E96-506 Modular Power System BaileWARNING notices as used nths manual apply to hazards or unsate pract ces wh ch cou d resut n personal nyury or death CAUTION not ces apply to hazards or unsafe pract ces wh ch cou d resut n property damage NOTES high ight procedures and contan nformat on whch assst the operator n understand ng the information conta ned 1 this manua WARNING INSTRUCTION MANUALS DONOT NSTALL MA NTA NOROPERATE TH SEQU PMENT W THOUTREAD NG UNDERSTAND NG AND FOLLOW NG ‘THE PROPER Balley Controle NSTRUCT ONS AND MANUALS OTHERW SE NJURY OR DAMAGE MAY RESULT RADIO FREQUENCY INTERFERENCE MOST ELECTRON CEQU PMENT S NFLUENCEDBY RAD OFREQUENCY NTERFERENCE (RF ) CAUT ONSHOULDBE EXERC SED W TH REGARD TO THE USE OF PORTABLE COMMUN CAT ONS EQU PMENT NTHE AREA AROUND SUCH EQU PMENT PRUDENT PRACT CED CTATES THAT S GNS SHOULD BE POSTED NTHE VC N TY OF THE EQU PMENT ‘CAUT ON NG AGA NST THE USE OF PCRTABLE COMMUN CAT ONS EQU PMENT POSSIBLE PROCESS UPSETS MA NTENANCE MUST BE PERFORMED ONLY BY QUAL F ED PERSONNEL AND ONLY AFTER SECUR NG EQU PMENT CONTROLLED BY TH SPRODUCT ADJUST NG OR REMOV NG TH S PRODUCTWH LE T'S NTHESYSTEMMAY UPSET ‘THE PROCESS BE NG CONTROLLED SOME PROCESS UPSETS MAY CAUSE NJURY OR DAMAGE AVERTISSEMENT MANUELS D'OPERATION NE PAS METTRE ENPLACE REPARER OUFA RE FONT ONNER CE MATER EL SANS AV ORLU COMPR SETSU V LES. NSTRUCT ONS REGL MENT A RES OE Balley Controls TOUTE NEGL GENCE A CET EGARD PRA TETRE UNE CAUSE DACC DENT OU DE DEFAILLANCE DU MATER EL PERTURBATIONS DE LA FREQUENCE RADIOPHONIQUE, LA PLUPART DES EQU PEMENTS ELECTRONIQUES SONT $ NS BLES AUX PERTURBAT ONS DE LA FREQUENCE RAD O DES PRECAUT ONS DEVRONT ETRE PR SES LORS DE LUT L SAT ON DE MATER EL DE COMMUN CAT ON, PORTATF LA PRUDENCE EXGE QU LES PRECAUT ONS A PREDRE DANS CE CAS SOENT SGNALEES AUX ENDRO “S VOULOUS DANS VO"RE US NE PERTES PROCEDE RENVERSEMENTS: LENTRET ENDO TETRE ASSURE PAR UN PERSONNEL QUAL F EETENCONS DERAT ONDE ASPECT SECUR TA RE DESEQU PEMENTS CONTROLES PARCEPRODU T L ADJUSTEMENTETIOUL EXTRACT ON ECE PRODU TLORSQU L EST NSERE AUN SYSTEME ACT F PELT OCCAS ON NNER DES A COUPS AU PROCEDE CONTROLE SUR GERTA NS. PROCEDES CES A COUPS PEUVENT E GALEMENT OCCAS ONNER DES DOMMAGES OU BLESSURES, NOTICE The nformaton contaned nth s documert s subject to change w thout not ce Ba eyContros Company tsaft ates empoyees andagents and the authors of and contr butors toth s pub caton specfica y dscama ab tes and warrant es express and mip ed (tc udng warrant es of merchantab ty and fines for a partcu ar purpose) forthe accuracy currency competeness andiore ab ty ofthe nformat on conta ned here n and’or forthe! tness for ‘any part cu ar use andlor for the performance of any mater a and/or equ pment se ected n who or part wth the user ofr 1 re ance upon ntormat onconta nedheren Se ect on ofmater a sand/orequ pent sattheso er s3 voc) GENERAL Radio Frequency Va ues not ava lab e at ths t me Interference Keep cab net doors c osed D2 not use ‘commun cat on equipment any c oser than 2 meters from the cabinet Mounting Power Supply Modules occupy one slot in the, NF 90 Module Mount ng Unt (MMU) Fastens ‘to MMU w th two half turn latches on the face pate Physical Dimens ons IECABO1 Cabinet He ght 87 nehes (220 cm) Width 24 inches (61 om) Depth 30 nches (76 cm) We ght {800 pounds maximum (362 kg) SPEC F CAT ONS (cont aves) 17INTRODUCTION Baillely) SPECIFICATIONS (cont nuse) GENERAL (cont nus) Physical Dimensions Pos EreuT Rowers na Ta fe —| 10/249 we oraz: va |] ayeoe She | weer Fee | nr ar moarnuucs Joss Ear] _ way = me Figure 2 1, Modular Power System Architecture Block Diagram NTRODUCTION E96 506A 24THEORY OF OPERATION POWER ENTRY PANEL JEPEPO1 IEPEPOS AC Transfer Module POWER ENTRY PANEL 22 Baile The AC bus bar distributes AC power from the Power Entry Panel to the Module Mounting Unit backplanes The bus bar has quick connect tabs to connect cables from the panel and to the mounting unit ‘The eight layer DC Bus Bar distnbules regulated DC volt ages, Power Module Status and Power Fal Interrupt signals This bus bar also has quick connect tabs A cable from the Power Entry Panel to the DC bus bar allows the system to monitor bus voltages and status signals High current, multi conductor flat cables connect regulated voltage outputs and status signals from the MMU backplane to the bus bar Extra tabs are available at the bottom of the DC bus bar for con necting +24 VDC 1/0 power to field termination units or to other cabinets Tabs are also available to connect DC com mon and I/O common to the system safety common bus bar at the cabinet bottom ‘The IEPEPOL connects 120/240 VAC (50/00 Hz) line power to an Infi 90 system cabinet and distributes power to the Power Supply Modules and Fan Assembly This version has no circuit breakers There are two terminal blocks One 1s for line input, the other for output to the AC bus bar for distribu tion to the power modules The PEP has surge suppression and filtering to protect the power modules An internal circuit board monitors input line voltage It generates a Power Fail Interrupt (PFI) signal for low voltage or a loss of voltage The panel mounts in any standard 19 inch rack frame ‘The IEPEPO3 connects single or redundant 120/240 VAC (50/60 Hz) ine power to an Inft 90 system cabinet It also distributes power to the Power Supply Modules and Fan As sembly This version has circuit breakers for each power line input Like the IEPEPOI, this panel also has surge suppres sion and filtering ‘Two modules reside in the PEP They are the AC Transfer Module and Bus Momtor Module These modules and their functions are discussed next The AC Transfer Module (ATM) monitors both AC mputs and its own cireutry If an AC input 1s lost or faulty, the module automatically transfers to the redundant input ‘The ATM generates a Power Fail Interrupt signal sf both lines are lost or below the low voltage threshold It sends this signal to TESS 506KTHEORY OF OPERATION the Bus Monitor Module (BMM) The BMM sends the PEI signal to the appropnate process control modules, thereby interrupting their operation Visible through the front panel are three LED indicators The red/green LED at the top shows whether the module is operating normally (green) or not (red) The two other LEDs (LINE 1 and LINE 2) provide AC input status (green good, red bad) ‘The Bus Monitor Module (BMM) monitors the regulated bus voltages (+5, +15, 15 and +24 VDC) and module status from the distribution bus bar A cable connection between the bus bar and the J2 connector on the PEP provides the path The BMM can also monitor two additional external power supply voltages at the PEP terminal blocks User configured ump ers allow the module to momitor esther 24, 48 or 125 VDC for up to two auxihary power supplies There are two open col lector or contact inputs for monitonng system status signals ‘Two red/green LEDs on the module's faceplate provide sta tus mformation The topmost LED shows whether the module ts operating properly (green) ornot (red) The System Status LED 1s red when voltages are low or other inputs are bad The Status Signal goes to the Communication System hardware, which 1s the Bus Interface Module for Plant Loop ‘Systems, and the Network Interface Slave for Infi Net Sys tems Once on the Communication Loop, any Infi 90 operator interface can use the signal There are two alarms PWR SYS ALARM and BUS VOLT ALARM The PWR SYS ALARM becomes active when a power system problem occurs The BUS VOLT ALARM be comes active when any bus voltage (+5, +15, 15 or +24 VDC) falls out of tolerance The BMM also generates a Power Fail Interrupt (PFI) signal if st receives a PFI from the AC Trans fer Module, or if the +5 VDC bus voltage 1s low It distributes this signal to process control modules 1n the Infi 90 system cabinet NOTE: The Bus Mon tor Module rece ves powar trom the AC Trans fer Modu e Therefore the AC Transfer Modu @ must be npace and ‘operat ng propery betora the Bus Mon tor Modue w work The Fan Assembly (IEFAN01/02) contains sx fans that mount in one chassis Its purpose is to keep the power sup phes cool The fans draw cooling air up through the Module Mounting assembles and force it through exhaust vents (when present) in the top of the cabinet door FAN ASSEMBLY =~ Bus Monitor Module ~~ FAN ASSEMBLY ~~ E96 506K 23‘THEORY OF OPERATION MODULE MOUNTING UNIT ‘The Module Mounting Unit (IEMMUO1/02) provides mount ing for the power modules and process control modules Two five conductor flat cables link the Power Fail Interrupt and Power Module Status signals, +5, +15, 15 and +24 VDC from the DC Bus Bar to the MMU A three wire cable from the AC Bus Bar to the MMU backplane supplies the power modules with AC Cables are required to connect the communication busses between multiple MMUs The Module Bus uses a three wire, twisted cable, while the Slave Expander Bus uses a flat, 40 conductor mbbon cable POWER SUPPLY MODULES The AC System Power Module (IEPASO1) converts the 120/240 VAC at the MMU backplane to a primary voltage of 325 VDC nominal DC to DC Converters convert this pn mary voltage to secondary regulated voltages of +5, +15, 15 and +24 VDC These voltages travel through the DC Bus Bar to other Module Mounting Units for distribution to process control modules See Figures 2 Zand 2 3 suse PomEP ENTP« PAI EL DET ne Fonte Fa Bel d 48 vic 50 ste 10 pmocess| cuit. fees Figure 2 2 Block Diagram Power Distribution to the PAS MODULE MOUNT NG UN T. 24 E96 506A,THEORY OF OPERATION =~ = Lb ronmw =i © eure onmmen ~ © wv ervownaune Daan ass © wre stow © onmerae sto Figure 2-3 Block Diegram PAS Converter and Status Circuitry Alll output voltages are preset at the factory In an N+1 redun dant environment, proper operation of each module’s output 1s based on this preset voltage If an output requires more current, the module automatically compensates NOTE: The factory presat vo tages are not fed adjustab © ‘The AC Field Power Module (IEPAFO1) 1s functionally the same as the IEPASO] except that it provides only +24 VDC The IEPAFO1 provides power to field termination devices when separate termination cabinets are used, or when it 1s desirable to separate the I/O power supplies from the module power supplies _— POWER SUPPLY MODULES E06 506A 25THEORY OF OPERATION ul STATUS SIGNALS The block diagram in Figure 2 4 shows the flow of status signals through the system The following text explains this flow Figure 2 4 Status Signal Block Diagram STATUS S GNALS. 26 TESS 506ATHEORY OF OPERATION Power System Status Bus Voltage Status Power Module Status a Customer Alarm Outputs ~ TE96 506K All status lines (AC line, Bus Voltages, External Power In puts, External Customer Status Inputs and Power Module Status) are ANDed in the Bus Monitor Module Internal Bus Monitor circuitry determines if any status line 1s bad If any status 1s bad, the Bus Monitor Module generates a low true output signal to the communication system hardware, which 1s the Bus Interface Module for Plant Loop Systems, and the Network Interface Slave for Infi Net Systems The DC Bus voltages are ANDed together in the BMM and output to an isolated customer alarm output If any bus volt age signal falls out of specification, a Bus Voltage Alarm 1s, generated The Power Modules generate their own status signals These signals travel on the Bus Bar to the the Bus Monitor Module The Bus Monitor Module then ANDs this signal with the other status signals If it or any other signal 1s bad, a Power System Status alarm 1s generated There are two customer alarm outputs Bus Voltage and Power System Status Alarm The Bus Voltage alarm 1s nor mally closed Tt activates (opens) af any bus voltage goes low ors lost The Power System Status Alarm activates for any bad status. These outputs are optically isolated and can dive relays or annunciator panels STATUS $ GNALS 2:7BaliINTRODUCTION SECTION 3 - INSTALLATION Completely install and prepare (1,2, attach winng to terminal blocks, etc ) the hardware before applying power This sec tion explains hardware preparation in detail UNPACKING AND INSPECTION HANDLING Special Handling TE06 506A The power modules are in separate packages from the rest of the power system Handle these modules per the steps in Handling. NOTE: Aways use Ba ey s Fed Statc Kt (wrst strap ground cord assemby a gatore p P/N 194838542) when work ng with modu es Tho kt 8 des gned to connect a tachn can and the stat ¢ Ad ssipative work surface to the sama ground po nt ta pravent dam age to the modu ¢s by @ ectrostatc d scharge The Power Supply Modules use Electrostatic Sensitive (ESD) devices Follow Steps 1 through 4 when handling 1 Keep the modules m their special anti static bag until you are ready to install them in the system Save the bag for future use 2° Ground the anti static bag before opening 3. Venfly that all devices connected to the module are prop erly grounded before using them 4 Avoid touching the cxrouitry when handling the module 1 Examune the hardware immediately to verify that it has not been damaged 1n transit 2 Notify the nearest Bailey Controls 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 orginal packing matenal and container to store the hardware INTRODUCT ON a4INSTALLATION ‘SYSTEM INSTALLATION SYSTEM _NSTALLAT ON 2 5 Store the hardware mn an environment of good air quahty, free from temperature and moisture extremes. ‘The following factors determine location of the system cab net 1 Humidity must not go above 95% noncondensing at 55° (31°F) 2. Floor must have load bearing of 800 pounds 3.3 foot clearance both front and back for opening cabinet doors 4 A source for single phase 120/240 VAC, 30 amp standard service must be available Refer to Product Instruction I E93 900 5, Site Planning Preparation and Equipment Installation for additional infor mation ‘The standard cabinet configuration 1s Power Entry Panel at the top, with the Fan Assembly placed between the Power Entry Panel and the Module Mounting Units See Figure 31 NOTE Norma y your cab net $ fu y wred and ready to go upon fecep The fo owng nformaton 8 prov ded n the event that you Need to repar rep ace rewre add ate ATM SLOT pm sLor 120/240 VAG N AC BUS BAR nosis Figure 3.1 System Cabinet (Rear View) TES6 506AINSTALLATION OFF as you do these steps. Do not turn this breaker on until the instructions tell you. ‘Au moment d'effectuer ces etapes, velller a ce que le dis- Joncteur de l’alimentation de ligne colt ETEINT. N’allumer le disjoncteur qu’a I’etape Indiquee dans le manus NOTE: Pug your wrst strap ground cord nto the receptace a bbe ed WR ST STRAP GND when work ng wth the system 1 Place circuit breakers CBI and CB2 (Figure 3 2) on the front of the panel to the OFF position before connecting AC power input wining 2. Connect 120 VAC or 240 VAC pnmary ac power to TBI 1, TB1-2 and TBI 3. 3__ Connect the secondary ac power input (if used) to TBI 4, ‘TBI-5 and TBI-6, Both inputs must be the same nominal voltage level If only one ac power input is being used, proceed with Step 4 If not, skip to Step 5 4 Connect TBI-1 to TBI 4, TB1 2 to TBI-5, and TBI 3 to TBI-6. Use 12 AWG minimum, 6 AWG maximum Note E96 506A ’ Power Entry Panel (IEPEPO3) WARNING AVERTISEMENT ~ =~ 0616 Figure 3 2. Curcutt Breakers CB1/CB2 ‘SYSTEM INSTALLAT ON 33INSTALLATION ‘SYSTEM NSTALLATON, 34 that this step avoids false bad status information because it connects line 1 and line 2 inputs together 5 Connect cable 6637813 1 from J2 on the Power Entry Panel to the DC Bus Bar. This provides connections to sam ple the DC bus voltages, monitor the Power Module Status Signal and to output a Power Fail Interrupt signal Sec the winng diagrams at the end of this manual (Foldout 1) for correct DC bus bar connections 6 Connect cable 6637814 1 from TB2 terminals 4, 5, and 6 on the panel to the AC bus bar for distribution of az power to the Module Mounting Unit 7 Connect cable 6637818 1 from the AC bus bar to each Module Mounting Unit backplane 8 Connect the Fan Assembly power cable to connector J4 labeled FAN OUT on the panel 9 Connect a wire equivalent to power wirng but not less than 10 AWG from the GND stud of the panel to the cabmet frame for AC safety grounding 10 There are two extra voltage monitor inputs available to monitor customer external power supply voltages Use ter minal block TB4 labeled AUX BUS MONITOR for this purpose Attach one input fo terminals 1(+) and 2(~) labeled CHI. Connect the other mput to terminals 3(+) and 4(-) labeled CH2 Inputs can be +24, +48 or +125 VDC Set sumpers J1 and J2 for the desired voltage Refer to Table 3 21n the Bus Monitor Module section 11_ Wire the auxihary status inputs to Termmal Block TB3, terminals 1, 2 (COM), and 3 (STATUS IN). Ensure that the inputs are low true, open collector or contact type referenced to DC common (terminal COM) The alarm inputs must have the current carrying capability to sink at least 1 mA If the system uses Plent Loop, do Step 12 If not, go to Step 13 12. Connect cable 6634205 1 from TBS terminal 4 STATUS OUT to the P3 card edge connector of the Bus Interface Module (BIM) Doig so enables the BIM to send the status message to the Loop Interface Module (LIM) and to the Plant Loop Go to Step 16 13 Connect an 18 AWG wire from TB3 terminal 4 STATUS. OUT to TBI terminal 8 on the NTCLO1 Termination Unit TES6 506ATESS 506A AC Transfer Module INSTALLATION 14 If redundant Network Interface Slave Modules are beng used with the NTCLO1 Termination Unit a. Put two 18 AWG wires on a lug Attach the lug to TB3 terminal 4 STATUS OUT b Attach the primary wire to TBI terminal 8; the secondary to TB3 termnal 8. 15. If redundant Network Interface Slave Modules are being sed with the NICLOL Termination Module a Put two 18 AWG wires on a lug Attach the lug to TB3 terminal 4 STATUS OUT b Attach the primary wire to TB2 terminal 4; the secondary toTB2 terminal 5. 16 Use TB3 terminals 5, 6, 7 and 8 for connecting the alarms Use 18 AWG wire Terminals 5(+) and 6(~) are labeled PWR SYS. These are the output connections for the Power System Alarm Terminals 7(+) and 8( ) labeled BUS VOLT are the bus voltage alarm annunciators NOTE: Wre your system per the coor codes n the wrng da grams of Fo dout 1 atthe end of ths manua Before installing the AC Transfer Module, set switch S1 to the rear for 120 VAC operation (silkscreened 110 on board), or to the front for 240 VAC operation (sikscreened 220 on board) See Figure 3 5 for switch location NOTES: + Butt the AC “ia ser ard Bus Mor tor Modu es niount from the ‘cab net The AC Transfer Modue mounts n the Bus Mon tor Modu e mounts n the r ghtmost s ot ‘The board edge connectors are keyed to prevent mount ng n ncor oct s ots 2 Ba carefu not to bump switch 1 when nsta_ng the AC Transfer Modue Accdenta y moving the swich to the 240 poston w cause the modu. to go nto arror mode. To mount the module 1 Grasp the sides of the faceplate 2. Line up cirouit board edges with card guides in Power Entry Panel opening 3. Gently shde the module in until it locks in place SYSTEM NSTALLAT ON 35INSTALLATION ‘Bus Monitor Module igure 3 3 AC Transfer Module Switch SI Before mounting the Bus Monitor Module, set switch SI and jumpers J1/J2 Refer to Tables 3 1 and3 2 for recommended ‘settings see Figure 3 4 for locations. Table 3 1 Bus Monstor Module Switch Settings Switch | Factory si | Sening_| Funetion 2 0 | Mon or system 24 VDC enabled Sue "Mon tor extera power GHt suppy dsabied 4 Mor tor externa power CH2 suppydsabed Notes 10. Enabe (Cosed or ON) 1 D sab o (Open ot OFF) 2. Unused monitor nputs must be pul nO sob 6 poet on 3 Donoter ‘Wichas et once Dong so cause @ Bad Status ¢ gna Table 3 2 Bus Monitor Module Jumper Settings Jumper | _ Setting Function Z| yt | 12 _| Seects 24 VC teve tor external power Ej on 24 | Selects 48 VOC eve for extema power bla 2.9" | Seecis 125 VOG evel or externa power s ve 12 ‘Se ects 24 VDC eve for externa power 22 24 | Seects 48 VOC love for external power 5 | ve | 28" | Sects 125 VDC leve tor external power + Factory eet ng SYSTEM NSTALLATON a6 TEO6 506AINSTALLATION Figure 3 4 Bus Monitor Module Fan Assembly The Fan Assembly (Figure 3 5) mounts directly beneath the Power Entry Panel and above the first Module Mounting Unit Attach the fan power cable to the J4 connector on the Power Entry Panel = Figure 3 5 Fan Assembly SYSTEM INSTALLAT ON TEoe 506m 37INSTALLATION Power Supply Modules WARNING AVERTISSEMENT SYSTEM NSTALLAT ON. 38 Power Supply Modules (Figure 3 6) mount directly in the Module Mounting Unit (MMU) Any slot except the nghtmost (Sot 12) can be used Install the modules per Steps 1 through, 5 and as shown in Figure 3 7 This installation scheme pro vides the best heat dissipation and power distribution NOTES: 1. For opt mum heat ss paton and power dstrbut on do not exceed more than two EPASO1 modues n any Modu e Mount ng unt 2 _nsta at east one EPASO! modue nthe Modu e Mount ng Unt wth the argest oad (eg an MMU contanng severe Mut Funct on Processor Modu es) ‘The plastic covers on the module mounting unit backplane protect against accidental contact with ac Do ne remove these covers. Les couvercles de plastique de jue arriere du chassis de montage des modules (mmu) assurent une protection contre exposition au courant alternatif. No pas retirer ces couvercles. Before handling the Power Supply Modules + Venfy that all devices connected to the module are properly grounded before using them + Avoid touching the circuitry when handling the module + Always use grounding straps (field static kits) when Working ‘with the modules 1 Set Jumper Jt for 120 or 240 VAC operation Jumper pins 1 and 2 (position B) for 240 VAC; pins 2 and 3 (position A) for 120 VAC See Figure 3 6 2. Set Jumper J2 for bus voltage monitoring Jumper pins 1 and 2 (position A) for #24 VDC monitonng only, pins 2 and 3 (position B) for +5, +15, 15 and #24 VDC monitoring NOTE: When using the IEPAFOI, use postion A Tn fotentiometers R5 and R6 are factory set and locked into position Do not attempt to re-adjust them. 3. Grasp the module faceplate handle TESS 506A,INSTALLATION Be oO Q 5 jo Oo} |O ae E06 506A Figure 3 6 Power Supply Module (IEPASO1 shown) i 1S E78 901 I : Tost tt A A eG 5 s| yi 7 + 1 P P : A A > le 2 T 5 E Pie A alo riser Tepe A A : 5 s Figure 3 7 Recommended Power Supply Module Layout 4 Ahgn the top and bottom edges of the cirowit board with the guides in the Module Mounting Umit 5 Hold the module by the faceplate handle and shde it into the slot, push until the rear edges are firmly seated in the backplane connectors 6 Firmly press the module handle as you use a blade screw dnver to push and turn the two concentric screws one half turn clockwise to lock the module in place ‘SYSTEM INSTALLATION 39INSTALLATION WARNING AVERTISSEMENT WARNING AVERTISSEMENT To remove the module, push and turn the two concentric screws one half turn in either direction Shde the module part way out To prevent shock when removing the Power Supply Module, wait 5 seconds to allow line filter capacitors to discharge before handling the module. Then, slide the module the rest of the way out. Do not grab the module by the heat sink (it may be hol), support it by the bottom edge of the circuit board, Pour eviter les chocs electriques, attendre 5 secondes avant de toucher au module afin de permetire la dissipation de energie emmagasinee dans les condensateurs de filtration. On peut ensuite retirer le module completement en le tirant vers sol Ne pas tenir le module au niveau du dissipateur thermique, mais plutot au niveau de fa partie inferieure de la carte de dircutts Imprimes. Disconnect power before Installing dipshunts for slave mod- ules on the MMU backplane (slave expander bus). Failure to do 80 could result in severe or fatal shock. Couper ('alimentation avant d'installer les dipshunts sur la plaque arriere du chassis de montage de modules (MMU). Toute negligence a cet egard constitue un risque de choc pouvant entrainer des blessures graves, voire moretlles. POWER ENTRY PANEL (IEPEPO1) NOTE Ths Power Entry Pane requres you to suppy an externa rout breaker of fuse The breaker oF 1use must 8 ade 10 nang e the current and vo tage sted n Spec feat ons n Section 1 1 Set the slide switch (accessible through the chassis) to either 120 V or 240 V depending on your line voltage This 1s used for the Power Fail Interrupt (PFI) detection cucuit for determining low level or loss of input See Figure 3 8 CAUTION ATTENTION Improper switch setting can cause permanent damage to the PFI Board if exposed to the higher input voltage. Un reglage Inadequat des Interrupteurs peut entrainer des carte PFI (interruption due a une POWER ENTRY PANEL (EPEPO? 3 10 TES6 506AComer > INSTALLATION Figure 3 8 IEPEPO1 Rear View 2. Connect cable 6638084 1 from connector PFI on the rear of the panel to the DC Bus Bar for distribution to the process control modules in the cabinet 3. Connect cable 6637814 1 from TB2 on the rear of the panel to the AC Bus Bar for distribution to the Module Mount ing Unit backplanes Thus supphes the power to the Power Modules 4 Plug the Fan Assembly power cable into the FAN OUT. connector on the rear of the panel 5 Connect a wire equivalent to the power wiring but not less than 10 AWG from the GND stud of the panel to the cabinet frame for AC safety grounding (see Foldout 2, Wir sng Diagram for wire color) 6 Apply power by connecting the 120/240 VAC, 50/60 Hz power input to terminal block TBI on the rear of the panel NOTE: We your system per the co or codes n the wrng d agram of Fodout 2 CONNECTING MULTIPLE MODULE MOUNTING UNITS ‘Most system cabinet configurations have multiple Module Mounting Units There must be continuity between each of the MMU busses This requires two cable assemblies the three wire, twisted cable for Mcdule Bus, and the flat, 40 conductor nbbon cable for Slave Expander Bus NOTE. For proper operat on and max mum nose reducton con ‘ect the cab es 80 that the bus = a a serpent ne arrangement Ths ‘8 mnates the dead end stubs wh ch cause ref ect ons and over/un dershoot See F guie3 9 CONNECT NG MULT PLE MODULE MOUNTING UN TS TE96 506A ottINSTALLATION Module Bus Cable (Three Wire, Twisted parr) 1 Attach one end of the cable to the second column of three tabs on the lower left of the MMU backplane (facing from behind) 2. Attech the other end of the cable to the first column of three tabs on the lower left of the next MMU backplane ‘Slave Expander Bus Cable (Ribbon) 1 Attach the cables as shown in Figure 3.9. 2 Insert the nbbon connector in the hole in the upper MMU backplane (bottom position) Shde the latch to the left to lock into place Insert the bottom nbbon connector in the lower MMU holes (top position) Slide the latch to the night to lock into place Repeat this until all MMUs are ted together {youconno0n ll oooeonanonn 3 iL. OO000000000 0) Si¥--———______—, LiL NORTUOROH pe Figure 3 9 Connecting Cables to Multiple Module ‘Mounting Units (CONNECT NG MULT PLE MODULE MOUNT NG UN TS 312INTRODUCTION LED INDICATORS AC Transfer Module Bus Monitor Module Power Supply Module E96 506A SECTION 4 - OPERATION ‘This section covers what must be known to operate the Modular Power System The first part of this section pro vides a step by step approach to start up The remainder of this section explains the LED indicators on the AC Transfer, Bus Monitor and Power Supply Modules, and other general operating mformation NOTE: The Modu ar Power System requ res no user ca braton a ‘components are factory ca brated When the Modular Power System 1s operating, observe the Status LEDs The following paragraphs explain how to interpret these LEDs Also, refer to Table 4 1 The AC Transfer Module has three LEDs Module Status, Line 1 and Line 2 All LEDs are red/green When the system 1s receiving power and operating normally, the Module Sta tus LED 1s green, as are the Line 1 and 2 Status LEDs The only tme the Module Status LED tums red is if the module fails A failure means that the ntenally generated supply voltages or references have fallen below the mimmum ac ceptable level In a redundant supply line configuration, a failure in the pnmary input turns Line I LED red, a failure in the secondary input turns Line 2 LED red The Bus Monitor Module has two LEDs Module Status and System Status The Module Status LED 1s green when the module 15 operating properly It turns red if the module fails A failure means that the internally generated supply voltages or references have fallen below the mimmum acceptable level The System Status LED 1s green when everything in the system 1s satisfactory If for some reason a bus voltage fails or falls out of tolerance, one of the AC inputs fails, external status, auxiliary power supply inputs are low, or the ATM fails, the LED turns red ‘The Power Supply Module has one LED Module Status This LEDs green when the module 1s operating normally It turns red if an overload occurs, if one or more outputs fail, or if temperature goes beyond acceptable levels NTRODUCTION 4OPERATION ely! Table 4 1 LED Conditions [ modute LeD/Color Condition Status Green Normal Red — Modue has fa ed A™. Lne #1 Green Lne #1 nput s good Red |Lne#1 nputhas ta ed Line #2 Green |Lne #2 input s good Red |Lne #2 input has ta ed Status Green | Norma Red | Modue has fa ed BMM t = system Green | Norma Status Red _| Bad Power System Status Pasjpar | Status Green |Norma Red | Over oad fa ure or overtemperature AC TRANSFER MODULE/BUS MONITOR MODULE REMOVAL DURING OPERATION ‘While the Power System 1s in operation, do not remove the AC Transfer Module without first verifying that line 1 1s operational When the ATM 1s removed, 1t causes the system to transfer to hne 1 If the ATM had already transferred from line 1 to line 2 because of a problem, the whole system will go down when the ATM ts removed Before removing the ATM, line 1 must be operational Additionally, removal of the ATM takes the Bus Mon.tor Module off Isne as it 1s powered by the AC Transfer Module To avord unintentional tnggening of the PET signal when han dling the Bus Monitor Module or the AC Transfer module msert or remove the Bus Monitor Module only when the AC ‘Transfer Module remains in its designated slot RECOMMENDED START UP PROCEDURES: Follow the procedures in Steps 1 through 7 before applying power to the system 1 Verify that all connections are secure 2. Ensure that all unused AC Bus Bar receptacles are cov ered with insulated receptacles AC TRANSFER MODULE/BUS MON TOR MODULE REMOVAL DUR NG OPERAT ON a2 E96 506AOPERATION 3. Install the Power Modules only (refer to Installation sec ‘ion for details) 4 Turn power on 5. Measure the bus voltages at the test jacks of the Bus Monitor Module (+5, +15 and 15 VDC are with respect to MOD COM, +24 VDC with respect to 1/0 COM) Acceptable levels are +475VDC to +525VDC for +5 VDC #1465 VDC to +1575VDC for +15 VDC 1465VDC to 1575VDC for 15 VDC +15VDC for +24 VDC 6 When the bus voltages are at acceptable levels, start adding process contro! modules NOTE. A rod status ght at ths pont may nécate an over oad condton or detect ve modue ths happens rep ace the suspect power modue {the condton st exsts add power modu es per the formu a n Secton 1 7 Continue adding process control modules until the system cabinet is filled 8 For optimum cooling, put blank faceplate (Bailey P/N 6636586 A1) in any unused slots RECOMMENDED START UP PROCEDURES TESS 506K 43Bailie- SECTION 5 - TROUBLESHOOTING INTRODUCTION ‘The flowcharts in Figures 5-1, -2 and 3 represent basic troubleshooting procedures. They are not mtended to be all ‘encompassing Forstep-by step details, refer to the support ive text following these charts Ca [se | Ca Seo io! PACE Nn < Ss — ee

t] see, LE = Figure 5 1 Power Entry Pane! (IEPEP03) Troubleshooting Flowchart INTRODUCT ON TE96 506K B14TROUBLESHOOTING. oon ec rem Feat wk Lee ee SFLME Levees " att Figure 5 2 Bus Monitor/Power Supply Module Troubleshooting Flowchart INTRODUCTION 52 7 TESS 506A,TROUBLESHOOTING es SPF yes SGAAL LOW u. a 7] 7S ponte te D0 POWER ‘Module are correctly set for the voltage levels beng moni tored (refer to Table 3 2 for jumper settings) 16 If switch settings are okay, measure the voltages be tween terminals 1 and 2 and/or terminals 3 and 4 of TB4 on the PEP Voltages should be greater than 22 VDC sf set for 24 VDC greater than 44 VDC if set for 48 VDC greater than 115 VDC if set for 125 VDC If the voltages are correct, there 1s a problem in one of the auxiliary status mputs (STATUS IN) at terminal block TB3 on the PEP. 17 Measure the voltage from terminal 1 and/or terminal 3 with respect to terminal 2 of TB3 If either voltage measures less than 25 VDC, the mput status 1s bad To venify the ‘external device causing the bad status, remove the suspect input wire The SYSTEM STATUS LED should turn green if the external device was pulling the put low Troubleshooting 1EPEPOt Systems ‘With IEPEPOL Systems, only the AC power input is moni tored There are no bus voltage or other power system status indicators on the Power Entry Panel If AC input power is ost or goes low, a Power Fail interrupt (PFI) signal is sent to the process control modules Follow Steps 1 through 5 to troutleshoot the system 1 Check System and I/O power If System and 1/0 power are good, an overload condition may exist in the Power Sup- ply Modules 2. Check for red Status LEDs on Power Supply Modules 3 Install additional Power Supply Modules. 4 Check Power Supply Modules that had red LEDs If they are still green, they have failed Remove and replace them 5 Check PFI signal [fit 1s good the Power Entry Panel has failed and must be replaced Thns should be done by a quali fied technician or serviceman INTRODUCT ON TE96 506K 3-5Baile!SECTION 6 - MAINTENANCE INTRODUCTION ‘While the Modular Power System requires minimal mainte nance, it 1s very smportant for long, troublefree service Please note that only qualified personnel should perform maintenance MAINTENANCE SCHEDULE Table 6 11s the maintenance schedule These tasks are tobe performed at the specified intervals. Table 6 1 Maintenance Schedule E task totervt i ‘Gean and t ghten al power and | grounding connect ons Every 6 months or dur ng plant shutdown, wh chever comes f rst =~ Verity a 6 fans are operat onal Use a stat c safe vacuum cleaner to remove dust from. Every 6 months or dunng p ant Modu es. shutdown, whichever comes f rst Modu e Mount ng Unt Fans Power Entry Pane NTRODUCT ON TEO6 506K 61TE96 506A SECTION 7 ~ REPAIR/REPLACEMENT PROCEDURES INTRODUCTION SPARE PARTS Although the Modular Power System 1s designed to give long, troublefree service, some components may need to be re placed penodically ‘This section explains the procedures for replacement and lists recommended spare parts, ‘The parts in Table 7 1 are Bailey recommended spare parts, Bailey suggests having at least one of each on hand to mint muze system downtime NOTE, Use a8a ey F ed Statc Kt when work ng w th the modu es ‘AC TRANSFER MODULE REPLACEMENT NOTES: 1. The AC Transter Modu e can be removed under power t not s Mon tor Modue goes off ne when the AC Transfer joved The Bus Montor Modu e MUST BE removed FIRST Then remove the AG Transfer Module 3 Moasure_ne 1 10 vor ty that ts oporat ona and wth a to erence (#102 to +182 VAC for 120 VAC nput +204 to +264 for 240 VAC. put) f ne 1S good you can remove the AG Transfer Modu e without os ng power to the cabnet {ne 1 snot good tum off the Power Entry Pane crcut breaker for ne 1 before you remove the modue To replace the AC Transfer Module 1 Grasp the Bus Monitor Module's lower faceplate, push the Jatch up and slide the module out 2. Grasp the lower faceplate, push the latch up and slide the module out 3. Set switch SI on the replacement to match the setting of the ATM ust removed 4 Insert the replacement AC Transfer Module. Grasp it by the faceplate Align the top and bottom edges of the circutt board with the guides in the panel 5 Hold the module by the faceplate and shde it into the slot, push until the rear edges are firmly seated in the backplane connectors, INTRODUCT ON 71REPAIR/REPLACEMENT PROCEDURES Bailey) 6 Remsert the Bus Monitor Module Grasp it by the face plate Algn the top and bottom edges of the circuit board with the guides in the panel 7 Hold the module by the faceplate and slide it mto the slot, push until the rear edges are firmly seated n the backplane connectors ‘BUS MONITOR MODULE REPLACEMENT FAN ASSEMBLY Fuse Replacement NOTE: The Bus Montor Modue can be removed under power Hop ace w in anotner Bus Mon tor Mou # &5 Soon as poss be To replace the Bus Monitor Module 1 Grasp the lower faceplate, push the latch up and slide the module out 2. Set switch SI and jumpers J1/J2 on the replacement to match the settings of the BMM you have just removed 3. Grasp the replacement module by the faceplate 4. Align the top and bottom edges of the cucutt board with the guides in the panel 5 Hold the module by the faceplate and shide st into the slot, push until the rear edges are firmly seated in the backplane connectors To replace a fuse 1 Unplug Fan Assembly Remove fuseholder cover Remove fuse from fuseholder Replace with identically rated fuse (eg, AGC2 for EFANOI (120 VAC), AGC! for IEFANO2 (240 VAC)) 1 Fan Assembly Replacement 1 Unplug Fan Assembly. 2 Remove the four screws that attach the assembly to the cabinet frame BUS MON TOR MODULE REPLACEMENT. 72 E96 506ATESe S06R REPAIR/REPLACEMENT PROCEDURES 3. Gently slide the assembly out Be careful not to disturb other cabinet wining 4 Verify that replacement assembly 1s the same rating as the one just removed 5. Shide replacement assembly in 6 Secure with the four screws removed in Step 2 7 Plug power cord into Power Entry Panel 8 Listen for fan rotation NOTE: Power Suppy modu #s can be removed under power 1 Use a flat blade screwdnver to turn the two concentne screws one half turn in either direction Shde the module part way out To prevent shock when removing the Power Supply Module, walt 5 seconds to allow line filter capacitors to discharge before handling the module. Then, slide the module the rest of the way out. Do not grab the module by the heat sink (it may be hot); support it by the kottom edge of the circuit board Pour eviter les chocs electriques, attend: de toucher au module afin de permett energie emmagasinee dans les condensatours de filtration. On peut ensulte retirer fe module completement en le tirant vers sol. Ne pas tenir le module au niveau du dissipateur thermique, mals plutot au niveau de la partie Inferleure de la carte de dircults imprimes. 2. Grasp the faceplate handle and slide the module out 3. Once the module has cooted, lay it on the anti static mat 4 Locate fuse Fl (at the rear of the module by the P1 edge connector See Figure 3 6 5 Use a fuse removel tool to extract fuse Fl 6 Insert anew 2 amp slow blow fuse ~~ POWER SUPPLY MODULE Fuse Replacement =~ WARNING AVERTISSEMENT =~ POWER SUPPLY MODULE 73REPAIR/REPLACEMENT PROCEDURES. Module Replacement Follow Steps 1 through 3 for Fuse Replacement 1 Set the jumper settings on the replacement module to match those of the one yust removed 2. Grasp the replacement module by the faceplate 3._Ahgn the top and bottom edges of the circutt board with, the guides in the panel 4 Hold the module by the faceplate and slide st unto the slot push until the rear edges are firmly seated in the backplane connectors 5 Finnly press the module handle while using a flat blade screwdnver to push and turn the two concentne screws one half turn clockwise to lock the module in place 6 Venfy the Status LED turns green Table 7 1 Recommended Spare Parts List Description Part Number Remarks. AO System Power Modu e E>Asot AG F ed Power Modue EPAFOT = AC Transfer Modu e 6637827 1 a _| Used n EPEPOS Bus Mon tor Modu e 6637830 1 Uses n EPEPOS Cabe 194850240340 Connects § ave Expander Bus jee ae from MMU to MMU. Fan 120 VAC 194741941 Fan 240 VAG 394741942 _ Fuse 2Amp Bussman® AGC2 or equ vaent Used n EFANOt (120 VAC) z __| 484776412001 : Fuse 2amp Lit ofuso” $ 0B o 218002 Used n EPASOI EPAFOI (or equiva ent 1948182A32001 Fuse 1 Amp Bussman AGO! or equ va ent Used n EFANO2 (240 VAC) 154776A1 1001 ‘nou ated Quek 124852901 Connect Recantac e Be red Trademark of NeGrew Ed xo Company POWER SUPPLY MODULE 74 TESS 506AGENERAL INFORMATION SECTION 8 - SUPPORT SERVICES Bailey Controls 1s ready to assist in the use and repatr of its products Requests for sales and/or applications services along with installation, repair, overhaul and/or maintenance contract services should be made to the nearest sales office REPLACEMENT PARTS AND ORDERING INFORMATION TRAINING When making repairs at your facility, order replacement parts through a Bailey saies office Provide the following information to expedite the handling of parts orders 1 Part descnption, part number and quantity 2. Model and senal numbers (if applicable) of the assembly for which the part has been ordered 3 Bailey publication number, page number and reference figure used in identifying the part When ordenng standard parts from Bailey Controls, use part numbers and descriptions from respective Renewal Parts sections of applicable equipment manuals Parts which do not have a commercial description provided in the description column of the Renewal Parts sections must be ordered from the nearest Batley Controls sales office Bailey Controls has a modem training facility equipped to provide service and repair instruction. This facihty 1s avail able for in plant training of your personnel Contact a Bailey Controls sales office for specific information pertaining to covered assemblies and available scheduling TECHNICAL DOCUMENTATION TEOe 506A Obtain additional copies of this manual through the nearest Bailey sales office Extra copies are available at a reasonable charge GENERAL INFORMAT ON 3-1Bai letAPPENDIX A - QUICK REFERENCE MATERIAL Use Table A 1 as a quick reference to check jumper and switch settings TableA 1 Swatch and Jumper Setting Reference Voltage Fan Device | SwitctyPosition | Jumper/Position ATM, St tothe rear ‘BM S1-0011 Jt pns2and3 22 pns2and3 s20VAC JEFANOS | PAS 1. postion A V2 poston PAF Jt poston A 22 postomA amy ‘St tothe tront a BMM 1 0011 Jy pns2and3 22 pns2and3 240 VAC EFANO2 | PAS Jt. post on B 32 postion B PAF Jt postion 8 2 post on A ~ TEO6 506A a4Baii ee Bs 8 B+ : Lee" REE I ames 2 58 a wean wt ¢ ——— aede seen {ERB em oldout 1 IEPEP03 System Cabinet Wiring Diagram E96 506 Foldout 1Bailey} ~ Me & 4 ue a B+ 3 i - pj 7 5 : cS dz : i+ : 7 7 Foldout 2 IEPEPO1 System Cabinet Wiring Diagram 1 E96 506 Foldout 2Form E96 SOGA Lino nUSA 689 For a compete stof censees representat ves and aif ates n over 50 countr es wor dw de contact Bailey Controls Company Cooyrght 1989 by Ba ey Centro s Company