Substation PLC and SCADA

In Salah Gas
Substation PLC and SCADA Operating & Maintenance Manual – Revision 6
Change Record Narrative Sheet
Revision 0: Initial Issue for Customer Comment.
Revision 1: Section 1.1.6 - ‘PLC Panel Layout’ Added.

Section 3.12 – ‘Westermo MD45’ Added.
Section 9.1 – ‘PLC Changeover Design’ revised for modified extended timer
changeover philosophy.
Section 12 - ‘PLC Panel Electrical Load’ Added.
Section 13 – ‘PLC Panel Schematic Drawings’ Added.
Revision 2: Various site technical additions.
Revision 3: Safety Section Added.

Section 1.1.5 – ‘KITZ Units’ Added.
Sections 1.1.2, 1.1.3, 1.1.4, 3.3, 3.6, 3.7, 3.8, 3.9, 3.13.1, 3.13.2, 3.14.2 -
Document References Added.
Revision 4: Section 4.3.2 – Section Updated.
Revision 5: Section 4.3.2 – Section Updated.
Revision 6: Section 1.1.6 – KITZ Bitmaps Updated.

Section 4.3.2 – Event File Name / Location Defined.
Sections 3.4, 3.5, 4.7.1, 4.7.2, 6.1, 6.3, 7.1, 8.1, 10 (all).
– Updated for Proficy ME Software.
Section 10.5 Programmer / Monitor Modes Added.
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Contents
Safety Section ............................................................................................................................................. 7
Health and Safety ...................................................................................................................................... 7
Explanation of Symbols and Labels ........................................................................................................... 7
Installation, Commissioning and Servicing ............................................................................................... 7
Equipment Connections ............................................................................................................................ 7
Battery Replacement ................................................................................................................................ 8
Insertion / Removal of PC Equipment and PLC Modules .......................................................................... 8
1. Substations PLC System Overview ................................................................................................. 9
1.1. Introduction .................................................................................................................................. 9
1.1.1. PLC System ................................................................................................................................ 9
1.1.2. Gemview SCADA ....................................................................................................................... 9
1.1.3. Gemstart 4 .............................................................................................................................. 10
1.1.4. Micom Relays .......................................................................................................................... 10
1.1.5. KITZ Units ................................................................................................................................ 11
1.1.6. Generic Overview .................................................................................................................... 12
1.1.7. PLC Panel Layout ..................................................................................................................... 13
2. System Component List .................................................................................................................. 15
2.1. PLC Equipment ............................................................................................................................ 15
3. Component Functionality, Parameters and Indications .............................................................. 16
3.1. Gemview Indication Inspection for Failures ............................................................................... 16
3.2. PLC LED Status for Healthy System ............................................................................................. 18
3.3. PLC Rack (IC693CHS391) ............................................................................................................. 20
3.4. PLC Power Supply (IC693PWR330) ............................................................................................. 21
3.4.1. PLC Power Supply (IC693PWR330) – Normal Indications ....................................................... 22
3.5. PLC Processor (IC693CPU364)..................................................................................................... 23
3.5.1. PLC Processor (IC693CPU364) – Normal Indications .............................................................. 25
3.6. Communications Module – DCS (IC693CMM311) ...................................................................... 26
3.6.1. Comms Module - DCS (IC693CMM311) – Normal Indications ............................................... 26
3.7. Programmable Communications Module - Gemstart (IC693PCM311) ...................................... 27
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3.7.1. PCM - Gemstart (IC693PCM311) – Normal Indications .......................................................... 27

3.8. Programmable Communications Module - Micom (IC693PCM311) (Krechba only) .................. 28
3.8.1. PCM - Micom (IC693PCM311) – Normal Indications .............................................................. 28
3.9. RTU Master Module - Micom (HE693RTM705) (Hassi, Reg, Teg only) ....................................... 29
3.9.1. RTU Master - Micom (IC693PCM311) – Normal Indications .................................................. 29
3.10. Mixed Input / Output Module (IC693MDR390) ...................................................................... 30
3.10.1. Mixed I/O (IC693MDR390) – Normal Indications ................................................................... 31
3.11. Input Module (IC693MDL655) ................................................................................................ 32
3.12. Output Module (IC693MDL940) ............................................................................................. 33
3.13. Westermo MD-42 and MD-44 Converters .............................................................................. 34
3.13.1. Westermo MD-42 and MD-44 – Normal Indications .............................................................. 34
3.13.2. Westermo MD42/MD44 DIP Switches – Diagrammatical and Physical Location ................... 36
3.14. Westermo MD45– MD42/MD44 Replacement ...................................................................... 38
3.14.1. Westermo MD45 – Normal Indications .................................................................................. 38
3.14.2. Westermo MD45 DIP Switch Settings– Diagrammatical and Physical Location ..................... 38
4. Inspection and Maintenance Schedule ......................................................................................... 40
4.1. Inspection and Maintenance Introduction ................................................................................. 40
4.2. Authority to Work ....................................................................................................................... 41
4.3. Gemview EWS – (3month) .......................................................................................................... 42
4.3.1. Gemview Restart ..................................................................................................................... 42
4.3.2. Manual Archive of Event Data – (3 month) ............................................................................ 43
4.3.3. Gemview PC Clock Synchronisation – (3 month) .................................................................... 44
4.4. PLC Status – 3 month .................................................................................................................. 45
4.5. Gemview Indication Status – (1 week) ....................................................................................... 46
4.6. PLC Battery Replacement – (3 years) .......................................................................................... 47
4.7. Software Backup / Verification – 1 Year ..................................................................................... 48
4.7.1. Master & Slave PLC Software Verification .............................................................................. 48
4.7.2. Master & Slave PLC Software Backup ..................................................................................... 51
4.7.3. KITZ202 Software Verification / Backup ................................................................................. 52
4.7.4. Gemview EWS Backup ............................................................................................................ 54
5. Recommended Spares .................................................................................................................... 55
5.1. Equipment Order Codes.............................................................................................................. 55
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6. Troubleshooting Guide .................................................................................................................... 56

6.1. General PLC System Communications Troubleshooting ............................................................. 56
6.1.1. DCS Communications Troubleshooting .................................................................................. 58
6.1.2. Gemstart Communications Troubleshooting (Online PLC) ..................................................... 58
6.1.3. Micom Communications Troubleshooting.............................................................................. 60
6.1.4. Gemstart Communications Troubleshooting (Offline PLC)..................................................... 61
6.2. Gemview EWS Communications Troubleshooting ..................................................................... 63
6.3. Identifying Hardware Faulted I/O Modules ................................................................................ 64
6.4. Replacing Hardware Faulted I/O Modules .................................................................................. 65
7. Disaster Recovery Procedure ........................................................................................................ 66
7.1. Master / Slave PLC Recovery....................................................................................................... 66
7.2. KITZ Recovery .............................................................................................................................. 67
7.2.1. KITZ Addressing ....................................................................................................................... 67
7.2.2. KITZ Mapping Download ......................................................................................................... 68
7.3. Gemview EWS Recovery ............................................................................................................. 71
8. Recommended Manuals ................................................................................................................. 72
8.1. Resource Manuals ....................................................................................................................... 72
9. System Event and Failure Design Behaviour .............................................................................. 73
9.1. PLC Changeover Design............................................................................................................... 73
10. Using Proficy ................................................................................................................................. 76
10.1. Connecting to the PLC ............................................................................................................. 76
10.1.1. Via Serial Connection .............................................................................................................. 77
10.1.2. Via Ethernet Connection ......................................................................................................... 78
10.2. Selecting/Viewing Ladder Program and Navigating Subroutines ........................................... 79
10.3. Viewing Variable States via Reference View Tables ............................................................... 81
10.4. Search Commands .................................................................................................................. 83
10.5. Programmer / Monitor Modes ............................................................................................... 84
10.6. Forcing PLC I/O ........................................................................................................................ 85
10.7. Reinstalling PLC Software (Using Flash Memory) ................................................................... 86
10.8. Fault Tables ............................................................................................................................. 88
11. Loading Gemstart Drivers ........................................................................................................... 89
11.1 Termf Software ........................................................................................................................... 89
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11.2 PCM Programming Cable Connections ....................................................................................... 90

11.3 Procedures for Loading PCM ...................................................................................................... 91
12. PLC Panel Electrical Load .......................................................................................................... 92
12.1 230VAC Power Consumption ...................................................................................................... 92
12.2 24VDC Power Consumption ........................................................................................................ 93
12.3 30Watt PLC PSU Power Consumption ........................................................................................ 94
13 Referenced Panel Schematic Drawings ................................................................................... 95
13.1 Referenced Schematic Drawings ................................................................................................ 95
13.1.1 Hassi R’Mel Schematic Drawings ............................................................................................ 95
13.1.2 Krechba Schematic Drawings .................................................................................................. 95
13.1.3 Reg Schematic Drawings ......................................................................................................... 95
13.1.4 Krechba Schematic Drawings .................................................................................................. 96
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Safety Section
Health and Safety
The information in the Safety Section of this Operations and Maintenance manual is intended to
ensure that all activities carried out on the related equipment is performed in a safe manner, to
prevent injury to personnel and damage to equipment. It is assumed that all personnel using the
equipment are familiar with the contents of this Safety Section.
Explanation of Symbols and Labels

The meaning of symbols and labels which may be used on the equipment or referred to in this, or
other associated documentation, is given below:
Caution: refer to product documentation Caution: risk of electric shock
Protective / safety earth terminal
Functional earth terminal.

Note: this symbol may also be used for a protective/safety earth
Terminal if that is part of a terminal block or sub-assembly eg.
PLC power supply.
Installation, Commissioning and Servicing
Equipment Connections
Personnel undertaking installation, commissioning and servicing work on the
referenced equipment should be aware of correct working procedures to ensure
safety.
Terminals exposed during installation, commissioning and maintenance may present a
hazardous voltage unless the equipment is electrically isolated.
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Battery Replacement
Where internal batteries are fitted they should be replaced with the recommended type
and be installed with the correct polarity, to avoid possible damage to the equipment.
Insertion / Removal of PC Equipment and PLC Modules

These must not be inserted or removed from equipment whilst it is energised, since
this may result in damage to equipment and/or injury to personnel.
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1. Substations PLC System Overview

1.1. Introduction
1.1.1. PLC System
One Hot Standby RTU PLC system is installed at each package substation at the Krechba, Hassi
R’Mel, Reg and Teg sites. Each PLC system is dedicated to provide the control and monitoring of
the associated switchgear located within each substation.
Each PLC system is made up of two identical GE Fanuc PLC racks. At any one time, one PLC rack
performs ‘duty’ mode operations (or online) providing communications functions to each part of the
system, while the other PLC is in ‘standby’ mode (offline), ready to take the ‘duty’ status in the
event of failure of the other PLC or other system component. As far as is practicable each PLC
rack utilises its own system components to provide the system with the greatest measure of
redundancy possible.
The PLC system communicates via serial links to Gemstart 4 units, Micom units (via KITZ) and the
DCS Yokagawa system. It also provides communication to the Gemview SCADA system and
between each pair of PLC racks via a TCP/IP Ethernet network.
1.1.2. Gemview SCADA

The Gemview system is a bespoke SCADA
system that communicates to the ‘duty’ (online)
PLC via a TCP/IP Ethernet network. The Gemview
SCADA uses the PLC system communications
links to provide monitoring and configuration of the
Gemstart4 units, and monitoring and control of the
Micom units.
Various data screens are available for the retrieval

and monitoring of data. Available functions include,
but are not limited to:
Gemstart and Micom status screens Running / tripped / alarm status, communications
status, fault codes, analogue measurement values,
etc.
Gemstart Motor Trending Real time trend graphs for all Gemstart motor
currents, including historical trend current database.
Event Log Database that logs all Gemview SCADA events and
alarm, trip and communications events for Gemstart
and Micom units
Single Line Diagram Pictorial overview of the electrical distribution system
for the substation, denoting circuit breaker states and
conditions.
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For further system specification and operation please refer to ‘Gemstart Help’ file which is installed
as part of the Gemview installation.
(Please note: No other specific Gemview documentation currently exists).
1.1.3. Gemstart 4
Gemstart 4 units are low voltage motor protection relays. They provide a number of configurable
motor and circuit protection functions. The Gemstarts have the ability to communicate via a serial
link to the PLC system to provide monitoring data to the system and to accept control commands
and configuration changes.
The PLC system references the Gemstarts by their serial link number and serial link address. This
is clearly displayed on the left side of the LCD:
Link Number Link Address

(1 or 2) (00 to 99)
For further Gemstart 4 specifications please refer to Areva documents: 15G0007, 15G0008 and
15G0009.
1.1.4. Micom Relays

A range of Micom units are installed in the
switchgear to provide motor and transformer
protection. Micom units have the ability to
communicate on a serial link to the PLC via a KITZ
unit.
The PLC system references the Micoms by their

serial link address. This is defined from the front
LCD / keypad interface under the column heading
‘Communication’. The address range is defined as
1 – 20 per serial link. (Note: The Gemview SCADA
references Micom link 2 addresses 1-20 as 21-40).
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For further Micom relay details please refer to Areva specification documents:
P12x_ent_f75 (P120/P121/P122/P123)
P14x/EN M/B64 (P141/P142/P143)
P220/EN T/B43 (P220)
1.1.5. KITZ Units

The KITZ unit is an intermediary device that provides protocol
conversion and data concentration between the Micom relays and PLC
system. The PLC system is then able to receive data from, and send
control commands to the Micom relays via the KITZ unit.
The KITZ unit requires data mappings to be programmed specific to the

number and type of connected Micom relays. Each KITZ has the
capability of communicating with up to a maximum of 20 Micom relays.
The KITZ unit is also programmed with its own serial link address of 21
(with addresses 1-20 being reserved for the use of any connected
Micom relays).
For further KITZ202 specifications please refer to Areva document: R8566c.
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1.1.6. Generic Overview
PCS
RS485 RS485
GEMVIEW EWS PLC CABINET

Westermo MD45 Westermo MD45
(RS232 -> RS485 converter) (RS232 -> RS485 converter)
Ethernet
RS232
RS232
GE Fanuc OK
P1
OK
P1
OK
P1
OK
P1
A 12345678 A 12345678 A 12345678 A 12345678 A 12345678 A 12345678 GE Fanuc OK
P1
OK
P1
OK
P1
OK
P1
A 12345678 A 12345678 A 12345678 A 12345678 A 12345678 A 12345678
Series 90-30 P2 P2 P2 P2 B 12345678 B 12345678 B 12345678 B 12345678 B 12345678 B 12345678 Series 90-30 P2 P2 P2 P2 B 12345678 B 12345678 B 12345678 B 12345678 B 12345678 B 12345678
HIGH CAPACITY HIGH CAPACITY

POWER SUPPLY POWER SUPPLY
C C P R I 32 32 16 16 I C C P R I 32 32 16 16 I
P M C T / I I O O / P M C T / I I O O /
U M M U O P P P P O U M M U O P P P P O
MASTER PLC SLAVE PLC

RS232
Westermo MD45’s
(RS232 -> RS485 converter)
RS485 RS485 RS485
KITZ202 Units
(Modbus ->Courier
Protocol Converter)
Gemstart Link 1
Micom Link 2
(Krechba Only)
Gemstart 4 Units
Gemstart Link 2
(Gembus Protocol)
Micom Link 1
Micom Relays
HARDWIRED I/O OMITTED FOR CLARITY (Courier Protocol)
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1.1.7. PLC Panel Layout

Following are photographs of the Krechba PLC panel, which is typical for all four PLC panels
installed as part of the substation projects. Key components are identified.
GEMVIEW
EWS PC
KITZ 1 KITZ 2
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Westermo PTC’s 1 2 3 4 5 6 7 8 9 10
KITZ
MASTER PLC
SLAVE PLC
ETHERNET
HUB
MCBs
MASTER 24VDC SLAVE 24VDC

SUPPLY SUPPLY
UPS
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2. System Component List

2.1. PLC Equipment
Each substation PLC system is made up from the following component list:
Description Part Number HRM KBA REG TEG

PLC Modules (per PLC)
10 Slot PLC Rack IC693CHS391 1 1 1 1
PLC Power Supply IC693PWR330 1 1 1 1
Processor Module IC693CPU364 1 1 1 1
(User Must Program Logic Before Use)
Programmable Communications Module IC693PCM311 1 1 1 1
(User Must Load Gemstart Driver into New
Module Before Use)
Modbus Slave Communications Module IC693CMM301 1 1 1 1
RTU Master Communications Module HE693RTM705 1 1 1
(Communications to Micoms via KITZ)
Programmable Communications Module IC693PCM301 0 1 0 0
(User Must Install the Driver EEPROM
Below Before Use)
Modbus Master Driver EEPROM PCM301-MBUS-2H 0 1 0 0
(User Must Install in IC693PCM301 Above)
Mixed Input / Output Module IC693MDR390 1 2 1 1
(Inter-PLC Status Indication)
32 Point 24VDC Input Module IC693MDL655 0 2 1 1
16 Point Output Module IC693MDL940 0 2 1 1
Associated Equipment (per PLC)
Westermo Isolated RS232 – RS485 MD-42DC 1 1 1 1
Converter
Westermo Isolated RS232 – RS485 MD-44DC 3 4 3 3
Converter (Intelligent)
Omron 24VDC Power Supply S82K-24024 1 1 1 1
Associated Equipment (per PLC Panel)
Dell PC Desktop Dimension 4500S 1 1 1 1
Dell Monitor E151FPp 1 1 1 1
KITZ Micom Data Concentrator KITZ20201L15CEA 1 2 1 1
MGE UPS Pulsar Extreme 1 1 1 1
1000C
Finder Relay 24VDC 55.34.9.024.0040 0 6 2 2
Finder Relay Base 94.74.0SMA 0 6 2 2
Schrack Relay 24VDC V23092-A1024- 0 65 0 0
A301
Schrack Relay Base ST4FLC4 0 65 0 0
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3. Component Functionality, Parameters and Indications

3.1. Gemview Indication Inspection for Failures
In addition to providing running data monitoring for Gemstarts and Micom relays, each Gemview
SCADA system should be viewed periodically to identify any failures that have occurred in the whole
of the PLC system. The ‘Log’ tab stores any failures, alarms and trips of all connected devices and
also provides indication in the case of a whole communications link failure.
The following screen shot identifies some faults that have been logged, along with the timestamp
when the event was detected by the Gemview SCADA:
The above highlighted examples are:
1: The PLC system has lost communications to Gemstart Link 1 address 97.
2: Micom address 39 (Link 2 address 19) has a ‘CB status’ alarm.
3: The PLCs have changed over on a failure and the SCADA has redirected its communications to
the online PLC (from 3.0.0.2 – Slave to 3.0.0.1 – Master)
4: The PLC system has detected a persistent link failure and entered into the ‘Extended Changeover
Timer Mode’ (see 5. below). The last changeover was from the Master PLC and was caused by ML1
(Micom Link 1) failure.
5: The PLC system has entered into the ‘Extended Changeover Timer Mode’. This occurs when the
PLC detects a persistent failure on one or more of its communications links. When such a fault is
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detected the Master and Slave PLCs changeover control / online status every twenty seconds, to try
and regain communications with the faulted link. After ten consecutive changeovers, the changeover
timer is increased from twenty seconds to five minutes to make the system more stable. When the
system enters this mode the cause of any further changeovers will be identified (see 4. above).
Possible indications will be GL1 (Gemstart Link 1), GL2 (Gemstart Link 2), ML1 (Micom Link 1), ML2
(Micom Link2 –KBA only) and DCS.
The active status of the ‘Extended Changeover Timer Mode’ and the cause of any PLC changeovers
while in this mode is also identified on the ‘Options’ -> ‘PLC Page’ tab. The below example indicates
the PLC is in the ‘Extended Changeover Timer Mode’ and that the Slave PLC was last to perform a
changeover because it detected failure of Micom Link 2 and the DCS Link.
Both the ‘Log’ page and the ‘PLC Page’ can be used to provide indication as to the focus of further
investigation. Sections 3 and 6 of this document should then be referenced.
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3.2. PLC LED Status for Healthy System

MASTER (KBA)
A 12345678
B 12345678
* PULSED
VARIOUS
NOT USED MOTOR /
(SPARES) BREAKER
STATUS
SLAVE (KBA)
A 12345678
B 12345678
*
VARIOUS
NOT USED MOTOR /
(SPARES) BREAKER
STATUS
* The STAT LED can be ON or OFF in normal operation

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MASTER (HRM, REG, TEG)
A 12345678
B 12345678
* PULSED
VARIOUS
MOTOR / BREAKER
STATUS
SLAVE (HRM, REG, TEG)
A 12345678
B 12345678
*
VARIOUS
MOTOR / BREAKER
STATUS
* The STAT LED can be ON or OFF in normal operation

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3.3. PLC Rack (IC693CHS391)

The PLC rack includes the backplane communications bus that allows communications between
all modules fitted onto the rack. It also provides a +5 VDC and +24 VDC power bus to any relevant
cards installed. The design of the rack allows for installation of one power supply unit, one
processor and nine options modules (assuming maximum power supply guidelines are observed).
There are no visual indications on the PLC rack as to its operational status.
Each module hinges onto the top of the rack via a pivot hook and is then secured with a sprung
level that clips to the bottom of the rack (as below).
For further PLC rack and GE Fanuc general specifications please refer to GE Fanuc specification
document: GFK0356.
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3.4. PLC Power Supply (IC693PWR330)

The PLC power supply is installed to provide power to the PLC rack and installed PLC modules. It
is supplied via the UPS battery system which provides a stabilised 230 VAC supply to the PLC
system. The operating ranges for the supply voltage to the module are:
Specified Range 100 to 240 VAC Actual Range 85 to 264 VAC

Specified Range 125 VDC Actual Range 100 to 300 VDC
The power supply unit in turn provides a maximum combined operational power of 30 Watts for the
following derived DC supplies for the PLC rack:
Supplied Maximum Application

Voltage Output
+5VDC 30 Watts Supplies backplane operational / communications
power to all modules via the PLC rack
+24VDC (relay) 15 Watts Supplies relay contact power for hardwired output
modules
+24VDC 20 Watts Supplies internal detection pickup power for hardwired

(isolated) input modules and an external +24VDC supply which
can be utilised for I/O module external wiring
The power requirements and total system power loading is automatically calculated in the
‘Hardware Configuration’ block of the project folder in the Proficy PLC programming software.
Alternatively the GE Fanuc referenced documents detailing the power requirements for individual
modules installed have been used to formulate PLC power usage as detailed in section 12.3.
The following diagram identifies the available indications of the Power Supply module:
POWER PWR
OK
SUPPLY PWR
RUN
BATT
OK
RUN
} All 3 LEDs should be ON,
for the PLC to be Healthy
and Operational
Connection for AC / DC
Power Source { BATT } If ON, the Battery (if fitted) needs
replacement
Internal Power
Source of 24 VDC { RS485 Programming Port
Memory support battery compartment
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The individual LEDs represent the following module statuses:
LED State Indication

Power is being applied from AC / DC Power Source
PWR
No power is being applied from the external AC / DC Power Source
The module has powered up and correctly and can communicate via the
backplane to the installed Processor. The PLC has no major hardware faults.
OK
The module has detected a fault internally, with communications to the
Processor or a major hardware fault exists (relevant only if PWR LED is on)
The PLC has powered up correctly, the Processor is in ‘Run’ mode and is
processing the software logic.
RUN
The Processor is ‘Halted’ from either a programming command or hardware fault
(relevant only if PWR LED is on)
The battery that provides power to enable the processor memory to be stored
while the PLC is not powered up has fallen below the acceptable voltage level
BATT
and needs to be replaced
The battery voltage is acceptable (relevant only if PWR LED is on)
For further module specifications please refer to GE Fanuc specification document: GFK0356.
3.4.1. PLC Power Supply (IC693PWR330) – Normal Indications
PLC LED Normal State

PWR
OK
MASTER
RUN
BATT
PWR
OK
SLAVE
RUN
BATT
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3.5. PLC Processor (IC693CPU364)

The PLC Processor is located in slot 1 on the PLC rack, next to the power supply. The Processor
has an internal memory that holds all the PLC logic and the hardware configuration for the PLC
rack and options modules.
The main function of the Processor is to perform logic execution of the installed PLC program. It
also controls the data exchange between the installed PLC modules and any external devices
connected to those modules (e.g. DCS, Gemstart, Micom, etc.)
Installed within the Processor module is an Ethernet daughter board which provides a direct high
speed TCP/IP Ethernet communication via the 10 Base T port located on the front of the module
(To allow multiple node access this port is connected to a network hub). The Ethernet port
provides not only communications facilities (used for Gemview SCADA and PLC to PLC
synchronisation) but can also be used as a programming port to load, store and modify the PLC
program. Alternatively programming of the processor can be performed via the RS485 port located
in the power supply unit.
The Processor also stores PLC and I/O fault table information. When maintenance activities are
undertaken, it is good practice that these two fault tables are viewed using the Proficy
programming software and any the meaning of any entries understood.
The following diagram identifies the available indications of the Processor module:
Indicates activity on the power

SNP
supply serial programming port
when using VersaPro serial lead
Should be lit at all times if the

EOK
Ethernet is healthy
LAN The LAN LED should flash indicating

Ethernet communications activity
STAT This can be either lit or not lit. See

the following table for further details
Ethernet Port
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The individual LED patterns represent the following Ethernet statuses:
LED State Where Possible Cause Corrective Actions

Stopped
EOK A Fatal Hardware Error  Make sure the PLC has power.
 Examine PLC fault table for
LAN
Hardware clues.
STAT Failure  Recheck PLC programmer
configuration.
 Power off rack, inspect the
Ethernet Interface for loose
components, reseat the CPU
module, and press the Ethernet
Restart button.
 If the problem persists please
replace the PLC hardware.
EOK B  Restart pushbutton until  Connect a Proficy laptop and
the bottom LED turns reload PLC software.
LAN Software ON.  Cycle power or press the
STAT Loader  Station Manager LOAD Ethernet Restart button again for
command issued. less than 5 seconds to restart
All LEDs blink in  Software corrupt. the Ethernet Interface and clear
unison.
the load request.
EOK C  Did not configure slot  Use the Proficy laptop to reload
using the Proficy laptop. PLC software to configure the
LAN Waiting for  CPU not communicating Ethernet Interface then store the
STAT Configuration with Ethernet Interface. configuration to the PLC CPU.
from PLC  (Condition can last a  Power cycle the PLC.
maximum of 2 seconds.)  Clear faults and press the
Ethernet Restart button.
EOK D Interface’s IP address has Use Proficy laptop to configure the
not been configured or has Ethernet Interface with non-zero IP
LAN
Waiting for IP been configured as 0.0.0.0. address by reloading the PLC
STAT Address software configuration.
EOK and STAT

blink in unison.
EOK E  Press Ethernet Restart  If you did not intend to enter

button until the bottom Maintenance press the Ethernet
LAN
Maintenance two LEDs turn ON. Restart pushbutton for less than
STAT  Station Manager MAINT 5 seconds. This clears the
command issued. Maintenance request.
 Internal system error  Examine PLC fault table for
when interface was clues.
operational caused a  If you need to use the Station
restart and entrance into Manager to troubleshoot a
Maintenance. problem, see GFK-1186. TCP/IP
Ethernet Communications for
Series 90 PLC Station Manager
Manual.
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EOK F If the LAN LED is off, the  Connect cable and transceiver
Operational problem may be: properly. Replace transceiver.
LAN
 Network cable not  Terminate network cable
STAT connected or transceiver properly.
not connected to  SET SQE ON transceiver in
Ethernet Interface or accord with manufacturer’s
bad transceiver. instructions.
 Network cable not
terminated properly.
 SQE not enabled on
transceiver.
If the STAT LED is OFF, an  Examine PLC fault table to find
exception condition has out why the STAT LED is OFF.
occurred.
For further module Ethernet specifications please refer to GE Fanuc specification document:
GFK1541.
3.5.1. PLC Processor (IC693CPU364) – Normal Indications

EOK
MASTER LAN
STAT
EOK
SLAVE LAN
STAT
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3.6. Communications Module – DCS (IC693CMM311)

The communications module provides two communications ports that can use any combination of
a number of factory pre-programmed protocols. In each of the four PLC systems port 1 utilises the
Modbus RTU protocol as a Slave node and communicates to the DCS as the Modbus Master
Node. Port 2 is spare and not used.
The following diagram identifies the available indications of the CMM module:
CMM OK
COPROC US1
US2
OK Should be lit at all times if the

module is healthy
US1
US1 should flash when DCS serial
US2 comms. is taking place on Port 1.
D-type connector provides 2 comms

ports via supplied ‘Y’ cable splitter
For further CMM311 specifications please refer to GE Fanuc specification document: GFK0582.
3.6.1. Comms Module - DCS (IC693CMM311) – Normal Indications

OK
MASTER US1
US2
OK
SLAVE US1
US2
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3.7. Programmable Communications Module - Gemstart

(IC693PCM311)
The Programmable Communications Module provides two communications ports that both use the
installed communication protocol.
The module is supplied with no protocols installed. The required Gembus protocol, used to
communicate to the Gemstarts, requires to be installed into the module using the bespoke ‘Termf’
software, using an RS232 cable connected to port 1. Once installed the protocol driver is retained
in volatile memory by the internal 3V lithium battery. This battery should be periodically replaced to
ensure no memory loss occurs.
The following diagram identifies the available indications of the PCM Gemstart module:
PCM 311 OK
COPROC US1
US2

module is healthy
US1 US1 & US2 should flash when

US2
} serial comms. is taking place on
Ports 1 & 2
Memory support battery

See section 11.3 for details of re-loading the Gembus driver in the Gemstart PCM.
For further PCM311 specifications please refer to GE Fanuc specification document: GFK0255.
3.7.1. PCM - Gemstart (IC693PCM311) – Normal Indications

OK
MASTER US1
US2
OK
SLAVE US1
US2
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3.8. Programmable Communications Module - Micom

(IC693PCM311) (Krechba only)
The Programmable Communications Module provides two communications ports that both
use the installed communication protocol.
The module is supplied with no protocols installed. The required Modbus Master protocol,
used to communicate to the KITZ units, is provided on an EEPROM chip (part no. PCM301-
MBUS-2H) which is required to be installed. This non volatile memory prevents loss of
memory even if the internal 3V lithium battery is not present.
This combination of a Programmable Communications Module and the Modbus Master

EEPROM is used at Krechba only. It differs from the RTU Modbus Master Module used at
Hassi R’Mel, Reg and Teg sites in that it is a later implementation of the software interface
allowing for faster throughput of communications and data to the connected KITZ/Micom
units.
The following diagram indicates the normal operating indications of the PCM Micom module:
PCM 311 OK
COPROC US1
US2

module is healthy
US1 US1 & US2 should flash when

US2
Ports 1 & 2

(not required)

For further PCM311 specifications please refer to GE Fanuc specification document:
GFK0255.
3.8.1. PCM - Micom (IC693PCM311) – Normal Indications

OK
MASTER US1
US2
OK
SLAVE US1
US2
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3.9. RTU Master Module - Micom (HE693RTM705) (Hassi, Reg,

Teg only)
The RTU Master Module provides two communications ports that both use the installed Modbus
Master RTU communication protocol used to communicate to the KITZ units. This is provided on a
preinstalled EEPROM chip. This non volatile memory prevents loss of memory even if the internal
3V lithium battery is not present.
This RTU Master Module differs from the Modbus Master protocol used at Krechba in that it is an
earlier implementation that was used and has a slower throughput of communications and data to
the connected KITZ/Micom units.
The following diagram indicates the normal operating indications of the RTU Micom module:
RTU OK
MASTER US1
US2

module is healthy
US1 US1 should flash when

US2
Port 1

(not required)

For further RTU Master Module specifications please refer to Horner specification document:
MAN0076-06.
3.9.1. RTU Master - Micom (IC693PCM311) – Normal Indications

OK
MASTER US1
US2
OK
SLAVE US1
US2
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3.10. Mixed Input / Output Module (IC693MDR390)

The Mixed I/O module provides 8 Input (row A) and 8 Output (row B) hardwired points to be used
and controlled by the PLC system. When the corresponding LED is lit, the relevant input or output
is active.
The Mixed I/O Module located in slot 5 has dedicated system functions and inter-PLC signals to
control the synchronising and changeover facilities of the Master / Slave PLC. These functions are
detailed below. (Please note some signals relating to the auto restart function may have been
removed following modifications to remove this functionality).
Slot 5 I/O module is used as follows:-
A1 2 3 4 5 6 7 8
B1 2 3 4 5 6 7 8 Digital INPUTS : %I0889 - %I0896

A1 : Other PLC Online
A2 : Other PLC Healthy
A3 : NPS (Auto Restart Signal)
A1
A4 : Emerg. Restart (Auto Restart Signal)
A2 A5 : -
A3
A6 : -
A4
A5 A7 : -
A6 A8 : Master PLC Identification
A7
A8
B1
B2
Digital OUTPUTS : %Q0889 - %Q0896
B3 B1 : This PLC Online
B4
B5
B2 : This PLC Healthy
B6 B3 : Allow Output Energising
B7
B8
B4 : Allow Output Energising
B5 : Allow Output Energising
B6 : -
B7 : DCS Heartbeat Pulse
B8 : Enable DCS Communication
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3.10.1. Mixed I/O (IC693MDR390) – Normal Indications

The following table indicates the normal operating indications and functions of I/O of the Mixed
I/O Module located in slot 5:
SLOT 5 MIXED I/O Module

Normal Condition
Row Point Function Description (On State)
Master Slave
OFF ON Other PLC The other PLC is Online, performing
1
Online duty functions
ON ON Other PLC The other PLC is healthy and
2
Healthy detects no failure conditions
ON ON Normal Power Source. The system
NPS (Auto power is stable and operating
3
Restart Signal) normally, not fed from the Emergency
generator.
A OFF OFF Emerg. Restart Normal Power Source has failed,
(Input) 4 (Auto Restart commence auto restart of selected
Signal) Gemstarts
5 OFF OFF - -
6 OFF OFF - -
7 OFF OFF - -
ON OFF This input is continually high for the
Master PLC Master PLC so the software can
8
Identification identify the Master and Slave
designation
ON OFF This PLC is Online, performing duty
1 This PLC Online
functions
ON ON This PLC This PLC is healthy and detects no
2
Healthy failure conditions
ON OFF Allow energising of output modules via
Allow Output
3 relays to prevent back feeding to other
Energising
PLC.
ON OFF Allow energising of output modules via
Allow Output
Energising
PLC.
B ON OFF Allow energising of output modules via
(Output) Allow Output
Energising
PLC.
6 OFF OFF - -
ON OFF This is pulsed each time the DCS
(PULSE) DCS Heartbeat
7 heartbeat (alive signal) is received via
Pulse
the DCS serial communication link.
ON OFF Master PLC only. The Master PLC is
Enable DCS in a position to take the online/duty
8
Communication status therefore allow DCS to
communicate with the Master PLC
Please note: an additional IC693MDR390 module is fitted to the PLC rack slot 10 to provide
input / output functionality for other purposes. Slot 10 internal PLC address allocations for the
I/O points are:
Inputs: %I0985 - %I0992
Outputs %Q0985 - %Q0992
For further I/O module specifications please refer to GE Fanuc specification document:
GFK0898.
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3.11. Input Module (IC693MDL655)

This 32 point input module is split into 4 isolated groups of 8 inputs, as detailed in rows A, B, C and
D on the front of the module. When the corresponding LED is lit, the relevant input or output is
active.
A1 – A8 (Inputs 1- 8)
B1 – B8 (Inputs 9 – 16)
C1 – C8 (Inputs 17 – 24)
D1 – D8 (Inputs 25 – 32)
If the module is located in slot 6 the internal PLC address allocation for the inputs are: %I0921 -
%I0952.
If the module is located in slot 7 the internal PLC address allocation for the inputs are: %I0953 -
%I0984.
For further I/O module specifications please refer to GE Fanuc specification document: GFK0898.
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3.12. Output Module (IC693MDL940)

This 16 point output module is split into 4 isolated groups of 4 outputs. 2 groups in row A and 2
groups in row B. When the corresponding LED is lit, the relevant input or output is active.
A1 – A8 (Outputs 1- 8)
B1 – B8 (Outputs 9 – 16)
A1 2 3 4 5 6 7 8
B1 2 3 4 5 6 7 8
A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
B4
B5
B6
B7
B8
If the module is located in slot 8 the internal PLC address allocation for the inputs are: %Q0921 -
%Q0936.
If the module is located in slot 9 the internal PLC address allocation for the inputs are: %Q0937 -
%Q0952.
For further I/O module specifications please refer to GE Fanuc specification document: GFK0898.
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3.13. Westermo MD-42 and MD-44 Converters
The Westermo MD-42’s and MD-44’s are isolated

RS232 to RS485 convertors. The isolation ensures
any spurious dangerous electrical voltages from a
serial link wiring fault are blocked from damaging the
PLC hardware.
RS232
Serial link ports of the PLC have a physical layer
based upon RS232 hardware, having a single
transmit and a single receive wire. RS232
transmissions operate at voltages between + / -
5V....15V, that are referenced to 0V. Such
transmissions are extremely susceptible to electrical
noise and as such have a limited transmission
distance, currently recommended at a maximum of
15m. RS232 is designed to operate as a point to
point network, therefore providing communication
between 2 devices only.
RS485
RS485 transmissions operate at voltages between -
7V and +12V. The network hardware is based upon
either 2 twisted pairs (full duplex) or 1 twisted pair
(half duplex). The signal reference is based upon the differential between the wires of each pair (+
and -), rather than to a 0V reference.
When electrical noise is induced in the cable, because the wires are twisted this helps to limit the
noise, and due to the signal detection being differential, any noise is produced on both wires
equally, so although voltage levels are changed in both wires the differential remains the same.
This design for signal integrity allows for longer transmissions and allows for communication
between multiple devices.
The Westermo MD-42’s are configured to their DCS application. The Westermo MD-44’s are set to
one of two configurations depending on their application (either Gemstart or Micom). The
configuration switch settings for Gemstart and Micom and DCS communication is detailed later.
Please note: Although Westermo MD-42 and MD-44 units are in service at ISG sites, these
units have now been superseded by the MD-45 unit. The MD-45 is a direct
replacement for both the MD-42 and MD-44 units, assuming correct configuration
switch settings. For details of the MD-45 see section 3.14.
3.13.1. Westermo MD-42 and MD-44 – Normal Indications
The configuration settings for the Westermo line converters (MD-42 and MD-44) are
determined by the dip switch settings internally in the Westermo unit (see section 3.13.2).
If the LED states don’t match the configuration detailed in the following diagrams then a fault
has occurred.
If the LEDs that should be continuously lit are not then the problem is within the Westermo
hardware itself, either hardware failure or dip switch settings are incorrect. The dip switch
settings for each application are detailed in section 3.13.2.
If the LEDs that should be flashing are not then this could be a hardware failure, software
failure or a wiring fault.
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The normal LED indications are determined by the mode (Online or Offline) state of the
connected PLC (Master or Slave).
Gemstart application MD-44 Westermos operate as below (assuming link is healthy):
Connected to Online PLC Connected to Offline PLC
DCS application MD-42 Westermos operate as below (assuming link is healthy):
Micom / KITZ application MD-44 Westermos operate as below (assuming link is healthy):
Continuous illumination LED, i.e. always

active:
Flashing LED (frequency variable depending

upon application):
Continuous off LED:
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For further specifications please refer to Westermo installation documents: 6152-2002 (MD42)
and 6155-2010 (MD44).
3.13.2. Westermo MD42/MD44 DIP Switches –

Diagrammatical and Physical Location
There are 2 banks of switches within the Westermo MD42, MD44 (S2 and S3) and MD-45 (S1
and S2). These dip switches determine the communications configuration of the unit. Three
configuration settings are used at In Salah. The three types of configuration are detailed below:
Removing the top blanking cover along the side of the 9 screw terminal black connector
accesses the dip switches. (Additional switches may be installed in the switch banks but are
unused. Only the switches that have functions are referenced below and in the manufacturer
manuals.)
MD42 MD44
Westermo MD44 Dip Switch Settings for Gemstart Applications.
1 2 3 4 5 6 7 ON 1 2 3 4 ON
S2 S3
Westermo MD44 Dip Switch Settings for Micom Applications
1 2 3 4 5 6 7 ON 1 2 3 4 ON
S2 S3
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Westermo MD42 Dip Switch Settings for DCS Applications
1 2 3 4 5 6 ON 1 2 3 4 5 6 ON
S2 S3
For further specifications please refer to Westermo installation documents: 6152-2002 (MD42)
and 6155-2010 (MD44).
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3.14. Westermo MD45– MD42/MD44 Replacement

The Westermo MD42 and MD44 units are now discontinued and obsolete. The replacement unit
for both types is the MD45 unit. Although identical in size and able to perform identical operations
the internal dip switch settings for configuration are different (depending on operation), as detailed
in section 3.14.2.
3.14.1. Westermo MD45 – Normal Indications

The indications for MD45 under normal operation for Gemstart, Micom and DCS are unclear at
this time. This detail will be included at a later date following any requirement for installation
and commissioning of the MD45, following a failure of the MD42 /MD44 units that are currently
in service.
3.14.2. Westermo MD45 DIP Switch Settings– Diagrammatical

and Physical Location
Removing the top blanking cover along the side of the 9 screw terminal black connector
accesses the dip switches. (Additional switches may be installed in the switch banks but are
unused. Only the switches that have functions are referenced below and in the manufacturer
manuals.)
MD45
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Westermo MD45 Dip Switch Settings for Gemstart Applications.
1 2 3 4 5 6 7 ON 1 2 3 4 ON
S1 S2
Westermo MD45 Dip Switch Settings for Micom Applications
1 2 3 4 5 6 7 ON 1 2 3 4 ON
S1 S2
Westermo MD45 Dip Switch Settings for DCS Applications
1 2 3 4 5 6 ON 1 2 3 4 ON
S1 S2
For further specifications please refer to Westermo MD45 installation document: 6157-2002
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4. Inspection and Maintenance Schedule
4.1. Inspection and Maintenance Introduction
It is recommended that periodic maintenance and inspection be carried out at time intervals as
advised below for the prevailing site conditions and duty cycles. ISG may decide that, with the
benefit of experience gained in use and maintenance of the equipment, the suggested frequency
between maintenance should be amended for various parts of the equipment.
The following maintenance programme has been devised to maintain the efficient operation of the
PLC systems. The program therefore aims to optimise system performance especially in relation to
the components required for system redundancy, thus in the event of a failure minimising the
impact to the operation of the plant.
Due to the nature of the components of the PLC systems, it is recommended that any defective
component should not be repaired but be replaced with an identical (or compatible) unit. When
replacing any failed component, it is important to establish the reason for the failure and eliminate
the cause, before replacing the component.
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4.2. Authority to Work

No work of any kind is to be undertaken without first obtaining prior authorisation. The responsible
supervisor must ensure that all safety procedures have been carried out before any work
commences, that all key personnel are informed of the actions to be carried out and that any
required risk assessments have been completed.
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4.3. Gemview EWS – (3month)

4.3.1. Gemview Restart
To maintain basic PC performance and optimum communications performance between the
Gemview EWS PC and the PLC system, it is essential that all historical data files are
compacted on a regular basis.
As part of the start up routines the Gemview EWS automatically performs the required data
compaction of all relevant files. It is therefore recommended that each EWS system is shut
down and restarted periodically to allow this operation to take place.
The following procedure should be performed:
1. Login to Gemview. Use the menu ‘System -> Login

Operator’ to enter the saved log in password. The
default for User 1 and User 2 is ‘0’ and ‘1’
respectively, although this may have been changed
for security reasons by ISG.
2. When Login is successful the User Name is displayed in the top header bar (e.g. User 1):
3. Use the menu ‘System ->

Exit’ or press the Close
windows cross at the top OR
right of the header bar to
shut down the Gemview
EWS application.
4. Once the Gemview EWS application has shutdown, restart it using the
Gemview Icon on the windows desktop. Check data is received from the
switchboard devices after approximately 1 minute from start-up.
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4.3.2. Manual Archive of Event Data – (3 month)

The Gemview ‘Log’ tab stores any failures, alarms and trips of all connected devices and also
provides indication in the case of a whole communications link failure. Due to PC resource
restrictions and response times, this database is limited to 1000 entries. As new entries are
stored the oldest are removed.
In order to maintain historical records of events, in addition to the ‘Log’ tab database, the
Gemview system creates and archives a CSV (comma Separated Variable) database file each
day at midnight (for the current day’s events). These database files are stored in the directory
(along with the Gemstart historical current trends), named with the days date in the following
format:
‘C:\Program Files\Apstar\P1064\OldData\YYYY MM DD\...’. (Phase 1)

‘C:\Program Files\Ariva\Gemview\OldData\YYYY MM DD\...’. (Compression)
Each date folder typically contains the following files:
The ‘Events.csv’ file is the file that contains all the event data. This can be opened in any
compatible program (e.g. Excel, Access, etc) either on the Gemview PC or elsewhere once the
files are extracted from the Gemview PC.
These files are to be extracted from the PC and stored safely. They are automatically removed
from the PC by Gemview when they are one year old to ensure the harddrive capacity is never
filled.
1. Open Windows Explorer or My Computer and navigate to the relevant directory e.g.
‘C:\Program Files\Apstar\P1064\OldData\...’.
th
2. Select all the folders for the dates required to be copied (e.g 2015 02 12 is 12 February
2015).
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3. Manually copy all selected folders to a CD or USB flash drive for safe storage.
4. Once safely copied to external media, these folders can be deleted from the Gemview PC if
required or left for Gemview to automatically delete once they are one year old.
5. Empty the Windows Recycle bin to ensure any files deleted manually or automatically free
the harddrive space.
4.3.3. Gemview PC Clock Synchronisation – (3 month)

To maintain correct time logging facilities within the Gemview EWS system, it is essential that
the PC clock be accurately maintained. It is therefore recommended that the PC clock be
periodically checked manually against the DCS clock, via substation telephone. If the clock is
more than 2 seconds out of synchronisation then it should be adjusted using the standard
Microsoft Windows ‘Date and Time Properties’ interface, accessed by double clicking on the
time display in the windows menu bar.
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4.4. PLC Status – 3 month
Perform a general check of all LED status indications for each PLC module and Westermo units as
per section 3 of this document, to ensure the online status of each Master PLC and the healthy
status of each PLC module. Any deviations from the expected status should be referred to CASE
Systems Limited for assistance in system status identification.
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4.5. Gemview Indication Status – (1 week)

Perform a general check of Gemview ‘Log’ page as per section 3.1 of this document, to ensure the
online status of each Master PLC and the healthy status of each PLC module and associated
serial links. Any deviations from the expected status should be referred to CASE Systems Limited
for assistance in system status identification.
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4.6. PLC Battery Replacement – (3 years)

Each PLC contains a number of lithium batteries that provide memory backup for the PLC logic
and installed communications drivers. It is recommended that these batteries be replaced at least
every three years to mitigate data loss in the event of UPS power failure.
One battery exists in the Power Supply Module (slot 0), one in the Gemstart Programmable
Communications Module (slot 3) and one in the Micom Programmable Control Module / RTU
Module (slot 4 – although this battery is not required due to the installed eeprom, for completeness
this can also be replaced).
All batteries should be replaced while power is applied to the PLC, to ensure each module always
has either backplane or battery power applied.
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4.7. Software Backup / Verification – 1 Year
Annual software backup / verification of all programmable software is required for two reasons:
 To ensure an accurate backup of software that can be restored in the event of a failure
and replacement of programmable equipment.
 To check no software corruption has developed that may cause system malfunction.
The software backup / verification is recommended for following equipment:
 Master and Slave PLCs

 KITZ202 software
 Gemview EWS
4.7.1. Master & Slave PLC Software Verification

To verify the integrity of the PLC software connect to the Master and Slave PLCs in turn
performing the below actions:
1. Connect an Ethernet cable from the Proficy programming laptop to the Ethernet hub
located on the right inside the PLC panel.
2. Open the Proficy programming software.
3. The following popup window appears. (If it does not use the ‘File -> Open Project...’
menu).
4. Ensure the ‘Open an existing project’ and ‘All Projects’ radio buttons are checked. Then
select to the required project from the Project list displayed and click the ‘Ok’ button. The
selected Project will then be opened.
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5. Initiate the connection between Proficy and the PLC via the connection button (circled in
red below) or from the menu ‘Target -> Go Online with “xxxxx”’
6. Once connected, Proficy will perform an automatic verification of the ladder software.
The result will be displayed. When connected, Proficy automatically checks the logic and
hardware configuration for differences between that of the current folder on the Proficy
laptop and the PLC RAM. EQ (Equal) or NE (Not Equal) is displayed for the Config and
Logic at the bottom right of the Proficy screen. If the verify completed successfully
‘Config EQ, Logic EQ’ is displayed, a backup of the software is not necessary.
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NOTE: If ‘Config NE’ (Not Equal) or ‘Logic NE’ (Not Equal) is displayed use the menu ‘Target
-> Online commands -> Verify Equality...’ , tick the item(s) that are not equal (i.e.
‘Hardware Configuration and Motion’ and/or ‘Logic’), for a detailed analysis of the
differences.
Once the comparison is done the items that are different/not equal are displayed in
the ‘Feedback Zone’ pane at the bottom of the screen.
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4.7.2. Master & Slave PLC Software Backup

1. Follow steps 1-6 of section 4.7.1 above. If both the ‘Config’ and ‘Logic’ report as equal
then a software backup is not necessary. If one or both the ‘Config’ and ‘Logic’ report as
not equal, a decision should be made whether to backup the software (from the PLC to
the Proficy laptop) or download the software (from the Proficy laptop to the PLC). If
download is chosen see section 10.7. If upload is chosen, continue to follow step 2
below.
2. Use the menu ‘Target -> Upload “xxxxx” from Controller...’ to backup the software in
the PLC to the Proficy folder that is currently open. The options to load ‘Hardware
Configuration and Motion’ and ‘Logic’ should be selected as follows:
NOTE: This operation will overwrite the current folder with the software upload from the PLC,
which may include loss of comments and mnemonics. Please ensure that a safe copy
of the existing folder is located in a separate directory on the laptop or on an external
backup source (e.g. CD, USB Flash drive, hard drive, etc).
3. Once the program has uploaded and translated, the logic and/or Config may still indicate
NE (Not Equal) at the bottom right of the Proficy screen. To complete the upload, a
verification should be made. Follow step 6 ‘note’ of section 4.7.1 above to ‘Verify
Equality’. The upload is then complete.
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4.7.3. KITZ202 Software Verification / Backup

The KITZ202 unit can be programmed using either the DOS based PAST software (Protection
Access Software & Toolkit) or the windows based Micom S1 / Suite software. For simplicity, the
following details the use of the PAST software.
No verification utilities exist for comparison of the KITZ software configuration. Therefore
backup is essential and manual comparison with existing backup files required if any
possibilities of corruption are evident.
1. Connect an RS232 serial communications lead from the programming laptop ‘com1’ to
the front port (P0) of the KITZ202.
2. Run the PAST software.
3. To initiate communications with the KITZ202, ensure that the background

communications scan has started. This is identified at the right hand side of the base line
of the program with the word ‘1 BACKGROUND’. If the background scan is not running
the words shown are ‘0 BGND OFF’. If the background has not started this can be
started manually by using the menu ‘Options -> Start Background’.
Total Number of Current Address of Background Scan

Relays / KITZ Found Background Scan Status
4. To check communications are established to the KITZ use the menu ‘Access’. This
should display the device and tag of the KITZ202 connected if healthy communications
are established.
5. Use the menu ‘Records -> Relay Settings....’ to enter the setting menu and then the
menu ‘Store to File’
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6. Select the unit which the backup is to be taken from (i.e. the KITZ address 21).
7. Enter the file name and location that the files will be saved to. Two files are produced a
xxxx.set file (setting file coded for download/upload to KITZ) and a xxxx.lst file (text file of
settings for operator review using WordPad, notepad, etc).
8. When prompted answer YES to store non settable cells. These include time and date
settings, serial numbers, etc.
9. When requested enter the password ‘AAAA’. Confirm operation using ‘CTRL+F10’ when
requested. The ‘Alarm’ LED on the front of the KITZ will begin to flash to indicate that the
password has been accepted. Once confirmed additional operator text can be added, for
example the date, operator and description of action taken can be stored in the settings
files when downloaded. When complete confirm with ‘CTRL+F10’.
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10. The settings will then be downloaded one cell at a time. P0 Tx and Rx LEDs on the front
of the KITZ will begin to flash rapidly as the file is uploaded. The upload process will take
approximately 5 minutes after which the files can be archived / compared as required.
4.7.4. Gemview EWS Backup

Backups of the Gemview EWS should be carried out to maintain an up-to-date backup that
would encompass any tag changes, device additions, function additions and log data, which
would not be included in the original installation CD. This would allow reinstallation of the
original CD and for the latest backup to be copied over the top of the generic installation.
The backup should be made to an archive media such as CD, USB Flash Drive or external hard
disk. The following process should be performed.
1. Shut down Gemview EWS program as detailed in section 4.3.1 steps 1-3.
2. Copy the following entire directory to the archive media, ensuring to indicate the relevant
date of archive: C:\Program Files\Apstar\P1064...
3. Restart the Gemview EWS program.
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5. Recommended Spares
5.1. Equipment Order Codes
It is recommended that at least one spare unit of each component be retained as maintenance
spares, to service all four sites. Additional quantities of some components are advised due to their
susceptibility to failure either inherently or due to their sensitivity to external abnormal conditions
(i.e. voltage spikes, heat tolerance, etc):
Manufacturer Part Number Item Description Item Qty

Fanuc IC693CPU364# PLC Processor 4
Fanuc IC693CPU374 PLC Processor 4
Fanuc IC693CHS391 PLC 10 Slot Rack 2
Fanuc IC693PWR330 PLC Power Supply 4
Fanuc IC693PCM311 PLC Prog. Comms Module 2
Fanuc IC693CMM311 PLC Modbus Slave Module 2
Fanuc IC693PCM301 PLC Prog. Comms Module 2
Fanuc PCM301-MBUS-2H PLC Modbus Master EEPROM 1
Fanuc IC693MDR390 PLC Mixed I/O 2
Fanuc IC693ACC301 CPU/PCM Backup Battery (2off)
*** 5 year shelf life ***see GE Fanuc Doc. 8
GFK-0356P
Westermo MD-44DC* RS232-RS485 Line Convertor 4

Westermo MD-42DC* RS232-RS485 Line Convertor 2
Westermo MD-45DC RS232-RS485 Line Convertor 6
Areva KITZ20201L15CEA Micom Relay Data Concentrator 2
Omron S82K-24024 24V Power Supply 2
Netgear EN104 4 port Ethernet Hub 1
MGE Pulsar Extreme 1000c UPS

1
Rack
Dell Dimension 4500s Cubiclised PC / Monitor 15”

1
(or equivalent)
* - obsolete, replaced by Westermo MD-45

# - obsolete, replaced by Fanuc IC693CPU374
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6. Troubleshooting Guide
NOTE: Some actions performed during the course of fault finding may cause further disturbance
to the PLC system and therefore to the plant operation. Before performing any actions
please ensure that all necessary measures have been taken to limit the effect on plant
operations.
6.1. General PLC System Communications Troubleshooting

If a fault is detected in the PLC system, the Master and Slave PLCs will changeover at
predetermined time periods. Although this aids to maintain system integrity it can make fault
finding very difficult, due to the speed of response of the changeover. Therefore it is recommended
in such circumstances, that if feasible, one of the PLC be powered off so that investigation can be
made on one PLC only.
If the PLC system has detected the fault then the fault will be clearly indicated on the healthy rung
in the ladder program. The following steps can be used to view the state of this rung:
1. Open the correct PLC project folder and then connect to the Proficy laptop to the PLC
(see section 10.1).
2. To navigate to the ‘HEALTHY’ subroutine, in the ‘Navigator’ pane either, right click on the
‘HEALTHY’ subroutine and select ‘Open’ (as below), or double click on the ‘HEALTHY’
subroutine.
3. When the ‘HEALTHY’ subroutine is displayed in the ‘Software Detail Pane’, scroll down
to rung 42 which looks as follows (coloured boxes have been added for this document):
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NOTE: For Compression Project PLC systems the rung number will be either 66
(REG/TEG) or 68 (KBA). The rung components and reference addresses will
be slightly different but the philosophy is identical with ‘TPLCHLY’ coil at the
right side of the rung.
The coil ‘TPLCHLY - %Q00890’ is lit when the PLC is in a healthy status, if it is not lit the PLC
is in a failed state.
Preceding the coil are 3 contacts that need to be lit whether the PLC is online or offline these
are: ‘PCMFAIL - %M00059’ (Gemstart PCM firmware failure)
‘LANFAIL - %M00070’ (Ethernet network failure)
‘BOOTDUN - %M00062’ (PLC Boot up timer).
The rung has three initial branches marked in red (branch 1), green (branch 2) and blue
(branch 3):
Red – This is the branch used to decide the PLC healthy state when the PLC is online, and
starts with the online status bit ‘TPLCONL - %Q00889’. When this contact is lit then
the red part of the rung should be analysed.
Green - This is the branch used to decide the PLC healthy state when the PLC is offline, and
starts with the offline status bit, a normally closed ‘TPLCONL - %Q00889’. When
this contact is lit then the green part of the rung should be analysed.
Blue – This is used when the PLC initially becomes online. It ensures the PLC stays online
even if it is faulted for the initial period and uses ‘OFF_DLY - %M00064’. This
branch is not required to be analysed when fault finding.
4. If the coil ‘TPLCHLY - %Q00890’ is not lit then look at the first contact in branch 1 (red)
or branch 2 (green). Whichever is lit then analyse that branch.
NOTE: It is better to fault find on the online PLC when the other PLC is powered off, in
which case branch 1 (red) would be analysed.
If analyzing branch 1 (red) for online PLC, find the contact that is not lit:
‘DCS1FON - %M00057’ (DCS heartbeat communications- see section 6.1.1.)
‘GLKFAIL - %M00060’ (Gemstart communications - see section 6.1.2.)
‘MICFAIL - %M00069’ (Micom Link 1 communications - see section 6.1.3.)
‘MIC2FAL - %M00086’ (Micom Link 2 communications - see section 6.1.3.)
If analyzing branch 2 (green) for offline PLC, find the contact that is not lit:
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‘DCS1FOF - %M00058’ (DCS heartbeat communications - see section 6.1.1.)

‘FAILGLK’ - %M00061’ (only if ‘OPLHLY’ to the left is lit – Gemstart listen/standby
communications see section 6.1.4.)
6.1.1. DCS Communications Troubleshooting

DCS communications are detected by the PLC system by a heartbeat signal. This is a digital bit
that is set high (‘1’) by the DCS, the PLC immediately then sets it low (‘0’). The PLC monitors
the time frame between the DCS setting the bit high to determine the health of communications
link. The DCS heartbeat bit is located at the PLC Fanuc address ‘DCSHTB1 - %Q00529’. The
Modbus equivalent for the DCS is 00,529.
If the DCS communications indicate an unhealthy state in the PLC (DCS1FON for the online
PLC or DCS1FOF for the offline PLC) is not lit and output B7 of PLC slot 5 on the Online PLC is
not pulsing, first confirm the healthy state of the DCS end of the link and that the DCS is
operating correctly, then following steps should be followed:
1. Check the relevant Westermo unit in the PLC panel (Master PTC5 / Slave PTC6). Is the
PWR LED lit?
Yes: Go to step 2.
No: Check the voltage at the power terminals at the Westermo. If the correct
voltage is present, then the Westermo has failed and should be replaced.
(Ensure to set the correct internal dip switch settings of the replacement
Westermo see section 3.13.2).
2. Check the relevant Westermo unit in the PLC panel (Master PTC5 / Slave PTC6). Is the
RD LED flashing?
Yes: Go to step 3.
No: Check for good connections at Rx+ and Rx-, and corresponding end at the
DCS. Confirm that the link at the DCS end is healthy and running. If so then the
Westermo has failed and should be replaced. (Ensure to set the correct internal
dip switch settings of the replacement Westermo see section 3.13.2).
3. Check the CMM module (slot 3) of the relevant PLC rack. Is US1 LED flashing?
Yes: Power cycle (turn off / on) the PLC. If still faulted replace the CMM module.
No: Check for good connections of the RS232 serial link from the Westermo to the
CMM. If OK, power cycle (turn off / on) the PLC. If still faulted replace the CMM
module.
6.1.2. Gemstart Communications Troubleshooting (Online PLC)

For suspected Gemstart serial link faults the following sequence checks below will help to
identify basic causes for Gemstart communications faults:
NOTE: Please check that a number of relevant Gemstart units are powered up / energised.
1. Are all Gemstarts on a particular serial link (Link 1 or 2) indicating ‘Link Fail Warn’? (see
note).
Yes: Go to step 2.
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No: Go to step 6.
2. Check the relevant Westermo (Master PLC: Link1 PTC1 / Link2 PTC2, Slave PLC: Link1
PTC3 / Link2 PTC4). Is the TD LED flashing rapidly?
Yes: Go to step 3.
No: Go to step 8.
3. Check the wiring from the Westermo to the switchboard. Are all connections secure?
Yes: Go to step 4.
No: Secure connections and test connections.
4. In the switchboard disconnect the serial link after the first Gemstart closest to where the
serial link enters the switchboard. Are communications established to the first Gemstart?
Yes: Reconnect the serial link after the first Gemstart. Go to step 5.
No: The Westermo unit may have failed and should be replaced. (Ensure to set the
correct internal dip switch settings of the replacement Westermo see 3.13.2).
5. Disconnect the serial link after the second Gemstart. Check communications and repeat
for the third, fourth.... until a defective Gemstart is identified.
6. Inspect the serial link between the last healthy Gemstart and the first Gemstart that
displays a ‘Link Fail Warn’ (see note). If required replace the first failed Gemstart to try to
rectify the problem. Are communications established to that Gemstart?
Yes: Repeat step 6.
No: Go to step 7.
7. Disconnect serial link after failed Gemstart. Are communications established to that
Gemstart?
Yes: Reconnect and repeat step 7 for next failed Gemstart.
No: Investigate wiring for the chassis of failed Gemstart.
8. Is the PCM port (US1 or US2) LED for the connected Westermo flashing rapidly?
Yes: Check wiring between PCM and Westermo, and Westermo hardware.
No: Power cycle PLC. If not rectified the PCM module may be faulty. Replace the
module ensuring the Gemstart driver is correctly loaded into the replacement
PCM (see section 11.3).
NOTE: Gemstarts configured as Manual (i.e. ‘M’ before the serial link address on the LCD)
do not indicate a serial link failure message on the LCD. Also, a higher priority
message can ‘mask’ a serial link fault on any particular Gemstart. For example
‘Interlock’ would mask all serial link faults.
Additional information regarding communications status can be found by using the Gemstart
HHP. Connect the HHP and pressing the ‘LINK’ button will indicate the current status of the
serial link. The possible options are:
Active(G10Stat) – Indicates normal active operation
Baud Rate Scan – Gemstart has detected serial link activity and it is trying determine baud
rates
No Bytes Received – No communications are being detected
TX RX Lines Crossed – The 2 pairs of serial link cable are crossed.
TX Line Fault – The Transmit serial link wires from the Gemstart to the PLC are faulty
Scrolling down to the bottom of the ‘LINK’ menu display the ‘CRC and Timeout Error’ count.
These values give a clear indication of the state of the serial link from the perspective of that
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Gemstart. It can indicate whether the fault is with the serial link as a whole, or the individual
Gemstart, when compared similarly with other Gemstarts on the same serial link.
Theses counters can be reset by pressing the ‘RESET’ and then the ‘LINK’ buttons on the
HHP. This sequence resets the CRC and Timeout counters for the one connected Gemstart
only.
6.1.3. Micom Communications Troubleshooting

For suspected Micom serial link faults, it is important to isolate the area of the fault either
between the PLC and KITZ unit, or between the KITZ unit and the Micom relays.
The following sequence checks below will help to identify basic causes for Micom
communications faults:
NOTE: Please check that a number of relevant Micom units are powered up / energised.
1. On the front of the KITZ202 is the ‘Healthy’ LED illuminated? (note: Krechba has 2off
KITZ/Micom links)
Yes: Go to step 2.
No: Check terminals 3 and 5 at the rear of the KITZ202 for correct voltage. If the
correct voltage is present, the KITZ202 unit has failed and should be replaced.
(Ensure the database mappings are downloaded into the replacement KITZ202
unit – see section 7.2).
2. On the front of the KITZ202 are ‘P3’ Tx and Rx LEDs flashing?

Yes: Go to step 3.
No: Go to step 8.
3. On the front of the KITZ202 is ‘P1’ Rx LED flashing (monitor for at least 60 seconds)?
Yes: Go to step 4.
No: Go to step 6.
4. On the front of the KITZ202 is ‘P1’ Tx LED flashing?

Yes: Go to step 5.
No: The internal database may have locked. Reboot (power cycle) the KITZ202
unit.
5. On the relevant Westermo (Master PLC: Link1 PTC7, Slave PLC: Link1 PTC8), is the RD
LED flashing?
(For Krechba - Master PLC: Link1 PTC7 / Link2 PTC8, Slave PLC: Link1 PTC9
/ Link2 PTC10)
Yes: Check for good connections of the RS232 serial link from the Westermo to the
PCM. If OK (power cycle) the PLC. If still faulted replace the PCM module.
No: Check for good connections of the RS485 link from the Westermo to the
KITZ202 unit. If connections are OK, either the Westermo or KITZ202 unit has
failed, replace each in turn and recheck.
6. On the relevant Westermo (Master PLC: Link1 PTC7, Slave PLC: Link1 PTC8), is the TD
LED flashing?
(For Krechba - Master PLC: Link1 PTC7 / Link2 PTC8, Slave PLC: Link1 PTC9
/ Link2 PTC10)
Yes: Check for good connections of the RS485 link from the Westermo to the
KITZ202 unit. If connections are OK, either the Westermo or KITZ202 unit has
failed, replace each in turn and recheck.
No: Go to step 7.
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7. On the relevant PCM (slot 4) is the relevant port LED (US1 or US2?) flashing (monitor for
at least 60 seconds)?
Yes: Check for good connections of the RS232 serial link from the Westermo to the
PCM. If connections are OK, the Westermo unit has failed and should be
replaced. (Ensure to set the correct internal dip switch settings of the
replacement Westermo see section 3.13.2).
No: Power cycle the PLC. If still faulted replace the PCM module. (Ensure the
relevant EPROM chip is fitted if appropriate).
8. On the front of the relevant KITZ202 is ‘P3’ Tx LED flashing?

Yes: Go to step 9.
No: The internal database may have locked. Reboot (power cycle) the KITZ202
unit. If still faulted, the KITZ202 unit has failed and should be replaced. (Ensure
the database mappings are downloaded into the replacement KITZ202 unit –
see section 7.2).
9. Check the serial link connections from the relevant KITZ202 P3 terminals to the
switchboard / Micoms. Are they ok?
Yes: Go to step 10.
No: Rectify the wiring error.
10. Using the PAST software on the programming laptop, connect to P0 on the front of the
relevant KITZ and attempt to communicate with the connected Micom relays (see section
7.2). Are communications established?
Yes: Power cycle the KITZ and recheck PLC communications (go back to step 1).
No: Power cycle the KITZ and recheck. If communications still are not established
the KITZ202 unit has failed and should be replaced. (Ensure the database
mappings are downloaded into the replacement KITZ202 unit – see section
7.2).
6.1.4. Gemstart Communications Troubleshooting (Offline PLC)

With one PLC is online and healthy, if the other (offline) PLC is unable to listen to the
communications between the online PLC and Gemstart units, it assumes the serial link is
broken as indicated by the contact ‘FAILGLK.’
The nature of this fault identification requires that one PLC is online and healthy and the other
PLC indicating this fault is offline. If changeovers continue to occur please resolve online fault
conditions before continuing with the following troubleshooting tests for the offline PLC.
For suspected offline PLC Gemstart serial link faults the following sequence checks below will
help to identify basic causes for such Gemstart communications faults:
NOTE: Ensure one PLC is stable remaining online and in a healthy condition without any
changeovers before continuing.
1. For the offline PLC, check the Westermo for Gemstart link 1 (Master PLC: PTC1, Slave
PLC: PTC3), is the RD LED flashing?
Yes: Go to step 2.
No: Go to step 4.
2. For the offline PLC, check the Westermo for Gemstart link 2 (Master PLC: PTC2, Slave
PLC: PTC4), is the RD LED flashing?
Yes: Go to step 3.
No: Go to step 4.
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3. For the offline PLC, are the PCM ports (Slot 3 - US1 and US2) LEDs flashing rapidly?
Yes: Power cycle offline PLC.
No: Check wiring between PCM and Westermo, and Westermo hardware. Power
cycle offline PLC. If not rectified the PCM module may be faulty. Replace the
module ensuring the Gemstart driver is correctly loaded into the replacement
PCM (see section 11.3).
4. Check connections from the relevant Westermo (Master PLC: Link1 PTC1 / Link2 PTC2,
Slave PLC: Link1 PTC3 / Link2 PTC4) to the switchboard, then internally in the
switchboard to the first Gemstart with healthy communications to the online PLC. (Can
be checked from the Auto indication on Gemstart LCD or using the ‘LINK’ button on the
HHP). Are connections ok?
Yes: Power cycle offline PLC. If fault remains contact CASE Systems.
No: Rectify the wiring error.
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6.2. Gemview EWS Communications Troubleshooting

The Gemview EWS system is preconfigured to communicate to the relevant PLC system
connected. The communications are based upon a TCP/IP Ethernet communication. In the event
of a communication failure (resulting in no data refreshing and very slow response from mouse
and keyboard commands) when the PLC is powered on, the following steps should be followed:
1. Shutdown the Gemview system and restart windows on the PC. When windows has
completed loading start the Gemview EWS from the desktop shortcut. If a warning of
Gemview incorrect shutdown appears and you are prompted to restore the database,
select ‘yes’. Have communications been restored?
Yes:
No: Go to step 2.
2. Check the Gemview EWS log for the error “WSAETimeout”. This is an indication that
there are no responses from the PLC to the messages sent from the Gemview EWS.
Does the error exist?
Yes: Go to step 3.
No: Check PLCs for continual changeovers that may interfere with Gemview
communications.
3. Shutdown the Gemview EWS. Start a DOS “Command Prompt” from the windows Start
menu -> Programs -> Accessories. Type ‘ping 3.0.0.1’ and press ‘return’ at the DOS
prompt. Four messages will then be sent to the Master PLC, an indication of the reply or
timeout will be shown for each of the four messages. Have all four messages timed out?
Yes: Go to step 4.
No: Restart Gemview. Reinstall Gemview from installation CD if problem persists.
4. Connect the programming laptop into the Ethernet hub and perform the same ‘ping
3.0.0.1’ command at a DOS prompt on the laptop. Have all four messages timed out?
Yes: Go to step 5.
No: The Ethernet hardware to/in the PC is faulty. Check Ethernet leads and PC.
5. Press the white Ethernet restart button on the PLC CPU. Retry the ‘ping 3.0.0.1’
command. Have all four messages timed out?
Yes: Go to step 6.
No: The error has cleared. Restart Gemview.
6. Power cycle (power off and on) the PLC. Retry the ‘ping 3.0.0.1’ command. Have all four
messages timed out?
Yes: Contact CASE Systems. The Master CPU may need to be replaced. Repeat
steps 3 to 6 for the Slave PLC, using ‘ping 3.0.0.2’.
No: The error has cleared. Restart Gemview
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6.3. Identifying Hardware Faulted I/O Modules

In addition to faults of modules being recorded in the PLC I/O fault tables (see section 10.8)
indication of faults relating to blown fuses are displayed on the front of the low density I/O module.
If a module experiences a fault current then the modules internal fuse

will blow. All I/O point LED indications of the module will be A12345678
extinguished and the ‘F’ LED will be illuminated. This indicates a blown F
fuse. The module should then be replaced. B12345678
Other faults that are not indicated by a fuse blown may be traced as follows:
Outputs Modules
If it is determined that an output point should be in the ON state but the connected device /
indication / lamp is not receiving power flow, then the relevant output LED of the output module
should be checked:
If the LED is illuminated, then voltage checks should be made at the output module terminals,
to determine that the output relay is functioning correctly. If the output relay is open then a
fault has occurred and the output module should be changed.
If the LED is not illuminated, then the software output reference (%Q????) relating to the
output point should be checked in the Proficy software to identify its driving state (see section
10.3). If the software output reference is in the ON state (which can be double checked by
forcing the reference – see section 10.6) then a fault has occurred and the output module
should be changed.
Inputs Modules
If it is determined that an input point should be in the ON state but the Proficy programming
software identifies the point to be in the OFF state, then the relevant input LED of the input module
should be checked:
If the LED is illuminated then the software input reference (%I????) relating to the input point
should be checked to ensure that no forces are applied (see section 10.6). If no forces are
applied, then a fault has occurred and the input module should be changed.
If the LED is not illuminated, then voltage checks should be made at the input module
terminals, to determine that the input point has faulted. If so, then the input module should be
changed.
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6.4. Replacing Hardware Faulted I/O Modules
Changing I/O modules should always be performed when the connected PLC rack is powered off.
‘Hot swapping’ modules while the PLC rack has power applied can cause damage to the PLC
module, rack baseplate and malfunction of the PLC software. However, only the power to the
affected rack need be isolated. For example if the module to be changed is located in the Slave
PLC rack then power can be maintained to the Master PLC rack if required.
When changing a PLC module that has a 20 point screw terminal strip, the terminal strip can be
removed by operating the lever on the left side just below the LED indication panel of the I/O
module, and using a screwdriver to unclip the connection at the base of the terminal strip.
Therefore this allows the module to be swapped without the need to rewire the I/O terminals.
The following diagram shows the replacement procedure. Removal is the reverse of the
replacement.
.
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7. Disaster Recovery Procedure

7.1. Master / Slave PLC Recovery
In the event of a complete failure of either PLC, or failure of the PLC Processor (IC693CPU364),
the following procedure should be followed to reinstate the software to the Processor.
Note: When replacing any failed component, it is important to establish the reason for the failure
and eliminate the cause, before replacing the component.
1. Isolate power to the failed PLC rack by turning off the associated MCB, located on the left
side of the panel.
2. Remove and replace the failed component(s). Removal and insertion of any PLC component
must be performed when power is isolated to avoid further damage.
3. Apply power to the PLC by turning on the associated MCB, located on the left side of the
panel.
4. Start the Proficy application program.
5. Open the correct project folder on the Proficy for the PLC that is to be recovered, follow
section 10.2.
6. Follow steps to reinstall the PLC (using FLASH memory) in section 10.7. If replacing the
Processor or it is suspected that the Processor memory has been lost, then follow connection
steps for serial communications (section 10.1.1).
7. Once the PLC software has been successfully downloaded and Logic Equal is displayed the
PLC can then be started. Use the menu ‘Target -> Online Commands -> Start Controller’
or the Start button:
8. Check healthy rung (see section 6.1).
9. Check that the PLC regains healthy communications with the other PLC and that the PLC is
now displaying a healthy status (see sections 3.5 (CPU) and 3.10 (Mixed I/O)).
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7.2. KITZ Recovery

If a replacement KITZ202 unit is required and all communication between the PLC and KITZ have
failed, to stop repeated PLC Master/Slave changeovers, it may be advised to power off one of the
PLCs at the MCB.
7.2.1. KITZ Addressing

If the replacement KITZ202 unit has never been configured, then before programming the
mappings, the KITZ unit requires to be configured with a serial link address to allow
communications to the PAS&T programming software. In this case the following steps should
be performed:
Total Number of Current Address of Background Scan

Relays / KITZ Found Background Scan Status
4. Use the menu ‘Units -> New Address’. Enter the serial number of the new replacement
KITZ202 unit. This is located on the front of the KITZ and is formatted 6 numbers and 1
letter (e.g. 123456A).
For the new serial number formats xxxxxxx/xx/xx, the first seven characters only are
required. For this format omit the first number and add it at the end of the number string,
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but referenced as a letter (0=A, 1=B, 2=C....). For example serial number 1054417/03/09
would be 1054417 and so entered as 054417B.
1=B
NOTE: The TEST ID label on the front of the KITZ should also display the correct
number formatting as above.
5. Enter the old relay address as ‘255’.
6. Enter the new serial address as ‘21’. This is the address assigned to all KITZ202 units
installed at In Salah.
7. After approximately 30 seconds, check that the addressing has completed successfully
by going to the menu ‘Access’. The new replacement KITZ should appear as address
21.
7.2.2. KITZ Mapping Download

If the replacement KITZ202 unit has never been configured, then before programming the
mappings, the KITZ unit requires to be configured with a serial link address to allow
communications to the PAS&T programming software. In this case follow steps in section 7.2.1
first.
If not already performed go to section 7.2.1 and follow steps 1-3 to initiate communications with
the KITZ202 unit. If steps in section 7.2.1 have been completed go to step 4.
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4. To check communications are established to the KITZ use the menu ‘Access’. This
should display the device and tag of the KITZ202 connected if healthy communications
are established.
5. Use the menu ‘Records -> Relay Settings....’ to enter the setting menu and then the
menu ‘Load from File’.
6. Select the unit which the settings are to be sent to (i.e. the KITZ address 21).
7. Enter the file name and location that the backup setting file is located. (A caution
indication will appear to show comparisons between stored and actual serial numbers
and models since the new replacement KITZ202 will be a different serial number. Accept
the error and continue).
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8. When the setting file is selected, an error file must be created for error reporting during
the download procedure. Provide an appropriate name for the file and the location it
should be created on the hard drive.
9. When requested enter the password ‘AAAA’. Press CTRL+F10 to confirm when
prompted to accept the password setting. The ‘Alarm’ LED on the front of the KITZ will
flash indicating the password has been accepted.
10. The download will begin and take approximately 2 minutes. P0 Tx and Rx LEDs will
begin to flash rapidly as the file is downloaded. If any errors occur they will be reported in
the error file
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7.3. Gemview EWS Recovery

This installation procedure should be used if all other attempts of recovery have failed. If possible
before proceeding, copy the existing ‘C:\Program Files\Apstar\P1064...’ directory to a safe location
on the hard disk and name it accordingly. This will ensure any recoverable data will be retained
that may be re implemented into the new installation.
The proceeding steps should be followed:
1. If installing on the existing hard drive, use Windows ‘Control Panel -> Add remove programs’
to uninstall the corrupted copy of the Gemview EWS program, if applicable.
2. Insert the original Gemview EWS installation CD into the PC.
3. Run ‘D:\setup.exe’ and follow the onscreen prompts, choosing the default options where
applicable.
4. When the Gemview installation has completed, navigate to the ‘D:\dongle...’ (on the
installation CD) and run the ‘Sentinel Protection Installer’ program. This will install the
required files for the USB license key. Follow the onscreen prompts, choosing the default
options where applicable.
5. Run the Gemview EWS program from the relevant short cut (either Hassi, Krechba, Reg or
Teg), to check the correct operation of the basic software installation.
6. Shut down the Gemview EWS program.
7. Insert the backup Gemview EWS CD, and copy all of the ‘....Apstar\P1064’ directory from
the CD to the hard drive at ‘C:\program Files\Apstar\P1064....’ This will copy the latest
settings and log files into the Gemview program.
8. Run the Gemview EWS program from the relevant short cut (either Hassi, Krechba, Reg or
Teg), to check the correct operation of the backup installation.
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8. Recommended Manuals
8.1. Resource Manuals
For each component in the system the following manuals provide valuable information and can be
referenced for guidance before commencing any maintenance or repair activities.
GE Fanuc Manuals
Document Reference Document Description Comments
GFK0356q Installation and Hardware General Installation
Manual Backplane Specifications
CPU Specifications
GFK1541b TCP/IP Ethernet CPU Ethernet Communications
Communications Parameters
GFK0255k PCM and Support Software PCM Configurations
Users Manual
GFK0487c PCM Development Software PCM Driver Installation
GFK0582d PLC Serial Communications PLC Programming via PSU
Serial Port
DCS Serial Communications
GFK0898f I/O Module Specifications All I/O Modules
GFK1670c Proficy Software Users Manual
Westermo Manuals
6157-2002 Rev A MD45 Installation Manual
Areva Manuals
15G0010 Rev D Gemstart 4 Technical Manual
Volume 1
15G0011 Rev E Gemstart 4 Technical Manual
Volume 2
15G0012 Rev F Gemstart 4 Technical Manual
Volume 3
P12x/EN T/F75 P120,P121,P122 and P123
Technical Manual
P14x/EN M/B64 P141,P142 and P143 Technical
Manual
TG1.1552 P220 Technical Guide
P1064 InSalah FDS_A004 Substation PLC System PEL004-0029 Rev4
Functional Design Specification (ISG Doc Ref.)
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9. System Event and Failure Design Behaviour

9.1. PLC Changeover Design
The PLC system is designed as a hot standby philosophy to maximise the integrity of the system
in the case of a failure. When a failure is detected the PLC is designed to react in a controlled way
that attempts to bypass or minimised the fault.
Each PLC system is made up of two identical PLC racks (designated as Master and Slave), which
are designed to operate as an online / offline system. Each PLC system also has several
components and subsystems that are continually controlled and monitored. Any changes in
operational or communication states are noted and acted upon by the Master / Slave PLC pair.
Upon failure detection of any component or subsystem, depending on the severity and the current
state of the standby PLC, a changeover will be initiated in an attempt to maintain the integrity of
the communications system as a whole.
When a PLC changeover occurs, the PLC that takes the online status will remain online for a
minimum of 20 seconds, in order to allow communications to subsystems (e.g. Gemstart links,
Micom links, etc) to establish. If this PLC detects a fault and remains in an unhealthy condition, the
changeover sequence will again be initiated, swapping online status back to the original PLC.
If the unhealthy condition remains, the changeover sequence will continue. If the fault is not
rectified after 10 consecutive changeovers between the Master and Slave PLC, the changeover
timer will increase from 20 seconds to 300 seconds, in an effort to stabilise the connected healthy
subsystems. The changeover timer will remain at 300 seconds (extended changeover timer mode)
until the fault has been rectified and is identified as healthy by either PLC for at least 330 seconds.
The changeover timer will then reduce back to 20 seconds in preparation for any future failures.
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The flow diagram below gives a basic outline of the sequence:
Start
Check Duty
PLC &
Subsystems
Has Duty PLC

Are Duty PLC Yes & Subsystems Yes Reset
& Subsystems Remained Changeover
Healthy ? Healthy for 330 Counter
Seconds ?
Gemview
No No Normal C/O
Indication and
Changeover to DCS Digital Bit
Standby PLC
Increment
Changeover
Counter
Have 10
Gemview
Consecutive Yes Extended C/O Wait 300 Seconds
Changeovers
Indication and
Occured ?
DCS Digital Bit
No
Wait 20 Seconds
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Dependant on the state of the offline PLC, a changeover is initiated if one of the following
scenarios occurs:
a. Failure to communicate to the DCS system.

b. Failure to communicate to all Gemstarts of Gemstart link 1.
c. Failure to communicate to all Gemstarts of Gemstart link 2.
d. Failure to communicate to all Micoms of Micom link 1.
e. Failure to communicate to all Micoms of Micom link 2 (Krechba).
f. Failure of the Ethernet interface.
g. Failure of PLC hardware.
The PLCs will changeover for any of the above conditions affecting the online PLC, however the
following rules take priority:
 If healthy the Master PLC will always take online status.

 Any failure to the offline status will not affect a changeover.
 If the offline PLC cannot listen to communications between the online PLC and the Gemstarts
it is considered a failure (i.e. the PLC becomes unhealthy), unless the online PLC is unhealthy
(e.g. cannot itself communicate with the Gemstarts).
 No changeover will be initiated if the Ethernet has failed for both PLCs.
 When offline, the Slave PLC, does not require communications from the DCS to be healthy.
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10. Using Proficy

10.1. Connecting to the PLC
A compatible PC loaded with the Proficy programming software can be connected to a GE Fanuc
PLC via either a serial connection, or preferably via an Ethernet cable.
1. Start Proficy using the Windows ‘start’ menu, then ‘Programs -> Proficy ->Proficy
Machine Edition -> Proficy machine Edition’. Alternatively via the desktop icon
(if available).
2. The following popup window appears. (If it does not use the ‘File -> Open Project...’ menu).
3. Ensure the ‘Open an existing project’ and ‘All Projects’ radio buttons are checked. Then select
to the required project from the Project list displayed and click the ‘Ok’ button. The selected
Project will then be opened.
4. After opening the project, connect the preferred connection (serial lead or Ethernet lead) from
the laptop to the PLC (see sections 10.1.1. or 10.1.2. below).
5. Initiate the connection between Proficy and the PLC via the connection button (circled in red
below) or from the menu ‘Target -> Go Online with “xxxxx”’
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10.1.1. Via Serial Connection

Serial connection is made from the ‘comport’ of the laptop, to the programming port of the PLC
located under the door in the PSU (Power Supply Unit) of the PLC using the dedicated
programming lead.
Right click on the ‘Target’ and use the menu ‘Properties’. This will open the ‘Inspector’
window. To connect via a serial connection, for the ‘Physical Port’ item select the appropriate
comport to be used (usually COM1). Close the ‘Inspector’ window using the cross box at the
top right corner.
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Connection to the PLC will now always be attempted via the chosen serial comport.
When communications are initiated from Proficy and are received at the PLC the ‘PS Port’ LED
on the CPU will flash.
10.1.2. Via Ethernet Connection
Ethernet connection is via the RJ45 Ethernet port of the laptop to either ‘Port 1’ or ‘Port 2’ of the
CPU module for the CPU374 model, and the ’10 base T’ of the CPU module for the CPU364
model. (Connection to these ports may be via an Ethernet switch/hub).
Once the Ethernet lead is connected the relevant ‘Link/Act’ LED will illuminate along with the
‘LAN’ LED near the top of the module. (The 100Mbps LED may illuminate depending on the
Ethernet speed capability of the laptop). This illumination indicates that an Ethernet network is
available to use although no communications have yet been initiated.
Right click on the ‘Target’ and use the menu ‘Properties’. This will open the ‘Inspector’
window. To connect via an Ethernet connection, for the ‘Physical Port’ item select ‘ETHERNET’
and then for the ‘IP Address’ item enter the appropriate address if not already configured (e.g.
3.0.0.1.) Close the ‘Inspector’ window using the cross box at the top right corner.
Connection to the PLC will now always be attempted via the Ethernet port of the Proficy laptop.
When communications are initiated from Proficy, the ‘Link/Act’ and ‘LAN’ LEDs will change from
a steady state to a rapid flash when communications are received at the PLC.
NOTE: If the CPU has previously not been programmed (unused and blank), then the program
must initially be downloaded using a serial connection (refer to Section 1.3.1), since no IP
address exists in the CPU to establish Ethernet communications with the Proficy laptop.
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10.2. Selecting/Viewing Ladder Program and Navigating

Subroutines
To open a project file for a particular project (e.g. Krechba Master PLC, Teg Slave PLC, etc) use
the ‘File -> Open Project...’ menu.
Ensure the ‘Open an existing project’ and ‘All Projects’ radio buttons are checked. Then select to
the required project from the Project list displayed and click the ‘Ok’ button. The selected Project
will then be opened.
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Proficy by default provides 3 multi tabbed viewing panes for Project structure navigation and
overview, software detail viewing/editing and information reporting.
This manual will focus on the following tabs for each of the panes:
Navigator Pane: Project tab
Software Detail Pane: All dynamically generated tabs
Feedback Zone Pane: Messages tab
Navigator Pane Software Detail Pane

(Project Overview) (Ladder View)
Feedback Zone
(Information) Pane
To view a program block (subroutine), either...
 Right click on the block call instruction in the current ladder view and select to ‘Open
Block’ (as above) ...or...
 Double click on the block call instruction in the current ladder view ...or...
 Double click on the block in the Navigator Pane (under Logic -> Program Blocks....)
The block will be opened in a new tab in the ‘Software Detail Pane’.
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10.3. Viewing Variable States via Reference View Tables

Reference view tables can be used to view the state of any / all references addresses in the PLC
at once. They consist of 2 types:
Default Table:
A contiguous table of all reference addresses by type (e.g. %AI, %AQ, etc) starting at
address 1 through to the configured maximum memory reference address.
User Defined Table:

User defined table with a configurable number of lines. Each line representing 64
digital bits or 10 16 bit analogue words (dependant on memory type). The table can
contain lines of mixed reference types. Each line can start at any 16 bit reference
address or any byte aligned digital reference address (dependant on memory type).
Any existing User Defined Reference View Tables can be modified if required, or new ones can be
added, without risk of modifying the PLC code. To make a new Reference View Table right click on
the ‘Reference View Tables’ item in the Navigator pane, and use the menu ‘New’. A new User
Defined table will be generated. Provide a name to the table....
...and then double click to open it in the ‘Software Detail Pane’...
Obviously the table can only display real time values when connected to the PLC.
The table displays any user configured lines saved in the table, for example line 1 displays digitals
%I00001 - %I0064 reading from right to left. Line 3 displays analogues %R00711 - %R00720. The
cursor has highlighted %R00713 in line 3. Information relating to the highlighted cell is displayed at
the top of the table:
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Type of Current Bit Referenced Reference

Value Value Address
The table displays any configured lines and a blank line at the bottom, this is ready for the user to
enter a new line reference to view. The new reference is entered in the blank cell at the bottom in
the ‘Address’ column, as in progress below:
A line can be also modified by highlighting the cell in the address column to be modified and
overwriting the existing start reference with the new reference required.
Similarly lines can be deleted by right clicking the line and selecting ‘Delete Row’.
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10.4. Search Commands

To find where a particular reference variable or I/O point is used the search command is used. It is
initiated from the menu ‘Search -> Find In “xxxx”’.
The following search command box is

displayed. Searches for references may be
performed by using the reference address
or the reference address variable name:
When the ‘Find’ button is pressed the search commences and the results are displayed in the
‘Feedback Zone (information) Pane:
The results are displayed, one per line for each occurrence found. It identifies the subroutine of the
contact, the rung number and the type of contact. Double clicking on the line of the occurrence will
automatically open the relevant block, variable table or hardware component and jump to the
relevant position of the search reference.
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10.5. Programmer / Monitor Modes

The default startup mode for Proficy when communications are established to the PLC is monitor.
As symbolised by the deselected green hand icon...
In monitor mode no actions can be performed that will interfere with PLC operation.
To perform any action that will change the PLC program, PLC state or Reference address values
the Proficy software must be in Programmer mode. To enter Programmer mode select the green
hand icon or use menu ‘Target -> Online Commands -> Set Programmer Mode’.
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10.6. Forcing PLC I/O

PLC Inputs and Outputs represented in the PLC code as %Ixxxx and %Qxxxx can be temporarily
forced by Proficy to assist with fault finding. When a force is applied to an I/O point reference, the
force remains active until it is removed by Proficy.
To override / force an input or output:

1. Ensure Proficy is in Programmer mode (refer to Section 10.5).
2. Select the input/output either from the ladder diagram (example in the lower pane) or from
the reference view table (example in the top pane). If required use the search commands to
find the I/O point required – refer to Section 10.4, or Reference View tables – refer to
Section 10.3.
3. The reference can then be toggled by either right clicking the reference / contact and from
the menu select ‘Force ON’ or ‘Force OFF’.
4. Once the override/force is

enabled for the reference an
underscore appears
underneath the reference in the
ladder diagram view and the
reference view table.
5. The force can be removed by right clicking the reference / contact and from the menu select
“Remove Force”.
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10.7. Reinstalling PLC Software (Using Flash Memory)

The software in the PLC can be stored in 2 ways, either into the RAM memory or the Flash
memory (EEPROM). All the PLCs used at ISG are programmed to use Flash memory on startup.
This means that when the PLC is powered up (supply voltage applied), the program in the Flash
memory is written to the RAM memory, therefore any changes which had previously been made to
the RAM memory only and not the Flash memory will be overwritten and lost.
It is therefore advised that any changes be made to the Flash memory, and in the case of a
complete CPU failure of the PLC requiring a complete reload, it is essential to load the Flash
memory. Loading the flash memory requires that the PLC be in the stopped state.
1. Follow steps in Section 10.1 to connect to the PLC either by serial or Ethernet link.
NOTE: If the CPU has previously not been programmed (unused and blank), then the
program must initially be downloaded using a serial connection (refer to Section 10.1.1.),
since no IP address exists in the CPU to establish Ethernet communications with the
Proficy laptop.
2. When connected Proficy checks the PLC hardware configuration and logic for differences
between that of the current folder on the laptop and the PLC RAM. EQ (Equal) or NE (Not
Equal) is displayed at the bottom right of the Proficy screen.
NOTE: The equality of Logic does not check the Flash memory for equality only the RAM.
Therefore if there is any chance that the Flash memory is not current then a download
should be performed at the next available time when the PLC can be put into a stopped
state.
3. To download the program into Flash memory (recommended) the PLC must be in the
stopped state as identified at the bottom right of the Proficy screen and that the RUN LED
on the PLC Power Supply is extinguished. If the PLC is running, and you wish to stop it
use menu ‘PLC -> Stop’ or the Stop button (Proficy must be in ‘Programmer’ mode refer to
Section 10.5):
4. When connected to the PLC, to initiate the download of the PLC program, use menu
‘Target -> Download “xxxxx” to Controller...’
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5. The following box is displayed and the options should be selected as below and then OK
button pressed:
The first item selects to

download the PLC hardware configuration.
The second item selects to download the PLC

logic.
The fourth item selects to write the program to

Flash memory
The progress of the download will be displayed in the ‘Feedback Zone (Information) Pane’
of Proficy.
Once complete, a message will confirm successful download to Flash/EEPROM memory
and that the store is complete.
If the error ‘Flash/EEPROM/EZ Programmer write unsuccessful’ is displayed the following

should be performed:
Use menu ‘Target -> Online Commands -> Clear...’ to display the following:
Select the tick boxes ‘Hardware

Configuration and Motion’ and ‘Program
Logic’, then click ‘OK’.
Then reattempt to download using the

‘Target -> Download “xxxxx” to
Controller...’ menu as before (step ‘4’).
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10.8. Fault Tables

As part of the onboard diagnostics of the PLC system, any hardware or firmware error detected in
the system is logged and identified in the PLC fault tables. The fault tables hold the last 256 errors
which have been detected. The faults are stored chronologically and detail the precise time of the
fault, the type of fault that occurred and the module that was effected by the fault.
To access the fault tables while connected to the PLC use the ‘Target -> Diagnostics...’ menu.
There are two fault tables used. One for the PLC system and one for the I/O hardware. The display
is switched between the two by means of the two radio buttons at the top left of the above window
labelled: ‘PLC’ and ‘IO’.
Each table displays any faults that have not been acknowledged by the user. The faults are logged
chronologically, the most recent fault appearing at the top of the list. Each fault is identified by
‘Fault Location’ i.e the rack.slot number, (e.g. 1.5 – rack 1 slot 5). The fault description identifies
the type of fault and the date and time of the fault are also logged.
The example above indicates 5 faults. The first to occur was the ‘Lan Transceiver fault; OFF
network until fixed’ identified on 0.1 (rack 0, slot 1 – i.e. the CPU). The second fault ‘Loss of, or
missing option module’ was identified on 0.2. (rack 0, slot 2).
The tables indicate the number of overflowed entries in the fault table if the fault list exceeds 256
(oldest is deleted). The date and time stamp of the last time the table was cleared is indicated,
along with the current date and time stamp of the CPU clock.
To clear the fault tables click ‘Clear Controller Fault Table’ at the bottom left of the pane. To clear
the fault tables Proficy is required to be in Programmer mode (refer to Section 10.5). If Proficy is in
monitor mode the ‘Clear Controller Fault Table label does not appear.
The PLC fault table and the IO fault table are cleared individually.
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11. Loading Gemstart Drivers
11.1 Termf Software

The ‘TERMF’ software package has been provided for use in connection with the GE Fanuc PCM
PLC modules. This software is the tool by which all the PCM modules are programmed with the
Gemstart Protocol driver.
The root directory where it is located on the laptop is normally ‘C:\PCOP\TERMF.EXE’.
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11.2 PCM Programming Cable Connections
The PCM programming cable has the following connections:
9 Way D-Type, Pin... Linked to... 25 Way D-Type, Pin...

- Cable Shield 1
2 2
3 3
4 8
5 7
7 5
8 20
One end is a 9 way D-type female to connect to the laptops comport and the other end is a 25 way
D-type male to connect to the PCM Y cable port 1 (or directly into the PCM if necessary).
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11.3 Procedures for Loading PCM

The required files for the Gemstart protocol are found at ‘C:\PCOP\…’
Loading of GEMSTART application software:
1. Power up the PLC ensuring the PLC is stopped (i.e. ‘RUN’ LED is not illuminated).
2. Connect from the PC’s comport 1 to the PCM’s port 1 of the ‘Y’ cable, using the supplied
cable (see section 11.2).
3. From the PCOP directory (i.e. C:\PCOP), type ‘Termf’ and press ‘return’.
4. Hard reset the PCM (i.e. hold the white reset button located under the front PCM cover for
10 secs).
5. Wait until ‘->’ appears onscreen.
6. Type '!!' and press ‘return’.
7. Type 'L GEMSTART\GEMSTART.EXE' and press ‘return’.
8. Type 'Q GEMSTART.EXE 0' and press ‘return’.
9. Type 'L GEMSTART\PCMEXEC.BAT' and press ‘return’.
10. Press ALT/Z and press ‘return’.
11. Power cycle the PLC (turn off and on).
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12. PLC Panel Electrical Load
12.1 230VAC Power Consumption

Each substation PLC panel is supplied with 230V control supply. Due to the critical operation
performed by the PLC systems, and the susceptibility of corruption of the EWS PC equipment on
power failure, each panel is fitted with a UPS system to maximise the integrity of the electrical
supply.
The Pulsar Extreme 1000c UPS system is rated at 1000VA / 700W and provides overload / surge
protection as required. At full load it will provide 11 minute runtime.
The UPS system provides a stable 230V output to the following devices:
Device 230VAC Power Consumption – VA (max)

HRM KBA REG TEG
Master PLC PSU
73.8 (100) 92.7 (100) 81.7 (100) 81.7 (100)
(assume 70% efficiency)
Slave PLC PSU
73.8 (100) 92.7 (100) 81.7 (100) 81.7 (100)
Master OMRON 230VAC /
24VDC Converter in parallel 12.9 (700) 43.7 (700) 20.4 (700) 20.4 (700)
Slave OMRON 230VAC /
24VDC Converter in parallel 12.9 (700) 43.7 (700) 20.4 (700) 20.4 (700)
KITZ Converter #1 7 7 7 7
KITZ Converter #2 - 7 - -
Netgear 4 Port Ethernet Hub
7.5 7.5 7.5 7.5
EN104
Dell EWS PC Base Unit 180 180 180 180
Dell EWS PC Monitor 140 140 140 140
Panel Light 18 18 18 18
Total Power 525.9 632.3 556.7 556.7
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12.2 24VDC Power Consumption

Each substation PLC panel is supplied with 2off OMRON 230VAC / 24VDC Converters (S82K-
24024) operating in parallel via a blocking diode. The input supply to the AC/DC Converters is
230VAC via the UPS (see section 12.1).
Each OMRON S82K-24024 converter is capable of providing a total output of 240 Watts (10amps)
at 24VDC.
The 24VDC load list, which in normal operation is shared between the 2off PSUs, is as follows:
Device OMRON 24VDC Power Consumption

HRM KBA REG TEG
Westermo MD42 (1.8 W ea.) 3.6 (2off) 3.6 (2off) 3.6 (2off) 3.6 (2off)
Westermo MD44 (1.8 W ea.) 10.8 (6off) 14.4 (8off) 10.8 (6off) 10.8 (6off)
32 point PLC Input Module
- 10.8 (64off) 5.4 (32off) 5.4 (32off)
(7mA per point)
Finder 24V Relay (1.5 W ea.) - 9 (6off) 3 (2off) 3 (2off)
Schrack 24V Relay (0.17 W
- 11.1 (65off) - -
ea.)
Total Power 14.4 48.9 22.8 22.8
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12.3 30Watt PLC PSU Power Consumption

Each substation PLC is powered by a PSU located on the PLC rack. The input supply to the PLC
PSU is 230VAC via the UPS (see section 12.1).
Each PLC PSU is capable of providing a total output of 30 Watts (combined across its 3 output
supplies – Internal +5VDC, Internal +24VDC Relay Power, External +24VDC Isolated). Please
note the +24VDC Isolated supply of the PLC PSU is not used since the required +24VDC Isolated
supply is derived from the OMRON PSU (see section 12.2).
The utilised PLC load list imposed by each module on each PSU is as follows (worst case scenario
is assumed i.e. all I/O active):
Device DC PLC Power Consumption – Watts

HRM KBA REG TEG
+5V +24V +5V +24V +5V +24V +5V +24V
Processor (CPU364) 7.6 - 7.6 - 7.6 - 7.6 -
Micom Horner (RTM705) 2.2 - - - 2.2 - 2.2 -
Gemstart or Micom CPI 4 -
2 - - 2 - 2
(PCM311) (2off)
DCS Slave (CMM311) 2 - 2 - 2 - 2 -
Mixed I/O (MDR390) 0.8 3.4 1.7
0.4 1.7 0.4 1.7 0.4
(2off) (2off)
32 Point I/P (MDL655) 2 -
- - - 1 - 1
(2off)
16 Point O/P (MDL940) 0.1 6.6 3.3
- - 0.1 3.3 0.1
(2off) (2off)
Total Power (Watts) 14.2 1.7 16.5 10 15.3 5 15.3 5
Grand Total (Watts) 15.9 26.5 20.3 20.3
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13 Referenced Panel Schematic Drawings
13.1 Referenced Schematic Drawings

The following schematic drawings should be referenced in conjunction with this manual. Reference
should be made particularly in the case of fault finding exercises to ensure a fault is accurately
traced to the correct component.
13.1.1 Hassi R’Mel Schematic Drawings

General Arrangements
PEL004-1160 HRM PLC Panel External GA L-EC-082002
PEL004-1161 HRM PLC Panel Internal GA L-EC-082002
Schematics
PEL004-1162 HRM PLC Panel Diagram for Control Supply
PEL004-1165 HRM PLC Panel Gemstart Link Connections
PEL004-1166 HRM PLC Panel CCU to DCS Serial Link
PEL004-1167 HRM PLC Panel Micom Relays Serial Link
PEL004-1168 HRM PLC Panel Input/Output Cards
PEL004-1173 HRM PLC Panel Kitz Bus Connections
13.1.2 Krechba Schematic Drawings

PEL004-2275 Krechba PLC Panel External GA L-EC-082002
PEL004-2276 Krechba PLC Panel Internal GA L-EC-082002
Schematics
PEL004-2277 Krechba PLC Panel Diagram for Control Supply
PEL004-2270 Krechba PLC Panel Digital Outputs Slot 8
PEL004-2281 Krechba PLC Panel Gemstart Link Connections
PEL004-2282 Krechba PLC Panel CCU to DCS Serial Link
PEL004-2283 Krechba PLC Panel Micom Relays Serial Link
PEL004-2284 Krechba PLC Panel Input/Output Cards
PEL004-2285 Krechba PLC Panel Digital Outputs Slot 6 Point 1 -16
PEL004-2288 Krechba PLC Panel Digital Outputs Slot 7 Points 17-32
PEL004-2289 Krechba PLC Panel Digital Inputs Slot 7 Points 1-16
PEL004-2290 Krechba PLC Panel Digital Inputs Slot 6 Points 17-32
PEL004-2292 Krechba PLC Panel Input/Relay Output Cards
PEL004-2280 Krechba PLC Panel Kitz Bus Connections
13.1.3 Reg Schematic Drawings

PEL004-4160 Teg PLC Panel External GA K-EC-082002
PEL004-4161 Teg PLC Panel Internal GA K-EC-082002
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Schematics
PEL004-4162 Reg PLC Panel Diagram for Control Supply
PEL004-4163 Reg PLC Panel Digital Outputs Slot 8
PEL004-4165 Reg PLC Panel Gemstart Link Connections
PEL004-4166 Reg PLC Panel CCU to DCS Serial Link
PEL004-4167 Reg PLC Panel Micom Relays Serial Link
PEL004-4168 Reg PLC Panel Input/Output Cards
PEL004-4169 Reg PLC Panel Digital Inputs Slot 6 Point 1 -16
PEL004-4170 Reg PLC Panel Digital Outputs Slot 6 Points 17-32
PEL004-4173 Reg PLC Panel Kitz Bus Connections
13.1.4 Krechba Schematic Drawings

PEL004-3160 Teg PLC Panel External GA L-EC-082002
PEL004-3161 Teg PLC Panel Internal GA L-EC-082002
Schematics
PEL004-3162 Teg PLC Panel Diagram for Control Supply
PEL004-3163 Teg PLC Panel Digital Outputs Slot 8
PEL004-3165 Teg PLC Panel Gemstart Link Connections
PEL004-3166 Teg PLC Panel CCU to DCS Serial Link
PEL004-3167 Teg PLC Panel Micom Relays Serial Link
PEL004-3168 Teg PLC Panel Input/Output Cards
PEL004-3169 Teg PLC Panel Digital Inputs Slot 6 Point 1 -16
PEL004-3170 Teg PLC Panel Digital Outputs Slot 6 Points 17-32
PEL004-3173 Teg PLC Panel Kitz Bus Connections
Page 96 of 96

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In Salah Gas

Substation PLC and SCADA Operating & Maintenance Manual – Revision 6

Change Record Narrative Sheet

Revision 0: Initial Issue for Customer Comment.

Revision 1: Section 1.1.6 - ‘PLC Panel Layout’ Added.

Revision 2: Various site technical additions.

Revision 3: Safety Section Added.

Revision 4: Section 4.3.2 – Section Updated.

Revision 5: Section 4.3.2 – Section Updated.

Revision 6: Section 1.1.6 – KITZ Bitmaps Updated.

3.7.1. PCM - Gemstart (IC693PCM311) – Normal Indications .......................................................... 27

6. Troubleshooting Guide .................................................................................................................... 56

11.2 PCM Programming Cable Connections ....................................................................................... 90

Explanation of Symbols and Labels

Caution: refer to product documentation Caution: risk of electric shock

Protective / safety earth terminal

Functional earth terminal.

Installation, Commissioning and Servicing

Insertion / Removal of PC Equipment and PLC Modules

1. Substations PLC System Overview

1.1.2. Gemview SCADA

Various data screens are available for the retrieval

Link Number Link Address

1.1.4. Micom Relays

The PLC system references the Micoms by their

1.1.5. KITZ Units

The KITZ unit requires data mappings to be programmed specific to the

For further KITZ202 specifications please refer to Areva document: R8566c.

1.1.6. Generic Overview

GEMVIEW EWS PLC CABINET

HIGH CAPACITY HIGH CAPACITY

MASTER PLC SLAVE PLC

RS485 RS485 RS485

1.1.7. PLC Panel Layout

MASTER 24VDC SLAVE 24VDC

2. System Component List

Description Part Number HRM KBA REG TEG

3. Component Functionality, Parameters and Indications

The above highlighted examples are:

2: Micom address 39 (Link 2 address 19) has a ‘CB status’ alarm.

3.2. PLC LED Status for Healthy System

* The STAT LED can be ON or OFF in normal operation

MASTER (HRM, REG, TEG)

SLAVE (HRM, REG, TEG)

* The STAT LED can be ON or OFF in normal operation

3.3. PLC Rack (IC693CHS391)

3.4. PLC Power Supply (IC693PWR330)

Specified Range 100 to 240 VAC Actual Range 85 to 264 VAC

Supplied Maximum Application

+24VDC 20 Watts Supplies internal detection pickup power for hardwired

Memory support battery compartment

The individual LEDs represent the following module statuses:

LED State Indication

3.4.1. PLC Power Supply (IC693PWR330) – Normal Indications

PLC LED Normal State

3.5. PLC Processor (IC693CPU364)

Indicates activity on the power

Should be lit at all times if the

LAN The LAN LED should flash indicating

STAT This can be either lit or not lit. See

The individual LED patterns represent the following Ethernet statuses:

LED State Where Possible Cause Corrective Actions

EOK and STAT

EOK E  Press Ethernet Restart  If you did not intend to enter