1 FAULT FINDING INSTRUCTIONS /

TROUBLESHOOTING

APMS is built with advance PLC which has BITE technology and provides
information’s for failure notification. BITE technology will guide the operator from
mimic pages and can find location of fault and reason for the same. PLC itself
has LED’s which will indicate the status of DI, DO etc. For system interface
details refer APMS architecture.

1.1 The following table gives brief description of troubleshooting:

Sr. Problem Possible Cause To be checked
No.
MSB Remote I/O PLC
1. Switching “ON” MCB’s but No Input Wiring of MCB and Check Wiring of MCB or
power Supply is delivered to Output Wiring of MCB are loose Check Wiring Connections
PLC or Fuse blown. fuse terminal and fuse
healthiness.
2. Switching “ON” all MCB’s and Input wiring to PLC Module Check wiring.
PLC is OFF. CPS3020 might not be proper. Check availability of 24VDC
supply.
3. Switching “ON” all MCB’s and Input Voltage is not within range Check Wiring and remove
PLC Power supply OK LED is (21-26vdc) or Power supply the PLC from tier slot & re-
OFF module is not properly installed install the PLC Power supply
on their PLC rack slot. module at their PLC slot and
fit properly.
4. PLC is ON and some alarms & PLC Connector wiring to Check wiring and also check
indications are not showing on Terminal Block or Field cables whether that alarm
HMI display. on Terminal Block might be corresponds to their
loose. respective channel number
which can be visualized on
Input Modules with a Green
LED Indication (Refer
Channel List).
5. PLC is ON and Output LED PLC Connector Wiring to Check Wiring.
corresponding to Buzzer ON, Interposing Relay or Looping of Check Whether Interposing
Digital Output from PLC is Power supply to Relay might not Relay functions properly or
generated but Interposing relay be proper. not.
does not switch ON.
6. DG Electrical parameters & Modbus Connection loose or Check the Polarity of Data+
Mechanical parameters are not wrong termination. and Data- termination as per
 updating on HMI SWBD drawing scheme and
properly fix it.
7. P Load sharing & Q load sharing Relay of P Load sharing and Q Check relay and its
not coming to PPU when load sharing may not be connection between relay
switchboard is in remote mode. activated or cable termination contacts to PPU terminal.
will be loose from relay contact
to PPU. For details refer below PPU
documents:-
a) ML-2 operators
manual 4189340579
b) General guidelines for
commissioning
4189340703
c) ML-2 quick start guide
4189340603
8. Ethernet switch and PLC is off Power Supply cable might not be Check for the power supply
however 24vdc power supply connected or must be loose. cable and if loose connect it
available at SMPS & MCB is properly.
ON.
9. HMI display is not being power Power supply may not be Check Power supply at
up. available at MFCs display. MFCs power input terminals.
10. Ethernet Switch is ON, but CAT6 cable may not be Check for the CAT 6 cable if
Ethernet port’s LED does not connected or must be loose. connected and if loose,
glow. Ethernet port must also be connect it properly. Check
faulty. whether there is breakage in
the cable or any kind of
physical damage in cable.
Check for Ethernet port as
well.
11. HMI Display is ON but not Ethernet cable must be loose or Check for the Ethernet cable
showing field status. not connected properly. and if loose, connect it
properly. Check for cable
breakage if any.
12. Online Alarm is showing on Speaker/ amplifier terminals Check the connection at
HMI display, but Speaker is not connection may not be proper. terminal of amplifier /
sounding. speaker.
13. HSBY PLC changeover not Interlinking cable termination Check all Ethernet cable
happening not proper which are connected at PLC
CPU & NOC as per System
architecture.

Table 1 Troubleshooting Instruction

For all PLC LED indications meaning refer this table:-
LED ON Flashing ON OFF
RUN (green) PLC running normally, PLC in stop mode or blocked PLC not configured;
program executing by a software execution application missing,
invalid or
incompatible.
ERR (red) Processor or system error - PLC not configured. Normal state.
- PLC blocked by a No internal Error.
software error.
- PLC bus error
IO (red) Input / output errors coming PLC bus error Normal state.
from a module, a channel or No internal error.
a configuration error.
ETH ACT Communication Activity - No communication
(green) detected activity detected.
ETH LINK Ethernet Link detected - No Ethernet Link
(green) detected.
ETH STS (green) Communication OK 2 flashes : Invalid MAC -
Address.
3 flashes : Link not connected.
4 flashes : Duplicate IP
address.
5 flashes : Waiting for a served
IP addresses.
6 flashes : Safe Mode. Default
IP.
7 flashes : Configuration
conflict ( rotary switches /
internal configuration)
SER COM - Communication activity -
(yellow)
CARDERR (red) Card missing or not usable - Card is correct and
or card content inconsistent application is
with Internal Application consistent with CPU
RAM. Internal Application
RAM.
CARDAC Card Access enabled Card being accessed Card access disabled.
(green)
Memory card The CPU can access the SD The CPU does not recognize The CPU attempts to
status memory card the SD memory card access the SD memory
card
 DL(Downloaded - Firmware upgrade in progress
) in progress
BACKUP The memory card or CPU
flash memory is missing or
inoperable
MS  Configured,
 Recoverable
detected error
NS  Configured,
 Recoverable
detected error
A The CPU set as “A” station
B The CPU set as “A” station
Remote RUN The remote PLC is in RUN
state
PREM The Local PLC is primary
STBY The Local PLC is standby
Table 2 Fault Finding Instructions
- The memory card or
 Powering ON.
 Not Configured
 Valid IP address but no
Ethernet connection
The remote PLC is in STOP
state
The local PLC is in wait state
The local PLC is in wait state
No Firmware upgrade
CPU contents is valid,
the application in the
execution memory is
identical
Power off
 Power off
 In-valid IP
address
Off indicates local
CPU A/B/Clear rotary
switch is not set to
“A”.
Off indicates local
CPU A/B/Clear rotary
switch is not set to
“B”.
The local PLC cannot
read the status of
remote PLC. Both the
HSBY link and
Ethernet link are lost.
The Local PLC is not
primary
The Local PLC is not
standby

VISUAL INDICATORS AND MEANING FOR H57 24M

LED Continually lit Flashing Off

 2,5s ON, 500ms OFF :
RUN PLC running in Primary PLC running in Standby PLC not configured :
(green) mode, full program mode, only first application missing,
execution section execution. invalid or
500ms ON, 2,5s OFF : incompatible
PLC running in Offline
mode, no program
execution.
500ms ON, 500ms OFF :
PLC in STOP mode or
blocked by a software
error
- PLC not configured
ERR Processor or system - PLC blocked by a Normal state,
(red) error software error no internal error
- memory card battery
error
- X bus error
Input/output errors
I/O Normal state,
coming from a module, X bus error
(red) no internal error
a channel or a
configuration error
TER Terminal port link
Link not active
(yellow) active

VISUAL INDICATORS AND MEANING FOR TSX ETY4103

RUN ERR STS COL TX RX Meaning

O O O ns ns ns No supply to module
O O P ns ns ns Module running self-test
P O O ns ns ns Module ready
O P O ns ns ns Module not operational
O P P ns ns ns Software operation error
O F P,F ns ns ns Module not configured or configuration in progress
P O P ns ns ns Module configured, operational
Module configured:
ns ns F ns ns ns - 2 flashes: module has no MAC address
- 3 flashes: ETHERNET cable not connected on the
module or Hub side
- 4 flashes: the module IP address is duplicated
by another IP address on the network
- 5 flashes: module configured as a BOOTP client
and is waiting for a BOOTP server response
P O P O F O Ethernet communication sending
P O P O O F Ethernet communication receving
P O P O F F Ethernet communication in sending/receving
P O P F F O Module has detected collision
P = Permanently on, F = Flashing, O = Off, ns = not significant