Bailey Infi 90 6642016 2 Series User manual

®
®
Process Control and
Automation Solutions
from Elsag Bailey Group
Relay Assembly
Part No. 6642016M2

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.

WBPEEUI210501A0
Preface
Relay Assembly part number 6642016

2 allows a Multi-Func-
tion Processor (MFP) module, through the IMDSO04/14 Digital
Output Module, to control a process using standard relays.
The outputs can be used for switching, annunciation, etc. This
relay assembly is a direct replacement for the existing standard
relay panel part number 6639890

.
This product instruction explains how to install and maintain
the relay assembly.

WBPEEUI210501A0
®
List of Effective Pages
Total number of pages in this instruction is 24, consisting of the following:
Page No. Change Date
Preface Original
List of Effective Pages Original
iii through vi Original
1-1 through 1-4 Original
2-1 through 2-7 Original
3-1 through 3-2 Original
4-1 through 4-2 Original
5-1 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.

WBPEEUI210501A0 v
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 insure that contact with
energized parts is avoided when servicing.
SPECIFIC
CAUTIONS Remove a module from its assigned slot before installing or remov-
ing a cable assigned to that slot. Failure to do so could result in
damage to the module. (p. 2-3)
Use only Elsag Bailey approved relays on the relay assembly.
Using unapproved relays could improperly route signals and dam-
age equipment connected to the relay and the relay itself. CSA cer-
tification is voided when unapproved relays are used.(p. 2-4, 4-1)
It is strongly recommended that all power (cabinet, I/O, etc.) be
turned off before doing any wiring. Verify all connections before
applying power. Failure to observe these precautions could result in
equipment damage. (p. 2-5)

vi WBPEEUI210501A0
Sommaire de Sécurité
®
AVERTISSEMENTS
D’ORDRE
GÉNÉRAL
Environnement de l’équipement
Ne pas soumettre les composants à une atmosphère corrosive lors
du transport, de l’entreposage ou l’utilisation.
Possibilité de chocs électriques durant l’entretien
Débrancher l’alimentation ou prendre les précautions pour éviter
tout contact avec des composants sous tension durant l’entretien.
ATTENTIONS
D’ORDRE
SPÉCIFIQUE
Avant de retirer ou de brancher un câble, retirez le module logé
dans la coulisse correspondante. Autrement, le module risque
d'être endommagé.(p. 2-3)
N'utilisez que des relais approuvés par Elsag Bailey les panneaux
de relais standard. Sinon, les signaux risquent d'être acheminés de
façon inadéquate et ainsi endommager l'équipement relié au relais
ou le relais lui-même. La certification CSA n'est pas valable lor-
squ'on utilise des relais non approuvés. (p. 2-4, 4-1)
Il est fortement recommandé de débrancher toute source d'alimen-
tation (armoire, E/S, etc.) avante d'effectuer du travail au câblage.
Vérifiez toutes les connexions avant de rétablir l'alimentation. Ces
précautions permettent d'éviter des dommages à l'équipement.
(p. 2-5)

Table of Contents
Page
WBPEEUI210501A0 v
SECTION 1 - INTRODUCTION....................................................................................................1-1
OVERVIEW ..................................................................................................................1-1
INTENDED USER.........................................................................................................1-1
HARDWARE DESCRIPTION..........................................................................................1-1
INSTRUCTION CONTENT .............................................................................................1-1
HOW TO USE THIS MANUAL .......................................................................................1-2
GLOSSARY OF TERMS AND ABBREVIATIONS .............................................................1-2
REFERENCE DOCUMENTS..........................................................................................1-2
NOMENCLATURE ........................................................................................................1-2
SPECIFICATIONS.........................................................................................................1-3
SECTION 2 - INSTALLATION.....................................................................................................2-1
INTRODUCTION...........................................................................................................2-1
UNPACKING AND INSPECTION ....................................................................................2-1
INSTALLATION.............................................................................................................2-1
Relay Assembly to Back Panel ................................................................................2-1
NKTU01 and NKTU11 Cable...................................................................................2-2
Relay .....................................................................................................................2-4
WIRING........................................................................................................................2-5
Coil Power .............................................................................................................2-5
Fuse Monitor ........................................................................................................2-5
Relay ....................................................................................................................2-6
SECTION 3 - MAINTENANCE.....................................................................................................3-1
INTRODUCTION...........................................................................................................3-1
PREVENTIVE MAINTENANCE SCHEDULE ...................................................................3-1
EQUIPMENT AND TOOLS REQUIRED ..........................................................................3-1
PREVENTIVE MAINTENANCE PROCEDURES...............................................................3-2
CHECKING CONNECTIONS .........................................................................................3-2
SECTION 4 - REPAIR/REPLACEMENT PROCEDURES...........................................................4-1
INTRODUCTION...........................................................................................................4-1
RELAY ........................................................................................................................4-1
FUSE ...........................................................................................................................4-1
RELAY ASSEMBLY.......................................................................................................4-2
SECTION 5 - SUPPORT SERVICES...........................................................................................5-1
INTRODUCTION...........................................................................................................5-1
REPLACEMENT PARTS AND ORDERING INFORMATION ..............................................5-1
TRAINING ....................................................................................................................5-1
TECHNICAL DOCUMENTATION ...................................................................................5-1

vi WBPEEUI210501A0
No. Title Page
List of Figures
®
2-1. Relay Assembly and Back Panel Dimensions ......................................................... 2-2
2-2. Relay Assembly Cable Connection ......................................................................... 2-3
2-3. Typical Relay Application....................................................................................... 2-6
2-4. Relay Assembly Schematic..................................................................................... 2-7
List of Tables
No. Title Page
1-1. Glossary of Terms and Abbreviations ..................................................................... 1-2
1-2. Reference Documents ............................................................................................ 1-2
1-3. Nomenclature........................................................................................................ 1-3
1-4. Relay Assembly Specifications ............................................................................... 1-3
1-5. Relay Specifications............................................................................................... 1-3
2-1. Relay Assembly Cable Applications ........................................................................ 2-3
3-1. Preventive Maintenance Schedule.......................................................................... 3-2
5-1. Spare Parts List..................................................................................................... 5-1

OVERVIEW
WBPEEUI210501A0 1 - 1
SECTION 1 - INTRODUCTION
OVERVIEW
The INFI 90®OPEN Relay Assembly (part number 6642016

2)
provides a conventional process interface for INFI 90 OPEN
system applications. Sixteen electromechanical relays, each
providing two Form C contacts, operate in conjunction with
standard INFI 90 OPEN IMDSO04/14 I/O modules. These out-
puts can be used for switching, annunciation, etc.
INTENDED USER
Personnel installing, operating, or maintaining the standard
relay assembly should read this manual before performing any
installation, operation, or maintenance procedures. Installa-
tion requires an engineer or technician with experience in han-
dling electronic circuitry.
HARDWARE DESCRIPTION
The relay assembly circuit board is 189 millimeters
(7.43 inches) wide by 356 millimeters (14 inches) high. It is
mounted on a back panel that is 483 millimeters (19 inches)
wide by 356 millimeters high. Two relay assembly circuit
boards can mount on one back panel. The assembly fits into an
INFI 90 OPEN cabinet and other standard 483-millimeter
(19-inch) wide electronics racks. The relay assembly is
equipped with 16 relays. Each relay is socketed for easy,
plug-in replacement. Connector P1 accepts NKTU01 or
NKTU11 cables connected to an IMDSO04/14 Digital Output
Module.
INSTRUCTION CONTENT
This manual contains five sections:
Introduction Contains an overview of the features, specifications and a
description of the standard relay assembly.
Installation Describes precautions to observe when handling the relay
assembly and installation procedures required for assembling
the relay assembly on the back panel and wiring connections
for power and fuse monitoring.
Maintenance Provides a maintenance schedule.
Repair/Replacement
Procedures Details how to replace a defective relay or relay assembly.
® INFI 90 is a registered trademark of Elsag Bailey Process Automation.

INTRODUCTION
HOW TO USE THIS MANUAL
1 - 2 WBPEEUI210501A0
®
Support Services Describes the support services (spare parts, training, docu-
mentation, etc.) available from Elsag Bailey.
HOW TO USE THIS MANUAL
Read this manual through in sequence. Read the installation
section thoroughly. It is important to become familiar with the
entire contents of this instruction before using the relay
assembly. Refer to the table of contents or index to find specific
information after the standard relay assembly is operating.
1. Read and perform all steps in the installation section.
2. Refer to the maintenance section for scheduled mainte-
nance requirements.
3. Go to the repair/replacement procedures section to find
instructions on how to replace the relays or relay assembly.
4. Refer to the support services section for replacement part
and warranty information.
GLOSSARY OF TERMS AND ABBREVIATIONS
Table 1-1 lists definitions of abbreviations used in this instruc-
tion that are unique to Elsag Bailey.
REFERENCE DOCUMENTS
Table 1-2 lists the documents referenced in this instruction.
Refer to it as needed.
Table 1-1. Glossary of Terms
and Abbreviations
Term Definition
IMDSO04/14 Digital output module
Table 1-2. Reference Documents
Number Document
I-E96-285 Rail Termination System
I-E96-313 IMDSO04 Digital Output Module

INTRODUCTION
NOMENCLATURE
WBPEEUI210501A0 1 - 3
NOMENCLATURE
Table 1-3 is a list of related hardware.
SPECIFICATIONS
Table 1-4 lists the specifications for the relay assembly. Table
1-5 lists the specifications for just the relay.
Table 1-3. Nomenclature
Nomenclature Description
6641067

1 Termination back panel
IMDSO04/14 Digital output module
NKTU01 Termination unit cable (PVC)
NKTU11 Termination unit cable (non-PVC)
Table 1-4. Relay Assembly Specifications
Property Characteristic/Value
Power requirements +24 VDC at 895 mA; 21.1 W typical (all relays energized)
Outputs 2 Form C contacts per relay (maximum of 16 relays)
Socket material and flame rating Nylon. Socket flame rating UL 94-V2
Socket CTI (comparative tracking
index)1260-399
Mounting Requires 356-mm (14-in.) vertical space of an INFI 90 OPEN cabi-
net or standard electronics mounting rack.
Two relay assemblies can be mounted side-by-side on a back
panel, part number 6641067

1
Ambient temperature When mounted in an enclosure or cabinet, the temperature rating
within the enclosure or cabinet shall apply. INFI 90 OPEN internal
cabinet rating: 0° to 70°C (32° to 158°F)
Relative humidity 5% to 95% up to 55°C (131°F), noncondensing
5% to 45% above 55°C (131°F), noncondensing
Air quality Noncorrosive
Accessories Relay hold down spring for securing the relay to the relay assem-
bly printed circuit board connector.
Order by part number: 1949479

1
Certification
(pending) CSA certified for use as process control equipment in an ordinary (nonhazardous) location
NOTE:
1. Refer to UL746C and IEC664A for CTI (comparative tracking index) information.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

INTRODUCTION
SPECIFICATIONS
1 - 4 WBPEEUI210501A0
®
Table 1-5. Relay Specifications1
Property Characteristic/Value
Contact data
Type 2 Form C (2PDT)
Material Silver cadmium oxide
Rating 10 A
Load switching
120 VAC, 24 VDC 125 VDC
10 A @ 80% PF 3A
NOTE: Blow out magnet for switching high voltage
direct current (125 VDC) loads.
Coil data
Voltage (nominal) 24 VDC
Voltage range 18 VDC to 26 VDC
Power 1.8 W @ 24 VDC
Resistance 320 Ω@ 25°C (77°F)
Operating time 15 ms (excluding bounce)
Release Time 10 ms (excluding bounce)
Temperature range -45° to +50°C (-49° to 122°F)
Dielectric strength
Between open contacts 1200 V rms
Between adjacent contacts 2200 V rms
Between contacts and coil 2200 V rms
Life expectancy 100,000 operations (within specifications)
Cover material and flame
rating Clear polycarbonate. Flame rating UL 94-V2
Cover CTI (comparative
tracking index)2600
NOTES:
1. Relay specifications apply to Elsag Bailey part number 1949480

1.
2. Refer to UL746C and IEC664A for CTI (comparative tracking index) information.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

INTRODUCTION
WBPEEUI210501A0 2 - 1
SECTION 2 - INSTALLATION
INTRODUCTION
This section explains how to install a relay assembly (part
number 6642016

2). Read, understand, and complete the
steps in the order they appear before operating a relay assem-
bly.
UNPACKING AND INSPECTION
1. Examine the hardware immediately for shipping damage.
2. Notify the nearest Elsag Bailey sales office of any such
damage.
3. File a claim for any damage with the transportation com-
pany that handled the shipment.
4. Use the original packing material and container to store the
hardware.
5. Store the hardware in an environment of good air quality,
free from temperature and moisture extremes.
INSTALLATION
The required installation steps are installing the relay assem-
bly on to the back panel, installation of the back panel into the
cabinet, and terminal block wiring.
Relay Assembly to Back Panel
The relay assembly with back panel requires 356 millimeters
(14 inches) of vertical space in an INFI 90 OPEN cabinet or
standard electronics mounting rack. The back panel sides are
slotted for mounting onto any standard 483-millimeter
(19-inch) EIA mounting rails. One or two relay assemblies can
be mounted vertically on one relay back panel (Fig. 2-1).
To install a relay assembly, use the following procedure.
1. Verify that the power is removed from the cabinet or rack
receiving the relay assembly.
2. Align the protrusions on the relay assembly board with the
slots in the back panel. Slide into position. Install two screws
in the holes marked for ground on the relay assembly board
and tighten to secure the board to the back panel. Repeat this
step if a second relay assembly is being installed.

INSTALLATION
INSTALLATION
2 - 2 WBPEEUI210501A0
®
3. Position the relay assembly and back panel in the desired
location in the cabinet or rack.
4. Align the mounting bolt cutouts, located on both sides of
the back panel, with the nearest mounting holes in the vertical
mounting rails of the cabinet or rack.
5. Secure the relay assembly and back panel to the mounting
rails with the hardware supplied.
NKTU01 and NKTU11 Cable
The relay assembly connects to the IMDSO04/14 Digital Out-
put Module using the NKTU01 or NKTU11 termination unit
cable. This cable passes the digital output signals of the
IMDSO04/14 module to the relays on the relay assembly. Refer
to Table 2-1 and Figure 2-2 for additional information.
Figure 2-1. Relay Assembly and Back Panel Dimensions
TP80579A
483
19.00
189
7.43
356
14.00
DIMENSIONS
MILLIMETERS
INCHES
RELAY ASSEMBLY
BACK PANEL
19513311715210614412816
19513311715210614412816
K1 K4K3K2
19513311715210614412816
19513311715210614412816
K5 K8K7K6
19513311715210614412816
19513311715210614412816
K9 K12K11K10
19513311715210614412816
19513311715210614412816
K13 K16K15K14
TB8
TB7
TB6
TB4
TB2
F1
MON. E3
E5
E6
RH
250 V
½A
F1
TB5
TB3
TB1
250 V
½A
F2
F2
MON. E4
+24
VDC E1
I/O
COM E2
P1
1
33
4
36
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
19513 311 715 210 614 412 816
K1K4 K3 K2
K5K8 K7 K6
K9K12 K11 K10
K13K16 K15 K14
TB8
TB7
TB6
TB4
TB2
F1
MON.
E3
E5
E6
RH
250 V
½A
F1
TB5
TB3
TB1
250 V
½A
F2 F2
MON.
E4
+24
VDC
E1
I/O
COM
E2
P1
1
33
4
36

INSTALLATION
INSTALLATION
WBPEEUI210501A0 2 - 3
CAUTION Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could
result in damage to the module.
ATTENTION Avant de retirer ou de brancher un câble, retirez le module logé dans la coulisse correspondante. Autrement, le module risque
d'être endommagé.
Table 2-1. Relay Assembly Cable Applications
Cable
Connections Maximum
Length
From To
Device Connector Device Connector m ft
NKTU01 (PVC) IMDSO04/14 P3 Relay assembly P1 70.2 230
NKTU11 (non PVC)
Standard 12 to 20
AWG wire Field and power wiring Field deviceor power source Relay assembly Appropriate terminal
blocks
N/A N/A
Figure 2-2. Relay Assembly Cable Connection
TP80601A
19513311715210614412816
19513311715210614412816
K13 K16K15K14
TB8
TB7
F1
MON. E3
E5
E6
RH
250 V
½A
F1
19513311715210614412816
19513311715210614412816
K9 K12K11K10
TB6
TB5
19513311715210614412816
19513311715210614412816
K5 K8K7K6
TB4
TB3
19513311715210614412816
19513311715210614412816
K1 K4K3K2
TB2
TB1
250 V
½A
F2
F2
MON. E4
+24
VDC E1
I/O
COM E2
P1
1
33
4
36
P1
P3
IMDSO04
IMDSO14
P2
NKTU01
NKTU11
J1
END J2 END

INSTALLATION
INSTALLATION
2 - 4 WBPEEUI210501A0
®
To install the cable:
1. Turn the IMDSO04/14 module latching screws ½-turn
either way to release them.
2. Pull the IMDSO04/14 module out several inches from the
module mounting unit backplane.
3. Insert the J2 end of the cable into the module mounting
unit backplane slot assigned to the IMDSO04/14 module.
4. Insert the J1 end of the cable into the P1 connector on the
relay assembly board.
5. Insert the IMDSO04/14 module into the module mounting
unit until the rear edges are firmly seated in the backplane
connectors.
6. Turn the two latching screws ½-turn either way to lock the
module into the module mounting unit.
Relay
Relays are included with the relay assembly and should
already be installed.
To install a relay:
1. Verify the relay is the same type listed in Table 5-1.
2. Align the keyed center prong of the relay with the keyed
center hole of the relay socket.
3. Push the relay into the relay socket until it is firmly seated.
4. If the optional hold down spring is installed, position the
wire clip over the relay to secure the relay to the board.
CAUTION
Use only Elsag Bailey approved relays on the relay assembly.
Using unapproved relays could improperly route signals and
damage equipment connected to the relay and the relay itself.
CSA certification is voided when unapproved relays are used.
ATTENTION
N'utilisez que des relais approuvés par Elsag Bailey sur les
panneaux de relais standard. Sinon, les signaux risquent d'être
acheminés de façon inadéquate et ainsi endommager l'équipe-
ment relié au relais ou le relais lui-même. La certification CSA
n'est pas valable lorsqu'on utilise des relais non approuvés.

INSTALLATION
WIRING
WBPEEUI210501A0 2 - 5
WIRING
Wiring for the relay assembly consists of connecting the power
wiring, fuse monitor wiring and relay contact wiring.
Coil Power
NOTE: Proper polarity of all signals must be maintained.
To connect coil power wiring:
1. Feed the power wiring into cabinet or rack and to the area
of the relay assembly circuit board.
2. Connect a 14 AWG wire from the +24 VDC source within
the cabinet to the +24 V terminal (E1) of the relay assembly.
3. Connect a 14 AWG wire from the DC common bus bar at
the bottom of the cabinet to the I/O COM terminal (E2) of the
relay assembly.
Fuse Monitor
The fuse monitor output terminals F1 MON and F2 MON allow
the condition of fuses F1 and F2 to be monitored. The condi-
tion of the fuses is monitored by connecting these terminals to
a power sensing device such as a 24 VDC input circuit. The
relay panel supplies a logic 1 (fuse good and power present) or
logic 0 (fuse blown or no power) signal. To connect fuse monitor
wiring:
1. Feed the fuse monitor wiring into the area of the relay
assembly.
2. Connect the appropriate positive (+) fuse monitor wire (cus-
tomer wiring) to the F1 MON terminal (E3) of the relay
assembly.
3. Connect the appropriate positive (+) fuse monitor wire (cus-
tomer wiring) to the F2 MON terminal (E4) of the relay
assembly.
CAUTION
It is strongly recommended that all power (cabinet, I/O, etc.) be
turned off before doing any wiring. Verify all connections
before applying power. Failure to observe these precautions
could result in equipment damage.
ATTENTION
Il est fortement recommandé de débrancher toute source d'ali-
mentation (armoire, E/S, etc.) avante d'effectuer du travail au
câblage. Vérifiez toutes les connexions avant de rétablir l'ali-
mentation. Ces précautions permettent d'éviter des dommages
à l'équipement.

INSTALLATION
WIRING
2 - 6 WBPEEUI210501A0
®
4. Connect the negative (-) fuse monitor wires (customer wir-
ing) for both fuses to the SYS COM bus bar.
Relay
NOTE: Elsag Bailey strongly recommends that the appropriate
safety precautions be observed when connecting field wiring to a
relay assembly.
Wiring of the relay contacts is dependent on how the field
devices are to be controlled. This is the responsibility of the
customer. Figure 2-3 shows an example of wiring for two field
devices connected to the relay assembly with power and device
wiring supplied by the customer. Refer also to the following
notes that apply to Figure 2-3.
NOTES:
1. Maximum wire size for relay board connections is 12 AWG.
2. Maximum current from the relay assembly is 10 A.
3. All inductive loads to be suppressed with the suppressor
installed at the field device.
Refer to Figure 2-4 for a schematic diagram of the relay assem-
bly.
Figure 2-3. Typical Relay Application
(83)
S4
S5
S6
S7
S8
S9
S10
S11
DOGRP
TB1-1
TB1-3
TB1-2
TB2-1
TB2-3
TB2-2
+
–
K1
1
TB1-1
TB1-3
TB1-2
TB2-1
TB2-3
TB2-2
+
–
K2
3
TB1-1
TB1-3
TB1-2
TB2-1
TB2-3
TB2-2
+
–
K3
5
TB1-1
TB1-3
TB1-2
TB2-1
TB2-3
TB2-2
+
–
K4
7
DO1
DO2
DO3
DO4
FIELD DEVICE
2
FIELD DEVICE
1
SPARE
24 V
TP80604A
TO BREAKER
OR FUSE
ARC
SUPPRESSOR
+
+
+–
–
–
CUSTOMER POWER

INSTALLATION
WIRING
WBPEEUI210501A0 2 - 7
The relay assembly is ready for operation if:
1. Fuses are installed and verified good.
2. Relays are properly installed.
3. All required cables and wires are installed and verified.
4. Power is connected and applied to the relay assembly.
Figure 2-4. Relay Assembly Schematic
GROUND E5 1
110
3
TB1-13
TB2-13
TB2-15
TB2-14
TB1-14
TB1-15
11
5
4
9
7
K4
110
3
TB1-9
TB2-9
TB2-11
TB2-10
TB1-10
TB1-11
11
5
4
9
7
K3
110
3
TB1-5
TB2-5
TB2-7
TB2-6
TB1-6
TB1-7
11
5
4
9
7
K2
110
3
TB1-1
TB2-1
TB2-3
TB2-2
TB1-2
TB1-3
11
5
4
9
7
K1
110
3
TB3-13
TB4-13
TB4-15
TB4-14
TB3-14
TB3-15
11
5
4
9
7
K8
110
3
TB3-9 TB3-5 TB3-1
TB4-9 TB4-5 TB4-1
TB4-11 TB4-7 TB4-3
TB4-10 TB4-6 TB4-2
TB3-10 TB3-6 TB3-2
TB3-11 TB3-7 TB3-3
11
5
4
9
7
K7
110
311
5
4
9
7
K6
110
311
5
4
9
7
K5
110
311
5
4
9
7
K12
110
311
5
4
9
7
K11
110
311
5
4
9
7
K10
110
3
TB5-1TB5-5TB5-9TB5-13
TB6-1TB6-5TB6-9TB6-13
TB6-3TB6-7TB6-11TB6-15
TB6-2TB6-6TB6-10TB6-14
TB5-2TB5-6TB5-10TB5-14
TB5-3TB5-7TB5-11TB5-15
11
5
4
9
7
K9
110
311
5
4
9
7
K16
110
311
5
4
9
7
K15
110
311
5
4
9
7
K14
110
3
TB7-1TB7-5TB7-9TB7-13
TB8-1TB8-5TB8-9TB8-13
TB8-3TB8-7TB8-11TB8-15
TB8-2TB8-6TB8-10TB8-14
TB7-2TB7-6TB7-10TB7-14
TB7-3TB7-7TB7-11TB7-15
11
5
4
9
7
K13
P1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1E1
1E2
1E3
1
-24V
1947180A36
F1 MON.
I/O COM.
F2 MON.
GROUND E5
CCOM
1
E4
F1 - ½A
F2 - ½A
TP80602A

INTRODUCTION
WBPEEUI210501A0 3 - 1
SECTION 3 - MAINTENANCE
INTRODUCTION
The reliability of any stand-alone product or control system is
affected by the maintenance of the equipment. Elsag Bailey
recommends that all equipment users practice a preventive
maintenance program that will keep the equipment operating
at an optimum level.
This section presents procedures that the customer should be
able to perform on site. These preventive maintenance proce-
dures should be used as a guideline to assist in establishing
good preventive maintenance practices. Select the minimum
steps required to meet the cleaning needs of the system.
Personnel performing preventive maintenance should meet the
following qualifications.
•Maintenance personnel should be qualified electrical tech-
nicians or engineers that know the proper use of test equip-
ment.
•Maintenance personnel should be familiar with the relay
assembly, have experience working with process control
systems, and know what precautions to take when working
on live AC systems.
PREVENTIVE MAINTENANCE SCHEDULE
Table 3-1 is the preventive maintenance schedule for the relay
assembly. The table lists the preventive maintenance tasks in
groups according to their specified maintenance interval. Some
tasks in Table 3-1 are self explanatory. Instructions for tasks
that require further explanation are covered under PREVEN-
TIVE MAINTENANCE PROCEDURES.
NOTE: The preventive maintenance schedule is for general pur-
poses only. Your application may require special attention.
EQUIPMENT AND TOOLS REQUIRED
The tools and equipment required for maintenance procedures
are:
•Antistatic vacuum.
•Bladed screwdriver suitable for terminal blocks.