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TROUBLESHOOTING

ON-LINE FAILURE

I-E96-322A

6 - 13

ON-LINE FAILURE

This part of the troubleshooting section covers on-line failures
and how to troubleshoot them. On-line failures are those that
occur during the course of normal operation.

Module Failure

To check for a module failure:

1. Check the LEDs on the faceplate of the HSS module.

2. Refer to Table

5-1

for a listing of LED states.

Restoring Operation

To restore module operation:

1. Use the troubleshooting flowchart in Figure

6-4

to locate

the problem.

2. Refer to Table

6-6

for corrective action.

3. If the HSS module continues to fail after completing
Steps 1 and 2, replace the module.

4. If replacing the module does not correct the problem, con-
tact Bailey technical support for assistance.

Содержание infi 90 IMHSS03

Страница 1: ...Process Control and Automation Solutions from Elsag Bailey Group E96 322 Hydraulic Servo Module IMHSS03...

Страница 2: ...UIPEMENTS LECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR FR QUENCE RADIO DES PR CAUTIONS DEVRONT TRE PRISES LORS DE L UTILISATION DU MAT RIEL DE COMMUNICATION PORTATIF LA PRUDENCE EXIGE QUE LES PR...

Страница 3: ...e the turbine speed The frequency counter module measures turbine speed by counting and timing pulses from a magnetic pickup on the turbine shaft The MFP module uses this count to calculate turbine sp...

Страница 4: ...ough 8 2 Original 9 1 Original A 1 through A 4 Original B 1 through B 6 Original C 1 through C 3 Original D 1 through D 2 Original E 1 through E 3 Original Index 1 through Index 2 Original When an upd...

Страница 5: ...Disconnect power before installing dipshunts on the module mount ing unit backplane Failure to do so will result in contact with cabinet areas that could cause severe or fatal shock p 3 10 There are e...

Страница 6: ...n avate d installer des dipshunts sur le fond de panier du ch ssis de montage des modules Sinon tout contact avec cette zone entra ne des risques d lectrocution s rieuse ou fatale p 3 10 L int rieur d...

Страница 7: ...tput 2 7 Digital to Analog Converter 2 8 Position Error 2 8 Servo Amplifier 2 8 Dither Oscillator 2 8 Position Feedback 2 8 Demodulator 2 8 Analog to Digital Converter 2 9 LVDT Oscillator 2 9 Digital...

Страница 8: ...6 1 IMHSS03 FACEPLATE LEDS 6 1 DIAGNOSTICS 6 2 DIAGNOSTIC DIPSWITCH SELECTION 6 2 ALARM AND EXCEPTION REPORTING 6 4 FUNCTION CODE 55 PROBLEM REPORTS 6 4 FUNCTION CODE 150 PROBLEM REPORTS 6 6 TROUBLES...

Страница 9: ...WITCH AND JUMPER SETTINGS A 1 LED STATES A 4 APPENDIX B FUNCTION CODE 150 CALIBRATION B 1 INTRODUCTION B 1 INITIAL CALIBRATION B 1 ANALOG CONTROL TUNING THEORY B 3 TUNING THE CONTROLLER GAIN B 4 ON LI...

Страница 10: ...LEDs 5 1 6 1 Diagnostic LED Display 6 1 6 2 Diagnostic Dipswitch Settings 6 3 6 3 Off Line Failure Troubleshooting Flowchart 6 8 6 4 On Line Failure Troubleshooting Flowchart 6 14 C 1 NTHS03 Circuit B...

Страница 11: ...6 3 6 2 Function Code 55 Module Problem Report 6 5 6 3 Function Code 150 Module Problem Report 6 7 6 4 Function Code 150 Output Errors 6 7 6 5 Troubleshooting Off Line Failures 6 11 6 6 Troubleshooti...

Страница 12: ...ociated hardware installation and calibra tion is required Operation and maintenance requires an indi vidual who knows turbine start up and plant operating procedures HSS MODULE DESCRIPTION The HSS mo...

Страница 13: ...s Performance improvements include High resolution analog to digital and digital to analog con verters more accurate LVDT signal condition an I H con verter interface and improved digital and analog i...

Страница 14: ...to prepare the module for opera tion It covers switch settings configuration and field wiring Calibration Explains how to calibrate the module and LVDT transformer and tune the control loop before pl...

Страница 15: ...mod ule dipswitch and jumper settings calibration and tuning using function code 150 and termination unit module jumper and dipshunt settings cable connections and terminal assignments REFERENCE DOCUM...

Страница 16: ...n a process control unit CTM Configuration and tuning module Provides a local means for system configuration tuning and monitoring of control modules over module bus CTT Configuration and tuning termi...

Страница 17: ...tation Integrated operator console with data acquisition and reporting capabilities It provides a digital access into the process for flexible control and monitoring Termination Module Provides input...

Страница 18: ...ter output 1 analog output Position panel meter output 1 analog output scaled feedback output Unscaled position feedback output 1 analog output Table 1 4 Specifications continued Property Characterist...

Страница 19: ...86 mi Humidity 5 to 90 relative humidity up to 55 C 131 F noncondensing 5 to 40 relative humidity above 55 C 131 F noncondensing Air quality Noncorrosive Mounting Occupies one slot in an INFI 90 modu...

Страница 20: ...change in turbine speed The position demand travels over the I O expander bus to the HSS module An on board microprocessor reads the demand and loads it into a digital to analog D A converter The resu...

Страница 21: ...LVDT secondary develops a differential voltage propor tional to the position of the hydraulic actuator The HSS mod ule converts the differential voltage to digital data and sends it to the MFP module...

Страница 22: ...ction code 145 defines the module address high low speed alarms and high low rate of change alarms The block output is frequency of input pulses in hertz The frequency counter continuously checks itse...

Страница 23: ...croprocessor direct module activity and interface the control loop Power enters the board by way of the module mounting unit backplane The I O expander bus interface provides I O module communication...

Страница 24: ...lected by setting a dipswitch on the HSS module The address byte precedes every data transfer The I O expander bus integrated circuit does an address comparison before allowing data to transfer on the...

Страница 25: ...nformation and status to the MFP module by way of the I O expander bus interface D A demand value Servo or I H output percent At null indicator Calculated demodulator and proportional gain inputs Actu...

Страница 26: ...contacts the operator tells the microprocessor to change the actuator position The micropro cessor also writes to a digital output to tell the operator the module is in the hard manual mode of operati...

Страница 27: ...wo servo drive outputs in parallel providing redun dancy in the control output Each output connects to separate coils Servo valve operation requires only one functioning coil One output can short to g...

Страница 28: ...is portion of the position feedback circuitry converts the analog feedback signal to a digital value The position feedback passes from the A D converter to the data buffers to the microprocessor to th...

Страница 29: ...the operator activates the contacts Figure 2 5 shows a schematic of a typical isolated digital input circuit Trip bias is the third digital input The trip bias input signal is sent to the position er...

Страница 30: ...c trostatic discharge 1 Use Static Shielding Bag Keep the modules in the static shielding bag until you are ready to install them in the system Save the bag for future use 2 Ground Bag Before Opening...

Страница 31: ...bling the manufacturer recommends INSTALLING THE TERMINATION UNIT OR MODULE For information about installing process wiring and the hydraulic servo termination unit THS digital I O termination unit TD...

Страница 32: ...nit MMU slot for the HSS module and to the termination unit 5 Follow the procedures in the termination unit product instruction to connect I O common and 24 VDC on the system power bus bar to the term...

Страница 33: ...itch settings are application dependent The information in this section covers the switch settings needed for initial installation Complete the steps in this part of the installation procedure to prep...

Страница 34: ...HSS02 module using function code 150 this dipswitch must have an initial setting for manual LVDT calibration Refer Table 3 1 Dipswitch S1 I O Expander Bus Address Example Settings Example Address Dips...

Страница 35: ...function code 150 this dipswitch must have an initial setting Refer to CONTROLLER TUNING in Appendix B to initially set S2 for manual controller gain tuning Refer to Table 3 3 for S3 dipswitch setting...

Страница 36: ...Dipswitch S5 is an eight pole dipswitch that sets the dither oscillator frequency and amplitude and the LVDT oscillator amplitude LVDT primary excitation voltage Set the dither oscillator amplitude a...

Страница 37: ...itude and LVDT Oscillator Amplitude Setting Dipswitch Pole User Setting 1 2 3 4 5 6 7 8 Dither oscillator frequency 300 Hz 0 1 Dither oscillator frequency 200 Hz 1 0 Dither amplitude 5 of current outp...

Страница 38: ...puts servo1 C1 and servo2 C1 outputs only 1 2 J10 J14 J18 J22 2 3 J8 J9 3 4 J15 J17 J23 J25 48 mA servo outputs servo1 C1 and servo2 C1 outputs only 1 2 J10 J15 J18 J23 2 3 J8 J9 3 4 J16 J17 J24 J25 5...

Страница 39: ...module is seated in the backplane connector Turn the 2 thumbscrews on the faceplate turn until the module locks in place Figure 3 2 IMHSS03 Jumper Layout J25 J24 J23 J22 J21 J20 J19 J9 J8 J18 J17 J16...

Страница 40: ...r procedures explaining how to do either automatic demodula tor gain only or manual calibration and tuning using function code 55 FUNCTION CODE 150 CONFIGURATION If the jumpers and dipswitches have be...

Страница 41: ...ep In automatic mode the HSS module performs the same steps without user action Demodula tor gain and controller gain are independent of each other there fore demodulator gain calibration can be done...

Страница 42: ...position When S12 is in the GO mode the actuator ramps to and holds at the LVDT null point LVDT secondaries have equal voltages While the actuator is held at the LVDT null point the mechanical zero o...

Страница 43: ...feedback information from the LVDT trans former so corrective action is required To automatically tune the demodulator gain 1 Set the demodulator gain constant to 0 S16 0 This initiates the tuning pro...

Страница 44: ...ion stroke times under 30 seconds are not recom mended for on line tuning 3 Go to the block address specified in S11 Set the calibrate mode enable to 1 S11 1 This places the HSS module into calibrate...

Страница 45: ...he calibration procedure All outputs will show bad quality and the HSS module will retain the previous calibration values The other error bits in the module status output blocks N 6 and the LVDT statu...

Страница 46: ...n 7 Observe the LVDT secondary voltage at the output block N and wait until the value stops changing 8 If the 100 position at output block N is greater than 8 5 V then decrease the value of the demodu...

Страница 47: ...lti function processor module has function code 55 in its configuration The block containing the calibrate mode enable specifica tion is set to disable S11 0 To manually tune the controller gain 1 Ent...

Страница 48: ...EDS There are nine LEDs visible through the faceplate of the IMHSS03 module There is one red green status LED and eight red LEDs see Figure 5 1 Three of the red LEDs one four and eight are used during...

Страница 49: ...ator interface 2 Refer to your plant operating procedure to determine the actuator position needed to maintain turbine speed 3 To maintain the load or speed demand adjust the hydraulic actuator positi...

Страница 50: ...odule NOTE If the HSS module enters hard manual mode by losing com munication to the MFP module the HSS module will exit hard man ual mode when the MFP module establishes communication with the HSS mo...

Страница 51: ...op LED red green indicates communication status between the HSS module and multi function processor mod ule and overall status see Figure 5 1 The next eight LEDs labeled one through eight are used for...

Страница 52: ...tic test number on LEDs one through four LEDs five through seven are not used LED eight is the fail LED The test number and the pass fail status of the test is displayed upon completion or failure of...

Страница 53: ...1 The watchdog timer is started An error code displays if it does not expire in 15 secs ROM test 02 x y 0 0 0 0 1 0 Verifies the checksum of the EPROM SRAM test 03 x y 0 0 0 0 1 1 Performs a walking o...

Страница 54: ...e test results on the IMHSS03 LED display see Fig ure 6 1 The selected tests will run repeatedly until the IMHSS03 module is reset The module will halt diagnostics if an error occurs while the module...

Страница 55: ...demodulator automatic tuning Error may also be indicated by FC 55 output N 7 1 Refer to FC 55 output N 7 to isolate error 2 Check LVDT connections If error persists replace indicated LVDT or IMHSS03 A...

Страница 56: ...alve or I H converter If error persists replace IMHSS03 or indicated servo valve or I H converter 9 Input failure Any nonfatal LVDT failure Redundant LVDTs LVDT 1 as primary S3 2 and any LVDT 1 error...

Страница 57: ...Type Module Error Corrective Action 1 No response wrong type Any I O expander bus communication failure Error will also be indicated by FC 150 output N 11 Remove IMHSS03 and reinsert If error recurs r...

Страница 58: ...the instal lation procedure 1 Locate the cause of the failure using the troubleshooting flowchart in Figure 6 3 2 Refer to Table 6 5 for corrective action Figure 6 3 Off Line Failure Troubleshooting F...

Страница 59: ...ect the problem call Bailey technical support for assistance Figure 6 3 Off Line Failure Troubleshooting Flowchart Page 2 of 3 HSS OPERATING TP27342A EXPANDER BUS DIPSHUNT CORRECT HSS SWITCH SETTINGS...

Страница 60: ...NO YES TU DIPSHUNTS SET A2 HSS OPERATING HSS OPERATING SERVO VALVE INSTALLED PROPERLY NO YES HSS OPERATING REPLACE THE HSS MODULE CHECK ACTUATOR AND LVDT INSTALLATION AND CABLE CHECK THE SERVO VALVE A...

Страница 61: ...y that the process wiring is connected to the correct terminals on the termination unit or module Refer to the appendices for terminal assignments 7 Check the valve hydraulic actuator LVDT and install...

Страница 62: ...necting cable 6 If the connecting cables are open or show an unusually high impedance replace the cables 7 If the cable continuity is good and there is no LVDT excitation check the LVDT and replace if...

Страница 63: ...ule failure 1 Check the LEDs on the faceplate of the HSS module 2 Refer to Table 5 1 for a listing of LED states Restoring Operation To restore module operation 1 Use the troubleshooting flowchart in...

Страница 64: ...ng Flowchart START DONE MACHINE FAULT TIMER TIMEOUT LOSS OF POWER HSS OPERATING HSS OPERATING SYSTEM POWER CHECKS GOOD YES NO NO YES YES YES NO NO NO YES CHECK SYSTEM POWER REPLACE MODULE CONTACT BAIL...

Страница 65: ...3 and check the system power 2 Refer to the appropriate power system instruction for troubleshooting procedures Loss of power and system power checks good All LEDs off Replace IMHSS03 1 Turn the thumb...

Страница 66: ...up and plant operating procedures PREVENTIVE MAINTENANCE SCHEDULE Table 7 1 is the preventive maintenance schedule for the IMHSS03 Hydraulic Servo Module The table lists the preven tive maintenance ta...

Страница 67: ...dge connectors Calibrating the LVDT transformer and hydraulic actuator Checking Connections Check all signal wiring power and ground connections for the HSS module and its associated termination unit...

Страница 68: ...dust and residue from the printed circuit board surface using clean dry filtered compressed air or an antistatic field service vac uum cleaner To wash the printed circuit board 1 Clean the printed cir...

Страница 69: ...nish ing brushes may also be used 2 Minimize electrostatic discharge by using the 80 20 iso propyl alcohol water solution during burnishing 3 Do not use excessive force while burnishing Use only enoug...

Страница 70: ...Part Number Nomenclature Description IMFCS01 Frequency counter module IMHSS03 Hydraulic servo module IMMFP01 02 03 Multi function processor modules NIDI01 Digital I O termination module 2 required for...

Страница 71: ...ated in the backplane connectors 5 Turn the 2 latching screws turn to lock the modules in place The module is locked into the module mounting unit when the open end of the slots on the latching screws...

Страница 72: ...ription part number and quantity 2 Model and serial numbers if applicable 3 Bailey instruction number page number and reference fig ure that identifies the part Order parts without commercial descript...

Страница 73: ...values of modules using function 55 refer to the Function Code Appli cation Manual To start demodulator tuning using function code 55 set the demodulator gain dipswitch S2 to two To start controller t...

Страница 74: ...Oscillator Frequency Amplitude and LVDT Oscillator Amplitude Setting Dipswitch Pole 1 2 3 4 5 6 7 8 Dither oscillator frequency 300 Hz 0 1 Dither oscillator frequency 200 Hz 1 0 Dither amplitude 5 of...

Страница 75: ...5 24 mA servo outputs 1 2 J10 J12 J18 20 2 3 J8 J9 J13 J16 J21 J24 3 4 J17 J25 32 mA servo outputs 1 2 J10 J13 J18 J21 2 3 J8 J9 J14 J17 J22 J25 40 mA servo outputs servo1 C1 and servo2 C1 outputs onl...

Страница 76: ...Off Off On HSS module waiting for MFP initialization data Green Off Off Off Normal operation On Off Off Automatic tuning of parameters or calibration in progress Off Off On Hard manual mode The MFP po...

Страница 77: ...interface i e EWS OIS etc 2 Verify that the following conditions exist a The valve for turbine hydraulic system must be in the controlling position and functioning properly b The controller or process...

Страница 78: ...block address specified in S5 Set the linear vari able differential transformer LVDT null bit to 1 9 Go to the block address specified in S4 Set the GO HOLD select bit to 1 10 Monitor the output bloc...

Страница 79: ...s of the servo valve LVDT transformer and hydraulic actuator such as operating specifications impedance tolerances line loses hydraulic system efficiency actuator spring tolerance and transformer perf...

Страница 80: ...llowing con ditions exist 1 Calibration of the HSS module hydraulic actuator and LVDT transformer is complete 2 The controller gain is set to 1 dipswitch S3 pole 8 is closed Refer to Table 3 3 for con...

Страница 81: ...the names of the personnel tuning the controller in the space pro vided in Table B 1 Update the controller tuning log when mak ing any adjustment in controller tuning NOTE Do not start operating the H...

Страница 82: ...FUNCTION CODE 150 CALIBRATION ON LINE CALIBRATION B 6 I E96 322A Table B 1 Controller Tuning Log Date Time Demodulator Gain Controller Gain Name of Personnel Tuning System...

Страница 83: ...ndix C serves as a quick reference of NTHS03 I O termi nal assignments jumper and dipshunt settings circuit board layout and cable connections Refer to the Hydraulic Servo Termination Unit NTHS03 inst...

Страница 84: ...nal Power 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 XU1 Hard manual 1 0 0 0 0 1 0 1 0 0 0 1 1 0 0 0 XU2 Lower contact XU3 Raise contact XU4 Trip bias NOTE 0 open or cut dipshunt strap 1 shorted or intact dipshu...

Страница 85: ...NTHS03 TERMINATION UNIT QUICK REFERENCE I E96 322A C 3 Figure C 3 NTHS03 Termination Cable Connection IMHSS03 MODULE NKHS03 NTHS03 TERMINATION UNIT J1 J3 P2 J2 P1 P1 P3 P2 TP25419A...

Страница 86: ...ine analog out puts three digital inputs and one digital output that terminate at the NIDI01 termination module QUICK REFERENCE Appendix D serves as a quick reference of NIDI01 I O terminal assignment...

Страница 87: ...OT USED NOT USED NOT USED UNSCALED FDBK NOT USED SERVO2 C1 LVDT2 S2 SERVO2 C2 TEST MODE OUT 4 20 mA FDBK LVDT2 S1 LVDT2 PWR OUT NIDI01 NO 2 NOTE Use termination unit cable connector J2 when terminatin...

Страница 88: ...at terminate at the NTDI01 termination unit QUICK REFERENCE Appendix E serves as a quick reference of NTDI01 I O terminal assignments dipshunt settings circuit board layout and cable connections Refer...

Страница 89: ...de Servo 1 drive Servo 2 drive 4 20 mA feedback output XU1 XU4 XU13 XU14 XU16 0 0 0 1 1 0 0 0 Digital inputs Lower input raise input trip bias con tacts powered by 24 VDC external power source 24 VDC...

Страница 90: ...B4 TB2 TB1 TB3 DIPSHUNT USED XU13 XU14 TP25421A SERVO 2 OUTPUT SERVO 1 OUTPUT 4 20 mA FDBK 1 2 3 4 5 6 7 8 DIPSHUNT USED XU9 XU11 RAISE INPUT LOWER INPUT LVDT PRI DRV OUT TRIP BIAS INPUT EMER MAN OUTP...

Страница 91: ...H Hard manual mode 5 2 I I O expander bus address dipswitch 3 4 IMFCS01 application 1 1 2 3 IMHSS03 A 1 Application 1 1 2 1 Calibration 4 1 Circuit board layout 3 5 Circuitry 2 5 Diagnostics 6 2 Dips...

Страница 92: ...tenance 7 1 Procedures 7 2 Schedule 7 1 Problem reports 6 4 R Raise lower contacts 5 2 Reference documents 1 4 Replacement procedures 8 1 S Spare parts 8 1 Special handling 3 1 Specifications 1 6 T Te...

Страница 93: ...8756 ASIA PACIFIC 152 Beach Road Gateway East 20 04 Singapore 189721 Telephone 65 391 0800 Telefax 65 292 9011 EUROPE AFRICA MIDDLE EAST Via Puccini 2 16154 Genoa Italy Telephone 39 10 6582 943 Telefa...

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