Phoenix Mecano wiener PL508 User manual

Water Interconnection Revision
Service Manual

14. Dezember 2015 I W-IE-NE-R
General Remarks
The purpose of this manual is to describe the required procedure to complete the
modification of the power supplies water cooling system.
W-IE-NE-R revises this product and manual without notice. Differences of the
description in manual and product are possible.
With this service manual, the user received a specific training from a
W-IE-NE-R authority. Therefore the trained user himself received precautions and
advises to be aware for possible damage occurring during service. If any of the
revisions causes malfunction of one or more products, a regular RMA has to be
opened with W-IE-NE-R or its contractor.
Safety advises referring to W-IE-NE-R Power supplies will be made at the
beginning of the Manual. Each user has to follow additional safety advises of its
home institution. W-IE-NE-R assumes that only certified electricians with familiarity
of IEC 60364-4-41 (2005-12) or comparable rules to prevent electrical shocks will
do the service. In any case, W-IE-NE-R is not responsible for direct or indirect
influences of health of human beings.
Products mentioned in this manual are mentioned for identification purposes only.
Product names appearing in this manual may or may not be registered trademarks
or copyrights of their respective companies.
No part of this manual may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language in any form by any means without
the express written permission of W-IE-NE-R.
In case of questions or problems don’t hesitate to contact our contractor
Magentasys, they my assist you or forward your concerns.
They’re located in 13/R-023 at Cern
W-IE-NE-R Plein & Baus GmbH
Linde 18
51399 Burscheid
Germany
[phone]
[e-mail]
MagentaSys
15, chemin de Sous-la-Ville
1272 Genolier
Switzerland
[phone]
[e-mail]

14. Dezember 2015 II W-IE-NE-R
Field of Application
This manual was made for one specific reason. – The revision of water
interconnections of W-IE-NE-R Power supply Units. Analogue given advises may
or may not correspond to other work steps given in other service manuals.
W-IE-NE-R does not recommend trying repair attempts to defective units
depending on advises given in this manual. W-IE-NE-R excludes completely any
liability for loss of profits, loss of business, loss of use or data, interrupt of
business, or for indirect, special incidental, or consequential damages of any kind,
even if W-IE-NE-R has been advises of the possibility of such damages arising
from any defect or error in this manual.
W-IE-NE-R gives a qualified training using a customer given selection of power
supplies instead. In case of issues / questions during the modification, please
contact our support.
Part number ranges of power supplies considered in this Manual:
0M02.xxxx, 0M05.xxxx, 0M21.xxxx, 0M22.xxxx, 0M24.xxxx
0P17.xxxx / 0P47.xxx
Further also referred to as PL508, PL512, Power-Supply or Maraton
according to CERN Database

14. Dezember 2015 III W-IE-NE-R
TABLE OF CONTENTS
1. Safety advice................................................................................................... 1
1.1. Charged Capacitors and Discharging........................................................ 1
1.2. Weight and Lever ...................................................................................... 1
1.3. Attention and awareness........................................................................... 1
1.4. General safety of electrical devices........................................................... 1
1.5. Functionality .............................................................................................. 1
1.6. Unit identification....................................................................................... 1
2. What to Do and Why ....................................................................................... 2
2.1. PL 5xx / Maraton – Watercooled ............................................................... 2
3. Preparations.................................................................................................... 3
3.1. Check for damage..................................................................................... 3
3.2. Purge......................................................................................................... 3
4. Opening the Power supply .............................................................................. 3
4.1. Capacitor Discharge.................................................................................. 5
4.2. Access to the Interior................................................................................. 6
4.3. Hints .......................................................................................................... 6
5. Modification..................................................................................................... 7
5.1. Main Differences between Units................................................................ 7
5.1.1.Standard Units („PFC“).............................................................................. 8
Front cover removal PFC...............................................................................9
5.1.2.Radiation Hard Units („MNE“).................................................................. 10
Front cover removal MNE............................................................................11
Backside access...........................................................................................11
5.2. Amount of Modules.................................................................................. 12
5.3. Age of Units / Different Tubing................................................................. 12
5.4. The Connector Block............................................................................... 13
Dismounting of Connector Block................................................................13
5.5. PFC Modification..................................................................................... 14
5.6. The Legris Tube ...................................................................................... 15
Cutting & Marking...........................................................................................15
Bending Radius / kinking................................................................................15
Plug & Unplug.................................................................................................16
Tube Circuitry / Typical Lengths.....................................................................16
6. Checkup, Front and Rear closing.................................................................. 17
7. Closing the Power supply.............................................................................. 19

14. Dezember 2015 IV W-IE-NE-R
8. Electrical tests ............................................................................................... 21
9. Leakage Check (AIR).................................................................................... 19
9.1. Check Procedure..................................................................................... 20
10. Pressure Test (Water)................................................................................... 20
10.1. Check Procedure..................................................................................... 20
11. Appendix ....................................................................................................... 21
11.1. List of Recommended Tools / Environment............................................. 22
11.2. Tubing examples (with water flow direction)............................................ 23
11.3. Pressure / Purge Environment Sketch..................................................... 24

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1. SAFETY ADVICE
The modification of Wiener power supplies, especially the work inside of them
requires a high level of attention. Further in this chapter, special advises should
extend the given state of knowledge to personal safety.
1.1. CHARGED CAPACITORS AND DISCHARGING
W-IE-NE-R Power supplies use an internal Voltage of 385VDC including
capacitors charged to this level. It is strongly recommended to use a
discharge resistor. How to identify the correct points to discharge and the
recommended resistor will be explained in chapter 4.1.
1.2. WEIGHT AND LEVER
The power supplies included in this revision are provided with a red lever.
This lever is designed to engage the units into the power bin, be careful not
to pinch your fingers.
Don’t underestimate the weight of the power supply units. Especially the
Magnetic Tolerant types contain iron shielding and weigh up to 30kg per
unit. Please follow general safety rules for proper handling bigger amounts
of heavy objects, available at your institutions safety advisor.
1.3. ATTENTION AND AWARENESS
Keep in mind that you want to improve running systems. Not to destroy
them. Therefore please raise awareness and attention while performing the
necessary steps advised by W-IE-NE-R employees and this manual.
1.4. GENERAL SAFETY OF ELECTRICAL DEVICES
Please note that this manual does not disable the electrical safety rules.
After modification, each unit has to be tested for electrical safety.
1.5. FUNCTIONALITY
A complete functional test before and after modification is highly
recommended to prevent damage on the unit or its environment.
1.6. UNIT IDENTIFICATION
It is highly recommended to mark the modified units. This prevents double
work. Please get in contact with PH-ESE for a unified marking and
database management.

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2. WHAT TO DO AND WHY
Now, that you are ready to begin the modification, it‘s the right moment to
hesitate and think about what you’ll do in the next time while following this
manual.
2.1. PL 5XX /MARATON –WATERCOOLED
W-IE-NE-R delivered a vast amount of watercooled power supplies to
CERN in the last decade. There are about 40 different units in use, a
complete amount of over 500 power supplies. They differ from each other in
many aspects depending on the experiments and collaborations. The
important differences will be explained later at 5.1. After longer operating
times it turned out that the build in water connectors get in trouble with
electrochemical corrosion. This caused leakage and damage in the past.
Therefore it is important to replace the old interconnections with new ones,
made out of stainless steel, capable of running over a long period without
problems. Further analyses of those issues are available at Vincent Bobilier
in the PH-ESE group.
Analysis figured out, that the main problem consists of 90° angled
connectors, at least 2 are used in every unit. According the named analyses
W-IE-NE-R supplies prepared and tested connection blocks, Legris tubes
and tools for tubing application as seen at chapter 5.6 .They will be
available in the PH-ESE group. This manual will show up how to exchange
those Blocks.

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3. PREPARATIONS
Before you can start, it is important to prepare your workspace. You’ll need
a stable, rugged surface with enough space for about 2x2 power supplies to
get best possible access. We recommend prefer plastics instead of wooden
surfaces due to possible abrasion. A complete list of tools / environment will
be given in chapter 11.1.
3.1. CHECK FOR DAMAGE
At first ensure that you have a functional and fully operational unit in front of
you. W-IE-NE-R recommends for this type of modification to refuse work on
obviously damaged units. Those should be declared for RMA to ensure
proper maintenance. To have a better approach of view if the unit doesn’t
work after modification, we recommend performing a functional test before
and after modification.
3.2. PURGE
Before opening the Power supply it is important to purge out all remaining
Water. Therefore connect a sufficient air supply with about 7bar to one of
the CPC Connectors (further CPC). Then use an open end CPC (or open
the external Valve if present) on the other Terminal. A connected tube
would be strongly recommended to dump the water where you want. Slowly
open the air supply, be aware that the connected Tube may swing around
when opening to fast! When the water is dumped, wait for about 5-10
seconds until the vapor fog disappears.
Please see chapter 11.3 for an Idea how to set up your environment.
If available, use oil filters for your air supply. Unless the amount of oil in the
pressure air system is small it could be better if you are in worry about your
cooling water cirquitry. See chapter 5.6 for further information about the
Tube.
DO NOT CHANGE THE PRESSURE RLIEF VALVE SETTING!
4. OPENING THE POWER SUPPLY
General precautions should be followed to improve the Quality of work.
We recommend to:
•Use a separate box for each screw type used in the power supplies,
also differentiate the lengths
•Clean the screw head from abrasion if needed before untighten it
•Don’t touch the interior before discharging.
•Please differ in loosening and removal of screws as told further. It
may save the units - and maybe your own health, too!
At first, remove the screws as seen in the uppermost Image, (referring to
chapter 5.3 you might ignore the back cover) and flip the unit upside down

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to begin with loosen the marked screws. Yet, it might be better not to
remove all screws, just let some in to hold the parts in place.
Only the red handle on the front and the bottom cover should be removed
now.

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4.1. CAPACITOR DISCHARGE
Discharge the capacitors by connecting two 10W / 47ΩResistors parallel to
the terminals as shown in the pictures. You may get better access by
removing the screws holding the front cover.
MNE
PFC