BFRV AND CHUTE OPERATION/TROUBLESHOOTING METHOD

I. SERVO DRIVE START UP PROCEDURE AFTER POWER FAILURE

Check incoming power supply to 3DAC panel.
Then check MCB (Q10) is ON.
Then check the following MCBs
Q11 for BFRV
Q12 for stand by
Q13 for Chute
Press below mentioned Push buttons if the above conditions are satisfied
QS1 ON for BFRV
QS2 ON for Stand by
QS3 ON for Chute
The following contactors will pick up and servo drives get powered up and
indication lamps glow on panel
KM1 for BFRV
KM2 for Stand by
KM3 for Chute
The following relays will energize when the servo drive is ready to operate.
KA1 for BFRV
KA5 for Chute
KA3 for Standby
Check for any fault indications in 3DAC panel and servo drives LED display. If any
fault message is there go through alarm and fault list document inside panel,
then fault can be reset using QS1, QS2 and QS3 push buttons on 3DAC panel. The
following relays will get energized if any fault occurs.
KA2 for BFRV
KA4 for Stand by
KA6 for Chute
The following conditions are to be satisfied in 3DAC panel for BFRV drive enable
in Auto/Panel/Field modes. Any of the below conditions and KA14 (LSV open
feedback) should be active.
KA19 - BFRV auto allowed from PLC
KA25 - Servo Open for BFRV from 3DAC Panel
KA26 - Servo Close for BFRV from 3DAC Panel
KA29 - Servo Open for BFRV from field local box
KA30 - Servo Close for BFRV from field Local box
The following conditions are to be satisfied in 3DAC panel for Chute drive enable
in Auto/Panel/Field modes.
KA20 - Chute auto allowed from PLC
KA27 - Servo Open for Chute from 3DAC Panel
 KA28 - Servo Close for Chute from 3DAC Panel
KA31 - Servo Open for Chute from field local box
KA32 - Servo Close for Chute from field local box
II. PLC operation of BFRV and CHUTE
Check the below mentioned BFRV and Chute position feedback signals on SCADA
from BF hydraulic PLC panel.
BFRV Open/Close
Chute Open/Close
LSV Open
If the above feedbacks are getting on SCADA then check the following DO relays
in PLC 21 panel.
K28 for BFRV close feedback
K29 for BFRV open feedback
K30 for Chute close feedback
K31 for Chute open feedback
K32 for LSV open feedback (only applicable for BFRV operation)
SA1 selector switch on 3DAC panel should be in auto position for both BFRV and
Chute. Also SA2 and SA3 selector switches in auto position for BFRV and Chute
respectively and following relays will be active and PLC gets drive ready
feedback.
KA 24 for BFRV
KA 34 for Chute
When Auto/Manual is selected from SCADA the following relays will energize in
PLC 21 panel.
K21 for BFRV
K22 for Chute
K21 and K22 will energize KA19 and KA20 in 3DAC panel for BFRV and Chute
respectively.
LSV Open feedback should be available. Relays are,
K32 in PLC 21
KA14 in 3DAC panel

If the above conditions are satisfied, then drive will operate according to set
point given on SCADA.( -10 to +10 V Analog Input from PLC 21)
If BFRV is closed then KA10 will energize and if opened KA11 will energize.
If Chute is closed then KA12 will energize and if opened KA13 will energize.
III. Manual operation for BFRV from 3DAC panel

SA1 selector switch should be in STOP position.

KA34 and KA33 should not be active, then KA23 will energize.
When SA2 in ON position, KA25 will energize and drive gets open command and
can be controlled by potentiometer on 3DAC panel. For opening, open feedback
(KA11) should not present.
When SA2 in OFF position, KA26 will energize and drive gets close command
and can be controlled by potentiometer on 3DAC panel. For closing, close
feedback (KA10) should not present.

IV. Manual operation for Chute from 3DAC panel

SA1 selector switch should be in STOP position.

KA34 and KA33 should not be active, then KA23 will energize.
When SA3 in ON position, KA27 will energize and drive gets open command and
can be controlled by potentiometer on 3DAC panel. For opening, open feedback
(KA13) should not present.
When SA3 in OFF position, KA28 will energize and drive gets close command
and can be controlled by potentiometer on 3DAC panel. For closing, close
feedback (KA12) should not present.

Manual operation conditions for both BFRV and Chute from 3DAC panel and field local box

The following relays or KA14 (LSV open feedback) should not active in 3DAC
panel for BFRV drive manual operation from 3DAC panel or from field local box.
KA19 - BFRV auto allowed from PLC
KA25 - Servo Open for BFRV from 3DAC Panel
KA26 - Servo Close for BFRV from 3DAC Panel
KA29 - Servo Open for BFRV from field local box
KA30 - Servo Close for BFRV from field Local box

The following relays should not active in 3DAC panel for Chute drive manual
operation from 3DAC panel or from field local box.
KA20 - Chute auto allowed from PLC
KA27 - Servo Open for Chute from 3DAC Panel
KA28 - Servo Close for Chute from 3DAC Panel
KA31 - Servo Open for Chute from field local box
KA32 - Servo Close for Chute from field local box
 V. Manual operation for BFRV from field local box

SA1 selector switch should be in MANUAL position.

KA33 relay will get energized.
When SA5 in ON position, KA29 will energize and drive gets open command and
can be controlled by potentiometer on 3DAC panel. For opening, open feedback
(KA11) should not present.
When SA5 in OFF position, KA30 will energize and drive gets close command
and can be controlled by potentiometer on 3DAC panel. For closing, close
feedback (KA10) should not present.
VI. Manual operation for Chute from field local box
SA1 selector switch should be in MANUAL position.
KA33 relay will get energized.
When SA6 in ON position, KA31 will energize and drive gets open command and
can be controlled by potentiometer on 3DAC panel. For opening, open feedback
(KA13) should not present.
When SA6 in OFF position, KA32 will energize and drive gets close command
and can be controlled by potentiometer on 3DAC panel. For closing, close
feedback (KA12) should not present.
VII. How to changeover servo drive?

If any of the running drives gets failed, the following procedure can be applied
for taking the standby drive in operation.
Change selection in SCADA.
Press QS2 pushbutton on 3DAC panel. KM2 contactor will energize and standby
drive gets powered up.
Select SA4 selector switch to either BFRV or Chute position according to the
requirement.
If SA4 towards BFRV, KA21 relay will energize & BFRV standby ready lamp will
glow on 3DAC panel. If SA4 towards Chute, KA22 relay will energize & Chute
standby ready lamp will glow on 3DAC panel.
The following relays should be active for BFRV operation in standby drive.
KA19
KA24
KA14
KA21
The following relays should be active for Chute operation in standby drive.
KA20
KA24
KA22
 3DAC PANEL SERVO SYSTEM RELAYS/CONTACTORS DESCRIPTION

SR NO OPERATION RELAY TAG FROM

1 Automatic control KA24,KA34
2 BFRV Auto operation allowed KA19 PLC21, K21
3 Chute Auto operation allowed KA20 PLC21, K22
4 Manual control from 3DAC panel KA23
5 Manual Control from Local box KA33
6 Servo control KA25
7 BFRV power ON/OFF KM1
8 Chute power ON/OFF KM3
9 Standby Power ON/OFF KM2
10 Selection of BFRV standby KA21
11 Selection of Chute standby KA22
12 BFRV servo controller ready KA1
13 BFRV fault alarm KA2
14 Standby servo controller ready KA3
15 Standby fault alarm KA4
16 Chute servo controller ready KA5
17 Chute fault alarm KA6
18 BFRV open command from 3DAC KA25
19 BFRV close command from 3DAC KA26
20 Chute open command from 3DAC KA27
21 Chute close command from 3DAC KA28
22 BFRV open command from field KA29
23 BFRV close command from field KA30
24 Chute open command from field KA31
25 Chute close command from field KA32
26 BFRV close limit KA10 PLC21, K28
27 BFRV open limit KA11 PLC21, K29
28 Chute close limit KA12 PLC21, K30
29 Chute open limit KA13 PLC21, K31
30 LSV open feedback KA14 PLC21, K32