Bailey infi 90 Modular Power System II User manual

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Process Control and
Automation Solutions
from Elsag Bailey Group
E96-506
AC Modular Power System
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WARNING notices as used in this instruction apply to hazards or unsafe practices that could result in
personal injury or death.
CAUTION notices apply to hazards or unsafe practices that could result in property damage.
NOTES highlight procedures and contain information that assists the operator in understanding the
information contained in this instruction.
WARNING
INSTRUCTION MANUALS
DO NOT INSTALL, MAINTAIN, OR OPERATE THIS EQUIPMENT WITHOUT READING, UNDERSTANDING,
AND FOLLOWING THE PROPER Elsag Bailey INSTRUCTIONS AND MANUALS; OTHERWISE, INJURY OR
DAMAGE MAY RESULT.
RADIO FREQUENCY INTERFERENCE
MOST ELECTRONIC EQUIPMENT IS INFLUENCED BY RADIO FREQUENCY INTERFERENCE (RFI). CAU-
TION SHOULD BE EXERCISED WITH REGARD TO THE USE OF PORTABLE COMMUNICATIONS EQUIP-
MENT IN THE AREA AROUND SUCH EQUIPMENT. PRUDENT PRACTICE DICTATES THAT SIGNS
SHOULD BE POSTED IN THE VICINITY OF THE EQUIPMENT CAUTIONING AGAINST THE USE OF POR-
TABLE COMMUNICATIONS EQUIPMENT.
POSSIBLE PROCESS UPSETS
MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIED PERSONNEL AND ONLY AFTER SECURING
EQUIPMENT CONTROLLED BY THIS PRODUCT. ADJUSTING OR REMOVING THIS PRODUCT WHILE IT IS
IN THE SYSTEM MAY UPSET THE PROCESS BEING CONTROLLED. SOME PROCESS UPSETS MAY
CAUSE INJURY OR DAMAGE.
AVERTISSEMENT
MANUELS D’OPÉRATION
NE PAS METTRE EN PLACE, RÉPARER OU FAIRE FONCTIONNER L’ÉQUIPEMENT SANS AVOIR LU,
COMPRIS ET SUIVI LES INSTRUCTIONS RÉGLEMENTAIRES DE Elsag Bailey. TOUTE NÉGLIGENCE À
CET ÉGARD POURRAIT ÊTRE UNE CAUSE D’ACCIDENT OU DE DÉFAILLANCE DU MATÉRIEL.
PERTURBATIONS PAR FRÉQUENCE RADIO
LA PLUPART DES ÉQUIPEMENTS ÉLECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR
FRÉQUENCE RADIO. DES PRÉCAUTIONS DEVRONT ÊTRE PRISES LORS DE L’UTILISATION DU MATÉ-
RIEL DE COMMUNICATION PORTATIF. LA PRUDENCE EXIGE QUE LES PRÉCAUTIONS À PRENDRE
DANS CE CAS SOIENT SIGNALÉES AUX ENDROITS VOULUS DANS VOTRE USINE.
PERTURBATIONS DU PROCÉDÉ
L’ENTRETIEN DOIT ÊTRE ASSURÉ PAR UNE PERSONNE QUALIFIÉE EN CONSIDÉRANT L’ASPECT
SÉCURITAIRE DES ÉQUIPEMENTS CONTRÔLÉS PAR CE PRODUIT. L’AJUSTEMENT ET/OU L’EXTRAC-
TION DE CE PRODUIT PEUT OCCASIONNER DES À-COUPS AU PROCÉDÉ CONTRÔLE LORSQU’IL EST
INSÉRÉ DANS UNE SYSTÈME ACTIF. CES À-COUPS PEUVENT ÉGALEMENT OCCASIONNER DES
BLESSURES OU DES DOMMAGES MATÉREILS.
NOTICE
The information contained in this document is subject to change without notice.
Elsag Bailey, its affiliates, employees, and agents, and the authors and contributors to this publication specif-
ically disclaim all liabilities and warranties, express and implied (including warranties of merchantability and
fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information
contained herein and/or for the fitness for any particular use and/or for the performance of any material and/
or equipment selected in whole or part with the user of/or in reliance upon information contained herein.
Selection of materials and/or equipment is at the sole risk of the user of this publication.
This document contains proprietary information of Elsag Bailey, Elsag Bailey Process Automation, and
is issued in strict confidence. Its use, or reproduction for use, for the reverse engineering, development
or manufacture of hardware or software described herein is prohibited. No part of this document may be
photocopied or reproduced without the prior written consent of Elsag Bailey.
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I-E96-506B1
Preface
The AC Modular Power System supplies system and I/O power
to the components within an INFI 90®system cabinet. This
manual provides information on the IEPAS02 and IEPAF02
Power Modules and their related system hardware. Related
hardware includes the IEPEP01, IEPEP02 and IEPEP03 Power
Entry Panels, IEMMU01 and IEMMU02 Module Mounting Units,
and IEPMU01 and IEPMU02 Power Mounting Units. The infor-
mation in this manual includes a procedure for sizing the power
system, installation instructions, operating procedures, trouble-
shooting, maintenance and repair/replacement procedures.
The IEPAS02 and IEPAF02 AC Power Modules supersede the
IEPAS01 and IEPAF01 AC Power Modules and are compatible
replacements. Refer to Appendix E for more information.
® INFI 90 is a registered trademark of Elsag Bailey Process Automation.
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I-E96-506B1
®
List of Effective Pages
Total number of pages in this instruction is 95, consisting of the following:
Page No. Change Date
Preface Original
List of Effective Pages Original
iii through ix Original
1-1 through 1-7 Original
2-1 through 2-7 Original
3-1 through 3-17 Original
4-1 through 4-4 Original
5-1 through 5-7 Original
6-1 through 6-8 Original
7-1 through 7-6 Original
8-1 Original
A-1 through A-2 Original
B-1 through B-10 Original
C-1 through C-5 Original
D-1 through D-8 Original
D-1 through E-2 Original
Index-1 through Index-2 Original
When an update is received, insert the latest changed pages and dispose of the super-
seded pages.
NOTE: On an update page, the changed text or table is indicated by a vertical bar in the outer mar-
gin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the
outer margin next to the figure caption. The date the update was prepared will appear beside the
page number.
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I-E96-506B1 vii
Safety Summary
GENERAL
WARNINGS Equipment Environment
All components whether in transportation, operation, or storage
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to ensure that contact with
energized parts is avoided when servicing.
Special Handling
This module uses electrostatic sensitive devices.
SPECIFIC
WARNINGS Verify the main power and power entry panel circuit breakers are
turned off before starting installation, retrofit, upgrade, or wiring pro-
cedures. Failure to do so could result in severe or fatal shock. Do
not turn the power on until the installation, retrofit, upgrade, or wiring
procedures are complete. (p. 3-2, 3-13, 7-6, D-1)
Do not remove the plastic covers on the module mounting unit back-
plane. These covers protect against accidental contact with AC volt-
age. Severe or fatal shock could result. (p. 3-9)
Allow five seconds for the line filter capacitors to discharge before
handling the module after removal. Failure to do so could result in
severe or fatal shock. (p. 3-11, 7-5)
Handle the module by surfaces other than the heat sink. The heat
sink may be hot and may cause severe burns. (p. 3-12, 7-5)
There are exposed AC and DC connections inside the cabinet.
These exposed electrical connections present a shock hazard that
can cause injury or death. (p. 6-1)
Never clean electrical parts or components with the AC power on.
Doing so exposes you to a fatal electrical shock hazard. (p. 6-1)
If input or output circuits are a shock hazard after disconnecting sys-
tem power at the power entry panel, then the door of the cabinet
containing these externally powered circuits must be marked with a
warning stating that multiple power sources exist. (p. 6-1)
Wear eye protection whenever working with cleaning solvents.
When removing solvents from printed circuit boards using com-
pressed air, injury to the eyes could result from splashing solvent as
it is blown off the printed circuit board. (p. 6-1)
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viii I-E96-506B1
Safety Summary(continued)
®
Sommaire de Sécurité
SPECIFIC CAUTIONS Verify the line voltage select switch is properly configured before
energizing the power entry panel. Failure to do so could perma-
nently damage the PFI circuit board by exposing it to improper input
voltage levels. (p. 3-12)
AVERTISSEMENT
D'ORDRE
GENERAL
Environment de l'equipment
Ne pas soumettre les composants a une atmosphere corrosive lors
du transport, de l'entreposage cu de l'utilisation.
Risques de chocs electriques lor de l'entretien
S'assurer de debrancher l'alimentation ou de prendre les precau-
tions necessaires a eviter tout contact avec des composants sours
tension lors de l'entretien.
Precautions de manutention
Ce module contient des composantes sensibles aux decharges
electro-statiques.
AVERTISSEMENT
D'ORDRE
SPECIFIQUE
Assurez-vous que le disjoncteur d'alimentation principal et le dis-
joncteur de panneau d'entrée des alimentatoins sont éteints avant
de procéder à l'installation, à la mise à jour, à l'extension ou au
câblage, dans le but d'éviter les chocs sérieux et même mortels. Ne
rétablissez pas l'alimentation tant que ces procédures ne sont pas
terminées. (p. 3-2, 3-13, 7-6, D-1)
Ne retirez pas les couvercles de plastique situés sur le panneau
arrière du châssis de montage des modules. Ces couvercles con-
stituent une protection contre les contacts accidentels avec la ten-
sion c.a., qui risquent de provoquer des chocs sérieux et même
mortels. (p. 3-9)
Après avoir retiré le module, laissez les condensateurs de filtres
antiparasites se décharger pendant cinq secondes avant de
manipuler celui-ci, afin d'éviter les chocs sérieux et même mortels.
(p. 3-12, 7-5)
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I-E96-506B1 ix
Sommaire de Sécurité (suite)
AVERTISSEMENT
D'ORDRE
SPECIFIQUE
(suite)
Le module diot être manipulé à l'aide de surfaces autres que le dis-
sipatour thermique. Ce dernier resque d'être chaud et de provoquer
des brûlures sérieuses. (p. 3-12, 7-5)
Cette armoire comporte des connexions c.a. et c.c. dénudées. Ces
connexions électriques présentent un danger d'électrocution pou-
vant entraîner des blessures ou la mort. (p. 6-1)
Il ne faut jamais nettoyer des piècesou des composants électriques
lorsqu'ils sont sous tension. Cedi présente un risque d'électrocution
fatale. (p. 6-1)
Si des circuits d'entrée ou de sortie sont alimentés à partir de
sources externes, ils présentent un risque de choc électrique même
lorsque l'alimentation du système est débranchée du panneau
d'entrée l'alimentation. Le cas échéant, un avertissement signalant
la présence de sources d'alimentation multiples doit être apposé sur
la porte de l'armoire. (p. 6-1)
Portez toujours des lunettes de protection lorsque vous utilisez des
solvants de nettoyage. L'aircomprimé servant à enlever le solvant
des cartes de circuits imprimés provoque des éclaboussures qui ris-
quent d'atteindre les yeux. (p. 6-1)
ATTENTION D'ORDRE
SPECIFIQUE Assurez-vous que l'interrupteur de sélection de la tension de ligne
est adéquatement configuré avant de mettre sous tension le pan-
neau d'entrée des alimentations. Toute négligence à cet égard ris-
que d'endommager de facon permanente la carte de détection des
coupures d'alimentation (PFI) en l'exposant à des niveaux
inadéquats de tension d'entrée. (p. 3-12)
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Table of Contents
Page
I-E96-506B1 iii
SECTION 1 - INTRODUCTION....................................................................................................1-1
OVERVIEW ..................................................................................................................1-1
HARDWARE DESCRIPTION..........................................................................................1-1
Power Entry Panel..................................................................................................1-1
Fan Assembly ........................................................................................................1-1
Power Modules.......................................................................................................1-2
Power Mounting Units............................................................................................1-2
Module Mounting Units .........................................................................................1-2
USER QUALIFICATIONS ..............................................................................................1-2
INSTRUCTION CONTENT .............................................................................................1-2
HOW TO USE THIS MANUAL .......................................................................................1-3
REFERENCE DOCUMENTS..........................................................................................1-4
NOMENCLATURE ........................................................................................................1-4
GLOSSARY OF TERMS AND ABBREVIATIONS .............................................................1-4
SPECIFICATIONS.........................................................................................................1-5
SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1
INTRODUCTION...........................................................................................................2-1
POWER DISTRIBUTION................................................................................................2-2
POWER ENTRY PANEL.................................................................................................2-2
IEPEP01 and IEPEP02 Panels ................................................................................2-2
IEPEP03 Panel .......................................................................................................2-2
AC Transfer Module ...............................................................................................2-3
Bus Monitor Module ..............................................................................................2-3
FAN ASSEMBLY ...........................................................................................................2-4
MODULE MOUNTING UNIT..........................................................................................2-4
POWER MOUNTING UNITS ..........................................................................................2-4
POWER MODULES ......................................................................................................2-4
STATUS SIGNALS ........................................................................................................2-5
Power System Status .............................................................................................2-5
Bus Voltage Status ................................................................................................2-6
Power Module Status .............................................................................................2-6
Customer Alarm Outputs.......................................................................................2-7
SECTION 3 - INSTALLATION.....................................................................................................3-1
INTRODUCTION...........................................................................................................3-1
UNPACKING AND INSPECTION ....................................................................................3-1
Special Handling....................................................................................................3-1
General Handling...................................................................................................3-2
IEPEP03 POWER ENTRY PANEL WIRING .....................................................................3-2
AC Transfer Module ...............................................................................................3-5
Bus Monitor Module ..............................................................................................3-7
Fan Assembly ........................................................................................................3-9
Power Modules.......................................................................................................3-9
IEPEP01 AND IEPEP02 POWER ENTRY PANEL WIRING .............................................3-12
IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION ...........................3-13
Required Tools .....................................................................................................3-14
Installation in the INFI 90 Cabinet .......................................................................3-14
Wiring Instructions ..............................................................................................3-14
SECTION 4 - OPERATING PROCEDURES................................................................................4-1
INTRODUCTION...........................................................................................................4-1
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iv I-E96-506B1
Table of Contents (continued)
Page
®
SECTION 4 - OPERATING PROCEDURES
(continued)
LED INDICATORS........................................................................................................ 4-1
AC Transfer Module............................................................................................... 4-1
Bus Monitor Module .............................................................................................. 4-1
Power Module........................................................................................................ 4-2
REMOVING ATM OR BMM MODULES DURING OPERATION ....................................... 4-3
RECOMMENDED START-UP PROCEDURES ................................................................ 4-3
SECTION 5 - TROUBLESHOOTING...........................................................................................5-1
INTRODUCTION .......................................................................................................... 5-1
TROUBLESHOOTING FLOWCHARTS ........................................................................... 5-1
IEPEP01 and IEPEP02 Systems ............................................................................. 5-1
IEPEP03 Systems .................................................................................................. 5-1
SECTION 6 - MAINTENANCE.....................................................................................................6-1
INTRODUCTION .......................................................................................................... 6-1
PREVENTIVE MAINTENANCE SCHEDULE................................................................... 6-2
EQUIPMENT REQUIRED ............................................................................................. 6-3
PREVENTIVE MAINTENANCE PROCEDURES .............................................................. 6-3
Cabinet Filter Cleaning/Replacement .................................................................... 6-3
Checking Connections ........................................................................................... 6-4
Checking Power Module Outputs ........................................................................... 6-5
Checking Bus Voltages on IEPEP01 and IEPEP02 Systems .............................. 6-5
Checking Bus Voltages on IEPEP03 Systems ................................................... 6-5
Power Entry Panel Inspection and Check ............................................................... 6-6
Printed Circuit Board Cleaning .............................................................................. 6-6
General Cleaning and Washing........................................................................ 6-7
Edge Connector Cleaning ................................................................................ 6-7
Cleaning Female Edge Connectors................................................................... 6-8
SECTION 7 - REPAIR/REPLACEMENT PROCEDURES...........................................................7-1
INTRODUCTION .......................................................................................................... 7-1
SPARE PARTS.............................................................................................................. 7-1
AC TRANSFER MODULE REPLACEMENT .................................................................... 7-2
BUS MONITOR MODULE REPLACEMENT ................................................................... 7-3
FAN ASSEMBLY .......................................................................................................... 7-3
Fuse Replacement ................................................................................................. 7-3
Fan Assembly Replacement ................................................................................... 7-3
POWER MODULE ........................................................................................................ 7-4
Power Module Replacement ................................................................................... 7-4
Power Module Fuse Replacement ........................................................................... 7-5
POWER ENTRY PANEL REPLACEMENT ....................................................................... 7-6
SECTION 8 - SUPPORT SERVICES...........................................................................................8-1
INTRODUCTION .......................................................................................................... 8-1
REPLACEMENT PARTS AND ORDERING INFORMATION ............................................. 8-1
TRAINING.................................................................................................................... 8-1
TECHNICAL DOCUMENTATION................................................................................... 8-1
APPENDIX A - QUICK REFERENCE GUIDE ............................................................................A-1
INTRODUCTION ..........................................................................................................A-1
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