etc.
For detailed software functions of Controller please refer to chapter 5, Operation.
4.7.3 Air Cushion Surge Chamber Control Board

(One) Air Cushion Surge Chamber Control Board
The board consists of 1 cubicle, equipped with:
 Control and supervision of air supplying system
 Control and supervision of air discharging system and their auxiliaries.
4.7.4 Intake Gate Control Board

(One) Intake Gate Control Board
The board consists of 1 cubicle, equipped with:
 Control and supervision of intake gates and other dam auxiliaries
 Supervision of water level, pressure loss through track racks etc.

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5. Operation
5.1 SCADA System and HMI

This document describes the design and operation functionality of the SCADA System SCALA 250
This description refers to the operator station in control room as well as to the local touch panels in the
different control boards as described in following Chapters.
5.1.1 SCADA Screens
The below picture will open at Start-up of SCADA Client.


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5.1.1.1 Toolbars
Icons Description
Open Plant Overview Page.
Open Internal Toolbar 1A & Unit 1 Overview.
Open Internal Toolbar 1A & Unit 1 Overview.
Open Internal Toolbar 2 & Single Line.

Open Internal Toolbar 3 & Oil Cont. System.
Open Intake Overview.
Open Internal Toolbar 4 & Topology Overview.
Open Report.
Open Curve.
Open Curve.
Refresh Key.
Screen Navigation.
Onscreen Keyboard
Open Chronological Event List
Open Acknowledgement State List.
Open System Setting.

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Hard Copy Print.
Close All Windows.
A. Overview:
Button for Plant Overview Page Screen.

A.1 In the Plant Overview Display, We have

(i) Important Parameters of Plant.
(ii) Start Stop Operation Sequence monitoring.
(iii) Status signals of Governors of Unit 1 & 2.
(iv) Status signals of Excitation System of Unit 1 & 2.
B. Unit1 & Unit 2

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B1. Internal Toolbar 1A
01. Button for Unit Overview.

B. 01 In the Unit Overview Display, We have

(i) Unit SLD with Command and Feedbacks.
(ii) Important Parameters of Both Unit 1 Individually.
(iii) Status signals of Governor System of Unit 1.
(iv) Status signals of Excitation System of Unit 1.
(v) Operation Selection & Sequence of Unit 1.
(vi) Protection Status Signals Information of Unit 1.

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02. Button for Unit Sequence Screen.

B.02 In the Unit Sequence Display, We have

(i) Start Stop Operation in Auto Mode.
(ii) Start Stop Operation in Step by Step mode.
(iii) Operation Mode Selection.
(iv) Feedback of each Step of Operation.

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03. Button for Unit OPU Screen.

B.03 In the Unit OPU Display, We have

(i) Complete Overview of Oil Pumping System.
(ii) Actual Status signals of Pumps and Valves used in OPU System.
(iii) Level & Temperature indication monitoring.

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04. Button for Unit MIV Screen.

B.04 In the Unit MIV Display, We have

(i) Overview of Oil Controlling in MIV System.
(ii) Feedbacks and Interlocks of Pumps and Valves used in MIV System.

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05. Button for Unit Cooling Screen.

B.05 In the Unit Cooling Display, We have

(i) Overview of Cooling Water System System.
(ii) Feedbacks and Interlocks of Pumps and Valves used in System.
(iii) Interfacing of Main Cooling Water System with Auxiliary Cooling System.

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06. Button for Unit Generator Cooling Screen.

B.06 In the Unit Generator Cooling Display, We have

(i) Overview of Cooling System Of Generator & Bearings.
(ii) Feedbacks and Interlocks.

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07. Button for Unit Generator Overview Screen.

B.07 In the Unit Generator Overview Display, We have

(i) Actual Temperature of Bearing, Stator Winding, Stator Core, etc.
(ii) Other Generator Parameters along with Alarms & trip limits highlighted.

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08. Button for Unit Generation Lubrication Screen.

B.08 In the Unit Generator Lubrication Display, We have

(i) Overview of Lubrication control system in Upper & Lower Bearing.
(ii) Actual Temperature display of important bearing related parameters.
(iii) Feedback & Control signals are displayed.

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09. Button for Unit Generator Braking Screen.

B.09 In the Unit Generator Braking Display, We have

(i) Controls & Interlocks of Braking System.
(ii) Feedbacks of Auxiliaries.

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10. Button for Unit Excitation Screen.

B.10 In the Unit Excitation Display, We have

(i) Important alarms and trip signals for Excitation System
(ii) Feedbacks of breakers and excitation panel.

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11. Button for Unit Protections.

B.11 In the Unit Protection Display, We have

(i) SLD of Unit Protection system.
(ii) Feedbacks and Interlocks.

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12. Button for Group Distribution Board Screen.

B.12 In the Group Distribution Board Display, We have

(i) SLD of Group Distribution Board.
(ii) Feedbacks of Circuit Breakers.

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13. Button for Trends Screen.

B.13 In the Trend Display, We have

(i) Graph of Parameters of Unit 1 & 2.
(ii) Also displays History of graph.

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14. Button for Chronological Event List.

B.14 In the Chronological Event List. Display, We have

(i) All Chronological Events in Record.

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15. Button for Acknowledgement State List.

B.15 In the Acknowledgement State List. Display, We have

(i) All Acknowledgement State List in Record.
16. : Button for Toolbar 1B

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B2. Internal Toolbar 1B:
01. Button for Auxiliary Control Distribution Board Screen.

B.16 In the Auxiliary Control Distribution Board Display, We have

(i) SLD of Auxiliary Control Distribution Board.

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02. Button for Unit DC Screen.

B.17 In the Unit DC Display, We have

(i) SLD of DC Supply Control Board.

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03. Button for Unit Transformer Phase U.

B.18 In the Unit Transformer Phase U Display, We have

(i) Feedback signals of Transformer of U phase.
(ii) Oil & Cooling System Monitoring.

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04. Button for Unit Transformer Phase V.

B.19 In the Unit Transformer Phase V Display, We have

(i) Feedback signals of Transformer of V phase.

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05. Button for Unit Transformer Phase W.

B.20 In the Unit Transformer Phase W Display, We have

(i) Feedback signals of Transformer of W phase.

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06. Button for Unit Load Diagram Screen.

B.21 In the Unit Load Diagram Display, We have

(i) Unit Load Distribution in Graphical Format.
(ii) Actual values of Power, Voltage etc.

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07. Button for Unit Hill Chart Screen.

B.22 In the Unit Hillchart Display, We have

(i) Hillchart format of water flow & Level values.

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08. Button for Unit Device-1 Screen.

B.23 In the Unit Device-1 Display, We have

(i) Control & Monitoring of Pumps used in Unit.
(ii) Feedbacks of pumps.

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09. Button for Unit Device-2 Screen.

B.24 In the Unit Device-2 Display, We have

(i) Control & Monitoring of Heater, Dust Collector & Pumps.
(ii) Actual Status of each Section.

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C. Switchyard:
1. Internal Toolbar 2
01. Button for Single Line Screen.

C.01 In the Single Line Display, We have

(i) Switchyard SLD with Commands & Feedbacks.
(ii) Important parameters of switchyard.

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02. Button for DC 5 Screen.

C.02 In the DC 5 Display, We have

(i) SLD of DC 5V Distribution Board.

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03. Button for Group Distribution Board Screen.

C.03 In the Group Distribution Board Display, We have

(i) SLD of Group Distribution Board.

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D. Common System:
01. Button for Low Pressure Air Compressor System Screen.

D.01 In the Low Pressure Air Compressor System Display, We have

(i) Interlocks of Operation.

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02. Button for Oil Contaminated System Screen.

D.02 In the Oil Contaminated System Display, We have


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03. Button for Water Contaminated System Screen.

D.03 In the Water Contaminated System Display, We have


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04. Button for Sewage Disposal System Screen.

D.04 In the Sewage Disposal System Display, We have


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05. Button for Water Supply System Screen.

D.05 In the Water Supply System Display, We have


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06. Button for Main Distribution Board Screen.

D.06 In the Main Distribution Board Display, We have

(i) SLD Of Main Distribution Board.

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07. Button for Float Cum Boost Charger-1 Screen.

D.07 In the Float Cum Boost Charger-1 Display, We have

(i) Controlling & Monitoring of Boost Charger-1.
(ii) Feedbacks and Interlocks of system.

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08. Button for Float Cum Boost Charger-2 Screen.

D.08 In the Float Cum Boost Charger-2 Display, We have

(i) Controlling & Monitoring of Boost Charger-2.
(ii) Feedbacks and Interlocks of system.

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09. Button for DC 1 & 2 Screen.

D.09 In the DC 1 & 2 Display, We have

(i) SLD of DC Supply Distribution Board.

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10. Button for Group Distribution Board-3 Screen.

D.10 In the Group Distribution Board 3 Display, We have

(i) SLD of Group Distribution Distribution Board 3.

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E. Topology:
01. Button for Topology Overview Screen.

E.01 In the Topology Overview Display, We have

(i) Topology of Control Room Network System.
(ii) Interface for individual sub-system overview..

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02. Button for Unit Topology Screen.

E.02 In the Unit Topology Display, We have

(i) Topology of PLC & Touch Panel System.
(ii) Actual Status of Input & Output Modules.

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03. Button for Switchyard Topology Screen.

E.03 In the Switchyard Topology Display, We have

(i) Topology of Switchyard PLC, Touch Panel & Bay Controller System.

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5.1.2 Other System Functions
A. Lists
Lists are used exclusively for the logging of events from the process data stream on the monitor, whereby
a certain memory range is available for buffering, in which one can browse using the scrollbars. If this
buffer is full, for each new event, the oldest event is removed from the buffer each time. Such events are
however not lost, but can be retrieved from the archive by means of reports.
Lists basically contain the entire event-stream of loggable events. It is valid for all lists that for the selec
tion a filter must be chosen, that specifies which events in these lists are to be displayed. The choice of
filter can either take place via a form operation for the selection or the filter already exists directly behind
this selection point due to construction and parameterization.
The filter criterion can be changed at any time using the menu line of the list.
With the lists, one differentiates between four types. Due to its function, each list type has its own special
operating cases and not every type is suitable for every task of the momentary process management.
Types of lists:
CEL Chronological event list
AEL Acknowledgeable event list
ASL Acknowledgeable state list
PSD Plant state display
Depending on the type of the list, there is a particular purpose. Not every list is suitable for all tasks of the
process management. Therefore the correct list must be selected for the momentarily required activity.
Chronological Event List (CEL)
Display example of a chronological event list
Purpose
The CEL contains all loggable events. The default sorting criterion is the event time. Data sources can
thereby be current data and archives.
By including filters a process-related selection of the events can be carried out. As a result, clear, techno-
logically related lists are created.
This list is used for precise analysis of chronological developments and sequences for the error analysis.

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Acknowledgeable Event List (AEL)
Display example of an acknowledgeable event list

Purpose
The AEL contains all acknowledgeable events in the chronological order of their occurrence.
The default sorting criterion is the event time.
This list can therefore be used for the display and acknowledgement of alarms.
Acknowledgeable State List (ASL)
Display example of an acknowledgeable state list
Purpose
The ASL contains all acknowledgement-obligated events as well as all events that are in an alarm state,
as long as this state remains. An automatic sorting is made that allows all unacknowledged events to ap-
pear at the beginning of the list.
This list is therefore used to alarm and inform the operator about the current alarm state in his process.

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Plant State Display (PSD)
Display example of a plant state display ( Only for reference )

Purpose
The plant state list represents the momentary state of process variables, regardless of whether it is alarm
states or not.
Consequently, this list is used for quickly creating an overview of the state of plant components that is not
available in this list in the form of plant displays.
Printing and Data Export from Lists
The new functions for "Printing from Lists" and "Data export from Lists" have been realized with a Look &
Feel common with modern software products. The aforesaid functionality is available universally with all
lists (PSD, CEL, AEL and ASL).
For the paper printout and the data export the same selection properties as in the currently visualized
monitor list are the starting point for the printing- and data export time. In this context, the most important
output parameters adopted from the monitor list are:
_ Data source (RAM/Data Stream Archive)
_ List filter
_ TA-Filter
_ Time-range specification based on present representation period
_ Column labeling (incl. user-defined columns)
_ List coloring
_ Font
_ Sorting order of the columns

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Comment for printing and data export

Input possibility for optional text that is also to appear in the list header.
Time range (chronological lists)

Time-range specification, for chronological lists, with which the print- and data export volume
can be even further limited with regard to list content of the monitor list.
Print page view

Input-/modification possibility for list fonts. By default, the font selected for the monitor list is always pre-
set.
HEADER ON EACH PAGE As a consequence, the output of the list header also takes
place with successive pages.
INCLUDE FOOTER ON PAGE This affects the output of the page footer sequence for every
page of the list.
Print formatting list line

HOLD MINIMIZED COLUMN WIDTH This causes a minimized text column to be kept minimized for
the print output; i.e. column text is visibly curtailed as with the
monitor list. Not clicked on the other hand reduces or expands
to the required column text width in respect of the entire print
data stock.

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AUTOSCALE (REDUCING
FONTSIZES) Depending on requirements, by reducing the list fonts attempts
to also get the last visible list column onto paper. Reduction
takes place down to a font size of 4. Not clicked, the preset font
does not change; i.e. the list line is if necessary curtailed on
reaching the right print margin.
Margins
Design possibility for text spacing. Specified in millimeters.
Common buttons
PRINT... This button enables printing; however the user must first select the printer in a Windows
standard dialog.
EXPORT... After actuating, a window is opened for selecting a folder. In this selected folder the file
is stored.
CANCEL Exit from this dialog without printing or exporting
Example for Printing


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Example for Export ( Only for reference )


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B. Curve Display
SAT 250 SCALA curve objects are used for the graphical representation of value characteristics over
thtime axis, whereby any number of curve objects is possible on one workplace.
A curve object can represent up to 12 process variables (values or states). The selection of the values to
be represented can be carried out via parameter transfer or by means of Drag & Drop.
Structure of a curve display

Explanation of the operation- and display fields
1. Color of the curve

The colors set for the 12 channels are displayed.
2. Group selection
Here, a group now to be displayed can be selected from the predefined PV-groups.
3. Time-Scrollbar
Enables the scrolling (paging) along the time axis, to make curve sections visible that are located
outside the currently represented time range.
4. Timescale
Time specification for the here represented time range.
The timescale also consists of a colored marking, whether the data represented above it come
from the temporary storage or the archive. If archive data are represented, then the timescale has
a colored background in this range.
5. Percentage scale
Shows the value as a percentage. The actual values for 0% and 100% are determined
for each PV by means of parameterization.

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6. Curves
That area in which the curve characteristics are represented.
7. Date of curve data

If the data represented in the curve area alter within one day, then for reasons of
clarity the date is not displayed in the timescale, but here instead; if the time range
stretches over several days, then the date is added in the timescale.
8. Unit
Displays the physical unit in the curves legend of the currently selected curve.
9. Value scale
The value scale in the curves legend is displayed for the currently selected curve in its
technological unit.
10. Value-Scrollbar
Enables scrolling (paging) in the vertical direction, if parts of the represented curves
are located outside the represented value range (e.g. caused by higher zoom level).
11. Color of selected curve

Here, the color of the selected curve currently in the curves legend is displayed.
Simultaneously the curve progression is also graphically emphasized.
12. Start/Stop-Buttons
Are used to switch between operator guide mode and pause.
13. Info texts

Here information is located about the currently represented curve and about the time
range available that can be used for the display.
14. Legend of the curves

The curves legend contains information about the PV's in the channels represented. It
is also used for modifying the classification of the curve representation by means of
Drag & Drop.
The curve representation displays the current process data, whereby the values are continuously updat-
ed and the oldest values - similar to the paper on a typewriter - are slowly shifted in the direction of the
left window border.
SAT 250 SCALA manages a transient memory that contains all changes to all process variables in the
last 30 minutes. With this, not a fixed grid is used for recording, but rather all changes received by the au-
tomation units (Transitions) are stored.
With that it is ensured, that with each curve activation at least a 30 minute time range is available for the
representation that provides a very accurate resolution.
By scrolling the time axis towards the past, possibly available archive data are seamlessly displayed. This
range is specially identified by a colored background of the scale. From here, the data are naturally pro-
duced in the cycle available in the archive.

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C. Archiving Functions
Export and Import of Archives
The archives exist in the form of files, whereby a file is created for each archive and for each day.
Archives are only kept for a particular - determined through configuration - time period on the hard disk.
This means, that with day change those files that fall out of this time period are always deleted.
In order to safeguard these archives for a longer period and be able to restore them back to the system,
there are two functions available.
1. Export of archives
With this function archives can be exported and thus secured against deletion.
2. Import of archives
With this function previously exported archives can be loaded back in the system.
So that an analysis by means of SAT 250 SCALA is again possible.
During export, the archives are copied to a drive/directory to be specified by the user; during
import, they are read again from this directory.
Exporting of Archives
After the start of the CAE Client you will find the export function on the left side in the folder Arch
ives (Import/Export).
Archive export function
Select the entry SCADA Server Archive Files.

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If a connection to the SCADA Server has not yet been established, then an information form appears that
a connection does not yet exist.
Request to establish a connection
Confirm this here with the button YES. If you select the button NO, no data will be imported.
After the connection to the SCADA Server has been established or if a connection exists, all marked ar-
chives are imported to the SCADA Server.
During the import procedure a status indicator is displayed.
Display of all active archives
The archives to be exported are first marked (Multiselects possible). In the context menu the entry EX-
PORT is then selected.

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Starting the export

If the export directory has not yet been defined or if it is invalid, the specification of an export directory is
requested.
Select a directory and confirm this with the button OK.
The selected archives are now exported to the specified or already defined directory.
During the export process a progress indicator is displayed.

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Export process
Once the progress indicator disappears, the selected archives are created in the export directory. These
can now be exported by the system with other tools (e.g. provision of a CRRW for long-term backup).
Importing of Archives
After starting the CAE Client, the import function is located at the left side in the folder Archives
(Import/Export).

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Archive import function

If you wish to restore archives from an external data-carrier to SAT 250 SCALA, then first copy the re-
quired archives to the specified export directory.
Select the entry Exported Archives File.
All archives existing in the export directory are now displayed.

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Display of all exported archives

The archives to be imported are first marked (Multi selects possible). In the context menu the entry IM-
PORT is then selected.

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Starting the import

If a connection to the SCADA Server has not yet been established, then an information form appears that
no connection has yet been established.
Request to establish a connection
Confirm this here with the button YES. If you select the button NO, no data will be imported.
After the connection to the SCADA Server has been established or if a connection exists, all marked ar-
chives are imported to the SCADA Server.
During the import procedure a status indicator is displayed.

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Import procedure
After the status indicator disappears, the selected archives are again available in SAT 250 SCALA.
These can now be analyzed again with the representations of SAT 250 SCALA (curves, reports etc.).

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D. Archive Editor
The archive editor is used for editing data in the cyclic archives of SAT 250 SCALA.
The selection of the archive editor is carried out from the interface of the SCADA Client.
With a click on this button the archive editor is started.
Following this an Excel-Window opens, in which the function of the archive editor is available.
The Work with the Archive Editor

After selecting the archive editor a workbook is displayed. In this the required PV's as well as the time
range are then entered by means of operator input.
Selection of Data by Using the Input-Mask

By selecting the button INPUT MASK from the toolbar the input mask is displayed for selecting the data
points and the time range.
The selection of the PV's can take place using two possibilities.

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Variant 1: Drop Zone

Here, PV's from other representations can be entered by means of Drag & Drop. You only need to select
the required PV's and drag them into the white field with Drag & Drop.
If all selections have been actuated, the entry into the Excel-worksheet is carried out by actuating the but-
tons APPLY.
Variant 2: Archive
If you know the PV's or would like to edit a particular archive, then this is carried out with the possibilities
of the archive-tab. With this you can reduce the number of PV's offered with the selection of a particular
archive, if you know it.
With the buttons ADD -> or <- REMOVE select the required PV's for subsequent manipulation.
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Further on there is the possibility to reduce the amount of PV's by using wildcards. If all selections have
been actuated, the entry into the Excel-worksheet is carried out by actuating the button APPLY.
Selecting the time range

In the time range tab carry out the selection of the start- and end time for the display of the values.
Similarly, the cycle in which you wish to have the values displayed is set.
If all selections have been actuated, the entry into the Excel-worksheet is carried out by actuating the but-
ton APPLY or OK.

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Completed data selection

This is how the completed data selection appears. Now the values can be fetched from the archive.

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Selection of Values from the Archive
The table completed with text addresses and time range can now be filled with values from the archives.
Read values from the archive

By selecting the button DATA _ from the toolbar and the menu item READ the table is filled with data.
Depending on the quantity of selected data the filling of the table takes more or less time.

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Display of Values by a Diagram

If the function DATA _ from the toolbar and the menu item READ is repeatedly selected or the archive
editor is restarted at a later point in time, then corrected values are identified by a light-grey font color.
Updating the diagram

The updating of the diagram must be carried out by selecting the button DATA from the toolbar and the
menu item DIAGRAM CREATE.
Following this the selected PV's can be viewed in the diagram. By selecting the worksheet
Diagram, the diagram is displayed.

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Representation in diagram form

Here the graphic of the previously executed change can be controlled.
E. Excel Reports
Excel reports are the customized way of data logging in a Tabular format using Excel application. This
will be finalized during detailed engineering and commissioning.

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5.2 Control Boards

5.2.1 Unit Control Board
The Unit Control Board (UCB) contains all equipment, necessary for fully automatic as well as manual con
trol and supervision of the entire unit:
 LCU (Local Control Unit or Controller) with LAN connection. For detailed configuration please refer to
 Touch Panel and LAN connection
 Auxiliary devices, such as miniature circuit breakers, control switches, relays, terminals etc.
5.2.1.1 Disposition of unit control board, +#CJA01,02,03
The UCB consists of three cubicles:


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5.2.1.2 Control & Supervision devices of Board
This panel provides manual and automatic control and sequencing as well as supervision of operation con
ditions of the unit, manual and automatic synchronization of the unit.
Control & Supervision devices:

5.2.1.3 Functions of Controller
The Controller executes two following independent software modules:
 Control and Sequencing as described in chapter 5.2.1.4
 Safety functions as described in chapter 5.2.1.5

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The controller is connected to the station LAN (Local Area Network) for communication to control room.
The Station LAN is an Ethernet LAN (TCP/IP) with protocol IEC 60870-5-104.
5.2.1.4 Control and Sequencing
This module executes following control functions of the unit:

 Common Control functions
– Place of control (local/remote)
– Control mode (step by step, automatic) via touch screen
– Communication with LAN
 Sequencing - automatic starting and stopping of the unit
The sequencing covers the complete automatic control under normal conditions and provides fully
automatic and step by step control of the unit set. It includes control of all auxiliary equipment of the
turbine/generator set.
Common Control Functions

(I) Place of control

The unit can be controlled
 Locally: from Unit Control Board (UCB) by means of touch panel for control modes
 Remotely: from Control Room or from Switchyard Control Room
The place of control can be selected by key-operated switch +#CJA02-S05:

a) Position 0: In this position of +#CJA02-S05 no control from unit control board, Touch panel or
Control Room is possible.
b) Local Position: Control of the unit in this mode is executed from the unit control board by means of
the touch panel. For control from touch panel please refer to chapter 5.1.
c) Remote Position: In this mode the unit can be controlled from the Operator station in the control
room in fully automatic mode by selection the required state of operation of the unit by means of
the corresponding buttons in the unit displays (please refer also to chapter 5.1).
(II) Control Modes

a) Manual Mode
This mode can be selected on the touch panel when +#CJA01-S05 is in position "Local" or is
active when +#CJA01-S05 is in position "Remote"
It is provided for maintenance and service works only and should only be performed by well
trained staff.
In this mode the unit can be controlled from the local Touch Panel or from the Operator station in
the control room by means of auxiliary control windows and feedbacks. Each individual auxiliary
pump or valve has to be initiated by a command, given by the operator.
In this mode the time monitoring of the sequencing is inactive – that means that the unit can stay
at any condition for unlimited time.
b) Step by Step mode
It is provided for maintenance and service works only and should only be performed by well
trained staff.
In this mode the unit can be controlled from the local Touch Panel or from the Operator station
In the control room by means of detailed sequence and step displays. Each step of a sequence
has to be initiated by a command, given by the operator.
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In this mode the time monitoring of the sequencing is inactive – that means that the unit can stay
at any condition for unlimited time.
c) Automatic mode
In this mode the unit can be controlled from the local Touch Panel or from the Operator station
in the control room in fully automatic mode by selecting the required state of operation of the
unit by the corresponding buttons in the unit displays.
Place of control in this mode – local Touch Panel or Operator Station – is determined by posi
tion of +#CJA02-05 Control from both places at same time is not possible!
(III) Communication functions

The LCU (controller) communicates via interface bus with the interface modules and is connect-
ed to the station LAN (Local Area Network). All communication of the LCU to other components
of the control system as well as to touch panel and operator station is effected via the LAN.
The LAN is using Ethernet (TCP/IP) with standardised protocol IEC 60870-5-104.
Automatic unit control - Sequencing

(I) States of Operation
The unit can permanently maintain four different "States of Operation", each of them being
determined exactly by a number of conditions:
 Standstill (ST-1)
 Turbine Operation (TO-2): auxiliaries on, unit ready for Excitation on
 No Load Operation (NLO-3): Excitation On and unit ready for synchronisation
 Line Operation (LO-4): unit connected with grid
Conditions, determining the states of operation are displayed on the Touch Panel and the Op
erator stations in the Control Room and are defined in detail in document. All other operating
conditions can only occur during transitions between these states of operation and during
abnormal conditions.
The states of operation are displayed and can be selected on Touch Panel and the Operator
Stations in the Control Room.
(II) Control sequences

A "Control Sequence" is a number of steps, each step giving one or more orders to actuate or
stop devices and/or auxiliaries.
For the execution of the orders of each step certain preconditions, which are the result of the
previous step, have to be fulfilled.
The below diagram gives an overview over states of operation and the connecting sequences:

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(III) MODE SELECTION

 AUTO MODE:
Completely automatic sequence – possible to give commands for various states of unit: standstill, tur-
bine operation and Load Operation.
 STEP BY STEP MODE:
Sequence behind each step for starting auxiliaries etc. is fully automatic.
 MANUAL MODE:
Operator has to go to window of operation of each auxiliary and give commands.

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(IV) Synchronizing
Independent of the Control Mode (Step by Step, Auto) the synchronising of the Unit can be done in
Automatic or Manual mode.
Synchronizing is effected with 220 kV breakers
Mode of synchronizing is selected with switch +#CJA02-S06 with three positions:
 manual
 automatic
For fully automatic start of the unit the selector switch must be in the "Automatic" position.
Manual synchronizing
Position of +#CJA2-S06: Manual
Unit can be synchronized manually in this position:
Pushbuttons Voltage raise/lower and Seed raise/lower (+#CJA02-S09 & S08) allow adjusting the
synchronizing parameters before closing of circuit breaker with +#CJA02-S10.
The Synchronoscope +#CJA12-P03 shows the phase difference between the Generator and grid by LED.
When the phase angle is zero, the green LED at the top in the form of an arrow is lit. This position
indicates that the Generator and the network are synchronous.
The Synchronoscope has an interlocking contact which is closed only when the phase angle is within
preset limits (synchrocheck function). The circuit breaker close command from +#CJA02-S10 is
interlocked with this contact to prevent closing of breaker at wrong time.
Automatic synchronizing
Position of +#CJA2-S06: Auto
Synchronizing is done automatically by the SYN3000, when position of switch +#CJA2-S07 Syn
Start/Stop is in the start condition.
As long as the synchronising is ongoing, the Manual Synchronizing Instrument +#CJA02-P05 is activated
and allow supervision of the process.
5.2.1.5 Alarms, Trip and Safety Systems
Analogue value monitoring
Where technically required, analogue measuring values, connected to the controller either as mA signals or
as Pt100 temperature values, are supervised for limit values. Normally two limits are preset:
Limit 1 - high An alarm signal is created

Limit 2 - too high A Quick Shutdown of the unit is
initiated
Where necessary further limits are supervised and handled internally in the controller for interlocking pur-
poses or alarm/trip purposes.
Alarms
All external and internally created signals (e.g. temperature exceeded) which are giving evidence of an ab-
normal condition in the plant, are treated principally as alarms, independent if the signal causes a trip of the
unit or not.
Every alarm is time tagged with a resolution of 1 msec. The SCADA system uses this time stamp for re-
ports, lists and archives. Please refer also to chapter “Operations”
Every alarm signal causes an acoustic alarm and is displayed on the Touch Panel and the Operator Sta-
tions in the Control Room in the alarm list (please refer also to chapter “Operations”)
Tripping Modes, Trip and lockout relays

Different fault conditions require different tripping modes:
 Emergency Shutdown (ESD)
The ESD trip is characterized by an immediate trip of the unit circuit breaker, independent of the actual

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load of the unit.

ESD’s are initiated and signalled by the fast acting relay KE#.
 Quick shutdown (QSD)

In case of a QSD trip the unit circuit breaker is not opened before the unit is unloaded.
QSD’s are initiated and signalled by the fast acting relay KQ#.
Both lockout relays are energized under normal operation conditions and de-energized under trip condi-
tions.
Both tripping relays require a manual reset action by the operator - without a reset the unit cannot be
started because the starting conditions require both relays to be in operation position!
Reset of 86M and 86E is possible by means of the corresponding pushbutton on unit control board in
local mode or from SCADA in remote mode.
A reset of ESD and QSD relay is only possible after all activating trip conditions are inactive again!
Tripping circuits
The tripping relays only operate the following tripping circuits:
 Generator circuit breaker - two tripping coils, not energized in operation
 Field breaker - two tripping coils, not energized in operation
 Turbine, shutdown valve - one valve, energized in operation
 Main inlet valve, closing valve - one valve, energized in operation
In case of any trip – mechanic trip as well as electric - a normal shutdown sequence of the unit by the
Controller is initiated. This ensures that the state of operation “Standstill” is reached and all auxiliaries are
Operated correctly
There are two types of tripping circuits:
 Circuits energized during normal operation conditions e.g. shut down valves
 Circuit which have to be energized for activation e.g. tripping coils for circuit breakers
Trips conditions and personnel safety

Abnormal conditions of the unit or its auxiliaries, which might cause damage to the equipment or to
personnel, require a trip of the unit and the signals referring to such conditions are called trip signals.
Two types of trip conditions have to be handled:
 Conditions which are potentially dangerous for equipment only
 Conditions which are potentially dangerous for personnel and equipment
Trip conditions can be detected by binary signals as well as by analogue signals.

Which conditions are attributable to group b) is determined by a risk assessment.
Trip conditions of type b) require implementation of functional safety features and accordingly a special
handling and use of special devices with certification of compliance with the required SIL (Safety Integrity
Level).
For details in respect of Safety Integrity Level please refer to standard EN/IEC 62061
Hardwired safety interlocking

Following hardwired interlocking, completely independent from the controller, are implemented:
 The mechanic brake can be activated only when speed of unit is less than 30 %
 Circuit breaker can be closed only when the field breaker is closed
 Opening of field breaker is only possible when the circuit breaker is open

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5.2.2 Common Control Board
The Common Control Board contains equipment, necessary for common auxiliary control and the Joint
Control system of the two units
5.2.2.1 Disposition of Common Control Board, +0CBD01
The Board consists of three cubicles:


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5.2.2.2 Control & Supervision devices of Board
This cubicle provides manual and automatic control of common auxiliaries.


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5.2.3 Intake Gate Control Board
The Intake Gate Control Board contains all equipment, necessary for control and supervision of the
Intakes.
5.2.3.1 Disposition of Intake Gate Control Board, +5CMF01
The Board consists of one cubicle:


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6. Maintenance
6.1 Control Boards & Control System Sicam 1703
6.1.1 Maintenance and inspection program
For detailed description of activities please refer to Chapter 6.1.2 below

6.1.2 Maintenance procedures
6.1.2.1 Cleaning of boards and equipment

Cleaning of boards is only required if it cable ducts, relays and other devices in the board are very
dusty. Permanent cleaning is not required and also disadvantageous for lifetime of the equipment.
Necessary equipment
 Oil free compressed air spray (if there is oil inside the compressed air the dust will start gluing on the
devices!)
 Small flat screw driver (3.5mm)
 Vacuum cleaner
 Anti-static arm-band
 AK-3-board "extraction tool" (should be at the AK-3 frame!)
Procedure for AK-3

 Inform operator that the LCU will be out of operation for approx. 30 to 60 minutes
 Switch Auxiliaries (Pumps, Breakers, Isolators) to local operation.
*** It is important that all devices (Circuit breakers, pumps etc.) are switched to local control in order to
prevent false orders by unintentional operating relays during cleaning procedure!

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 Check status of LED's of all electronic devices inside the cubicle: All RY-LED's should be on, no red
LED should be on! If one or more red LED's are on, please note the modules with activated red LED's
and report to responsible service staff
 Select on the Touch panel Shutdown Operation System (Windows XP Start Menu Item “Shutdown”)
and wait until the system confirms that it is ready for power off.
 De-energize all devices inside the cubicle by switching off all MCB in the cubicle. No device should be
energized (no LED’s, ventilation’s …).
 Clean Devices (cable channel, relays, …) carefully with compressed air. If the cubicle is strongly dusty,
use first the vacuum cleaner to prevent that dust is distributed in the surrounding area and afterwards
continue with compressed air.
 Remove the AK-3 front-panel with screwdriver (4 screws) - AK-3 boards are accessible.
 Put on anti-static arm-band
 Pull out each board with the "Extraction tool" fixed to the ACP frame
 Clean each board carefully with compressed air (both sides)
 Put the board back to the original slot.
*** Do not mix up the boards! Take care on the peripheral board address (PBA). If you are not sure which
the original slot was, please have a look in the configuration documentation.
 Return the "Extraction-tool" to the AK-3 frame.

 Once all boards are cleaned and back at the original slot, mount the AK-3 front panel.
 Switch on the MCB’s. Some LED's of the electronic devices should be on, that means the power
 supply is ok!
 Wait approx. 1 minute.
 The Ready (RY)-LED's of all boards should be on and no red LED (at the AK-3) should be on.
 Protection System and Touch Panel should start-up also.
 Ask the operator if there are no errors displayed at the SCADA system.
6.1.2.2 Backup handling of parameters of toolbox

After any change in the Toolbox II (OPM or PSR) at least one backup has to be performed with the
"Data distribution center" of the Toolbox II.
The backup file should be copied to a safe media like CD Rom or must be stored on a save drive
of a Server.
Create a backup
Necessary equipment
 Backup medium of Toolbox II data (file, CD-ROM, tape, etc...)
Procedure
 Start Toolbox II "Data Distribution Centre"

 Open "Export"-folder

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 Select with the mouse the root entry in the left window
 Hold the CTRL key and drag the selected root entry in the right window.
*** If the CTRL key is not held during drag and drop all selected parameters will be exported and kept
As read only in the database. In this case it will not be possible to modify them anymore.
 Select Start Export

 Specify backup file
 Finished

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Check or restore the existing backup files!

Necessary equipment
 Backup medium of Toolbox II data (file, CD-ROM, tape, etc...)
Procedure
 Start Toolbox II "Data Distribution Center"
 Open "Import"-folder
 Specify backup file
 Check if the "Data Distribution Center" is able to read the backup file
 Please do not import data when only a check shall be performed.

 24. To restore plant parameters press "Start Import"
Check of remote access to ACP components

Necessary equipment
 Toolbox II
Procedure
 Start Toolbox II
 Connect Toolbox II PC to the Network
 Start any Toolbox Tool (e.g. Diagnosis)
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 Click System | Remote operation

 Double click the station you want to test
 In a window a feedback about the established remote connection should appear. Leave this window
open!
 Now start the normal diagnosis of this station.
 When the diagnosis is working without any problems, the remote-connection is ok!
Reorganization of data base in toolbox

Necessary equipment
 Toolbox II at TBII server! The function is always performed at the local database!
 The database shall not be in use. No user shall be logged on!

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Procedure
 Start Toolbox II
 Start Toolbox II Presets
 Click Database | Reorganisation
Hint:
This function can also be performed automatically by the Windows scheduler. A description can be found
in the Toolbox O7nline Help!
*** Reorganisation of database can take several minutes!
6.2 Handling of Sicam 1703 Hardware

6.2.1 General
The hardware of ACP 1703 is developed according the latest available technology on the market. By
Using low power electronic modules, Flash Prom's, motionless elements etc. there are only a few
Maintenance activities recommended.
 People, handling electronic components or modules have to be electrically grounded (with arm bands or
ESD shoes). This also applies when handling processing signal connectors (plugs, terminals, etc.) on
equipped boards.
 Electronic components or boards may be transported only in electrically conductive containers or packag-
ing.
 Regular checking of all grounding devices and ESD workplaces to ensure their effectiveness.
6.2.2 Installation and Removal of AK-3 Modules
6.2.3
*** The activities described in this chapter presume that the grounding connection between Control
System and cabinet or rack has been properly carried out and that these are earthed.

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6.2.3.1 Preparations
Connect and put on Grounding Strap
The grounding strap can be connected directly to the mounting rack. The connection point i located
on the left side panel of the mounting rack: see in below picture:
Removing Front Panel
 Open the knurled screws* which connect the front panel with the mounting rack CM-2844:
 Take hold of the front panel at the knurled screws and remove it.

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6.2.3.1 Removal
This is included in the scope of supply of every mounting rack and must be inserted in the bracket,
provided on the mounting rack during installation.
 Connect/put on grounding strap and remove front panel
 Position the extracting tool between module and profile rail.
 Loosen the plug-in connector by pushing the unlocking clip upwards, or downwards.
 Grasp the module at the unlocking blocks and withdraw it from the mounting rack.

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6.2.3.2 Installation of communication and connection modules

Regardless of the method of communication the following tasks are to be carried out:
Installation of a Serial Interface Module (SIM) on master control element (CP-2016) or on processing-
and communication element (CP-2019)
 Fitting of the connection boards on Patch Plugs
 Installation of the connection boards on master control element or on processing- and communication
element
Installation of the Serial Interface Module (SIM)

The serial interface module can be installed on both, master control element CP- 2016 and on
processing- and communication element CP2019. The installation can only take place with the module
removed.
CP-2016 is designed for one SIM; CP2019 can manage two communication elements.

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SIM and module are connected by means of 3 connectors and 2 retainer clips. The connectors serve the
mechanical and electrical connection of both components. The clips provide an additional mechanical
hold:
For type of Patch Plug please refer to the relevant plant documents.
Installing Connection Board
*** Installation of connection boards is only allowed with removed CPU's.
The fitting is carried out by engaging the connection board in the red seating frame and subsequent
screwing with the fastening bracket on the underside of the mounting rack:

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 Insert the connection board into the mounting rack from below, until the point of the grip flap lies between
profile rail and seating frame . (Wall bracket and cover plate support this activity with the help of an inte-
grated guide plate.)
 Swing the lower part of the connection board forward . Ensure that the hook of the grip flap is guided
through the unlocking lever.
 Push the connection board upward until grip flap and seating frame are finally fixed together.
 Finally the front panel of the connection board is screwed with the fastening bracket on the underside of
the mounting rack .
Configuration Notes
Depending on the type of used connection board and the communication module (SIM) different interface
ports for connection of cables are available:

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 PS 2632 POWER SUPPLY FOR RACK

6.2.3.3 Installation and Removal of AK-3 Modules
Removal and mounting of modules
TM modules are installed on standard rail.

Removal and mounting does not require any tools.
*** The connecting and removal of modules is only permitted in a de-energized state. This state is
achieved by interrupting the power supply to the power supply unit and to the peripherals.
For mounting the locking clips on the top side of the module are pressed together, the module coupled
with the neighboring module by means of the guides at the corners of the housing and positioned on the
rail.

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Modules that are adjacent to each other are mechanically connected with each other by means of the guides
at the corners of the housing.
For the removal, the locking clips are pressed together and the module is withdrawn with clips pressed
together
6.2.3.3 Row Selector Module, Peripheral Board Address (PBA) PE 6410

The AK-3 controller can manage up to 16 interface row. Every row can be equipped with up to eight Interface
Modules.
Within a row the modules are numbered according their mechanical position in the group.
For the addressing of the row selector switch, defining the PBA is used. The PBA switch can be found on
every row selector module. The line selector module is always the second module in an interface row (the first
module always must be the power supply of the row).
The selector Switch will have a number from 0 to F for defining up to 16 PBA addresses. The required adjust-
ment can be found in the control system configuration document.
`
Guideline For The Replacement Of Modules
By means of the modular design of AK-3 the replacement of a faulty module is achievable in an easy
manner:
• The peripheral cables can be detached without tools.
• The modules are detached from the rack with the unlock tool TA2-105 (scope of delivery).
• Serial interface modules and connection boards can be detached without tool.
• The user data (parameters and application program) are stored non-volatile on the flashcard.

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• The flash card can be withdrawn from the removed master control module.
• For the commissioning of a new module the TOOLBOX II is not required.
*** For the replacement of system elements a shutoff of the power supply is not required. By means of
that, the function of the subsystems which are not affected by the replacement is maintained.
*** For peripheral elements that operate with voltages > 60 V (e.g. DI-2111) care must be taken that mani
pulation on the peripheral connectors may only be carried out in a de-energized state.
Recognize and Replace a Faulty Module

During operation AK-3 monitors the configured hardware. A faulty or failed system element is signaled as
follows:
• Red ER-LED on the master control element
• Function DIAGNOSTIC | AUTOMATIC DIAGNOSTIC
• Function DIAGNOSTIC | AU OVERVIEW DIAGNOSTIC
If a hardware error is present, a replacement of the respective system element by the same type (with the
same firmware, even if a later revision level is present) is necessary.
When replacing a system element with another type, a change of the project data with the
TOOLBOX II is required (the necessary functionality of the system must be recovered by means of re-
parameterization). After the loading of the changed configuration into the target system, a startup of the
system must be performed.
Replacement of the Master Control Element

After removing the master control element from the mounting rack, the function of the system is naturally
not present. An exception forms an "autarchic" subsystem, whose function independently of the master
control element is running in a processing and communication element.
The flash card can be taken out of the removed master control element, and being plugged into the new
master control element.
After plug-in of the new master control element the startup takes place. Thereby, the project data
(parameters and application program) are being loaded from the flash card.
Replacement of A Processing and Communication Element

After removing the processing and communication element from the mounting rack, the function of the af-
fected subsystem is naturally not present.
After plug-in of the new processing and communication element, this is detected by the master control
element, and the project data (parameters and application program) are being loaded from the flash card
of the master control element.
Since for the replacement of a processing and communication element a shutoff of the power supply is
not required, the function of other basic system elements and their subordinate system elements is
maintained.
Replacement of A Serial Interface Module

For the replacement of a serial interface module first the basic system element (carrier module) must be removed
from the mounting rack. For this, please consider the previously mentioned consequences for the system.
Upon replacement of a serial interface module the parameters already stored on the flashcard of the master control
element are automatically utilized on the new module.
Replacement Of A Peripheral Element

After the replacement of a peripheral element the parameters already stored on the flash card of the master control
element are automatically utilized on the new module.

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6.3 Software for AK-3

The programming and diagnosis tool for the AK-3 control system is the TOOLBOX II. This software
package allows to
 modify plant parameters
 load firmware and plant parameters to the controller CPU's and
 perform diagnosis
The TOOLBOX II is installed on a PC or notebook.
*** For replacement of CPU boards no parameter loading procedure with Toolbox is required, as long
as no parameters have to be modified and the Flash Card/SIM Card is not exchanged!
All required parameters; Firmware as well as plant parameters are stored on the Flash Card / SIM Card.
6.3.1 Loading of Controller Parameters

For changing and loading of changed parameters the Toolbox PC has to be connected to the concerned
AK 1703 automation unit (controller) and a Flash Card must be inserted in the slot of the master control
element (CP-2016). For the MIC the SIM card must be inserted please refer to Chapter
6.3.1.1 Physical Connection between Toolbox PC und AK-3
Following types of connections between TOLLBOX and AK -3 controllers are possible:
 direct local via toolbox cable
 Ethernet (TCP/IP, TELNET)
Direct connection via toolbox cable

Toolbox PC and AK-3 are connected direct via the toolbox cable:

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Via Ethernet (TCP/IP, TELNET)

Toolbox PC and AK-3 are connected via Ethernet (TCP/IP, TELNET).
For this type of connection it is necessary that the master control element or processing- and
communication element is equipped with a network interface print SM-2551.
6.3.2 Storage media for Automation Units
6.3.2.1 Flash Card for AK-3

AK-3 uses a flash card for the storage of parameters, user programs and firmware codes for basic system
elements and supplementary system elements (e.g. peripheral elements, protocol elements). This Flash
Card is located on the master control element – CP-2016:

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• Messages with system information are either processed directly (e.g. station interrogation) or distributed
further based on their destination address (CASDU) (e.g. messages for remote maintenance)
6.3.3 Operation And Display Elements
AK 3 supports the use of peripheral elements of the systems AK 3
6.3.3.1 Master Control Element, Processing And Communication Elements

LEDs on the front panel display various states. The arrangement of the LEDs comprises
• System display elements

Display of operating- and error states of the system
• Function display elements
Display of the readiness of the protocol elements
• Communication display elements
Display of the operating- and error states of the protocol elements
Which states are displayed, is determined by
• The firmware implemented
• The protocol elements used

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The reset signal of the master control element affects the entire automation unit, this means
also the:
• Processing and communication elements
• Protocol elements
• Peripheral elements
The reset signal of a processing and communication element affects its belonging subordinate
• Protocol elements
• Peripheral elements
6.3.3.2 Peripheral Elements

LEDs on the front panel display various states. The arrangement of the
LEDs comprises
• System display elements
Display of operating- and error states
• Function display elements
Display of the state of the I/Os
Which states are displayed, is determined by
• the firmware implemented

• the peripheral control module used

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6.3.4 Checks And System Displays
During startup of the AK 1703 ACP system, checks of the hardware and the software are performed by
the individual system elements.
If an error is detected, this leads
• To a signaling via the LED-displays (an overview can be found below)
• Depending on the seriousness of the error, possibly to an abortion of the startup
After error-free startup of a system element, further checks are performed.

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Master Control Element, Processing And Communication Elements


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Protocol Elements

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Peripheral Elements

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6.3.5 Diagnosis
General
The following listing explains the different error categories and how the error messages are logged.
• Hardware errors
Monitoring of the individual system elements, communication and time synchronization by the firmware
of the target system in operation. Error information takes place by
─ Logging via diagnostic function (online)
─ Activation of the red error-LED on the master control element
• Software errors
─ Parameter setting
The input of the parameters with the help of the TOOLBOX II tools is subjected to – as far as logically
recordable - parameter-specific conventions or plausibility checks. Faulty inputs are notified or directly
prevented with the entry.
If a - in principle permitted - parameter setting, that however does not match the physically present
system elements, is loaded into the target system, the method of procedure is as with hardware errors.
─ Programming
Monitoring by the CAEx plus compiler and logging in an error information list during compiling of the
application program code.
• Operator errors
Are largely excluded due to plausibility checks or queries by the TOOLBOX II. Naturally, all operator
inputs, such as for example the loading of parameters or the online testing of application programs, are
subject to the responsibility of the user.
System Diagnosis
AK 1703 ACP contains extensive diagnostic functions for monitoring the system. Since the firmware
automatically executes the appropriate error monitoring routines, for this no settings of any kind by the
user are necessary.

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With the tool "Diagnostic", system states and errors can be read out and displayed in plain
text and printed out if required (online).
The following functions are available:

• Acknowledge network
With the function ACKNOWLEDGE NETWORK, the signals of all automation units located in the network
are reset, insofar as they are no longer present.
• Network overview diagnostic

The error messages of all automation units in the network are output in a report window with the function
NETWORK OVERVIEW DIAGNOSTIC (sum information).
• AU overview diagnostic
The error messages of all automation units in the network are output in a report window with the function
AU OVERVIEW DIAGNOSTIC (sum information for each system element able to report).
• History
The history of error messages is output in a report window with the function HISTORY DIAGNOSTIC.
• Automatic diagnostic
An overview of the error messages of all automation units in a network as well as their system elements is
output in a report window with the function AUTOMATIC DIAGNOSTIC. The outputs are structured hierar-
chically in
─ Network overview diagnostic
─ AU overview diagnostic
─ AU single diagnostic
─ History (if preset)

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System Performance
Information about the system performance of a selected automation unit can be interrogated
(Online) with the tool "Service Function Online":
• Display equipped system elements
• Read serial numbers
• Display/delete data flow routing
• Shut down selected system elements
• Shut down selected automation unit
• Startup selected system elements
• Startup automation unit
• Display time
• Memory check
• Data processing capacity
• Control- and bus runtime
Diagnosis Of The Open-/Closed-Loop Control Function
With the tool "CAEx plus" the following status information can be displayed for each task with the function
ONLINE-TEST:
• Parameterized cycle time
• Current runtime
• Minimum/maximum runtime
• Number of runtime time-outs
• Bus runtime
Further Information can be found in the manual AK-3 Common Functions System and
Basic System Elements, chapter "Automation", section "Open-/Closed-loop Control Function", section
"Display Status Information".
Errors that can occur with the creation of the function diagram (for example the linking of a binary signal to
an analog input of a function) are displayed in a separate report window ("POU error check"):
• Automatically with the incorrect input
• Manually with the function EARLY ERROR DETECTION (Pop-up menu in the function diagram).
All editing errors can be displayed at any time.
6.3.6 Update Of The System
In AK -3, new system elements or new revisions of system elements can be integrated, if required. The
updating of the system takes place in steps:
1. Import master data into the TOOLBOX II

- Firmwares for the tools of the TOOLBOX II
- Firmware codes for loading into the target system
2. Load firmware codes into the target system

- Processing of the updated system elements or functions by executing the firmware codes

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Interrogate Firmware Revision
The firmware revisions of all configured system elements (basic system element, peripheral element, pro-
tocol elements) can be displayed on the screen and printed out for a selected automation unit with the
tool "Revision Interrogation".
Further details about the tool can be found in the TOOLBOX II User Manual, chapter "Revision Interroga-
tion".
Import Master Data Into The TOOLBOX II

The importing of the master data into the TOOLBOX II is performed with the tool "Master Data Update".
For this, corresponding software revisions are issued by SIEMENS as files.
Errors When Loading The Firmware

When loading the firmware into flash PROM this is written completely new. For a perfect functioning of
the master control element, it is therefore absolutely necessary that this procedure completes without
errors.
If the tool "Load Firmware" terminates with an error indication, start the loading procedure again and at-
tempt to perform it without error. If an error occurs again, the master control element is no longer capable
of functioning. Check the LED display.
The following situations cause the master control element to be no longer capable of functioning:
• Voltage failure while loading procedure is running
• Abortion by the user while loading procedure is running
• Failure (defect, shutdown) of the PC
• Abortion due to hardware error
• Abortion or excessively long fault of the communication connection between PC and AK 1703 ACP

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6.4 SCADA system SCALA 250

The installation of the SCADA software is only required if the original installation has been removed
Or when hardware like the hard disk or the complete Computer replaced has been replaced!
6.4.1 Necessary equipment
 SAT SCALA CD
 License Sheet with activation codes
 SCALA Parameter Backup
6.4.2 Setup Operation System
6.4.2.1 NTP client Tardis

It's important that the computer is time synchronized with the NTP server. Not time synchronized
computer can cause problem with the SCADA software with archives handling and parameter
updates. To keep the computer time synchronized the Software Tardis needs to be installed. This
Software will be found on the SCADA software CD.
Start the installation and follow the instruction.
Select the recommended installation.

After installation open the Tool "Control Panel", "Tardis". The system will bring up a warning that
the windows NTP service needs to be deactivated, adjust the settings as follows:

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Default already three time sources are defined. This time sources should be deleted with the button "Clear All",
confirm the warning with "YES".

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Date 31.01.2014
Add a new Time source with the button "Add".

Protocol needs to be SNTP/NTP, Address and Name is the IP Address from the NTP Server. Enter the IP ad-
dress according the attached Network List.
To optimize automatic time adjustment following settings are recommended:

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For Event logging following settings is recommended:

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All other settings should be kept with default values.
6.4.3 Installation SCADA System SCALA 250
Procedure
 Insert SAT SCALA CD into CD-ROM drive. If the Computer is configured for automatic installation the
setup screen is displayed. For Manual start of the Setup select the Windows Explorer, open the CD
drive folder, sub directory SATSCALA and select the Program Setup.
 The installation Program will ask for the preferred language. Available is English and German. Select
the preferred language and follow the instruction of the installation program.
 Select Custom Installation to activate these software parts which are indicated on the license sheet. It
is not possible to install software, not listed on the license sheet.
 Choose the Software parts, which should be installed:

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The below table informs about the necessary part which should be installed:

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Date 31.01.2014
 Enter the destination drive for the SCALA (the normally proposed destination is in most cases correct) and
follow the instruction of the installation program.
 After successful installation of SCALA the setting screen will pop up. Keep the default settings and confirm
the Screen with OK.
 Last step is to restore the Plant parameter. In this case you should not interrupt the restore procedure you
should continue.
 Restart the computer, after this procedure the SCADA system should work.
6.4.4 Maintenance of computer System
6.4.5 Cleaning
Computers
Cleaning of PC's should be done one a year or when the machines are polluted heavy due to abnormal
conditions
Necessary equipment
 Oil free compressed air spray
 Small screw driver (Phillips screwdriver)
 Anti-static arm-band
 brush
 vacuum cleaner
Procedure
 Inform operator that Operator station will be out of operation for about 30 minutes.

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 Shutdown Operation System (Windows Start Menu Item “Shutdown”) and wait until the system confirms
that it is ready for power off.
 Switch off the PC and disconnect PC from 230 V AC-power supply
 Open PC according to manufacturer’s manual
 Clean PC inside with compressed air. If the PC is extremely dusty it is recommended to clean first with the
vacuum cleaner and afterwards with compressed air to prevent that the dust is distributed.
*** Do not touch the sensible electronic components with the pipe - it is recommended to have a
brush on top of the vacuum pipe!
 Close PC according to manufacturer’s manual and connect PC to 230VAC-power supply

 Switch on the PC
 Listen the sound of fan, if there is a singing sound or not regular sound the live time of the fan is reached
and it should be replaced
 Listen the sound of hard disk, if there is a singing sound or not regular sound the live time of the hard disk
is reached and should be replaced

 Verify the mo error messages are displayed!
 Check if operation system and application programs are starting up
Monitor
Necessary equipment
 - Appropriate cleaner
 - Soft cleaning cloth
Procedure
Careful cleaning of screen and housing of monitor
Printers
Necessary equipment
 Appropriate cleaner
 Soft cleaning cloth
 Compressed air spray or vacuum cleaner
Procedure
 Open the flap of the printer (please follow printer manual)
 Use compressed air spray or vacuum cleaner to clean the printers inside.
 Close the flap of the printer
 Use cleaning cloth and cleaner to clean printers housing.
 Use printer handbook to execute further maintenance like exchange of cartridge(s)
 Check if sufficient printer paper is available
 Check if sufficient spare cartridges are still available
Mouse
Necessary equipment
 Appropriate cleaner
 Soft cleaning cloth

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Procedure
 Clean mouse body with cleaner and cloth
 Clean mouse bottom with cleaner and cloth
6.4.5.1 Defragmentation of hard disk

Necessary equipment
No requirement
Procedure
 Open My computer Icon on the Desktop
 Select Hard disk Drive C press the right mouse button and select properties
 Open folder Tools and select Defragment Now
Select the first drive and press Defragment

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After finishing the defragmentation select the next drive in the defragmentation tool and start the
defragmentation again. Continue this step until all drives are defragmented.
6.4.6 Backup handling of parameters
After any change in SAT 250 SCALA at least one backup has to be performed.
The backup file should be copied to a safe media like CD Rom or save drive on a Server.
Create backup!
Necessary equipment
 Backup medium of SCALA 250 software (file, CD-ROM, tape, etc...)
Procedure
 Start "Start | Programs | SAT 250 SCALA | Data Storage Client"
 Select "Backup"

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 Next
 Select path of backup
 Next
 Select the check boxes for "SCADA client", "CAE Server", "User Data", "Scada Server"
 Select Finish

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Restore or Check the existing backup files!

Necessary equipment
 Backup medium of SCALA 250 software (file, CD-ROM, tape, etc...)
Procedure
 Start "Start | Programs | SAT 250 SCALA | Data Storage Client"
 Select "Restore"
 Next
 Select source path
 Check if "data storage info" are plausible

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 Select "Activate stored SCADA settings” and "Activate stored licenses"

 Next
 Select the check box for "SCADA client", "CAE Server", "User Data", "Scada Server"
 Check if "required space" is smaller than "available space"
e.g.
*** The last step of this procedure defines if a restore process is started or if the process is
cancelled!
 Cancel ends the check of backup files
 Finish will start the restore process

REGISTERED

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7. Spare parts and assembly devices

7.1 Specified Spare Parts
Spare parts as per list here under will be supplied as mandatory spares.
Quanti-
Sr.No. Description Unit Remark
ty
1 CPU-2016 No. 2 #
2 Process Input/ Output card
1. DI-card 6103 110/220V DC, Siemens No. 2 #
3 Push Button Set 1 #
4 Selector Switch Set 1 #
5 Indicating Lamp Set 1 #
10 Miniature Circuit breaker Set 1 #
7.2 Recommended Spare Parts

Spare parts as per list here under will be supplied as recommended spares.
Sr. Quanti-
Description Unit Remark
No. ty
1 Process Input/ Output card
1. DO-card 6212, 24-220V DC/230V AC, Siemens No. 2 #
2. AI-card 6300, (4to20mA), Siemens No. 2 #
2 Ethernet Interface Module No. 1 #
3 Touch Panel 19” No. 1 #
4 Electric Measuring Equipment Set 1 @
5 Synchronizer No. 1 *

REGISTERED

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Date 31.01.2014

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O&M Manual –Control & Monitoring system

3.2 Computer and Monitors 11

Client VSH Prep. ST Contract Nº.

1.1 About this manual

(i) Target Group

chine/plant (maintenance, inspection and repair).

 The entire chapter Safety and

(ii) Supplementing Instructions

1.2 Intended use

Client VSH Prep. ST Contract Nº.

1.3 Notice of claims

 Description of lack or damage (symptoms, detected by and when)

 The operator prepared a comprehensive general safety program.

Client VSH Prep. ST Contract Nº.

2.2 Basic safety instructions

2.2.1 Duties of operator

(i) Intended Use

(ii) Work Instructions

(iii) Qualification of assigned personnel

(v) Definition of Areas and Responsibilities

(vi) Inspections and Tests

The operator is obliged to:

(vii) Attachment of Safety Devices

2.2.2 General duties of personnel

 The wear of protective footwear in all the factory premises is mandatory.

2.2.3 Work on/in electrical systems

Client VSH Prep. ST Contract Nº.

 Regular inspection of electrical equipment of machine/plant. Lacks

2.2.4 Hydraulic, pneumatic

2.2.5 Lifting and transport of components

 Secure the loading properly before lifting and transport operations.

 Use 3D-lifting rings or eyebolts, if provided.

 Direction of crane operation by show of hands or wireless only by responsible specialist.

2.2.6 Mobile usable machines and components

 Attach appropriate warning signs.

 Remove transport and slinging means duly before re-commissioning.

 Connect the machines/components again with the system before re-commissioning.

 Re-commissioning only in accordance with the manual.

2.2.7 Gas, dust, steam, smoke

Client VSH Prep. ST Contract Nº.

 Wear protective goggles

2.2.10 Radio equipment

Only EMC-conform radio equipment must be used within the plant.

2.2.11 Gas extinguishing system

Client VSH Prep. ST Contract Nº.

3.1 Control Boards

Manufacturer: Rittal, Type TS 8 or equal

Material : Self-supporting profiled steel

External cables are connected directly to the interface modules.

3.2.1 SCADA Server A & B,

Client VSH Prep. ST Contract Nº.

3.2.2 Monitor Server A & B,

Type: DELL -U2412M 24” U2412M 24”

3.2.3 Engineering Station

Same specifications as SCADA Server A & B

3.3 Touch panels

Client VSH Prep. ST Contract Nº.

3.5 LAN Components

Type Cisco IE3000-8TC

3.6 NTP Server with GPS Antenna

3.7 Process Control

3.7.1 Processor Modules

3.7.1.1 Controller Main Processor