Basic Maintenance of DCS: Zhejiang SUPCON Technology Co.,Ltd

Basic maintenance of DCS
Zhejiang SUPCON Technology Co.,Ltd

General introduction
Why
Maintenance
？！
2
Tools
Tools for Anti-static
Brush, tweezers, wrist strap, glove…
3
Tools
Tools for Hardware Maintenance
simulator, process calibrator, FLUKE,
signal generator, resistance box…..
4
Tools
Tools for Software Maintenance
SC-Diagnose, real-time monitoring…
5
Tools
Tools for Network Maintenance
FLUKE, Cable Tester
6
Content
7
Routine Maintenance
8
Routine Maintenance
9
Routine Maintenance
• Central Control Room
System power supply
System grounding
Seal up cable holes (trays)
Temperature and Humidity control
Anti-Interference
Anti-Corrosion
10
Routine Maintenance
• System power supply
2 lines (AC and UPS) power supply

Voltage: AC220V±10% ；
frequency ： 50±3Hz ；
Compliance to IEC61000-3-2
11
Routine Maintenance
• UPS power supply maintenance
 Temperature: 20℃-30℃
 Check battery capacity
 Charge and discharge periodically
 Grounding of UPS shell
Do discharge test artificially if it works for a long time.

12
Routine Maintenance
• System grounding
All equipments must be grounded
Equal potential grounding is recommended
Compliance to System grounding specification
13
Routine Maintenance
Electrical working grounding protective grounding

grounding
equipment grounding general grounding
grounding system
14
Routine Maintenance
• Seal up cable holes
un-sealed ,
excrement of mouse
15
Routine Maintenance
• Temperature and Humidity control
Condensation 16
Routine Maintenance
• Anti-Interference
electromagnetic shielding
17
Routine Maintenance
• Anti-Corrosion
Modules have be
corroded
18
Routine Maintenance
• Anti-Corrosion
copper vulcanized copper chloridized

19
Routine Maintenance
20
Routine Maintenance
• Anti-Corrosion
Fresh air to
control room
Pin> Pout, 25Pa
21
Routine Maintenance
• Anti-Corrosion
Fresh air to
operation room
22
Routine Maintenance
• Anti-Corrosion
Seal the holes
23
Routine Maintenance
• Anti-Corrosion
Keep the doors and

windows closed
24
Routine Maintenance
• Control Station
System components management
Inspection of control station
25
Routine Maintenance
• Control Station
interference due to
transformer
26
Routine Maintenance
• Operation Station
Components management: keep clean, anti-interference…
Anti-virus: movable devices forbidden
Unnecessary multi-task forbidden
Backup important materials
Inspection of operation station
27
Routine Maintenance
• Network
Check connection
Check indicators of network components
Check dynamic data in HMI
Debug with “ping” command
28
Overhaul Maintenance
29
30
• Preparations before power-off
Check indicators of modules

Check fault diagnosis
Check working status of power supply modules
Redundancy testing(power supply, modules,
network)
Check network
UPS testing
I/O modules precision testing (optional) 31
• Procedure of power-off
32
• Overhaul Maintenance
Cleaning CS, ES &OS

Settling fault
Checking power supply lines
Checking network connection
Checking grounding system
Checking other devices
33
• Procedure of power-on
★ Before commissioning, do the same checking

as before system power-off.
34
• PID parameter setting and Commissioning
• Single loop
include PID parameter setting and adjuster setting (positive/negative)
adjuster
setting
PID parameter setting
35
• Cascade
Step 1: internal loop adjusting
stable
Manual status : MV Auto status: SV
Step 2: external loop adjusting

Cascade
internal loop control stable SV of Auto status
★ SV gradually increased.
36
PID parameter setting ：

 backup PID parameters before power-off.
 input the PID parameters before commissioning again.
37
After overhaul, the system behaviors as :
 Start up normally
 No fault left
 Aging components being replaced or repaired
 No fault alarm information
 No abnormal sound
 System keeping working well
38
Hardware Maintenance
39
40
• Power supply fault
Common fault : 5V, 24V indicators display

abnormal;
output abnormal;
Analysis :
AC input abnormal Check AC input
poor grounding Check grounding
Aging components, corrosion Replace41the power supply

• MCU fault
 The voltage of Li-Battery is lower than 3V
 Communication interface broken
 Address setting is wrong
 Power supply doesn’t meet the requirement
 Corrosion
42
• MCU fault
case 1
Problem :
When power ON, FAIL is ON, FAIL on the I/O modules a
re aslo ON. Then download the configuration, the fault
disappears.
43
• MCU fault
Analysis :
Check the Li-battery.
Solution : ?
44
• MCU fault
case 2
Problem :
Control Station can’t communicate with Operation Station.
45
• MCU fault
Analysis :
Check the address of the whole system, whether there is
address conflict.
Solution : ?
46
• MCU fault
47
• DTM fault
Common fault :
FAIL is ON.
Analysis :
Check module status by Diag. panel on HMI.
Check DB9 cable connection among I/O racks.
48
• DTM fault
Common fault :
COM is OFF, Diag. panel on HMI shows
SBUS failure, I/O controller of MCU failure.
Analysis :
Check address of DTM.

Check DB9 cable.
49
• DTM fault
case
Problem :
Replace a new DTM, but COM is OFF.
50
• DTM fault
Analysis :
Check the address.
Solution : ?
51
• I/O module fault
 Disturbance
 Poor grounding
 Transmitter failure
 Motherboard failure
 Poor contact between signal wire and terminal
52
Common fault :
Real-time data display abnormal.
Analysis :
Wrong setting(configuration, jumper, signal wire connection)
I/O module failure
Motherboard failure
Disturbance
53
Common fault :
Real-time data jump.
Analysis :
Disturbance
Transmitter failure
I/O module failure
Motherboard failure
54
Common fault :
Real-time data can't display.
Analysis :
Transmitter failure
Wrong setting( configuration, jumper, signal wire
connection)
Terminal board failure
Network failure
I/O module or rack failure
55
Problem :
case 1 A flow signal display “?” on
graphics.
Analysis :
First, check the configuration.
Second, check the signal wire.
Solution : ?
56
Problem :
case 2 Real-time data of signals on the same TC
module display abnormal.
Analysis :
First, replace the I/O module.
Second, check environment (disturbance, humidity,
corrosion ).
Solution : ?
57
Problem :
case 3 Set DO signal value ON, but the
solenoid valve related to the tag don't
work in the field.
Analysis :
First, check other channels on the same module.
Second, check the status of MCU.
Third, check 24V output to relay.
Solution : ?
58
• Operation Station fault
Common fault :
Display fault
Analysis :
First, change the display.
Second, change video card or motherboard.
59
Common fault :
Operator keyboard fault
Analysis :
Check individual key
Check connection between computer and keyboard
Replace keyboard
Check configuration
60
Common fault :
Operation Station crashes
Check Hard disk
Hardware Check motherboard
reason Check memory
Check video card
Analysis :
…
Virus
Software System default file deleted
reason Not enough hard disk capacity
Illegal operation
Memory conflict
61
Problem :
case Monitor flashes heavily, replace the monitor,
the problem still exist.
Analysis :
First, check the host.
Second, check environment (disturbance,
humidity, corrosion ).
Solution : ? 62
Software Maintenance
63
windows system
configuration software
monitoring software
64
• Tools
• Diagnosis
• Network test
• History data tool
65
• Common faults
 Real- time data show “?”

 Real-time data of the same tag is different among
operator stations
 Backup configuration can’t be used
 Time is different between 2 operator stations
66
• Trouble shooting
Problem :
case 1 Part of real-time data show “?”, and the
real-time data of the same tag is
different among operator stations.
67
Analysis :
possibility1:
communication/module/signal fault;
possibility2:
no publish or no download.
Solution:?
68
Problem :
case 2 There are breakpoints in the trend.
Vertical line part

is interrupt point
69
Analysis :
If period of trend record are set like this , interrupt point
maybe happens.
Solution :?
70
case 3
Problem :
Trend record interrupted in engineer station , but was
normal in operator station.
71
Analysis :
File of Trend record can be set in configuration.
Solution :?
72
case 4
Problem :
Time is different among operator stations
73
Analysis :
Time Synchronization function need setting server and
client nodes.
Solution :?
74
Network Maintenance
75
Network Maintenance
• Analyze Tools
76
Network Maintenance
• Analyze Tools
77
Network Maintenance
• Common Problems
 Communication errors of all operator stations

 One operator station is showing communication errors
 I/O controller failure , DTM failure , I/O module failure ,
SBUS failure
 Data not refreshed
 ……
78
Network Maintenance
• Common Problems
• Communication errors in the diagnose of all operator
stations ,and configuration can’t be downloaded.
79
Network Maintenance
• Common Reasons
• network equipment failure （ communication
cable ,network card , HUB or switch… ）
80
Network Maintenance
• Common Problems
• One operator station is showing communication
errors while other operator stations are normal.
81
Network Maintenance
• Common Reasons
• setting errors （ network card drivers 、 IP address ,
subnet mask , communication protocol ）
82
Network Maintenance
• Common Problems
• Diagnose window shows: MCU I/O controller
failure , DTM I/O failure , SBUS failure.
83
Network Maintenance
• Common Reasons
• Setting errors （ MCU address , DTM addres
s）
• MCU fault, Network cable fault
• SBUS are not connected correctly
84
Network Maintenance
• Common Problems
• Data not refreshed
85
Network Maintenance
• Common Reasons
• IO module fault
• MCU fault
• Power supply of MCU and switch fault
• IP setting of new computer fault
86
Network Maintenance
Case
Problem :
one project has 2 control stations , when one power
supply power off , control stations work well individual
, but they can’t communicate , failure indicator of
MCU flash.
87
Network Maintenance
Analysis :
2 redundant AC supplies of the switches are not
connected correctly, 1# control station switch A use
electric supply, switch B switch use UPS ， 2# control
station just the opposite choice 。
Solution :?
88
Configuration Maintenance
89
90
• Configuration management
• save
Disk D
The path to save configuration should not too deep,

no more than 3 layers.
91
• Configuration management
• backup
 before modification
 after modification
Disk E or Disk F
92
• Control station modification
• add tag
channel Parameter HMI Download,

I/O module
Setting Setting publish
• Signal type • standby • parameter • graphics • compile
channel
• alarm • standard panel • download
•add new
• trend • Associated • publish
I/O module
setting
93
• delete tag
channel Parameter HMI Download,

Setting Setting publish
• standby • parameter • graphics • compile
channel
• alarm • standard panel • download
• trend • Associated • publish
setting
94
• attentions
 Add I/O module

The I/O module is suggested install in the last slot
of the last I/O rack.
 Delete I/O module
The I/O module should be deleted off-line.
 Standby channel
All the standby channels of each module should be
configured. 95
• HMI modification
 Standard panel
 Alarm panel
 Graphics
 …
Compile, publish
96
• Download
 necessary to download
modification related with control station
(controller, I/O module, signal point and control
scheme etc).
 not necessary to download
modification related with operation station
(standard panel, alarm panel, graphics and report etc).
97
Function
• Function
Usually used for motor control panel
• Workflow
Professional training creates value.
98

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Basic maintenance of DCS

Zhejiang SUPCON Technology Co.,Ltd

FLUKE, Cable Tester

System power supply

Seal up cable holes (trays)

Temperature and Humidity control

2 lines (AC and UPS) power supply

Do discharge test artificially if it works for a long time.

All equipments must be grounded

Equal potential grounding is recommended

Compliance to System grounding specification

Electrical working grounding protective grounding

equipment grounding general grounding

copper vulcanized copper chloridized

Pin> Pout, 25Pa

Seal the holes

Keep the doors and

System components management

Inspection of control station

Components management: keep clean, anti-interference…

Anti-virus: movable devices forbidden

Unnecessary multi-task forbidden

Backup important materials

Inspection of operation station

Check indicators of network components

Check dynamic data in HMI

Debug with “ping” command

Check indicators of modules

Cleaning CS, ES &OS

★ Before commissioning, do the same checking

PID parameter setting

Step 2: external loop adjusting

PID parameter setting ：

 Aging components being replaced or repaired

 No fault alarm information

 System keeping working well

Common fault : 5V, 24V indicators display

AC input abnormal Check AC input

poor grounding Check grounding

Aging components, corrosion Replace41the power supply

 The voltage of Li-Battery is lower than 3V

 Communication interface broken

 Address setting is wrong

 Power supply doesn’t meet the requirement

Check address of DTM.

 Poor contact between signal wire and terminal

 Real- time data show “?”

Vertical line part

 Communication errors of all operator stations

The path to save configuration should not too deep,

channel Parameter HMI Download,

channel Parameter HMI Download,

 Add I/O module

Professional training creates value.

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