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Related Manuals for Phoenix Mecano wiener PL508
Summary of Contents for Phoenix Mecano wiener PL508
- Page 1 Water Interconnection Revision Service Manual...
- Page 2 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.
- Page 3 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.
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Page 4: Table Of Contents
ABLE OF ONTENTS 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 What to Do and Why .................. - Page 5 Electrical tests ....................21 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.
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Page 6: Safety Advice
AFETY 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. HARGED APACITORS AND ISCHARGING W-IE-NE-R Power supplies use an internal Voltage of 385V including... -
Page 7: What To Do And Why
HAT TO O AND 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 5 – W ARATON ATERCOOLED W-IE-NE-R delivered a vast amount of watercooled power supplies to CERN in the last decade. -
Page 8: Preparations
REPARATIONS 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. - Page 9 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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Page 10: Capacitor Discharge
4.1. APACITOR ISCHARGE Discharge the capacitors by connecting two 10W / 47Ω Resistors parallel to the terminals as shown in the pictures. You may get better access by removing the screws holding the front cover. 14. Dezember 2015 Water Interconnection Revision... -
Page 11: Access To The Interior
4.2. CCESS TO THE NTERIOR After discharging, now it is safe to access the interior. All further advises may differ in two major ways, depending on the type of power supply. This will be explained at chapter 5. 4.3. INTS From experience there are some points you should know and follow by opening the power supplies. -
Page 12: Modification
• During the training, there were some circumstances with prototypes of maraton units. The interieur made the common way in this manual nearly impossible. In this case it figured out to be better open the units from the top. So, the opening procedure is different, but the replacement of connector blocks and tubing stays the same, altough ist more difficult... -
Page 13: Standard Units („Pfc")
5.1.1. S („PFC“) TANDARD NITS As seen on the picture, this is a standard watercooled power supply. Best Part to see this is the PFC (Power Factor Correction) Module, clearly to identify with the big storage choke. Additional to new tubes (chapter 5.6) and the connector block (chapter 5.4) there has to be made an additional modification on the PFCs heat exchanger, as described in chapter 5.4... -
Page 14: Front Cover Removal Pfc
RONT COVER REMOVAL The best way of front cover removal is done by carefully opening it like a door as seen on the picture. After removing all screws, first unplug both tubes leading to the modules, they are the most obstructing parts. -
Page 15: Radiation Hard Units („Mne")
5.1.2. R („MNE“) ADIATION NITS The radiation hard units, or “Maraton” (Magnetic and Radiation Tolerant New Power supply System) can be identified with the big mains input module, the MNE ([Ger.] Modul Netz Eingang) here the tubing (chapter 5.6) and the connector block (chapter 5.4) have to be revisioned. -
Page 16: Front Cover Removal Mne
RONT COVER REMOVAL Similar to the PFC type, the best way of front cover removal is done by carefully opening it like a door. At first, additionally remove the screws and bolts as seen on the picture. Loctite used during production process, usage is recommended for remounting following the replacement... -
Page 17: Amount Of Modules
5.2. MOUNT OF ODULES At Cern, according to the PH-ESE database, most watercooled Power supplies are fully equipped with 6 Modules. Each module fewer, the part number varies corresponding. Example: 0M21.0102L 6 Modules 0M22.2004L-2 4 Modules 5.3. GE OF NITS IFFERENT UBING Since approximately 2006 we use the common Module heat exchanger with... -
Page 18: The Connector Block
5.4. ONNECTOR LOCK 0M4S.0000 0M4S.0001 Pretested and Ready-to-Mount units as seen on the picture will be delivered blow off at 16 from W-IE-NE-R. They are equipped with a pressure relief valve adjusted to −0 bar. There are two different Parts available, 0M4S.0000, 0M4S.0001, only differing in dimensions - not in function. -
Page 19: Pfc Modification
Reassemble by first attaching the rectifier (if present) including the adaption. Don’t forget to apply heat conducting paste at this point. A new M5 spring washer is recommended if the old one seem worn out. Finally tighten the block to the front cover. 5.5. -
Page 20: The Legris Tube
5.6. EGRIS For the internal tubing, we use a Legris Polyamide (PA) Tube. The cutting and handling will be explained in this chapter. It is important that any deformation of the tubes cross section or damage of the tube itself should be prevented. -
Page 21: Plug & Unplug
& U NPLUG To unplug push the tube into the connector, hold the securing ring down and firmly remove the tube. Be carefull not to damage anything by slipping out to fast. If needed use a suitable wrench as seen in the pictures. This improves the removal in case you can’t reach the connector with your hand. -
Page 22: Checkup, Front And Rear Closing
HECKUP RONT AND EAR CLOSING After completing all modification steps it is recommended to close the back and front cover vice versa you opened it. Take care not to squish wires! While working overlook critical edges for wires and tubes, be aware of pinching wires or damage something else. - Page 23 Tubing vs. Flat Cable - Avoid pushed flat wire Support PCBs when pushing is needed! – Prevent Broken SMD parts due Bending of the PCB. Avoid wire pinching – even when they are insulated 14. Dezember 2015 Water Interconnection Revision...
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Page 24: Closing The Power Supply
LOSING THE OWER SUPPLY It sounds easy. Maybe it will be easy after modifying about 30 Units. But never forget to do all steps at full attention. After closing the rear and front cover together with following the checkup list in the last chapter, now is the right time to hesitate. -
Page 25: Check Procedure
8.1. HECK ROCEDURE • Connect the same armature as for the purging before opening and flush with air for some seconds. • Replace the open end CPC with a closed valve • SLOWLY put the unit under pressure up to 7bar •... -
Page 26: Electrical Tests
LECTRICAL TESTS It is recommended to make a simple on-site measurement with a Digital Multimeter. Check the output terminals against each other and against ground for direct shorts by measuring the resistance. There may be capacitors whose charging behavior could take influence. Further electrical safety tests have to be performed, also a functional pretest is highly recommended. -
Page 27: Appendix
PPENDIX 11.1. IST OF ECOMMENDED OOLS NVIRONMENT Tools/Equip for each Worker, respectively for later maintenance Table & Chair, usable for mechanical work, not too sensitive. Philips Screwdriver, sizes PH0, PH1, PH2. Electric or Peumatic Drill for Torques <5Nm recomended Hex / Allen Key, at least size 4, better a set of keys „Small“... -
Page 28: Tubing Examples (With Water Flow Direction)
11.2. UBING EXAMPLES WITH WATER FLOW DIRECTION 14. Dezember 2015 Water Interconnection Revision... -
Page 29: Pressure / Purge Environment Sketch
11.3. RESSURE URGE NVIRONMENT KETCH 14. Dezember 2015 Water Interconnection Revision...
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