poe SSAS-21C Seen TROUBLE SHOOTING Boe Higher INSTRUCTION Reliability & Pec liles SYSTEM : SSAS-21C ICMS Integrated Control & Monitoring System YARD : Shipbuilding & Offshore division in SAMSUNG HEAVY INDUSTRIES SAMSUNG HEAVY INDUSTRIES CO.,LTD. ‘Automation System Team 493,BANWEOL-RI, TAEAN-EUP, HWASUNG-GUN KYUNGGI-DO, KOREA 445-970 TEL : 0082-331-252-1295 FAX : 0082-331-252-1304= HEAVY INDUSTRIES SSAS-21 ICMS sclie. - CONTENTS - 1. System start and Stop Procedure 1.1 System Start 1.2 System Stop 2. Network check “wens een eee eS) | 2.1 Configuration for SSAS-21 main network j 2.2 Network Changeover 2.3 Situations caused by Network Problems(LAN error) 2.4 How to check network status 2.4.1 Network monitoring with MS-DOS prompt(Ping command) 2.4.2 Network monitoring with NetMon program 2.5 Expecting caused by network problems and Clarifications 2.5.1 LAN cable problems 2.52 CPU & SSAS-COM problems _ 2.5.3 LAN cards problems 5 S CPU check nn eee eS 3.1 CPU Changeover(CPU hot backup) 3.2 LEDs Indications in Normal operating 3.3 Fault situations and Clarifications SSAS-COM indication check en eerste rerercrac ce 1) 4.1 LEDs Indications in Normal status 4.2 Fault situation and Clarifications 4.2.1, LAN Problem 4.2.2. Fieldbus Problem 4.23. WABS Problem 4.2.4, Alarm Printer Problem LCU Check... . on z zeal 5.1 Configuration 5.2 LEDs Indications at Normal status 5.3 Types of LCU fault 5.3.1 All LCU fault 5.3.2 One or another LCU fault 5.4 LCU Self Diagnosis methods WABS Check eee 16 6.1 Fault situation and Clarifications 6.2 Self Test procedure JUAL-SERVICE : ‘Automation System TeamCe LOLOL E HEAVY INDUSTRIES L SSAS-21 ICMS 7. In/Ourput Card check 7.1 Digital Input 7.1.1 Connection principle 7.1.2 Possible fault Causes and Clarifications 7.2 Digital Output 7.2.1 Connection principle 7.2.2 Possible fault Causes and Clarifications 73 Analog Input 73.1 Connection principle 7.3.2 Possible fault Causes and Clarifications 7.4 Rtd Input 7.41 Connection principle 7.4.2 Possible fault Causes and Clarifications 7.43 The different Readings between LOCAL GAUGE and CRT L-SERVICE a "Automation System Teame HEAVY INDUSTRIES SSAS-21 ICMS oar ystem START and SHUTDOWN procedure 1.1 System Start . Before system starting, All breakers & Switches Should be in OFF position Switch On UPS power Breaker. . Switch On Main Breaker at the rear of swing frame of Cabinet. Tum On Main power switch on the Cabinet front. Turn On LCU main switch on the Cabinet front. Tum On LCUs individual switches one by one. Switch On WABS Breaker inside Cabinet. Tum On WABS switch on the Cabinet front. Turn On FAN & Light switch. .2 System Shutdown Tum Off FAN & Light switches Tum Off WABS switch & LCUs individual switches. Turn Off LCU main switch. Turn Off Main power switch on the Cabinet front. Switch Off Main breaker at the rear of swing frame of Cabinet. Switch Off WABS breaker. Switch Off UPS Power breaker. - L-SERVICE ‘Automation System TeamHEAVY INDUSTRIES SSAS-21 ICMS ork check Configuration for SSAS-21 Main Network Fig. 1 is LAN a configuration for SSAS-21 main network. TANCARD) 4 4 Coxial cable i. LAN1 (Master) a — ———s | T-connector _LAN-connector Terminator(502) Terminator(502) Should be fit at the end of node + Fig. 1 Network Changeover 1) LANI to LAN2 : Remove Terminator(502) from LANI cable 2) LAN2 to LANI : Remove Terminator(S02) from LAN2 cable After a lapse of time, the network shall be changed to standby Situations caused by Network problems Following situations are caused by Network problems(LAN error) < Alarm printer | Normal operating Engine Room Buzzer : Activating © Ships on Main MIMIC : Stopping ~ Reading values on CRT : Freecing(No changing) ~The color on Point windows List(Ctrl + Alt + L) » Gray color - LAN LED on CPU cards : Stop flickering | || _>LAN LED on SSAS-COM board : Repeat ON/OFF at "A" & "B" CEL ~ Netwrok check program(Netmon.exe or Ping command) : Not connected yee! ) L-SERVICE ‘Automation System TeamHEAVY INDUSTRIES SSAS-21 ICMS ie 2.4 How to check network status 24.1 Network monitoring with MS-DOS prompt(Ping command) 1. On workstation, click right mouse button over START bottom left of desktop and select RUN and select PROGRAMS and choose COMMAND PROMPT. =,,Cn MS-DOS prompt, type csl>ping 202.20.223.189(190/200/201) and check Mhether connection is successful or no response and then do it repeatedly by changing IP address Refer to IP address per each node LANI connection : 202.20,223.xxx, xxx is IP number LAN? connection : 202,20.224. XXX, xxx is IP number Workstation! : 202,20.223(4).100 Workstation? : 202,20.223(4).101 CPU! for AMS : 202,20.223(4),200 CPU2 for AMS : 202,20.223(4).201 Notice : The IP address is increased when workstations and CPU cards are added. network is connected successfully from 202.20,222.189: bytes=32 times Halt indication(Hardware check) | \Div. : Divide indication | \Isol. : Isolation indication [Reset : Push button for CPU Reset ‘Abort : Push button for CPU abort Isol : Dip sw for Isolation used for Live insertion [Divide : Dip sw for Divide used for Live insertion ‘Changeover(Hot Backup) Reset & Abort push button at the same then Standby CPU over the Master and CPU1 will be Standby. Automation System TeamHEAVY INDUSTRIES SSAS-21 ICMS = 10 - CPUiy ‘Ds indications in Normal operating > Flickering | © Steady ON © Flickering IN : ON(Master control) < OFF = OFF VME : Flickering(Weaker than CPUI) RUN : Steady ON LAN : Flickering(Weaker than CPUI) SYSCON : OFF(standby) Fail: OFF Halt: OFF situation and Clarification all LEDs are showing different from Normal status as described above, CPU and check again. If no difference, contact maker. indication check Fig3 for SSAS-COM indication (ea © Power(Red) Tx(Green) / Rx(Yellow) / § coms coms 8 com OB cer a a L Idd Alarm Printer WABS ~~ LAN2 LAN1 ON coM1 + Fig. 3 - Power : Veo ON . CEL : LAN2 in Operating(Green) CEL : LANI in Operating(Green) Fieldbus! in Operating Fieldbus2 in Operating Alarm printer in Operating _WABS in Operating Automation System TeamHEAVY INDUSTRIES SSAS-21 ICMS LEDs indications in Normal operating. - Precondition - CPU : CPUI-Running, CPU2-Standby LAN : LANI-Running, LAN2-Standby ‘eld bus : F_busl-Running, F_bus2-Standby(COMI & COM2) SSAS-COM(Master) SSAS-COM(Slaver) j OFF(LAN?2 standby) 4 CEL : Normally OFF but never mind ON(LANI in operating) | |B CEL » Normally ON but never mind eRx) : Both LEDs Flickering COMI(TwRs) : Rx Flickering() eR:) : Both LEDs OFF || |CoM2(tv'Rx) : Both LEDs OFF Rx) : Both LEDs OFF || |CoMs(rwRx) : Both LEDs OFF | occurred, both Flickering | | I | COMs(tRs) + Re Flickering(Y) | Rt) = Both LEDs Flickering _| || situation and Clarification ings are possible fault situations on SSAS-COM board Problem : Refer to Network check for detail instruction Repeat ON/OFF at "A" & "B" CEL LAN LED on CPU cards : Stop flickering Ship on Main MIMIC and Readings are all Freezing. ible Causes Clarifications : Refer to Network Check directions for Detail check, LAN CABLE Loose-Joint : Check Network cable and Tighten it CPU or SSAS-COM fault : Changeover to CPU2 then, check again. LAN Card on each Workstation fault : Check Lan cards according to . Network check instructions. ss Problem : Indications(Tx/Rx) will move B CEL to A CEL repeatedly Causes and Clarifications : Refer to Field bus check for Detail instructions, CPU or SSAS-COM fault : Changeover to CPU2, a standby CPU. Fieldbus] fault : Check Fieldbus situation in accordance with Fieldbus check instructions. 8S Problem ‘One of the two indication LEDs(Tx/Rx) are not running WABS communication alarm will occurred on CRT. Causes and Clarifications CPU or SSAS-COM fault : Changeover to CPU2 then, check again. ‘Automation System TeamAVY INDUSTRIES SSAS-21 ICMS alee WABS control board in ECC fault : Replace it with spare. Supplying power(24Vdc) problem : Power reset with WABS switch. printer Problem : Printer will not operating. ible Causes and Clarifications CPU fault : Changeover to CPU2 then, check again Printer fault : Serial setting is wrong or Serial board is out of order. Contact to Maker HECK configuration a shown in Fig.4, all LCUs(Local Control Unit) are linked to CPU with RS485, Communication Line, -COM coma Fieldbus 2(RS485_serial_Link) Fieldbus. 1(RS485_serial_Link) LEDs LEDs eoee Lcu1 LCUn - Fig. 4 LCU configuration - ‘Automation System TeamVY INDUSTRIES SSAS-21 ICMS indications of LEDs in Normal operating » oO 0:0 0 oo Tx(G)_Rx(Y) Tx(G)_Rx(¥) Power(s) i te LCU board F busy Tx > OFF Re : OFF F bus? Tx Flickering Tx » Flickering ‘Re > Flickering Tz > OFF ‘Rx > OFF Rx > Flickering Steady ON Power = Steady ON ————= SSAS-COM(Master) Fieldbus1 Linked | When Fieldbus2 Linked J OM (Master) + Both LEDs Flickering COMI(Tx/Rx) : Both LEDs OFF Both LEDs OFF COM2(TwRx) : Both LEDs Flickering OM(Slaver) Rx Flickering(Y) Both LEDs OFF SSAS-COM(Slaver) |COMI(TwRs) : Both LEDs OFF | COM2(TwRx) : Rx Flickering(Y) of LCU Fault LCUs fault or another LCU fault ible fault causes & SSAS-COM problems problems(Address setting, DI counter setting) ication Chip(DS75176) Failure sause(AC Noise, Surge, Voltage Drop, etc.) fault CPU and check the situation. If no difference, Return to Original and veldbus! from COMI on SSAS-COM then, Field bus will be change to automatically in a lapse of time. If Fieldbus! is Master, then Fieldbus? us) If no difference, check the following directions one by one. Automation System TeamHEAVY INDUSTRIES SSAS-21 ICMS -14- ‘ault causes and Clarifications Voltage failure : Check the Fuse or Breaker. The available voltage measured at LCU panel should be over 22Vde. Communication cable problems. Loose-joint by the vibration : Tighten the connection, ‘Wrong connection : Check the cabling in accordance with Connection Dwg, Program probléms : Compare Node I/D & DI counter to Instructions on the System Configuration MIMIC. CPU problem : If LED indications are different from that of Normal operating described above, Run Standby CPU and check again. ‘Communication chip(DS75176) problem : Run Standby Field bus if the fault is retum to normal after that, Be sure the fault was caused by Chip problem. or another LCU fault( Individual LCU fault) ible Fault causes and Clarifications certain LCU fault alarm occurred, Reset power with LCU switch on the cabinet and check a condition. If LCU is not back to normal, be in panel and reset power with Local s/w on the LCU board again. power is measured on the LCU board, check the Fuse(10A/250Vac) in the ‘cabinet in accordance with Connection drawing. to the directions for detail checking offfon Local switch on the LCU board. followings. plying power : Over 22Vde should be feed from Power supply unit uree power LED on the LCU Board : Five LEDs for +5Vde, -5Vde +15Vde, -15Vde, 20Vde. if one of the LED is off, Replace it with spare board. leakage : Frame ground and 24Vde power line individually(+/-). Communication line(Tx/Rx). Individual sensor line. If measured resistance is Less than M2 considered Earth leakage and remove the cable from LCU terminal board indication : Tx/Rx_: Flickering, Power : ON ‘Automation System TeamVY INDUSTRIES SSAS-21 ICMS -15- ‘FE following situations on the LED are found, Be followed the instructions Fieldbus 1(Running) - Tx/Rx : Flickering, Fieldbus2(Standby) - Tx : Flickering(ON) or Rx : Flickering(ON) sure that one of the communication chips(DS75176) on one LCU or Other is cracked or bad condition by the Earth leakage or by the Noise methods how to find the faulty chip is as following” 1) Remove standby fieldbus from LCU board and check LED indication, If LED indications are back to normal, the communication chip for the fieldbus? is cracked. If no difference, 2) Remove running fieldbus and reconnect it to standby fieldbus and check LED indication, The LCU is still linked to main fieldbus but connected to standby fieldbus on the LCU. 3) If LED situation is not changeable, make sure the problem is affected by other LCU. Then, check the other LCU one by one as same methods as above noticed when chip is taken out the LCU should be switched o Diagnosis methods LCUs are running normally with fieldbus1, Fieldbus2 connector from LCU board. Fieldbus] from board and connect it to Fieldbus2 connector. e all normal with Fieldbus! and Fieldbus2 linked, make sure the board is fing. Refer to Fig.5 for further explanation. LCU Fielder |] (Reeve —————— Fieldbus? LJ (3) Test with Fieldbus? alone Fieldbus Fieldbus! 2) Test_with Fieldbus] alone | 4) Remove Fieldbus! and then! q |__connect it to Fieldbus? _| - Fig LCU Self Diagnosis Test methods - Automation System TeamINDUSTRIES SSAS-21 ICMS eusl ECK sing faults and Clarifications WCOM fault & All WABS Alarm are occurred ing Power Problems : (No power indication : Check the Power by referring Connection Dwg. Swer interrupt on the cable by surge or Noise : WABS switch on the front of Main cabinet S Communication fault = Standby CPU and check it. If with Standby CPU, Communication to normal, make sure Control chip(DS75176) is cracked and it. Chip replacement should be done Power off condition. in ECC fault control board with spare and check it again. ‘or another cabin's alarm(Fault alarm) is occurred. followings and take the action ‘out Lamp & Buzzer test with faulty panel : If no response, Replace board with Spare. Diagnosis test at Local or ECR with "F4 function key” on WABS ‘The test procedure is shown on WABS MIMIC on CRT(HELP KEY) to the Operating manual(WABS PART) in FINAL DWG. procedure(Available every WABS panel) OPERATING MANUAL(WABS PART) for detail procedure instruction on the MIMIC(F3 function key on keyboard) F4 Function key on WABS panel(ECR is the better) F4 Function key again corresponding to the instruction on the LCD. jing test can be shown on the LCD. = Lamp & Buzzer test ~ Communication test With SSAS-21(with CPU) ‘Communication test With WABS(WABS intemal testing) ‘With UP/DOWN key on the WABS panel, user can select ‘the wanted panel ‘Automation System TeaSSAS-21 ICMS in FigS the principle connection of Digital input card is as following, er —— boarc i DI32C Sigua IN t Closed | 18 + + e212 Opened | Signal IN io 3 [8 041 Oa tom Det ! [s[/® —— 06|® Feedback Sigr Rectifier in SSA‘ 21 Main cabinet! Fig. 5-2 Connection principle for Valve indication * connection for Individual Clarifications ‘or Sensor fault ; A certain alarm will be occurred ‘an alarm is occurred, Remove the cable from terminal board. Jumper and connected it instead of Sensor cable. ‘en alarm retum to normal, the alarm is caused by sensor fault, ‘en alarm is not cleared, make sure the channel is fault and then, the channel to spare channel. Regarding spare channel moving, to BUILDER MANUAL. ir: All alarms on one card will be occurred. Replace fault card with Spare. Output Connection principle Terminal Board [Doc-16C Close To VALVE Open. ; ig eee 24Vde from Valve Fig. 6 Connection principle for DOC card(Valve control) ‘Automation System T:SSAS-21 ICMS Pulse wave(24Vdc), or Continuous type, Specification dependen 28ec. as default, Adjustable. SA/250Vac RIES. type duration rating channel to Spare. LED indication is responding, But no action at the local Actuator Relay output contact by using simulation switch(Toggle s/w) on the front panel fault : No indications on the fault card. Card fault alarm will be occurrec corresponding card with spare Input onnection Principle shown Fig.7, two types of signals can be connected on AI card. Terminal Converter! board ‘Transmit AU-6C ove from AIC! | Ue 420A pe ° 2|8 ral —" 2avde External @3|@) Current Check | L supply 418 i 1 (| 5 1@ Live from PA be[@ pst gy | Current Check “ Fig 7 Connection principle for AI card(4-20mA) fault Causes and Clarifications Sensor fault: A certain alarm will be occurred an alarm is occurred, Remove Signal line(4-20mA) from Terminal board. input Current and Voltage with Tester above, Two types of signal can be connected AI CARD send 24Vde to P/l converter or transmitter and receive the Current(4-20mA). ‘Signal in normal status : itage measured at each side(terminal board, No.1&No.2) : 24V current : 4-20mA Extemal power is supplied to Al card. measured at Cable : Min, 14Vde put Current - 4-20mA Automation System TearINDUSTRIES SSAS-21 ICMS i: ALL alarms on one card will be occuired fault card with spare it Card jon principle - Te al board Pt100 Sensors IRid-16C [4 ule s i i ao ( re, 3 /@ Com | | a) a ; i B (| A a | 6/@}—com__T Fig. 8 Connection principle for Rtd card fault Causes if er Sensor fault : A certain alarm will be occurred an alarm is occurred, Remove Signal line from Terminal board. Resistance between "a" and "b” shown above. +1002 is for 0 Deg.C, 175.842 is for 200 Deg.C * and "Com." is always Zero ohm. If Com. cable is not connected, ‘the channel is to be fault ropriate resistance is not measured, Check the sensor. lt = ALL alarms on one card will be occurred fault card with spare different Readings between LOCAL GAUGE and CRT. well, two different sensors are connected to each side individually. ig values in SSAS-21 is fully depend on the Ptl00 temp. sensor. characteristics of Pt100 sensor is low or the Local gauge is bad condition fence on Both sides, SSAS-21 and Local Gauge, will be increased. channel is remarkably different from others, follow the above procedures. 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