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Bailey infi 90 Modular Power System II Instruction

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E96-542
®
®
Modular Power System II
Process Control and
Automation Solutions
from Elsag Bailey Group

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  • Page 1 E96-542 ® ® Modular Power System II Process Control and Automation Solutions from Elsag Bailey Group...
  • Page 2 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...
  • Page 3 Preface The INFI 90 ® OPEN Modular Power System II supplies 5, 15, -15, 25.5, 48 and 125 VDC power to an INFI 90 OPEN cabinet. This power system can operate on 120/240 VAC or 125 VDC input power. This power system is a direct replacement of the ™...
  • Page 4 ® List of Effective Pages Total number of pages in this instruction is 108, consisting of the following: Page No. Change Date Preface Original List of Effective Pages Original iii through x Original 1-1 through 1-13 Original 2-1 through 2-9 Original 3-1 through 3-24 Original...

  • Page 5: Safety Summary

    Safety Summary GENERAL Equipment Environment WARNINGS 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. Special Handling This device uses electrostatic sensitive devices.
  • Page 6 ® Safety Summary (continued) SPECIFIC Do not install the IPFLD48 and IPFLD125 field power modules CAUTIONS together in the same IPCHS01 chassis. Equipment damage will result. (p. 2-3, 3-23) Sommaire de Sécurité AVERTISSEMENTS Environnement de l’équipement D’ORDRE Ne pas soumettre les composants à une atmosphère corrosive lors GÉNÉRAL du transport, de l’entreposage ou l’utilisation.
  • Page 7 Sommaire de Sécurité (suite) AVERTISSEMENTS Si des circuits d'entrée ou de sortie sont alimentés à partir de D’ORDRE sources externes, ils présentent un risque de choc électrique même SPÉCIFIQUE lorsque l'alimentation du système est débranchée du panneau d'entrée d'alimentation. Le cas échéant, un avertissement signalant (SUITE) la présence de sources d'alimentation multiples doit être apposé...

  • Page 8: Table Of Contents

    Table of Contents Page SECTION 1 - INTRODUCTION ....................1-1 OVERVIEW ........................1-1 INTENDED USER ......................1-2 POWER SYSTEM DESCRIPTION...................1-2 System Power Module ....................1-2 Field Power Modules ....................1-2 Power Monitor Module ...................1-3 Power Module Chassis ...................1-4 Power Entry Circuit Breaker or Switch ..............1-4 Fan Chassis and System Fans ................1-4 FEATURES........................1-6 INSTRUCTION CONTENT .....................1-6...
  • Page 9 ® Table of Contents (continued) Page SECTION 3 - INSTALLATION (continued) IPMON01 Input Voltage Jumper Settings ............. 3-20 IPMON01 Auxiliary Input Trip Points Jumper Settings ......... 3-20 IPMON01 Temperature Trip Point Jumper Settings ..........3-21 IPMON01 Status Inputs Jumper Settings ............3-21 INSTALLING THE POWER MODULES ................
  • Page 10 Table of Contents Page 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 IPMON01 DIPSWITCH AND JUMPER SETTINGS ............A-1 IPMON01 LED STATES ....................A-4 IPSYS01 and IPFLD LED STATES ................
  • Page 11 ® List of Figures Table of Contents (continued) (continued) Page Title Page 4-1. IPMON01 Faceplate LEDs ..................4-2 4-2. IPSYS01 and IPFLD Faceplate LEDs ..............4-4 C-1. Alarms and Auxiliary Inputs Wiring Diagram ............C-1 C-2. 2N Redundancy System Wiring Diagram ..............C-2 C-3.
  • Page 12 ® Trademarks and Registrations Registrations and trademarks used in this document include: ® INFI 90 Registered trademark of Elsag Bailey Process Automation ® INFI-NET Registered trademark of Elsag Bailey Process Automation ® Network 90 Registered trademark of Elsag Bailey Process Automation...

  • Page 13: Section 1 - Introduction

    +15V +15V +15 VOLTS -15 VOLTS -15V -15V -15V -15V MODULE COM +25.5 VOLTS I/O COM PFI RESET Bailey Bailey Bailey Bailey Bailey Bailey B ailey B ailey B ailey in fi9 0 in fi9 0 in fi9 0 in fi9 0...

  • Page 14: Intended User

    INTRODUCTION ® mounting unit. Components of the Network 90 power system and INFI 90 OPEN modular power system cannot be used with components of the INFI 90 OPEN Modular Power System II. This system is designed to operate in several configurations of power module redundancy (N, N+1, N+x or 2N).

  • Page 15: Power Monitor Module

    INTRODUCTION 49.1 VDC and 125.6 VDC respectively. The field power mod- ules have the same power factor correction and internal moni- toring circuitry. There are only two red/green LEDs on the field power modules: one for the DC to DC converter status and one for the power factor corrector status.

  • Page 16: Power Module Chassis

    INTRODUCTION ® Power Module Chassis The IPCHS01 Power Module Chassis provides power input, power output bus bars, and various terminals for status inputs, outputs and mounting of up to eight power modules and one power monitor module. There are nine mounting slots total.

  • Page 17: Block Diagram Of Input Power For N, N+1 And N+X Redundant Systems

    INTRODUCTION ONE INPUT POWER SOURCE TO INFI 90 OPEN 120 VAC 240 VAC 125 VDC IPECB11 IPECB13 IPESW11 IPESW13 JUMPER ASSEMBLY POWER POWER DISTRIBUTION DISTRIBUTION FOR UP TO FOUR FOR UP TO FOUR POWER MODULES POWER MODULES POWER MODULES ARE NONREDUNDANT N+1 REDUNDANT N+X REDUNDANT...

  • Page 18: Features

    Repair and Replacement Contains procedures that explain how to replace power system Procedures components. It also has a spare parts list with Elsag Bailey part numbers for related parts, cables and fuses. Explains the services and training that Elsag Bailey makes Support Services available to their customers.

  • Page 19: How To Use This Instruction

    Site Planning and Preparation GLOSSARY OF TERMS AND ABBREVIATIONS Table contains those terms and abbreviations that are unique to Elsag Bailey or have a definition that is different from standard industry usage. HOW TO USE THIS INSTRUCTION I-E96-542B 1 - 7...

  • Page 20: Nomenclature

    INTRODUCTION ® Table 1-2. Glossary of Terms and Abbreviations Term Definition Power fail interrupt. A signal that causes active controller or processor modules (MFCs or MFPs) to reset and the communication system to be bypassed, when generated in the INFI 90 OPEN system by an out of tolerance bus voltage. Termination Module Provides input/output connection between plant equipment and the INFI 90 OPEN/ Network 90 modules.

  • Page 21: Introduction

    INTRODUCTION Table 1-4. Specifications Property Characteristic/Value MPS II inputs Input voltage Input Voltage External Ambient Temp. Nominal Operating Range 0° - 55°C 120 VAC 102 - 132 VAC (32° - 131°F) 240 VAC 204 - 264 VAC 125 VDC 102 - 144 VDC Input current 20 A max.
  • Page 22 INTRODUCTION ® Table 1-4. Specifications (continued) Property Characteristic/Value Power module outputs (IPSYS01, IPFLD01, IPFLD24, IPFLD48, IPFLD125) (continued) Load sharing Current shared equally between modules within 5% (highest current load to lowest current load) at full load Line regulation ±0.5% of the nominal output voltage over the input voltage range Load regulation Within specified minimum and maximum outputs from 0% to 100% load Hold up time...
  • Page 23 INTRODUCTION Table 1-4. Specifications (continued) Property Characteristic/Value Power monitor module (IPMON01) status signal inputs and outputs (continued) Status out 1 output, open collector driven (nonisolated), logic 0 = fault Logic 0 ≤ 0.8 VDC at 10 mA sink current Logic 1 ≥ 4.75 to 5.25 VDC at 80 µA source current Bus alarm 1 output, opto-isolated open collector driven (24 V), logic 1 = fault Logic 0 ≤...

  • Page 24: Introduction

    INTRODUCTION ® Table 1-4. Specifications (continued) Property Characteristic/Value Environmental (continued) Temperature Operating enclosure 0° to 70°C (32° to 158°F) (internal) Operating enclosure 0° to 55°C (32° to 131°F) (external) Storage and transport -40° to 85°C (-40° to 185°F) Relative humidity 20% to 90% up to 55°C (131°F) noncondensing Operating 20% to 45% at 55°...
  • Page 25 INTRODUCTION Table 1-4. Specifications (continued) Property Characteristic/Value Certification CSA C22.2, No. 142 Certified for process control equipment in an ordinary (nonhazardous) envi- ronment Class I, Division 2, Groups A, B, C, D SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE. SPECIFICATIONS I-E96-542B 1 - 13...
  • Page 26 +15V +15V +15 VOLTS -15 VOLTS -15V -15V -15V -15V MODULE COM +25.5 VOLTS I/O COM PFI RESET Bailey Bailey Bailey Bailey Bailey Bailey B ailey B ailey B ailey in fi9 0 in fi9 0 in fi9 0 in fi9 0...
  • Page 27 INTRODUCTION ® mounting unit. Components of the Network 90 power system and INFI 90 OPEN modular power system cannot be used with components of the INFI 90 OPEN Modular Power System II. This system is designed to operate in several configurations of power module redundancy (N, N+1, N+x or 2N).
  • Page 28 INTRODUCTION 49.1 VDC and 125.6 VDC respectively. The field power mod- ules have the same power factor correction and internal moni- toring circuitry. There are only two red/green LEDs on the field power modules: one for the DC to DC converter status and one for the power factor corrector status.
  • Page 29 INTRODUCTION ® Power Module Chassis The IPCHS01 Power Module Chassis provides power input, power output bus bars, and various terminals for status inputs, outputs and mounting of up to eight power modules and one power monitor module. There are nine mounting slots total.
  • Page 30 INTRODUCTION ONE INPUT POWER SOURCE TO INFI 90 OPEN 120 VAC 240 VAC 125 VDC IPECB11 IPECB13 IPESW11 IPESW13 JUMPER ASSEMBLY POWER POWER DISTRIBUTION DISTRIBUTION FOR UP TO FOUR FOR UP TO FOUR POWER MODULES POWER MODULES POWER MODULES ARE NONREDUNDANT N+1 REDUNDANT N+X REDUNDANT...
  • Page 31 Repair and Replacement Contains procedures that explain how to replace power system Procedures components. It also has a spare parts list with Elsag Bailey part numbers for related parts, cables and fuses. Explains the services and training that Elsag Bailey makes Support Services available to their customers.

  • Page 32: Reference Documents

    Site Planning and Preparation GLOSSARY OF TERMS AND ABBREVIATIONS Table contains those terms and abbreviations that are unique to Elsag Bailey or have a definition that is different from standard industry usage. HOW TO USE THIS INSTRUCTION I-E96-542B 1 - 7...

  • Page 33: Glossary Of Terms And Abbreviations

    INTRODUCTION ® Table 1-2. Glossary of Terms and Abbreviations Term Definition Power fail interrupt. A signal that causes active controller or processor modules (MFCs or MFPs) to reset and the communication system to be bypassed, when generated in the INFI 90 OPEN system by an out of tolerance bus voltage. Termination Module Provides input/output connection between plant equipment and the INFI 90 OPEN/ Network 90 modules.
  • Page 34 INTRODUCTION Table 1-4. Specifications Property Characteristic/Value MPS II inputs Input voltage Input Voltage External Ambient Temp. Nominal Operating Range 0° - 55°C 120 VAC 102 - 132 VAC (32° - 131°F) 240 VAC 204 - 264 VAC 125 VDC 102 - 144 VDC Input current 20 A max.
  • Page 35 INTRODUCTION ® Table 1-4. Specifications (continued) Property Characteristic/Value Power module outputs (IPSYS01, IPFLD01, IPFLD24, IPFLD48, IPFLD125) (continued) Load sharing Current shared equally between modules within 5% (highest current load to lowest current load) at full load Line regulation ±0.5% of the nominal output voltage over the input voltage range Load regulation Within specified minimum and maximum outputs from 0% to 100% load Hold up time...
  • Page 36 INTRODUCTION Table 1-4. Specifications (continued) Property Characteristic/Value Power monitor module (IPMON01) status signal inputs and outputs (continued) Status out 1 output, open collector driven (nonisolated), logic 0 = fault Logic 0 ≤ 0.8 VDC at 10 mA sink current Logic 1 ≥ 4.75 to 5.25 VDC at 80 µA source current Bus alarm 1 output, opto-isolated open collector driven (24 V), logic 1 = fault Logic 0 ≤...

  • Page 37: Specifications

    INTRODUCTION ® Table 1-4. Specifications (continued) Property Characteristic/Value Environmental (continued) Temperature Operating enclosure 0° to 70°C (32° to 158°F) (internal) Operating enclosure 0° to 55°C (32° to 131°F) (external) Storage and transport -40° to 85°C (-40° to 185°F) Relative humidity 20% to 90% up to 55°C (131°F) noncondensing Operating 20% to 45% at 55°...
  • Page 38 INTRODUCTION Table 1-4. Specifications (continued) Property Characteristic/Value Certification CSA C22.2, No. 142 Certified for process control equipment in an ordinary (nonhazardous) envi- ronment Class I, Division 2, Groups A, B, C, D SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE. SPECIFICATIONS I-E96-542B 1 - 13...

  • Page 39: Modular Power System Ii Architecture

    SECTION 2 - DESCRIPTION AND OPERATION INTRODUCTION Section 2 explains the functional operation of the INFI 90 OPEN Modular Power System II. The Modular Power System II consists of system power modules and field power modules, a power monitor module, power module chassis, power entry cir- cuit breakers or switches, power fan chassis and fan assem- blies.

  • Page 40: Power Entry

    DESCRIPTION AND OPERATION ® POWER ENTRY The IPECB11 or IPECB13 Power Entry Circuit Breaker and IPESW11 or IPESW13 Power Entry Switch connects 120/ 240 VAC (50/60 hertz) or 125 VDC line power to an INFI 90 OPEN system cabinet. The power entry circuit breaker or switch normally mounts on the rear of the IPFCH01 Power Fan Chassis.

  • Page 41: System Cooling

    DESCRIPTION AND OPERATION Do not install the IPFLD48 and IPFLD125 field power modules CAUTION together in the same IPCHS01 chassis. Equipment damage will result. Ne pas installer les modules d’alimentation de champ IPFLD48 ATTENTION et IPFLD125 dans le même châssis IPCHS01. CECI causerait des dommages à...

  • Page 42: Power Monitor Module

    DESCRIPTION AND OPERATION ® indicate the cause of the failure or problem. Refer to POWER MONITOR MODULE for more information on these features. FAN CONNECTOR FAN CONNECTOR – – – – – (–) (–) +15 -15 CONNECTOR LINE 1 LINE 2 AUX INPUTS STATUS ALARMS...

  • Page 43: Ac/Dc Inputs

    DESCRIPTION AND OPERATION POWER MONITOR MODULE SELF-CHECK POWER ENTRY LINE 1/LINE 2 CIRCUIT BREAKER/SWITCH LEDs 5 VDC +15 VDC IPMON01 120/240 VAC STATUS MONITORING POWER -15 VDC OR 125 VDC CIRCUIT SUPPLY INPUT 25.5 VDC H OT LINE 1 LED LINE NEUTRAL 125 VDC...

  • Page 44: Power Monitor Module Status

    DESCRIPTION AND OPERATION ® Power Monitor Module Status The power monitor module monitors the status of its internal power module voltage buses and reference voltages. If circuitry fails, resulting in an on-board power failure or out of tolerance voltage, a monitor module status signal drives the self-check LED (green for good status, red for bad status) on the module faceplate.

  • Page 45: Fan And Temperature Monitoring

    DESCRIPTION AND OPERATION voltage circuitry. The field I/O voltage monitoring circuitry can be enabled to use the I/O power or PFI LED (any combination) upon a bus failure or out of tolerance condition. Fan and Temperature Monitoring The power monitor module monitors fan rotation speed and cabinet temperature.

  • Page 46: Power Modules

    DESCRIPTION AND OPERATION ® the I/O power LED upon a bus failure or out of tolerance con- dition. The status inputs have additional circuitry for setting up oper- ation as N.O. or N.C. contacts. Status input one can be enabled to use the PFI and I/O power LEDs (any combination). Thus, a status input one failure can alarm via the PFI alarm, power system alarm, and I/O power bus alarm.

  • Page 47: Ipsys01 Status Signals

    DESCRIPTION AND OPERATION signal is monitored by the power monitor module (refer to Power Module Monitoring). Figure shows the field power module signal status. +5 V OC = OVERCURRENT -15 V -15 V DC/DC REFERENCE -15 V LED CONVERTER CIRCUIT FAIL -15 V OC -15 V FAIL...

  • Page 48: Section 3 - Installation

    SPECIAL HANDLING Observe these steps when handling electronic circuitry: NOTE: Always use Elsag Bailey's field static kit (part number 1948385 1 - consisting of two wrist straps, ground cord assembly, alligator clip, and static dissipative work surface) when working with the modules.

  • Page 49: Unpacking And Inspection

    1. Examine the hardware immediately to verify that it has not been damaged in transit. 2. Notify the nearest Elsag Bailey sales office of any damage. 3. File a claim for any damage with the transportation com- pany that handled the shipment.

  • Page 50: Installing System Power Cables

    INSTALLATION 10. Install the power monitor module, power modules and blank faceplates. INSTALLING SYSTEM POWER CABLES Connect the 5 VDC, MCOM, 25.5 VDC and I/O COM system power cables to the system power bus bar before installing anything else. Refer to Appendix C for wiring diagrams.

  • Page 51: Chassis Mounting

    INSTALLATION ® for a wiring diagram of the system power bus bar. Use a No. ¼-28 x 0.5-inch brass cap screw and nut with two external tooth lockwashers provided with the INFI 90 OPEN Modular Power System II. There should be a lockwasher used on each side of the system bus bar (Fig.

  • Page 52: Ipchs01 Power Module Chassis Mounting

    INSTALLATION × 10-32 × 10-32 1¼ SELF-LOCK BOLTS SEMS SCREWS 63.5 2.50 IPFCH01 57.2 CHASSIS 2.25 76.2 3.00 POWER MODULE 146.1 IPCHS01 CHASSIS 5.75 DIMENSIONS CLIP NUTS AND MILLIMETERS SELF-LOCK BOLTS INCHES TP80629A Figure 3-2. Clip Nut Spacing IPCHS01 Power Module Chassis Mounting Mount the power module chassis to the top side rails inside the INFI 90 OPEN or Network 90 cabinet.

  • Page 53: Installing The Fan Assembly

    INSTALLATION ® INSTALLING THE FAN ASSEMBLY Insure the fan blades have stopped rotating before removing the fan assembly from the fan chassis. Removing an operating WARNING fan assembly exposes rotating fan blades that can cause injury. S'assurer que les pales du ventilateur sont arrêtées avant de retirer le ventilateur de son châssis.

  • Page 54: Power Entry Circuit Breaker Or Switch Installation (Rear View)

    INSTALLATION INPUT VOLTAGE LABELS EARTH EART H EAR TH EART H BON D IN G BO ND IN G B ON DING BON D IN G PO IN T POINT PO IN T POIN T FAN CONNECTOR FAN CONNECTOR – –...

  • Page 55: Example Mounting Sequence (Ipmon01, Ipsys01, Ipfld01, Ipblk01, Ipfld125)

    INSTALLATION ® INPUT VOLTAGE LABEL ON FRONT OF FAN CHASSIS (BEHIND FAN FACEPLATE) EARTH EARTH BONDING BONDING POINT POINT WARNING WARNING R OTAT IN G FAN S C AN C AU S E IN J U RY. R OTAT IN G FA N S C A N C AU SE IN JU R Y. WA IT U N TIL BLA D E S TO PS RO TAT IN G WAIT U N T IL B LAD E ST OP S R OTAT IN G B EF OR E R EM OVIN G FAN A SS EMB LY...

  • Page 56: Power Entry Circuit Breaker Or Switch

    INSTALLATION INPUT VOLTAGE LABEL ON FRONT OF FAN CHASSIS (BEHIND FAN FACEPLATE) EARTH EARTH BONDING BONDING POINT POINT WARNING WARNING R OTAT IN G FAN S C AN C AU S E IN J U RY. R OTAT IN G FA N S C A N C AU SE IN JU R Y. WA IT U N T IL BLA D E S TO PS R OTAT IN G WAIT U N T IL B LAD E ST OP S R OTAT IN G B EF O R E R E MOVIN G FA N ASS EM BLY...
  • Page 57 INSTALLATION ® Verify the main power and power entry panel circuit breakers are turned off before starting installation, retrofit, upgrade, or WARNING wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, ret- rofit, upgrade, or wiring procedures are complete.

  • Page 58: System Power Wiring (Completion)

    Site Planning and Preparation instruction for power and grounding require- ments of Elsag Bailey control systems. The terminal screws on the power module chassis backplane should be tightened to 2.3 Newton meters (20 inch-pounds). Nuts and bolts that secure the cables that connect the power module chassis bus bars to the system power bus bar should be tightened to 6.8 Newton meters (±0.25 Newton meters) [60 inch-pounds...
  • Page 59 INSTALLATION ® 5. Connect the ring lug end of the +15 VDC cable to terminal strip TB1 (+15 terminal) on the power module chassis back- plane. 6. Connect the ring lug end of the -15 VDC cable to terminal strip TB1 (-15 terminal) on the power module chassis back- plane.

  • Page 60: Ac Safety Ground Wiring

    INSTALLATION 16. If redundant network interface modules are being used with the NICL01 termination module: a. Put ring lugs on both ends of two 18 to 14 AWG wires. Attach one end of each wire to the OUT terminal on termi- nal strip TB3 on the power module chassis backplane.

  • Page 61: Ac/Dc Feeder Lines

    INSTALLATION ® Verify the main power and power entry panel circuit breakers are turned off before starting installation, retrofit, upgrade, or WARNING wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, ret- rofit, upgrade, or wiring procedures are complete.

  • Page 62: Dipswitch Sw1

    INSTALLATION 2. Install the AC/DC feeder lines to the terminals on the power entry circuit breaker or switch. a. Install the hot power line (positive) to terminal L1. b. Install the neutral power line (negative) to terminal L2. c. Install the safety ground to the ground terminal. 3.

  • Page 63: Dipswitch Sw2

    INSTALLATION ® SELF CHECK LINE 1 LINE 2 POW ER SUPPLY CABINET TEMP O PEN FAN LEFT FAN RIGHT EXTERNAL SYSTEM POW ER I/O POW ER TEST POINTS: 1 2 3 +5 VOLTS +15 VOLTS O PEN OPEN -15 VOLTS 1 2 3 4 5 6 1 2 3 4 5 6 7 8 MODULE COMMON...

  • Page 64: Dipswitch Sw3

    INSTALLATION Table 3-2. IPMON01 Dipswitch SW1 Settings Dipswitch Pole User Option Enabled Setting Enable power source line 2 monitoring Enable 5/15/-15 VDC system bus monitoring NOTE: 0 = CLOSED or ON, 1 = OPEN or OFF. SW2 to set up a N.O. or N.C. contact input (Table 3-10). This input is physically located on terminal strip TB3 (STATUS 1 and STATUS COM terminals) on the power module chassis backplane.

  • Page 65: Ipmon01 Dipswitch Sw3 Settings

    INSTALLATION ® Table 3-4. IPMON01 Dipswitch SW3 Settings Dipswitch Pole Option Enabled User Setting Enables I/O power LED to indicate a STATUS 1 input fault Enables I/O power LED to indicate a STATUS 2 input fault Enables I/O power LED to indicate a CH2 AUX INPUT fault Enables I/O power LED to indicate a CH1 AUX INPUT fault...

  • Page 66: Dipswitch Sw4

    INSTALLATION Dipswitch SW4 Dipswitch SW4 is a six-pole dipswitch that enables or disables the power monitor module to generate a PFI signal when a fault occurs on one of the system buses (5, 15 and -15 VDC). The PFI LED on the module faceplate indicates when a PFI signal is generated.

  • Page 67: Ipmon01 Input Voltage Jumper Settings

    INSTALLATION ® Table 3-6. IPMON01 Dipswitch SW5 Settings Dipswitch Pole User Option Enabled Settings Latch PFI signal Not used, must be set to 1 NOTE: 0 = CLOSED or ON, 1 = OPEN or OFF. IPMON01 Input Voltage Jumper Settings There are six jumpers that tell the IPMON01 module what input voltage to expect on input lines one and two (three jump- ers for each input line).

  • Page 68: Ipmon01 Temperature Trip Point Jumper Settings

    INSTALLATION Table 3-8. IPMON01 Auxiliary Input Trip Points Jumper Settings Function Jumper Setting Jumper User Setting Auxiliary Input Trip Point 24 VDC 48 VDC 125 VDC High High IPMON01 Temperature Trip Point Jumper Settings Jumpers J15 and J16 select the internal cabinet temperature trip points that the power monitor module uses to generate a cabinet overtemperature warning.

  • Page 69: Installing The Power Modules

    2. Verify the fuses are installed and in good condition. Replace any fuses that are missing or damaged. Refer to Table for a list of Elsag Bailey part numbers and fuse rat- ings. 3. After setting the dipswitches and jumpers, grasp the sides of the faceplate and line up the circuit board edges with the center slot card guides in the power module chassis opening.
  • Page 70 LEDs). If a fuse is missing or damaged, install or replace it with an equiva- lent fuse. Refer to Table for the Elsag Bailey part number and description of this fuse. NOTE: Replace both fuses if one of the fuses is blown.

  • Page 71: Installing Blank Faceplates

    INSTALLATION ® 25.5 V +5 V +15 V -15 V TP25492A Figure 3-8. IPSYS01 Circuit Board Layout 5. If any of the LEDs are red, find and correct the problem before applying power to the cabinet control and I/O modules. Refer to TROUBLESHOOTING in Section 5 for assistance.

  • Page 72: Section 4 - Operating Procedures

    SECTION 4 - OPERATING PROCEDURES INTRODUCTION Section 4 contains information regarding INFI 90 OPEN Modu- lar Power System II operation. This section includes informa- tion on system and field power module status LEDs, and power monitor module status LEDs, test points, and the power fail interrupt (PFI) reset pushbutton.

  • Page 73: Ipmon01 Faceplate Leds

    OPERATING PROCEDURES ® Table 4-1. IPMON01 LED States (continued) LED State Meaning Cabinet temp Overtemperature Within limit Fan left Failed Operating Fan right Failed Operating External Fault Good System power Fault Good or disabled I/O power Fault Good or disabled PFI status Fault Good or disabled...

  • Page 74: Power System And Field Modules

    OPERATING PROCEDURES The self-check LED and line one LED are red/green status LEDs that are green during normal operation. The self-check LED turns red if the power monitor module detects an on-board hardware failure. The line one LED indicates the sta- tus of input power on N, N+1 or N+x redundant systems and turns red if the input power drops below the specified range.

  • Page 75: Test Points

    OPERATING PROCEDURES ® Table 4-2. IPSYS01, IPFLD01, IPFLD24, IPFLD48 and IPFLD125 LED States (continued) LED State Meaning 25.5 V, 5 V, +15 V, Green Good -15 V, 48 V and Blinking green Converter overcurrent 125 V Converter failure 125V 25.5V 25.5V 25.5V +15V...

  • Page 76: Section 5 - Troubleshooting

    SECTION 5 - TROUBLESHOOTING INTRODUCTION Section 5 provides troubleshooting tools consisting of tables containing troubleshooting procedures to help locate and cor- rect INFI 90 OPEN Modular Power System II problems. These are general troubleshooting guidelines and are not exhaustive of all possible causes. TROUBLESHOOTING PROCEDURES Tables contain troubleshooting procedures that...

  • Page 77: Ipmon01 Status Leds Troubleshooting Procedures

    TROUBLESHOOTING ® Table 5-1. IPSYS01 and IPFLD Field Modules LED Troubleshooting Procedures (continued) LED state Cause Corrective Action 5 V, +15 V, All red Blown power module 1. On 2N redundant systems, if all the LEDs on the power -15 V, and fuse.

  • Page 78: Ipmon01 Alarm Leds Troubleshooting Procedures

    TROUBLESHOOTING Table 5-2. IPMON01 Status LEDs Troubleshooting Procedures (continued) LED State Problem Corrective Action Line 2 Green Enabled and normal operation. None. Input power voltage out of tolerance. 1. Verify that the power entry circuit breaker or No power on line 2 on 2N redundant switch is on.
  • Page 79 TROUBLESHOOTING ® Table 5-3. IPMON01 Alarm LEDs Troubleshooting Procedures (continued) LED State Problem Corrective Action Fan right Normal operation. None. Bad fan or open fan fuses. Make a visual check of the right fan and verify that it is not rotating.
  • Page 80 TROUBLESHOOTING Table 5-3. IPMON01 Alarm LEDs Troubleshooting Procedures (continued) LED State Problem Corrective Action System bus voltage fault. Check the system power module LEDs for failed power (continued) modules. Check system bus voltages using the power monitor module faceplate test points. Repair system bus fault if voltages are low and power modules are good.

  • Page 81: Section 6 - Maintenance

    SECTION 6 - MAINTENANCE INTRODUCTION Section 6 contains an INFI 90 OPEN Modular Power System II preventive maintenance schedule and procedures. Doing the preventive maintenance procedures as scheduled maintains dependable modular power system operation. This section presents procedures that can be performed on-site.

  • Page 82: Equipment Required

    Inspect all control, I/O, and power modules, giving particular attention to power supply con- tacts and heat sinks. Clean as necessary. Refer to procedure. Replace power supply. Call Elsag Bailey sales and service for exchange information. (Compo- 5 years nents such as electrolytic capacitors deteriorate over time and need to be replaced.) Complete all checks and inspections in this table.

  • Page 83: Checking Connections

    MAINTENANCE 4. Either clean or replace the air filter. To clean the filter: a. If the air filter stays dry and relatively clean, use com- pressed air to blow dust and dirt free from the filter. b. Clean a dirty filter in water and a mild detergent (i.e., dishwashing soap).

  • Page 84: Checking Power Module Outputs

    MAINTENANCE ® tightened. If the connection is tight, the tightening action will verify that it is secure. There must not be any motion done to loosen the connection. 1. Verify that all positive and negative input, and grounding conductor connections on the power entry circuit breaker or switch are secure.

  • Page 85: General Cleaning And Washing

    MAINTENANCE SPECIAL HANDLING in Section 3 when handling printed cir- cuit boards. Never clean electrical parts or components with live power present. Doing so exposes you to an electrical shock hazard. WARNING Wear eye protection whenever working with cleaning solvents. When removing solvents from printed circuit boards using compressed air, injury to the eyes could result from splashing solvent as it is removed from the printed circuit board.
  • Page 86 MAINTENANCE ® To clean tarnished or deeply stained edge connector contacts: 1. Use an Eberhard Faber (400A) pink pearl eraser or equiva- lent to remove tarnish or stains. Fiberglass or nylon burnish- ing brushes may also be used. 2. Minimize electrostatic discharge by using the 80/20 iso- propyl alcohol/water solution during burnishing.

  • Page 87: Section 7 - Repair And Replacement Procedures

    SPARE PARTS Table lists a description and Elsag Bailey part number or nomenclature parts that can be stocked. It is impractical to specify a recommended quantity of spare parts because Elsag Bailey custom designs every system. Contact Elsag Bailey for help determining the quantity of spare parts to keep on hand for a particular system.

  • Page 88: Power Monitor Module

    REPAIR AND REPLACEMENT PROCEDURES ® Table 7-1. Spare Part Numbers or Nomenclatures (continued) Nomenclature/ Description Part Number NIDHA16008 10-32 x Sems screw NMPCC16002 10-32 clip nut 1945820 10310 mA, 125 VAC fuse (fuses F3 and F5 on the IPMON01) 1948182 22001 2 A, 250 VAC fuse (fuses F1, F2, F4 and F6 on the IPMON01) 1948182 32001 2 A, 250 VAC slo-blo fuse (fuses F1 and F2 on IPFAN11/12, fuse F1 on IPFAN13)

  • Page 89: Fuse Replacement

    Refer to Table for a description of the fuses and the Elsag Bailey part numbers. To replace a fuse: NOTE: Sets of fuses should be replaced in pairs, except for fuses F3 and F5 which are independent of each other. For example, if one of the fuses in the pair of F1 and F2 opens, replace both.

  • Page 90: Power Modules

    Replace sets of fuses in pairs (F1 and F2 are pairs, and F4 and F6 are pairs). Fuses F3 and F5 can be replaced individu- ally. Refer to Table for a list of Elsag Bailey part numbers and descriptions. POWER MODULES...

  • Page 91: Fuse Replacement

    There are two fuses (F5 and F6) on the IPSYS01 and the IPFLD modules that can be replaced. Refer to Table for a descrip- tion and the Elsag Bailey part number of these fuses. NOTE: If one of the fuses in the pair F5 and F6 opens, replace both fuses.
  • Page 92 REPAIR AND REPLACEMENT PROCEDURES ® 2. Pull the fan from the assembly to disconnect it from power, but do not remove it from the fan chassis until the fan blades stop rotating. When the fan blades stop rotating, sup- port it with both hands while removing it from the power fan chassis.
  • Page 93 REPAIR AND REPLACEMENT PROCEDURES 5. Remove the wiring from the power entry circuit breaker or switch to connector TB5 or TB6 terminals L1 (+), L2 (–) and ground on the power module chassis. 6. Use a screwdriver to loosen the three Sems mounting screws that secure the power entry circuit breaker or switch to the power fan chassis enough to lift the power entry circuit breaker or switch off of its mounting screws.

  • Page 94: Fan Assembly Replacement

    There are two fuses on IPFAN11 and IPFAN12 fans (F1 and F2) and one fuse on the IPFAN13 fan (F1) that are replaceable. Refer to Table for a description and list of Elsag Bailey part numbers. 1. Follow the steps under Fan Assembly Replacement remove the fan assembly from the power fan chassis.

  • Page 95: Power Entry Circuit Breaker Or Switch Replacement

    Use replacement fuses from the same manufacturer to main- tain CSA certification. Refer to Table for a list of Elsag Bailey part numbers and description. POWER ENTRY CIRCUIT BREAKER OR SWITCH REPLACEMENT Power to the cabinet must be off while replacing the IPECB11 or IPECB13 Power Entry Circuit Breaker and IPESW11 or IPESW13 Power Entry Switch.

  • Page 96: Power Module Chassis Replacement

    REPAIR AND REPLACEMENT PROCEDURES ® 6. Align the key holes on the replacement power entry circuit breaker or switch with the mounting screws and install by low- ering the key holes onto the mounting screws. NOTE: The power entry circuit breaker or switch mounts over the power fan and status cable (Fig.
  • Page 97 REPAIR AND REPLACEMENT PROCEDURES Verify the main power and power entry panel circuit breakers are turned off before starting installation, retrofit, upgrade, or WARNING wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, ret- rofit, upgrade, or wiring procedures are complete.
  • Page 98 REPAIR AND REPLACEMENT PROCEDURES ® d. Disconnect the power system status cable from the STATUS OUT terminal on the TB3 terminal strip. e. Disconnect any wiring for auxiliary inputs, status inputs, and customer alarm from terminal strips TB2, TB3 and TB4. Disconnect the ±15 VDC leads from terminal strip TB1.
  • Page 99 REPAIR AND REPLACEMENT PROCEDURES 16. Check for shorts on the system power outputs. If any shorts are evident, correct the wiring problem before continu- ing with installation procedures. 17. Replace the protective covers on the terminal blocks and power module chassis bus bars. 18.

  • Page 100: Fan Chassis Replacement

    REPAIR AND REPLACEMENT PROCEDURES ® FAN CHASSIS REPLACEMENT Power to the cabinet must be off while replacing the IPFCH01 Power Fan Chassis. Verify the main power and power entry panel circuit breakers are turned off before starting installation, retrofit, upgrade, or WARNING wiring procedures.
  • Page 101 REPAIR AND REPLACEMENT PROCEDURES 12. Align the four mounting screw holes on the side flanges of the fan chassis with the clip nuts on the side mounting rails inside the cabinet and secure the power mounting unit in place using the four self-lock bolts. 13.

  • Page 102: Section 8 - Support Services

    SECTION 8 - SUPPORT SERVICES INTRODUCTION Elsag Bailey Process Automation is ready to help in the use and repair of its products. Contact the nearest sales office to make requests for sales, applications, installation, repair, over- haul and maintenance contract services.

  • Page 103: Ipmon01 Dipswitch And Jumper Settings

    APPENDIX A - QUICK REFERENCE GUIDE INTRODUCTION Appendix A contains a quick reference guide of IPMON01 Power Monitor Module dipswitch and jumper settings and LED states. This section also contains IPSYS01 System Power Mod- ule and IPFLD Field Power Modules LED states. Use these tables to set power monitor module options using the dipswitches and jumper.

  • Page 104: Ipmon01 Dipswitch Sw3 Settings

    QUICK REFERENCE GUIDE ® Table A-3. IPMON01 Dipswitch SW3 Settings Dipswitch Pole User Option Enabled Setting Enables I/O power LED to indicate a STATUS 1 input fault Enables I/O power LED to indicate a STATUS 2 input fault Enables I/O power LED to indicate a CH2 AUX INPUT fault Enables I/O power LED to indicate a CH1 AUX INPUT fault...

  • Page 105: Ipmon01 Dipswitch Sw5 Settings

    QUICK REFERENCE GUIDE Table A-5. IPMON01 Dipswitch SW5 Settings Dipswitch Pole User Option Enabled Settings Latch PFI signal Not used, must be set to 1 NOTE: 0 = CLOSED or ON, 1 = OPEN or OFF. Table A-6. IPMON01 Input Voltage Jumper Settings Jumper Setting User Function...

  • Page 106: Appendix A - Quick Reference Guide

    QUICK REFERENCE GUIDE ® Table A-9. IPMON01 Status Inputs Jumper Settings Jumper Settings User Function Jumper Setting N.O. N.C. Status input 1, contact input Status input 2, contact input 48/125 VDC select (48 VDC) (125 VDC) NOTE: 1. N.O. = normally open, N.C. = normally closed. IPMON01 LED STATES Table A-10...

  • Page 107: Ipsys01 And Ipfld Led States

    QUICK REFERENCE GUIDE IPSYS01 and IPFLD LED STATES Table A-11 lists IPSYS01, IPFLD01, IPFLD24, IPFLD48 and IPFLD125 modules LED states. NOTE: The IPFLD01 and the IPFLD24 modules have only PFC and 25.5 V LEDs. The IPFLD48 module has only PFC and 48 V LEDs. The IPFLD125 module has only PFC and 125 V LEDs.

  • Page 108: Appendix B - Sizing The Power System

    NOTE: The power system sizing procedures in this instruction apply to the INFI 90 OPEN Modular Power System II only. Do not use these procedures to size other Elsag Bailey power systems. To size the INFI 90 OPEN Modular Power System II: 1.

  • Page 109: Calculating System Current Requirements

    SIZING THE POWER SYSTEM ® Table to calculate system powered I/O current require- ments. 1. Make a list of modules contained in the cabinet being sized for system and field power modules. 2. Calculate the 5 VDC current requirement for each cabinet. a.

  • Page 110: Dc Current Consumption For Infi 90 Open Modules

    SIZING THE POWER SYSTEM Table B-1. DC Current Consumption for INFI 90 OPEN Modules Current Consumption Per Module (mA) No. of INFI 90 Modules/ Total Total Total Total Modules 15 V -15 V 25.5 V Cabinet 15 V -15 V 25.5 V IISAC01 IMAMM03...

  • Page 111: Vdc Current Consumption Of Termination Units Or Modules

    SIZING THE POWER SYSTEM ® Table B-1. DC Current Consumption for INFI 90 OPEN Modules (continued) Current Consumption Per Module (mA) No. of INFI 90 Modules/ Total Total Total Total Modules 15 V -15 V 25.5 V Cabinet 15 V -15 V 25.5 V INIIT01...

  • Page 112: System And I/O Current Capacities

    SIZING THE POWER SYSTEM CALCULATING I/O CURRENT REQUIREMENTS The total current requirements of system powered analog inputs, analog outputs, digital inputs, digital outputs, and thermocouple inputs make up the system powered I/O current requirements. Fill in column two of Table B-3, then multiply it by column three (quantity of inputs or outputs times the cur- rent per input or output).
  • Page 113 SIZING THE POWER SYSTEM ® SIZING THE MODULAR POWER SYSTEM II The following text and equations explain how to calculate the number of IPSYS01 System Power Modules and IPFLD01, IPFLD24, IPFLD48 or IPFLD125 Field Power Modules needed for a particular system. The calculations take into account siz- ing the power system for N+1 and 2N redundancy.
  • Page 114 SIZING THE POWER SYSTEM Round up all values of N1 through N3 to the next highest integer. NP = total no. of IPFLD48 or IPFLD125 power modules are needed. If N5 < 1, NP = 1. If N5 ≥ 1 , NP = N5 rounded to the next highest integer. NS = largest of N1, N2 and N3 NF = total no.

  • Page 115: Maximum Power Entry Circuit Breaker Or Switch Current Draw

    SIZING THE POWER SYSTEM ® If using IPFLD48 or IPFLD125 modules: For N, N+1, or N+x redundancy, the number of power mod- ules required is NP + 1. For 2N redundancy, double NS, NF and NP (two power entry circuit breakers or switches are required). MAXIMUM POWER ENTRY CIRCUIT BREAKER OR SWITCH CURRENT DRAW The current draw of the system must be within the specifica- tions of the power entry circuit breaker or switch.

  • Page 116: Example Sizing Calculation

    SIZING THE POWER SYSTEM EXAMPLE SIZING CALCULATION Assume that the current requirements for a set of modules residing in a system cabinet has been calculated. Additionally, the current requirements for 24 VDC I/O power were calculated. The results are: A = 32 A (5.09 VDC current requirement) B = 0.9 A (15.1 VDC current requirement) C = 0.4 A (-15.1 VDC current requirement) D = 12 A (25.5 VDC and associated I/O current)

  • Page 117: Example Cabinet Current Draw Calculation

    SIZING THE POWER SYSTEM ® EXAMPLE CABINET CURRENT DRAW CALCULATION Using the figures from the example sizing calculation , the fol- lowing examples show how to calculate the current draw of N+1 and 2N systems. For an N+1 system calculation, there are two system power modules operating at full load, one system power module (the redundant power module in the N+1 system) operating at no load, and one field power module.

  • Page 118: Introduction

    APPENDIX C - WIRING DIAGRAMS INTRODUCTION Appendix C contains system cabinet wiring diagrams for the INFI 90 OPEN Modular Power System II. Figure shows how to wire the auxiliary inputs channels, status inputs and cus- tomer alarms. Figure shows a wiring diagram for a 2N redundant system.

  • Page 119: Appendix C - Wiring Diagrams

    WIRING DIAGRAMS ® IPFCH01 12 AWG MINIMUM IPECB11 IPECB11 IPECB13 IPECB13 GRN/YEL TO AC GRN/YEL SAFETY GRN/YEL GROUND CABLE P/N 6641554 1 FAN CONNECTOR FAN CONNECTOR +15 -15 6632285 53 – – – – – (–) (–) CONNECTOR OU T LINE 1 LINE 2 AUX INPUTS...

  • Page 120: N, N+1 And N+X Redundancy System Wiring Diagram

    WIRING DIAGRAMS IPFCH01 12 AWG MINIMUM IPECB11 FAN CABLE IPECB13 J1 CONNECTOR TO AC GRN/YEL SAFETY GRN/YEL GROUND CABLE P/N 6641554 1 FAN CONNECTOR FAN CONNECTOR +15 -15 (H ) 6632285 53 – – – – – (–) (–) CONNECTOR LINE 1 LINE 2 AUX INPUTS...
  • Page 121 Index Fan assembly Feeder lines ..........3-1, 3-14 Cable..............3-6 Input trip points ........... 1-10 Input power ............1-11 Safety ground ............. 3-13 Installation .............3-6 Alarm Labels..............3-6 Configuration ............3-15 Redundant.............2-3 Logic ..............1-11 Fan speed ..............2-3 Operation .............. 4-3 Fast transient susceptibility........1-11 Wiring..............
  • Page 122 ® Index (continued) Power monitor module Board layout............3-16 Operating environment..........1-11 Circuit description ..........2-4 Operation ..............4-1 Dipswitches........3-15, 3-17, A-1 Ordering information ...........8-1 Fuse replacement ..........7-3 Input..............1-10 Installation............3-15 Jumpers .............. 3-20 Part numbers...............7-1 LEDs ............4-1, 5-2, A-4 Operation ..............
  • Page 123 Index (continued) Redundancy ............... 1-4 Torque specification ..........3-3 Reference documents ..........1-7 Relative humidity ............1-12 Repair procedures ............7-1 Temperature Monitoring ............2-3, 5-3 Storage..............1-12 Self-lock bolt............... 3-4 Trip point configuration........3-21 Sizing the power system ..........B-1 Test points ..............4-4 Special handling ............
  • Page 124 Telefax 39-10-6582-941 Telephone 49-69-799-0 Telefax 65-292-9011 Telefax 49-69-799-2406 Form I-E96-542B Litho in U.S.A. 696 Copyright © 1996 by Elsag Bailey Process Automation, As An Unpublished Work ® Registered Trademark of Elsag Bailey Process Automation ™ Trademark of Elsag Bailey Process Automation...

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