Bailey Infi 90 Instruction

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Process Control and
Automation Solutions
from Elsag Bailey Group

®

AC Modular Power System

E96-506

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WARNING notices as used in this instruction apply to hazards or unsafe practices that could result in
personal injury or death.

CAUTION notices apply to hazards or unsafe practices that could result in property damage.
NOTES highlight procedures and contain information that assists the operator in understanding the

information contained in this instruction.

WARNING

INSTRUCTION MANUALS

DO NOT INSTALL, MAINTAIN, OR OPERATE THIS EQ UIPMENT WITHOUT READING, UNDERSTANDING,
AND FOLLOWING THE PROPER
DAMAGE MAY RESULT.

Elsag Bailey

INSTRUCTIONS AND MANUALS; OTHER WISE, INJURY OR

RADIO FREQUENCY INTERFERENCE

MOST ELECTRONIC EQUIPMENT IS INFLUENCED BY RAD IO FREQUENCY INTERFERENCE (RFI). CAU­TION SHOULD BE EXERCISED WITH REGARD TO THE USE OF PORTABLE COMMUNICATIONS EQUIP­MENT IN THE AREA AROUND SUCH EQUIPMENT. PRUDENT PRACTICE DICTATES THAT SIGNS
SHOULD BE POSTED IN THE VICINITY OF THE EQUIPMENT CAUTIONING AGAINST THE USE OF POR­TABLE COMMUNICATIONS EQUIPMENT.

POSSIBLE PROCESS UPSETS

MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIE D PER SONNEL AN D ONLY AFTE R SEC URING
EQUIPMENT CONTROLLED BY THIS PRODUCT. ADJUSTING OR REMOVING THIS PRODUCT WHILE IT IS
IN THE SYSTEM MAY UPSET THE PROCESS BEING CONTROLLED. SOME PROCESS UPSETS MAY
CAUSE INJURY OR DAMAGE .

AVERTISSEMENT

MANUELS D’OPÉRATION

NE PAS METTRE EN PLACE, RÉPARER OU FAIRE FONCTIONNER L’ÉQUIPEMENT SANS AVOIR LU,
COMPRIS ET SUIVI LES INSTRUCTIONS RÉGLEMENTAIRES DE
CET ÉGARD POURRAIT ÊTRE UNE C AUSE D’ACC IDENT OU DE DÉFAILL ANCE DU MA TÉRIEL.

Elsag Bailey

. TOUTE NÉGLIGENCE À

PERTURBATIONS PAR FRÉQUENCE RADIO

LA PLUPART DES ÉQUIPEMENTS ÉLECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR
FRÉQUENCE RADIO. DES PRÉCAUTIONS DEVR ONT ÊTRE PRISES LORS DE L’UTILISATION DU MATÉ­RIEL DE COMMUNICATION PORTATIF. LA PRUDENCE EXIGE QUE LES PRÉCAUTIONS À PRENDRE
DANS CE CAS SOIENT SIGNALÉES AU X ENDROITS VO ULUS DANS VOTR E USINE.

PERTURBATIONS DU PROCÉDÉ

L’ENTRETIEN DOIT ÊTRE ASSURÉ PAR UNE PERSONNE QUALIFIÉE EN CONSIDÉRANT L’ASPECT
SÉCURITAIRE DES ÉQUIPEMENTS CONTRÔLÉS PAR CE PRODUIT. L’AJUSTEMENT ET/OU L’EXTRAC­TION DE CE PRODUIT PEUT OCCAS IONNER DES À-COUPS AU PROCÉD É CONTRÔLE LORSQU’IL EST
INSÉRÉ DANS UNE SYSTÈME ACTIF. CES À-COUPS PEUVENT ÉGALEMENT OCCASIONNER DES
BLESSURES OU DES DOMMAGES M ATÉREILS.

NOTICE

The information contained in this docume nt is s ubj ect to change wi thout noti ce.
Elsag Bailey, i ts af fili at es , em pl oye es , an d a gen ts, a n d th e a u thor s an d co ntr ib utors to this publica ti on sp ec if-

ically disclaim all liabilities and warranties, express and implied (including warranties of merchantability and
fitness for a pa rt icu lar p urp os e) , fo r the ac cur a cy, cur r en cy, co mple t en ess, an d/ o r r eliability of the i nf or ma tion
contained herein and/or for the fitness for any particular use and/or for the performance of any material and/
or equipment selected in whole or part with the user of/or in reliance upon information contained herein.
Selection of materials and/or equipment is at the sole risk of the user of this publication.

This document contains proprietary i nformation of Elsag Baile y, Elsag Bailey Proces s Automation, and
is issued in strict confidence. Its use, or reproduc tion for use, for the re verse engineering, de velopment
or manufacture of hardware or software described herein is prohibited . No part of this docume nt may be
photocopied or reproduced without the prior written c onse nt of El sag B aile y.

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Preface

The AC Modular Power System supplies system and I/O power
to the components within an INFI 90

®

system cabinet. This
manual provides information on the IEPAS02 and IEPAF02
Power Modules and their related system hardware. Related
hardware includes the IEPEP01, IEPEP02 and IEPEP03 Power
Entry Panels, IEMMU01 and IEMMU02 Module Mounting Units,
and IEPMU01 and IEPMU02 Power Mounting Units. The infor­mation in this manual includes a procedure for sizing the power
system, installation instructions, operating procedures, trouble­shooting, maintenance and repair/replacement procedures.

The IEPAS02 and IEPAF02 AC Power Modules supersede the
IEPAS01 and IEPAF01 AC Power Modules and are compatible
replacements. Refer to Appendix E for more information.

® INFI 90 is a registered trademark of Elsag Bailey Process Automation.

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List of Effective Pages

Total number of pages in this instruction is 95, consisting of the following:

Page No. Change Date

Preface Original

List of Effective Pages Original

iii through ix Original
1-1 through 1-7 Original
2-1 through 2-7 Original
3-1 through 3-17 Original
4-1 through 4-4 Original
5-1 through 5-7 Original
6-1 through 6-8 Original
7-1 through 7-6 Original
8-1 Original
A-1 through A-2 Original

B-1 through B-10 Original
C-1 through C-5 Original
D-1 through D-8 Original
D-1 through E-2 Original

Index-1 through Index-2 Original

®

When an update is received, insert the latest changed pages and dispose of the super­seded pages.

NOTE:

gin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the
outer margin next to the figure caption. The date the update was prepared will appear beside the
page number.

On an update page, the changed text or table is indicated by a vertical bar in the outer mar-

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Safety Summary

GENERAL

WARNINGS

SPECIFIC

WARNINGS

Equipment Environment

All components whether in transportation, operation, or storage
must be in a noncorrosive environment.

Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to ensure that contact with
energized parts is avoided when servicing.

Special Handling

This module uses electrostatic sensitive devices.

Verify the main power and powe r entry panel circuit breakers are
turned off before starting installation, retrofit, upgrade, or wiring pro­cedures. Failure to do s o could result in severe or fata l shock. Do
not turn the power on until the installation, retrofit, upgrade, or wiring
procedures are complete. (p. 3-2, 3-13, 7-6, D-1)

Do not remove the plastic covers on the module mounting unit back­plane. These covers protect against accidental contact with AC volt­age. Severe or fatal shock could result. (p. 3-9)

Allow five seconds for the line filter c apacitors to dischar ge before
handling the module aft er removal. Failure to do so could result in
severe or fatal shock. (p. 3-11, 7-5)

Handle the module by surf aces other than the heat sink. The heat
sink may be hot and may cause severe burns. (p . 3-12, 7-5)

There are exposed AC and DC connections inside the cabinet.
These exposed electrical conn ections present a shock hazard tha t
can cause injury or death. (p. 6-1)

Never clean electrical parts or components with the AC power on.
Doing so exposes you to a fatal electrical shock hazard. (p. 6-1)

If input or output circuits are a shock hazard after disconnecting sys­tem power at the power entry panel, then the door of the cabinet
containing these ext ernally powered cir cuits mu st be m arked wi th a
warning stating that multiple power sources exist. (p. 6-1)

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 blown off the printed circuit board. (p. 6-1)

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Safety Summary

SPECIFIC CAUTIONS

(continued)

Verify the line voltage select switch is properly configured before
energizing the power entry panel. Failure to do so could perma­nently damage the PFI circuit board by exposing it to improper input
voltage levels. (p. 3-12)

Sommaire de Sécurité

AVERTISSEMENT

D'ORDRE

GENERAL

Environment de l'equipment

Ne pas soumettre le s comp osants a une atmo sphere corr osive lors
du transport, de l'entreposage cu de l'utilisation.

Risques de chocs electriques lor de l'entretien

S'assurer de debranche r l'alimentation ou de prendre les precau­tions necessaires a eviter tout contact avec des composants sours
tension lors de l'entretien.

AVERTISSEMENT

D'ORDRE

SPECIFIQUE

Precautions de manutention

Ce module contient des composantes sensibles aux decharges
electro-statiques.

Assurez-vous que le disjoncteur d'alimentation principal et le dis­joncteur de panneau d'entrée des alimentatoins sont éte ints avant
de procéder à l'installation, à la mise à jour, à l'extension ou au
câblage, dans le but d'éviter les chocs sérieux et même mortels. Ne
rétablissez pas l' alimentation tant que ces procédures n e sont pas
terminées. (p. 3-2, 3-13, 7-6, D-1)

Ne retirez pas les couvercles de plastique situés sur le panneau
arrière du châssis de montage des modules. Ces couvercles con­stituent une protection c ontre les contacts accidentel s avec la ten­sion c.a., qui risquent de provoquer des chocs sérieux et même
mortels. (p. 3-9)

Après avoir retiré le module, laissez les condensateurs de filtres
antiparasites se décharger pendant cinq secondes avant de
manipuler celui-c i, afin d'éviter le s chocs série ux et même morte ls.
(p. 3-12, 7-5)

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Sommaire de Sécurité

(suite)

AVERTISSEMENT

D'ORDRE

SPECIFIQUE

(suite)

Le module diot êt re m ani pul é à l 'ai de de su rf ac es au tr es qu e l e dis ­sipatour thermique. Ce dernier resque d'être chaud et de provoquer
des brûlures sérieuses. (p. 3-12, 7-5)

Cette armoire compor te des co nnexio ns c.a. et c.c. dén udées. Ces
connexions électriques présentent un danger d'électrocution pou­vant entraîner des blessures ou la mort. (p. 6-1)

Il ne faut jamais nettoyer des pièceso u des compos ants él ectriq ues
lorsqu'ils sont sous t ens io n. Cedi présente un risque d'éle ct ro cu tio n
fatale. (p. 6-1)

Si des circuits d'entrée ou de sortie sont alimentés à partir de
sources externes, ils présentent un risque de choc électrique même
lorsque l'alimentation du système est débranchée du panneau
d'entrée l'alimentatio n. Le cas échéant, un avertiss ement signalant
la présence de sources d'alimentation multiples doit être apposé sur
la porte de l'armoire. (p. 6-1)

Portez toujours des lu nettes de protection l orsque vous utilisez des
solvants de nettoyage. L'ai rcomprimé servant à enlever le solvant
des cartes de circuits imprimés provoque des éclaboussures qui ris­quent d'atteindre les yeux. (p. 6-1)

ATTENTION D'ORDRE

SPECIFIQUE

Assurez-vous que l 'interrupteur de sélec tion de la tension de li gne
est adéquatement configu ré avant de mettre sous tension le pan­neau d'entrée des al imentations. To ute négligence à cet égard ris ­que d'endommager de facon permanente l a carte de détecti on des
coupures d'alimentation (PFI) en l'exposant à des niveaux
inadéquats de tension d'entrée. (p. 3-12)

I-E96-506B1 ix

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Table of Contents

Page

SECTION 1 - INTRODUCTION....................................................................................................1-1

OVERVIEW ..................................................................................................................1-1

HARDWARE DESCRIPTION..........................................................................................1-1

Power Entry Panel..................................................................................................1-1

Fan Assembly ........................................................................................................1-1

Power Modules.......................................................................................................1-2

Power Mounting Units............................................................................................1-2

Module Mounting Units .........................................................................................1-2

USER QUALIFICATIONS ..............................................................................................1-2

INSTRUCTION CONTENT .............................................................................................1-2

HOW TO USE THIS MANUAL .......................................................................................1-3

REFERENCE DOCUMENTS..........................................................................................1-4

NOMENCLATURE ........................................................................................................1-4

GLOSSARY OF TERMS AND ABBREVIATIONS .............................................................1-4

SPECIFICATIONS.........................................................................................................1-5

SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1

INTRODUCTION...........................................................................................................2-1

POWER DISTRIBUTION................................................................................................2-2

POWER ENTRY PANEL.................................................................................................2-2

IEPEP01 and IEPEP02 Panels ................................................................................2-2

IEPEP03 Panel .......................................................................................................2-2

AC Transfer Module ...............................................................................................2-3

Bus Monitor Module ..............................................................................................2-3

FAN ASSEMBLY...........................................................................................................2-4

MODULE MOUNTING UNIT..........................................................................................2-4

POWER MOUNTING UNITS ..........................................................................................2-4

POWER MODULES ......................................................................................................2-4

STATUS SIGNALS ........................................................................................................2-5

Power System Status .............................................................................................2-5

Bus Voltage Status ................................................................................................2-6

Power Module Status .............................................................................................2-6

Customer Alarm Outputs.......................................................................................2-7

SECTION 3 - INSTALLATION .....................................................................................................3-1

INTRODUCTION...........................................................................................................3-1

UNPACKING AND INSPECTION ....................................................................................3-1

Special Handling....................................................................................................3-1

General Handling...................................................................................................3-2

IEPEP03 POWER ENTRY PANEL WIRING .....................................................................3-2

AC Transfer Module ...............................................................................................3-5

Bus Monitor Module ..............................................................................................3-7

Fan Assembly ........................................................................................................3-9

Power Modules.......................................................................................................3-9

IEPEP01 AND IEPEP02 POWER ENTRY PANEL WIRING .............................................3-12

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION ...........................3-13

Required Tools .....................................................................................................3-14

Installation in the INFI 90 Cabinet .......................................................................3-14

Wiring Instructions ..............................................................................................3-14

SECTION 4 - OPERATING PROCEDURES................................................................................4-1

INTRODUCTION...........................................................................................................4-1

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Table of Contents

SECTION 4 - OPERATING PROCEDURES

LED INDICATORS........................................................................................................ 4-1

AC Transfer Module............................................................................................... 4-1

Bus Monitor Module .............................................................................................. 4-1

Power Module........................................................................................................4-2

REMOVING ATM OR BMM MODULES DURING OPERATION ....................................... 4-3

RECOMMENDED START-UP PROCEDURES................................................................ 4-3

(continued)

Page

(continued)

SECTION 5 - TROUBLESHOOTING...........................................................................................5-1

INTRODUCTION .......................................................................................................... 5-1

TROUBLESHOOTING FLOWCHARTS........................................................................... 5-1

IEPEP01 and IEPEP02 Systems ............................................................................. 5-1

IEPEP03 Systems .................................................................................................. 5-1

SECTION 6 - MAINTENANCE.....................................................................................................6-1

INTRODUCTION .......................................................................................................... 6-1

PREVENTIVE MAINTENANCE SCHEDULE...................................................................6-2

EQUIPMENT REQUIRED ............................................................................................. 6-3

PREVENTIVE MAINTENANCE PROCEDURES .............................................................. 6-3

Cabinet Filter Cleaning/Replacement ....................................................................6-3

Checking Connections........................................................................................... 6-4

Checking Power Module Outputs ........................................................................... 6-5

Checking Bus Voltages on IEPEP01 and IEPEP02 Systems ..............................6-5

Checking Bus Voltages on IEPEP03 Systems ...................................................6-5

Power Entry Panel Inspection and Check ............................................................... 6-6

Printed Circuit Board Cleaning .............................................................................. 6-6

General Cleaning and Washing........................................................................ 6-7

Edge Connector Cleaning ................................................................................6-7

Cleaning Female Edge Connectors...................................................................6-8

SECTION 7 - REPAIR/REPLACEMENT PROCEDURES...........................................................7-1

INTRODUCTION .......................................................................................................... 7-1

SPARE PARTS.............................................................................................................. 7-1

AC TRANSFER MODULE REPLACEMENT .................................................................... 7-2

BUS MONITOR MODULE REPLACEMENT ................................................................... 7-3

FAN ASSEMBLY .......................................................................................................... 7-3

Fuse Replacement ................................................................................................. 7-3

Fan Assembly Replacement ................................................................................... 7-3

POWER MODULE ........................................................................................................ 7-4

Power Module Replacement ................................................................................... 7-4

Power Module Fuse Replacement........................................................................... 7-5

POWER ENTRY PANEL REPLACEMENT ....................................................................... 7-6

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

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Table of Contents

(continued)

Page

APPENDIX B - MODULE POWER REQUIREMENTS ...............................................................B-1

INTRODUCTION.......................................................................................................... B-1

CALCULATING CURRENT REQUIREMENTS................................................................ B-1

SIZING THE MODULAR POWER SYSTEM.................................................................... B-5

Sizing Systems with IEPAS02 Modules Only.......................................................... B-5

System Calculation Example Using IEPAS02 Modules Only................................... B-6

For Systems Using Both IEPAS02 and IEPAF02 Modules ...................................... B-7

System Calculation Example Using IEPAS02 and IEPAF02 Modules ...................... B-9

MAXIMUM POWER ENTRY PANEL CURRENT DRAW................................................. B-10

APPENDIX C - WIRING DIAGRAMS..........................................................................................C-1

INTRODUCTION.......................................................................................................... C-1

APPENDIX D - RETROFITTING THE MODULAR POWER SYSTEM.......................................D-1

INTRODUCTION.......................................................................................................... D-1

NETWORK 90 POWER SYSTEM REMOVAL ................................................................. D-2

Required Tools ...................................................................................................... D-2

Power Entry Panel Removal................................................................................... D-2

I/O Power Panel Removal...................................................................................... D-3

Module Power Panel Removal ................................................................................ D-3

Fan Assembly Removal ......................................................................................... D-4

Installing the INFI 90 Power System ...................................................................... D-4

Wiring the INFI 90 Power System .......................................................................... D-5

APPENDIX E - IEPAS01/IEPAF01 POWER MODULE REPLACEMENT.................................. E-1

INTRODUCTION.......................................................................................................... E-1

REPLACING POWER MODULES.................................................................................. E-1

POWER SYSTEM SIZING............................................................................................. E-1

LOAD SHARING .......................................................................................................... E-1

SYSTEM EFFECTS ON MODULE LEDS ....................................................................... E-2

List of Figures

No. Title Page

2-1. Modular Power System Architecture.......................................................................2-1

2-2. Power Distribution to the IEPAS02 System Power Module ......................................2-5

2-3. IEPAS02 Module Converter and Status Circuitry ....................................................2-6

2-4. Status Signal Block Diagram..................................................................................2-7

3-1. Circuit Breakers CB1/CB2 ....................................................................................3-3

3-2. AC Transfer Module, Switch S1 ..............................................................................3-5

3-3. IEPEP03 Power Entry Panel, Rear View ..................................................................3-6

3-4. Bus Monitor Module, Switch S1 and Jumpers J1 through J8 .................................3-7

3-5. Recommended Power Module Layout for Module Mounting Unit ...........................3-10

3-6. IEPAF02 and IEPAS02 Power Module Board Layout .............................................3-11

3-7. Rear of IEPEP01 and IEPEP02 Power Entry Panels ...............................................3-13

3-8. Heat Shrink Tubing for 5 VDC Connection ...........................................................3-15

3-9. Heat Shrink Tubing for 24 VDC Connection .........................................................3-16

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List of Figures

No. Title Page

5-1. Troubleshooting Flowchart, IEPEP01 and IEPEP02 Power Entry Panels ................. 5-2

5-2. Troubleshooting Flowchart, IEPEP03 Power Entry Panel (Page 1 of 3) ....................5-5

C-1. IEPEP03 Power Entry Panel and Module Mounting Unit Wiring Diagram ...............C-2

C-2. IEPEP03 Power Entry Panel and Power Mounting Unit Wiring Diagram..................C-3

C-3. IEPEP01/IEPEP02 Power Entry Panel and Module Mounting Unit Wiring Diagram C-4
C-4. IEPEP01/IEPEP02 Power Entry Panel and Power Mounting Unit Wiring Diagram ..C-5
D-1. Wiring Diagram of IEPEP03 Power Entry Panel and Power Mounting Unit,

Network 90 Cabinet...............................................................................................D-7

D-2. Wiring Diagram of IEPEP01 and IEPEP02 Power Entry Panel and Power Mounting Unit,

Network 90 Cabinet...............................................................................................D-8

(continued)

List of Tables

No. Title Page

1-1. Reference Documents ............................................................................................ 1-4

1-2. Nomenclature........................................................................................................ 1-4

1-3. Glossary of Terms and Abbreviations ..................................................................... 1-4

1-4. Specifications ........................................................................................................ 1-5

3-1. Bus Monitor Module Switch Settings ..................................................................... 3-8

3-2. Bus Monitor Module Jumper Settings.................................................................... 3-8

3-3. IEPAS02 and IEPAF02 Power Module Jumper Settings ........................................ 3-11

4-1. Status LEDs, AC Transfer and Bus Monitor Modules .............................................4-2

4-2. Status LEDs, Priority Level and Status Signal for IEPAS02 and

IEPAF02 Power Modules ........................................................................................ 4-2

4-3. Unloaded DC Bus Output Voltage Requirements ................................................... 4-4

6-1. Preventive Maintenance Schedule.......................................................................... 6-2

7-1. Spare Part Numbers and Description..................................................................... 7-1

A-1. Switch and Jumper Setting Reference Guide..........................................................A-1

B-1. DC Current Consumption for INFI 90 Modules ......................................................B-2

B-2. 24 VDC Current Consumption of Termination Units and Termination Modules ......B-4

B-3. System Powered I/O Current Consumption ...........................................................B-5

E-1. IEPAS01/IEPAS02 Modules Power and Current Outputs .......................................E-1

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OVERVIEW

HARDWARE DESCRIPTION

Power Entry Panel

SECTION 1 - INTRODUCTION

The INFI 90 AC modular power system provides +5, +15, -15
and +24 VDC to power process control modules and field ter­mination devices.

The system consists of the power entry panel, fan assembly,
power modules and their mounting unit, bus bars and associ­ated wiring. The power modules provide scalable power for
logic and I/O functions. The user has the option of selecting
N+1 power redundancy. In this type of redundancy, power
modules equally share output. If any power module fails, the
remaining power modules adjust their outputs to meet the
total system load. Therefore, redundancy can be provided by
one extra power module beyond the minimum number
required to power the system.

Fan Assembly

The power entry panel supplies line power to the system cabi­net. There are three versions: IEPEP01, IEPEP02 and IEPEP03
Power Entry Panel. The IEPEP01 panel is the basic version. It
has surge protection and power fail interrupt detection; how­ever, it does not have circuit breakers or DC voltage monitoring
capabilities. The IEPEP02 panel has one circuit breaker and is
identical to the IEPEP01 panel. The IEPEP03 panel has addi­tional features.

The IEPEP03 panel transfers redundant power to the system
cabinet and monitors system status. It contains the AC trans­fer module and the bus monitor module that perform these
functions. The AC transfer module monitors line voltage inputs
to the system cabinet, provides automatic AC line transfer (for
redundant AC lines) and generates a power fail interrupt (PFI)
signal. The bus monitor module monitors the power system
and provides status and customer alarm outputs.

The IEFAN01 and IEFAN02 fan assemblies provide air flow
cooling for the power modules and process control modules in
the system cabinet.

OVERVIEW

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INTRODUCTION

Power Modules

Power Mounting Units

®

There are two AC power modules: IEPAS02 System Power Mod­ule and IEPAF02 Field Power Module. The IEPAS02 module
provides +5, +15, -15 and +24 DC voltages. The IEPAF02 mod­ule provides +24 VDC only for field powered devices.

The IEPAS02 and IEPAF02 modules replace the IEPAS01 and
IEPAF01 modules. Both sets of modules can be used in the
same cabinet. The IEPAS02 and IEPAF02 modules are compat­ible with the IEPAS01 and IEPAF01 modules.

The IEPMU01 and IEPMU02 Power Mounting Units are
designed to provide housing and power connections to the
power modules. The power mounting units can service up to
ten power modules.

Power mounting units segregrate power modules from process
control modules and are built to handle heavier currents. The
IEPMU01 Power Mounting Unit is a rear mounted unit. The
IEPMU02 Power Mounting Unit is a front mounted unit.

Module Mounting Units

USER QUALIFICATIONS

INSTRUCTION CONTENT

The IEMMU01 Module Mounting Unit provides the housing,
power connections and signals for power supply and process
control modules. The module mounting unit is an alternative
to the power mounting unit.

The IEMMU02 unit has the same functionality as the
IEMMU01 unit, but it is a front mounted unit. Its primary use
is in smaller system cabinets like the MINI-90™ system.

This manual is not a tutorial. Therefore, the user should have
training as an electrical technician. That is, the user should
know the basics of, and precautions for, working with AC/DC
voltages, and how to use various measuring instruments such
as digital voltmeters.

This manual provides introductory, installation, operation,
troubleshooting and maintenance information. Read and

™ MINI-90 is a trademark of Elsag Bailey Process Automation.

USER QUALIFICATIONS
1 - 2 I-E96-506B1

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INTRODUCTION

understand this document before placing the power system
into service. A summary of section content follows:

Introduction

Description and

Operation

Installation

Operating Procedures

Troubleshooting

Maintenance

Repair/Replacement

Procedures

Support Services

Appendices

Provides an overview of the system, description of hardware,
glossary of unique terms, reference documentation, and physi­cal and electrical specifications.

Contains a block diagram to explain how key parts of the sys­tem operate.

Explains handling, inspection, location and safety consider­ations, setup (e.g., switch settings) and interfacing.

Covers start-up, how to use and individual controls.

Lists error indications, corrective actions, problem determina­tion and verification.

Provides guidelines to assist in establishing a preventive main­tenance program.

Provides procedures for user repair and replacement.

Explains services, training, replacement parts and warranty
policy.

Contain quick reference material, a modular power system siz­ing procedure, system wiring diagrams and a modular power
system retrofitting procedure.

HOW TO USE THIS MANUAL

Read this manual in sequence. To get the best use of this man­ual, read it from cover to cover, then go back to specific
sections.

1. Read and do the steps in Section 3.

2. Read Section 4 thoroughly before powering up the system.

3. Refer to Section 5 for what to do if a problem occurs.

4. Read Section 7 if system repairs are needed.

5. Section 8 lists ordering information, training and docu­mentation.

HOW TO USE THIS MANUAL

I-E96-506B1 1 - 3

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INTRODUCTION

REFERENCE DOCUME NTS

®

Table 1-1 lists reference documents.

Table 1-1. Reference Documents

NOMENCLATURE

Document

Number

I-E96-500 Site Planning and Preparation

Title

Table 1-2 lists nomenclatures associated with the IEPAS02
and IEPAF02 Power Supply Modules. Refer to Table 7-1 for
part numbers of related items such as cables and fuses.

Table 1-2. Nomenclature

Nomenclature Description

IEFAN01 Fan assembly - 120 VAC
IEFAN02 Fan assembly - 240 VAC
IEFAS01 INFI 90 fastener kit
IEMMU01 Module mounting unit (rear mount)
IEMMU02 Module mounting unit (front mount)
IEPAF02 AC field power module
IEPAS02 AC system power module
IEPEP01 Power entry panel with single AC feed and no circuit

breaker
IEPEP02 Power entry panel with single AC feed and circuit breaker
IEPEP03 Power entry panel with redundant AC feed and circuit

breakers
IEPMU01 Power mount ing unit (rear mount)
IEPMU02 Power mounting unit (front mount)

GLOSSARY OF TERMS AND ABBREVIATIONS

Table 1-3 is a glossary of terms and abbreviations used in this
manual.

Table 1-3. Glossary of Terms and Abbreviations

Term Definition

ATM AC transfer module.
BMM Bus monitor module.
Controlway High speed, redundant, peer-to-peer communication link. Used to transfer information

between intelligent modules within a process control unit.

REFERENCE DOCUMENTS
1 - 4 I-E96-506B1

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INTRODUCTION

Table 1-3. Glossary of Terms and Abbreviations

(continued)

Term Definition

Module Bus Peer to peer communication link used to transfer information between intelligent modules

within a process control unit.

MMU Mod ule mounting uni t. A card cage that provid es electrical an d communica tion support for

INFI 90/Network 90

®

modules.
PEP Power entry panel.
PFI Power fail interrupt. A signal generated by the power entry panel when there is a loss of

AC or DC input power, or an out-of-tolerance bus voltage.
PMU Power mounting unit.
I/O Expander

Parallel communication bus between the control and I/O modules.
Bus

Termination
Module

Provides input/output connection between plant equipment and the INFI 90/Network 90

modules.
Termination Unit Provides input/output connection between plant equipment and the INFI 90/Network 90

modules.

SPECIFICATIONS

Table 1-4 lists the modular power system specifications.

Table 1-4. Specifications

Property Characteristics

Power system input
requirements:

Power requirements
(jumper configurable )

Nom Min Max

120
240

Total harm onic distortion 5%
Frequency 47 to 63 Hz

IEPAS02 and IEPAF02 power
module characteristics:

Input voltage/current

Power Module

IEPAS02 120

IEPAF02 120

Inrush current <5 A peak per supply for 100 msecs
Crest factor 3 at 120 VAC

3 at 240 VAC

Power factor 0.7 typical

Voltage (VRMS)

102
204

Voltage (VRMS) Current (ARMS)

Nom Min Max Typ Max

240

240

132
264

90

180

90

180

132
264

132
264

2.25

1.40

1.75

1.00

3.00

1.55

2.25

1.25

® Network 90 is a registered trademark of Elsag Bailey Process Automation.

SPECIFICATIONS

I-E96-506B1 1 - 5

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INTRODUCTION

®

Table 1-4. Specifications

(continued)

Property Characteristics

IEPAS02 and IEPAF02 power
module characteristics:

(continued)

Output current/voltage/
regulation/power:

(Line regulation is less than

0.5% on all outputs.
All tolerances are maximum tol­erances and cumulative.)

Power Module

IEPAS02 4.0

IEPAF02 4.0 25.8

Current

(A)

13.0

0.8

0.8

Voltage Load

VDC %

25.8

5.225

+15.2

-15.2

±

0.5

±

0.5

±

2.3

±

2.3

±

0.5 1.5 102

Regulation

(%)

1.5
4
3
3

Max Power

(W)

130

(max output

per power

module)

Minimum output hold up time 17 msecs, output fully loaded
Heat dissipation 30 W per module maximum
Mounting Power su pply modules mount in a single slot of th e mo dule mounting unit

or power mounting unit.

IEPEP01/02/03
characteristics:

AC input monitoring a nd transfer
low voltage detect

96 VRMS (±6 VRMS) for 120 VAC nominal input

192 VRMS (±12 VRMS) for 240 VAC nominal input
Line interrupt detect time 2.3 msecs to 3.2 msecs
Redundant AC transfer time 16 msecs maximum (IEPEP03 only)
Maximum current 20 A

IEPEP03 characteristics:

Monitor trip points

Monitor

DC power 5

Auxiliary
voltage

Voltage

(VDC)

15

-15
24

24
48

125

Low Voltage

Trip Point

(Typical)

4.76

14.30

-14.30

24.50

21.8

43.7

114.0

Status and alarm requirements:

Power system alarm output to
system common

Open to alarm, 24 VDC maxi mum, 12 0 mA (indu cti ve loads req uir e diode
suppression)

Bus voltage alarm output Open to alarm, 24 VDC maxi mum, 12 0 mA (indu cti ve loads req uir e diode

suppression)

Status signal inputs Normally open (NO) or normally closed (NC) jumper selectable on BMM

module. Low ≤ 0.8 VDC, High ≥ 3.1 VDC at bus monitor test points

IEFAN01/02 power
requirements

Fan

Assembly

IEFAN01
(120 VAC)

IEFAN02
(240 VAC)

Current (ARMS)

Operating Inrush

1.2 1.6

0.6 0.9

SPECIFICATIONS
1 - 6 I-E96-506B1

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INTRODUCTION

Table 1-4. Specifications

(continued)

Property Characteristics

General system
specifications:

Module voltage requirements
(at bus monitor test points)

Electromagnetic/radio
frequency interferenc e

Physical dimensions

Module Voltage (VDC)

Nom Min Max

5

+15

-15
24

4.75

+14.30

-14.30

25.50

+15.75

-15.75

27.00

5.25

Max Ripple

(mV, p to p)

50
100
100
100

Values not available at this time. Keep cabinet doors closed. Do not use
communication equipment any closer than 2 meters from the cabinet.

Component

IEPEP01/02 132 5.2 428.6 19 114.3 4.5
IEPEP03 175.2 6.9 428.6 19 685.8 27
IEFAN01/02 44.4 1.75 428.6 19 33.0 13
IEPMU01/02 177.8 7.0 428.6 19 317.5 12.5
IEMMU01/02 177.8 7.0 428.6 19 317.5 12.5

Height Width Depth

mm in. mm in. mm in.

Environmental:

Room ambient temperature 0° to 55°C (32° to 131°F)
Maximum module ambient tem-

70°C (158°F)

perature
Humidity 5% to 90%, up to 55°C (131°F) noncondensing

0% to 45% at 70°C (158°F) noncondensing
Cooling (fan) 180 cfm typical
Atmospheric pressure Sea level to 3 km (1.86 mi)
Air quality Noncorrosive

Certification

Meets IEEE-472-1974 surge test requirements.

CSA certification as process control equipment in an ordinary

(nonhazardous) environment.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

SPECIFICATIONS

I-E96-506B1 1 - 7

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INTRODUCTION

SECTION 2 - DESCRIPTION AND OPERATION

This section uses block diagrams and supportive text to
explain how the main functional blocks of the power system
operate. The first diagram, Figure 2-1, shows overall system
architecture. Figure 2-2 shows power distribution to the
IEPAS02 module. Figures 2-3 and 2-4 show circuit details for
the system power module, and AC transfer and bus monitor
module.

120/240 VAC

LINE 1 LINE 2

SYSTEM

POWER

BUS BAR

EXTERNAL SUPPLY AND
CUSTOMER STATUS

BUS MONITOR
DETECTION POINTS
AND ALARM

+5 VDC
+24 VDC
–15 VDC
+15 VDC

MODULE ALARM

+5 VDC

–15 VDC
+15 VDC

+5 VDC
+24 VDC
–15 VDC
+15 VDC

MODULE ALARM

POWER ENTRY PANEL

MODULE MOUNTING UNIT

ANY INFI 90 MODULES

MODULE MOUNTING UNIT

ANY INFI90 M ODULES

MODULE MOUNTING UNIT

PAF

OR

PAS

PAF

OR

PAS

FAN

PAF

OR

PAS

ANY INFI90 M ODULES

PAF

OR

PAS

ALARM CONTACT
OUTPUT

120/240VAC

INPUT
POWER
BUS BAR

+24 VD C FOR I/O
+24 VD C COM MON

TP40011B

Figure 2-1. Modular Power System Architecture

INTRODUCTION

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DESCRIPTION AND OPERATION

POWER DISTRIBUTION

Bus bars distribute AC and DC power throughout the cabinet.
The AC bus bar has three separate conductor layers. The DC
bus bar has eight separate conductor layers. The use of bus
bars reduces hand wiring and improves reliability.

The input power bus bar distributes AC power from the power
entry panel to the module mounting unit (MMU) backplanes.
The bus bar has quick connect tabs to connect cables from the
panel to the mounting unit.

The eight layer system power bus bar distributes regulated DC
voltages, power module status and power fail interrupt signals.
This bus bar also has quick connect tabs. A cable from the
power entry panel to the system power bus bar allows the sys­tem to monitor bus voltages and status signals. High current,
multiconductor 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 system power bus
bar. These tabs are for connecting +24 VDC I/O power to field
termination units or to other cabinets. Tabs are also available
to connect DC common and I/O common to the system com­mon bus bar at the cabinet bottom.

®

POWER ENTRY PANEL

IEPEP01 and IEPEP 02 Panels

The IEPEP01 and IEPEP02 Power Entry Panels connect a sin­gle 120/240 VAC (50/60 hertz) line power to an INFI 90 system
cabinet and distribute power to the power modules and fan
assembly. The IEPEP01 panel has no circuit breakers, but the
IEPEP02 panel does.

There are two terminal blocks on each panel. One is for line
input, the other for output to the input power bus bar for distri­bution to the power modules. The power entry panel 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 AC line or a loss of volt­age. The panel mounts in any standard 19-inch rack frame.

IEPEP03 Panel

The IEPEP03 Power Entry Panel connects single or redundant
120/240 VAC (50/60 hertz) line power to an INFI 90 system
cabinet. It also distributes power to the power modules and fan
assembly. This version has circuit breakers for each power line
input. This panel also has surge suppression and filtering.

Two modules reside in the PEP panel. They are the AC transfer
module and bus monitor module.

POWER DISTRIBUTION
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AC Transfer Module

Bus Monitor Module

DESCRIPTION AND OPERATION

The AC transfer module (ATM) monitors both the AC inputs
and its own circuitry. If an AC input is lost or faulty, the mod­ule automatically transfers to the redundant input. The ATM
module generates a power fail interrupt signal if both lines are
lost or below the low voltage threshold. It sends this signal to
the bus monitor module (BMM). The BMM module sends the
PFI signal to the appropriate 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 panel provides the path.
The BMM module can also monitor two additional external
power supply voltages at the PEP terminal blocks. User config­ured jumpers allow the module to monitor either 24, 48 or
125 VDC for up to two auxiliary power supplies.

There are two contact inputs (NO or NC) for monitoring system
status signals. Two red/green LEDs on the module faceplate
provide status information. The top-most LED shows whether
the module is operating properly (green) or not (red). The sys­tem status LED is red when voltages are low or other inputs
are bad. The status signal goes to the communication system
hardware, which is the bus interface module for Plant Loop
systems, and the network interface module for INFI-NET

®

sys­tems. 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 becomes active
when any bus voltage (+5, +15, -15 or +24 VDC) falls out of tol­erance. The BMM module also generates a power fail interrupt
(PFI) signal if it receives a PFI from the AC transfer module, or if
the +5 VDC bus voltage is low. It distributes this signal to pro­cess control modules in the INFI 90 system cabinet.

NOTE:

fer module. Therefore, the AC transfer module must be in place and
operating properly before the bus monitor module will work.

The bus moni tor m odule receiv es po wer fro m the A C tra ns-

® INFI-NET is a registered trademark of Elsag Bailey Process Automation.

POWER ENTRY PANEL

I-E96-506B1 2 - 3

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DESCRIPTION AND OPERATION

FAN ASSEMBLY

The IEFAN01 and IEFAN02 fan assemblies contain six fans
that mount in one chassis. Their purpose is to keep the power
and system modules cool. The fans draw cooling air up
through the module mounting assemblies and force it through
exhaust vents (when present) in the top of the cabinet door.

MODULE MOUNTING UNIT

The IEMMU01 and IEMMU02 Module Mounting Units provide
mounting 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 card cage. A three-wire cable from
the AC bus bar to the MMU backplane supplies the power
modules with AC.

Cables connect the communication busses between multiple
MMU card cages. The module bus uses a three-wire, twisted
cable, while the I/O expander bus uses a flat, 40-conductor
ribbon cable.

®

POWER MOUNTING UNITS

POWER MODULES

The IEPMU01 and IEPMU02 Power Mounting Units mount and
segregate power modules from INFI 90 process modules. Each
PMU card cage is open on the top and bottom for air flow.
There are 12 pairs of guides for mounting power modules, two
side plates and the backplane. The power mounting unit back­plane uses bus bars rather than traces for heavier currents.

The IEPAS02 System Power Module converts the 120/240 VAC
at the MMU backplane to a primary voltage of 325 VDC nomi­nal. The DC-to-DC converters convert the primary voltage to
secondary regulated voltages of +5, +15, -15 and +24 VDC.
These voltages travel through the system power bus bar to
other module mounting units for distribution to process con­trol modules (see Figures 2-2 and 2-3). The power modules can
be inserted or removed from their mounting unit while under
power.

The IEPAF02 Field Power Module is functionally the same as
the IEPAS02 module except that it provides only +24 VDC. The
IEPAF02 provides power to field termination devices when
using separate termination cabinets, or when it is desirable to
separate the I/O power supplies from the system power
supplies.

FAN ASSEMBLY
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ALARMS

DESCRIPTION AND OPERATION

AC IN

STATUS OUT

ATM

BMM

PAS

DC

CONV

+5 VDC

POWER ENTRYPANEL

FANASSEMBLY

MODULE MOUNTING UNIT

POWER SUPPLY MODULE

OR

POWER MOUNTING UNIT

AC/DC

CONV

DC

CONV

±15 VDC

DC

CONV

+24 VDC

AC OUT

Figure 2-2. Power Distribution to the IEPAS02 System Power Module

STATUS SIGNALS

Power System Status

TO PROCESS

CONTROL
MODULES

TP50305B

The block diagram in Figure 2-4 shows the flow of status sig­nals through the system.

All status lines, AC line, bus voltages, external power inputs,
external customer status inputs, and power module status are
ANDed in the bus monitor module. Bus monitor circuitry
determines if any status line is bad. If any status is bad, the
bus monitor module generates a low-true output signal to the
communication system hardware, which is the bus interface
module for Plant Loop systems, and the network interface
module for INFI-NET systems.

STATUS SIGNALS

I-E96-506B1 2 - 5

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DESCRIPTION AND OPERATION

AC AC/DC

®

24 VDC/DC CONVERTER STATUS
5 VDC/DC CONVERTER STATUS
+15/-15 V UNDER/OVERVOLTAGE

24VDC UNDERCURRENT

5VDC UNDERCURRENT

24 VDC OVERTEMPERATURE

5 VDC OVERTEMPERATURE

DETECTION

DETECTION

24VDC OVERLOAD

5VDC OVERLOAD

DC/DC

DC/DC

DC/DC

I/O POWER 24 V
I/O COMMON

+5 V
SYSTEM

COMMON
+15 V

SYSTEM
COMMON

–15V

STATUS
ALARM

TP50311B

Bus Voltage Status

Power Module Status

Figure 2-3. IEPAS02 Module Converter and Status Circuitry

The system power bus voltages are ANDed together in the BMM
module and output to an isolated customer alarm output (refer
to Table 1-4 for customer alarm output specifications). If any
bus voltage signal falls out of specification, the BMM module
generates a bus voltage alarm.

The power modules generate their own status signals. These
signals travel on the system power bus bar to the bus monitor
module. The bus monitor module then ANDs this signal with
the other status signals. If it or any other signal is bad, the
BMM module generates a power system status alarm.

STATUS SIGNALS
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Customer Alarm Outputs

DESCRIPTION AND OPERATION

There are two customer alarm outputs (normally closed): bus
voltage and power system status alarm. The bus voltage alarm
activates (opens) if any bus voltage goes low or is lost. The
power system status alarm activates (opens) for any bad sta­tus. These outputs are optically isolated and can drive relays
or annunciator panels.

AC LINE 1
AC LINE 2

MODULE STATUS

DC BUS

PFI
+5V
+15V
–15V
+24V
PM STAT

AUX BUS MONITOR 1
AUX BUS MONITOR 2

STATUS IN 1

MODULE STATUS (BMM)

MODULE S TATUS (ATM)

STATUS IN 2

ATM

PFI

STATUS

IEPEP03

BMM

POWER

SYSTEM

STATUS

+
–

+
–

BUS

VOLT

ALARM

POWER

SYS

ALARM

IEPAS02

PM ST AT

PFI

IEPAF02 IEMMU01/02

MCS, OIS,

ETC.

PLANT LOOP

INFI-NET

LIM BIM

TU TU

NIS

TP50304B

Figure 2-4. Status Signal Block Diagram

STATUS SIGNALS

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INTRODUCTION

SECTION 3 - INSTALLATION

Completely install and prepare the hardware before applying
power (i.e., attach wiring to terminal blocks, etc.). This section
explains hardware preparation in detail.

UNPACKING AND INSPECTION

The power modules are in separate packages from the rest of
the power system. Follow the guidelines in Special Handling
when handling these modules.

Special Handling

Observe these steps when handling electronic circuitry:

1. Use Static Shielding Bag. Keep the modules in the static
shielding bag until you are ready to install them in the system.
Save the bag for future use.

NOTE:

receipt. Th e following information is provided i n the event t hat you
need to repair, replace, rewire or add to the modular power system.

NOTE:

consisting of two wrist straps, ground cord assembly, alligator clip
and static dissipative work surface) when working with the modules.
The kit grounds a technician and the static dissipative work surface
to the same ground point to pre vent da mage to the modu les by elec­trostatic discharge.

Normally, the cabinet is fully wired and ready to go upon

Always use Bailey's f iel d s tati c k it (p art n umber 1 948385A1 -

2. Ground Bag Before Opening. Before opening a bag con-
taining an assembly with semiconductors, touch it to the
equipment housing or a ground to equalize charges.

3. Avoid Touching Circuitry. Handle assemblies by the
edges; avoid touching the circuitry.

4. Avoid Partial Connection of Semiconductor. Verify that
all devices connected to the modules are properly grounded
before using them.

5. Ground Test Equipment.

6. Use Antistatic Field Service Vacuum. Remove dust from
the module if necessary.

7. Use a Grounded Wrist Strap. Connect the wrist strap to
the appropriate grounding plug on the power entry panel. The

INTRODUCTION

I-E96-506B1 3 - 1

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INSTALLATION

General Handling

®

grounding plug on the power entry panel must be effectively
connected to the earth grounding electrode system through the
AC safety ground.

8. Do Not Use Lead Pencils to Set Dipswitches. To avoid
contamination of switch contacts that can result in unneces­sary circuit board malfunction, do not use a lead pencil to set a
dipswitch.

1. Examine the hardware immediately to verify that it has not
been damaged in transit.

2. Notify the nearest Bailey Controls Company sales office of
any such damage.

3. File a claim for any damage with the transportation com­pany that handled the shipment.

4. Use the original packing material and container to store the
hardware.

5. Store the hardware in an environment of good air quality,
free from temperature and moisture extremes.

IEPEP03 POWER ENTRY PANEL WIRING

The appendices at the back of this manual show complete wir­ing diagrams of the modular power system. Figures C-1 and

C-2 show the IEPEP03 system cabinet wiring diagram.

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, ret­rofit, upgrade, or wiring procedures are complete.

Assurez-vous que le disjoncteur d'alimentation principal et le
disjoncteur de panneau d'entrée des alimentations sont éteints

AVERTISSEMENT

avant de procéder à l'installation, à la mise à jour, à l'extension
ou au câblage, dans le but d'éviter les chocs sérieux et même
mortels. Ne rétablissez pas l'aliment ation tant que ces procé­dures ne sont pas terminées.

NOTE:

WRIST STRAP GND when working with the system.

Plug your wrist strap ground cord into the receptacle labeled

1. Place circuit breakers CB1 and CB2 (see Figure 3-1) on the
front of the panel to the off position before connecting AC
power input wiring.

IEPEP03 POWER ENTRY PANEL WIRING
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WRIST
STRAP

GROUND

INSTALLATION

IEPEP03

CB2 CB1LINE 2 LINE 1

IEPAS0

IEFAN0





IEPAS0

IEPAS0





Figure 3-1. Circuit Breakers CB1/CB2

IEPAS0



TP25377B

2. Connect the primary 120 VAC or 240 VAC power lines to
TB1-1, TB1-2 and TB1-3.

3. Connect the secondary AC power lines (if used) to TB1-4,
TB1-5 and TB1-6. 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 TB1-1 to TB1-4, TB1-2 to TB1-5, and TB1-3 to
TB1-6. Use 12 AWG as a minimum and 6 AWG as a maximum.
Note 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 system power bus bar. This cable provides connec­tions to sample the DC bus voltages, monitor the power
module status signal and output a power fail interrupt signal.

IEPEP03 POWER ENTRY PANEL WIRING

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INSTALLATION

®

See the wiring diagrams at the end of this manual (see
Figure C-1) for the correct system power bus bar connections.

6. Connect cable 6637814_2 from TB2-4, TB2-5 and TB2-6
on the power entry panel to the input power bus bar for distri­bution of AC power to the module mounting unit.

7. Connect cable 6637818_2 from the input power bus bar to
each module mounting unit backplane (see Figure C-1).

8. Connect the fan assembly power cable to connector J1
labeled FAN OUT on the panel.

9. Connect a wire equivalent to power wiring but not less than
10 AWG from the GND stud of the panel to the cabinet frame
for AC safety grounding.

10. There are 2 extra voltage monitor inputs available to moni­tor external power supply voltages. Use terminal block TB4
labeled AUX BUS MONITOR for this purpose. Attach 1 input to
terminals 1 (+) and 2 (-) labeled CH1. Connect the other input
to terminals 3 (+) and 4 (-) labeled CH2. Inputs can be +24, +48
or +125 VDC. Refer to Bus Monitor Module in this section for
dipswitch and jumper settings to enable these inputs and
select the input voltage.

11. Wire the auxiliary status inputs to terminal block TB3-1
(STATUS IN 1), TB3-2 (COM), and TB3-3 (STATUS IN 2). Insure
that the inputs are low true, open collector or contact type ref­erenced to DC common (terminal COM) and reflect the jumper
settings of the bus monitor module (NO or NC). The alarm
inputs must have the current carrying capability to sink at
least 1 mA.

If the system uses the Plant Loop communication network con­tinue to Step 12. If the system uses the INFI-NET communica­tion network go to Step 13.

12. Connect cable 6634205_1 from TB3-4 (STATUS OUT) to the
P3 card edge connector of the bus interface module (BIM).
Doing so enables the BIM module to send the status message
to the loop interface module (LIM) and to other nodes on the
Plant Loop communication system.

Go to Step 16.

13. Connect an 18 AWG wire from TB3-4 (STATUS OUT) on the
power entry panel to TB1-8 on the NTCL01 termination unit.

14. If 2 NTCL01 termination units connect to redundant net­work interface I/O modules:

a. Put two 18 AWG wires on a lug. Attach the lug to TB3-4
(STATUS OUT) on the power entry panel.

IEPEP03 POWER ENTRY PANEL WIRING
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INSTALLATION

b. Attach the one wire to TB1-8 on the primary NTCL01
termination unit; the second wire attaches to TB1-8 on the
secondary termination unit.

15. If redundant network interface I/O modules are being used
with the NICL01 termination module:

a. Put two 18 AWG wires on a lug. Attach the lug to TB3-4
(STATUS OUT) on the power entry panel.

b. Attach the primary wire to TB2-4 on the primary
NICL01 termination module; the second wire attaches to
TB2-4 on the secondary termination module.

16. Use TB3-5, TB3-6, TB3-7 and TB3-8 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.

AC Transfer Module

NOTE:

in Appendix C.

Wire your system per the color codes of the wiring diagrams

Before installing the AC transfer module (IEPEP03 Power Entry
Panel only), set switch S1 to the rear for 120 VAC operation
(silk-screened 110 on board), or to the front for 240 VAC opera­tion (silk-screened 220 on board). Figure 3-2 shows the loca­tion of S1 on the AC transfer module.

CR56

CR2

CR1

240

P3

S1

120

TP50302A

Figure 3-2. AC Transfer Module, Switch S1

The AC transfer module mounts from the rear of the system
cabinet (see Figure 3-3). The AC transfer module mounts in the
left-most slot. This board has a keyed edge connector to pre­vent incorrect mounting.

IEPEP03 POWER ENTRY PANEL WIRING

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INSTALLATION

ATM

SLOT

BMM
SLOT

®

L(L1)

MAIN POWERINPUT

120/240 VAC 50/60 HZ

AUX BUS

MONITOR

CH2

CH1

+–

J2

TB4

+–
1

2

3

4

N(L2)

L(L1)

120 VAC
240 VAC

TB1 1 2 6543

L

N

L1

L2

L

N

L1

L2

N (L2)

AUX.POWER INPUT
120/240 VAC 50/60 HZ

FAN

ASSEMBLY

SYSTEM

POWER

BUS BAR

STATUS

IN

OUT

1COM2
15

26

37

TB3

48

ALARMS

PWR
SYS
+–

BUS

VOLT

+–

GND

FAN
OUT

TB2J1

120VAC
240VAC

12 6543

L
L1

AC OUT

N
L2

POWER ENTRY
PAN EL

IEPEP03
ROW 0

INPUT
POWER
BUS BAR

TP25378B

Figure 3-3. IEPEP03 Power Entry Panel, Rear View

To mount the module:

NOTE:

transfer module. Accidentally moving the switch to the 240 position
will cause the module to go into error mode.

Be careful not to bump switch S1 when installing the AC

1. Grasp the sides of the faceplate.

2. Line up circuit board edges with card guides in the power
entry panel opening.

3. Slide the module in until it locks in place.

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Bus Monitor Module

INSTALLATION

4. Turn the 2 locking screws on the AC transfer module face­plate 1/2-turn to lock the module in place.

Before mounting the bus monitor module (IEPEP03 Power
Entry Panel only), set switch S1 and jumpers J1 through J8.
Figure 3-4 shows the switch and jumper locations on the bus
monitor module circuit board. Refer to Table 3-1 for the bus
monitor module switch settings. Refer to Table 3-2 for the bus
monitor module jumper settings.

J3

1
2
3

2

3

J7

1
2
3

4

J2

1

4

2
3

P3

CR12

CR17

J4

1
2

3
4

J5

2

3

1

S1

ON

1234

J8

3

1

2

J6

1

J1

1
2
3

TP50301B

Figure 3-4. Bus Monitor Module, Switch S1 and Jumpers J1

through J8

The bus monitor module mounts from the rear of the system
cabinet (see Figure 3-3). The bus monitor module mounts in
the right-most slot. This board has a keyed edge connector to
prevent incorrect mounting.

To mount the module:

1. Grasp the sides of the faceplate.

2. Line up circuit board edges with card guides in the power
entry panel opening.

3. Slide the module in until it locks in place.

4. Turn the 2 locking screws on the bus monitor module face­plate 1/2-turn to lock the module in place.

IEPEP03 POWER ENTRY PANEL WIRING

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INSTALLATION

®

Table 3-1. Bus Monitor Module Switch Settings

Switch S1 Position

1234

Function

1

0 Enable 5, ±15 VDC monitoring
1 Disable 5, ±15 VDC monitoring

0 Enable 24 VDC monitoring
1 Disable 24 VDC monitoring

0 Enable auxiliary bus monitoring CH1
1 Disable auxiliary bus monitoring CH1

0 Enable auxiliary bus monitoring CH2
1 Disable auxiliary bus monitoring CH2

0 = CLOSED or ON, 1 = OPEN or OFF

NOTES:

1. Do not enable all inputs simultaneously. Doing so will cause a bad status signal. Unused monitor
inputs must be disabled. Figure 3-4 shows the factory settings of switch S1.

Table 3-2. Bus Monitor Module Jumper Settings

Jumper

Number

J1

J2

Jumper

Position

1-2
2-4
2-3

1-2

Function

1

Auxiliary bus monitor, channel 1:

Selects 24 VDC external power
Selects 48 VDC external power
Selects 125 VDC external power

Auxiliary bus monitor, channel 2:

Selects 24 VDC external power
2-4
2-3

J3

1-2
2-3

J4

1-2
2-3
3-4

J5

1-2
2-3

Selects 48 VDC external power

Selects 125 VDC external power

AC input voltage, line 2:

Selects 120 VAC input

Selects 240 VAC input

Auxiliary status input 1:

Normally open status input

Normally closed status input

Not used

Auxiliary status input 2:

Normally open status input

Normally closed status input

J6 1-2 Must be set as shown
J7

1-2
2-3

AC input voltage, line 1:

Selects 120 VAC input

Selects 240 VAC input

J8 2-3 Must be set as shown

NOTE:

1. Placing a shorting strap over the jumper pins selects the function.

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Fan Assembly

Power Modules

INSTALLATION

The IEFAN01 or IEFAN02 fan assembly mounts directly
beneath the power entry panel and above the power mounting
unit or the first module mounting unit (see Figure C-2). Attach
the fan power cable to the J1 connector on the power entry
panel.

Power modules mount directly in the module mounting unit or
power mounting unit. Use any slot except the right-most slot
(slot 12) when mounting a power module in a module mount­ing unit.

Mount the power modules in any slot when using a power
mounting unit. Figure 3-5 shows the recommended mounting
pattern and spacing when mounting power modules in module
mounting units. This installation scheme provides the best
heat dissipation and power distribution. For optimum heat dis­sipation and power distribution, do not exceed more than two
IEPAS02 modules in any module mounting unit. Install at least
one IEPAS02 module in the module mounting unit with the
largest load (e.g., a module mounting unit containing several
multi-function processor modules).

WARNING

AVERTISSEMENT

NOTE:

modules mou nted side by side . However the tot al fiv e VDC cur rent
load on the power mounting unit cannot exceed 100 amps. The total
24 VDC current load on the power mounting unit cannot exceed
60 amps.

Power mounting units can hold a maximum of 12 power

Do not remove the plastic covers on the module mounting unit
backplane. These covers protect against accidental contact
with AC voltage. Severe or fatal shock could result.

Ne retirez pas les couvercles de plastique situés sur le pan­neau arrière du châssis de montage des modules. Ces couver­cles constituent une protection contre les contacts accidentels
avec la tension c.a., qui risquent de provoquer des chocs
sérieux et même mortels.

Before handling the power modules:

1. Verify that all devices connected to the module are properly
grounded before using them.

2. Avoid touching the circuitry when handling the module.

3. Always use grounding straps (field static kits) when work­ing with the modules.

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INSTALLATION

1

2

3

4

56

7

PAS PAS

PAS PAS

89

PASPAS

10 11

12

NOT

USED

NOT

USED

NOT

USED

®

PASPAS

NOT

USED

TP50300A

Figure 3-5. Recommended Power Module Layout for Module

Mounting Unit

To install the power supply module:

1. Set jumpers J1 through J3 on the IEPAS02 module and set
jumpers J1 and J2 on the IEPAF02 module (the IEPAF02 mod­ule does not have J3) for the module operation desired. Table

3-3 lists the IEPAS02 and IEPAF02 jumper settings. Figure 3-6

shows the jumper locations on the IEPAS02 and IEPAF02
power modules. Refer to Table 4-2 for information on the mon­itoring priority levels of the power module jumper settings.

2. Grasp the module faceplate handle and align the top and
bottom edges of the circuit board with the guides in the mod­ule mounting unit.

3. Hold the module by the faceplate handle and slide it into
the MMU slot. Push on the faceplate until the rear edge con­nectors of the power module are firmly seated in the backplane
connectors.

4. Firmly press the module handle as you use a blade screw­driver to push and turn the 2 concentric screws 1/2-turn
clockwise to lock the module in place.

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INSTALLATION

123

J2

J1

1
2
3

F1

IEPAF02

123

J2
J3

123

J1

1
2
3

F1

IEPAS02

Figure 3-6. IEPAF02 and IEPAS02 Power Module Board Layout

Table 3-3. IEPAS02 and IEPAF02 Power Module Jumper

Settings

Jumper
Number

J1 1-2 120 VAC

J2 1-2 Enable 24 VDC undercurrent monitoring

1

J3

NOTE:

1. The IEPAF02 does not have jumper J3.

Jumper

Position

2-3 240 VAC

2-3 Disable 24 VDC undercurrent monitoring
1-2 Enable 5 VDC undercurrent monitoring
2-3 Disable 5 VDC undercurrent monitoring

Allow five seconds for the line filter capacitors to discharge

WARNING

before handling the module after removal. Failure to do so
could result in severe or fatal shock.

TP50307B

Function

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INSTALLATION

AVERTISSEMENT

®

Après avoir retiré le module, laissez les condensateurs de fil­tres antiparasites se décharger pendant cinq secondes a vant
de manipuler celui-ci, afin d'éviter les chocs sérieux et même
mortels.

WARNING

Handle the module by surfaces other than the heat sink. The
heat sink may be hot and may cause severe burns.

Le module doit être manipulé à l'aide de surfaces autres que le

AVERTISSEMENT

dissipatour thermique. Ce dernier resque d'être chaud et de
provoquer des brûlures sérieuses.

To remove the module:

1. Use a blade screwdriver to push and turn the 2 concentric
screws 1/2-turn in either direction.

2. Slide the module part way out.

3. Allow 5 seconds for the module capacitors to discharge.
Then remove the module from its mounting unit.

IEPEP01 AND IEPEP02 POWER ENTRY PANEL WIRING

NOTE:

external circuit breaker or fuse. The breaker or fuse must be able to
handle the current and voltage listed in the specifications table
(Table 1-4).

The IEPEP01 Power Entry Panel requires you to supply an

CAUTION

ATTENTION

Verify the line voltage select switch is properly configured
before energizing the power entry panel. Failure to do so could
permanently damage the PFI circuit board by exposing it to
improper input voltage levels.

Assurez-vous que l'interrupteur de sélection de la tension de
ligne est adéquatement configuré avant de mettre sous tension
le panneau d'entrée des alimentations. Toute négligence à cet
égard risque d'endommager de facon permanente la carte de
détection des coupures d'alimentation (PFI) en l'exposant à
des niveaux inadéquats de tension d'entrée.

1. Set the slide switch on the rear of the power entry panel to
either 120 V or 240 V to match the line voltage. This switch
sets the power fail interrupt (PFI) detection circuit to determine
low level or loss of input. Figure 3-7 shows this switch on the
rear of the IEPEP01 and IEPEP02 power entry panels.

2. Connect cable 6638084_1 from the PFI connector on the
rear of the panel to the system power bus bar. This connection
distributes a power fail interrupt to the process control mod­ules in the cabinet.

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Figure 3-7. Rear of IEPEP01 and IEPEP02 Power Entry Panels

AC OUT

TB2

120VAC
240VACLL1NL2

TP25389A

PFI

240 VAC

GND

FAN OUT

AC IN

TB1

120VAC
240VAC

WARNING/AVERTISSEMENT 120/240 V

LL1N

L2

WRIST

GROUND

STRAP

120 VAC

Figure C-3 shows a wiring diagram of the IEPEP01 and
IEPEP02 Power Entry Panels with module mounting units. Fig­ure C-4 shows the IEPEP01 and IEPEP02 Power Entry Panels
with a power mounting unit.

INSTALLATION

3. Connect cable 6637814_1 from TB2 on the rear of the
power entry panel panel to the input power bus bar. This con­nection places AC power on the input power bus bar.

4. Plug the fan assembly power cable into the FAN OUT con­nector on the rear of the panel.

5. Connect a yellow/green wire equivalent to the power wiring
size (not less than 10 AWG) from the GND bolt on the panel to
the cabinet frame for AC safety grounding (see Figure C-3).

6. Apply power by connecting the 120/240 VAC, 50/60 hertz
power input to terminal block TB1 on the rear of the panel.

NOTE:

of Figure C-3 or C-4 .

Wire your system usi ng the color codes in the wiring diagra m

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION

Verify the main power and power entry panel circuit breakers
are turned off before starti ng 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, ret­rofit, upgrade, or wiring procedures are complete.

Assurez-vous que le disjoncteur d'alimentation principal et le
disjoncteur de panneau d'entrée des alimentations sont éteints

AVERTISSEMENT

avant de procéder, à la mise jour, à l'ex tension ou au câblage,
dans le but d'éviter les chocs sérieux et même mortels. Ne
rétablissez pas l'alimentation tant que ces procédures ne sont
pas terminées.

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION

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INSTALLATION

Required Tools

The following tools are needed to install the power mounting
unit:

•

16-inch blade screwdriver.

•

7/16-inch nut driver.

•

Pliers.

•

Volt/ohmmeter.

•

Heat gun.

Installation in the INFI 90 Cabinet

®

Wiring Instructions

NOTE:

IEPMU02 unit from the front.

Install the IEPMU01 unit from the rear of the cabinet, the

1. Mount the power mounting unit directly beneath the fan
assembly.

2. Secure both sides of the power mounting unit to the cabi­net mounting rails.

3. Proceed to Wiring Instructions.

NOTE:

color-coded.

Do all wiring at the rear of the cabinet. Wires are

Steps 1 through 23 and Figures C-2 and C-4 apply to INFI 90
cabinets only. Refer to Appendix D for instructions on retrofit­ting the power mounting unit in Network 90 cabinets.

1. Attach the AC input wire harness (part number
6637814_2) to TB2 on the power entry panel (PEP). Attach the
other end of the wire harness to the terminal block on the right
side of the power mounting unit. Wire and terminal assign­ments on the PMU terminals are:

Green/Yellow - to ground tab (top)
Blue - to L2 Neutral (middle)
Brown - to L1 Hot (bottom)

2. On the left side of the PMU card cage starting at the third
conductive strip (from the top), attach one end of the first
heavy 0 AWG wire assembly (part number 6632285_45).

NOTE:

6632285_45) braide d wire, sh ape it in to a [ form to avoid overst ress­ing the PMU bus bar terminals.

For Steps 2 and 5, before installing the 0 AWG (part number

3. Attach the other end to the system MCOM tab at the top of
the system power bus bar.

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION
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INSTALLATION

4. Slide heat shrink tubing over the PMU card cage connec­tion (see Figure 3-8). After properly covering the connections,
use the heat gun to shrink the tubing into place.

6632285 47



6632285 45



HEA TSHRINK

TUBING

NOTE: AFTER JUMPER CONNECTION IS MADE, SLIDE HEAT SHRINK
TUBING SUPPLIED WITH P/N 6632285 45 AND 6632285 47 OVER
CONNECTION UNTIL CONNECTION IS COVERED COMPLETELY AND
SHRINK INTO PLACE WITH HEAT GUN.



MCOM

+5V

PMU
BUS BAR

STANDOFF

TP50376B

Figure 3-8. Heat Shrink Tubing for 5 VDC Connection

5. On the left side of the PMU card cage at the fourth conduc­tive strip (from the top), attach one end of the second heavy
0 AWG wire assembly (part number 6632285_45).

6. Attach the other end to the system +5 VDC tab at the top of
the system power bus bar.

7. Slide heat shrink tubing over the power mounting unit con­nection (see Figure 3-8). After properly covering the connec­tions, use the heat gun to shrink the tubing into place.

8. Attach one end of the 10 AWG wire assembly to the system
power bus bar I/O COM. Attach the other end to the PMU I/O
COM pick-up faston (see Figure 3-9).

NOTE:

another system power bus bar connection and attach it to the PMU
I/O terminals, or if de sired, stack the en ds going to the po wer mou nt­ing unit on a 6 AWG ring lug and connect to the heavy terminal.

For Steps 8 and 11, if more than 15 A are required, use

9. Attach one end of 10 AWG wire assembly to the system
power bus bar +24 VDC. Attach the other end of 10 AWG wire
assembly to the PMU +24 VDC.

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION

I-E96-506B1 3 - 15

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INSTALLATION



6632285 48



6632285 48

HEA TSHRINK

TUBING

NOTE: AFTER JUMPER CONNECTION IS MADE, SLIDE HEAT SHRINK
TUBING SUPPLIED WITHP/N 6632285 48 OVER CONNECTION
UNTIL CONNECTION ISCOVEREDCOMPLETELY AND SHRINK INTO
PLACE WITH HEAT GUN.



I/O COM

+24V

®

PMU
BUS BAR

STANDOFF

TP50375B

Figure 3-9. Heat Shrink Tubing for 24 VDC Connection

10. Attach one spade lug end of 10 AWG wire assembly to the
PMU +15 VDC. Attach the other spade lug end to system power
bus bar +15 VDC.

11. Attach one spade lug end of a 10 AWG wire assembly to
PMU -15 VDC. Attach the other spade lug end to system power
bus bar -15 VDC.

12. Attach the spade lug end of cable 6637813_1 (IEPEP03
panel only) to STATUS on the PMU card cage (see Figure C-2).

13. Make the other signal connections from J2 to the system
power bus bar using cable 6637813_1.

14. Use an ohmmeter to verify continuity between TB2 on the
IEPEP03 and the AC terminals on the power mounting unit.

15. Verify the circuit breakers on the PEP panel are in the off
position. If you are wiring an IEPEP01 panel, verify that the
external circuit breakers are in the off position.

16. Unplug all process and I/O modules from the MMU back­plane.

17. Verify that all wiring connections are complete before turn­ing the source power on.

18. Turn source power on.

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION
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INSTALLATION

19. Use a voltmeter to measure 120/240 VAC power at TB1.

20. Turn the PEP circuit breakers on.

NOTE:

on the power modules are correct. Refer to Table 3-3 for settings.

Before doing Step 21, verify that switch and jumper settings

21. Install the required number (calculated from SIZING THE

MODULAR POWER SYSTEM in Appendix B) of IEPAS02 and

IEPAF02 power modules in the PMU card cage, one at a time.
Slide one power module along the guides until it is seated in
the PMU backplane.

22. Turn the 2 latching screws until they lock. Verify that the
status LED turns green on each power module. If it does not,
refer to Section 5.

23. Do not install the process modules at this time. Refer to

RECOMMENDED START-UP PROCEDURES in Section 4,

Steps 5 through 9.

IEPMU01 AND IEPMU02 POWER MOUNTING UNIT INSTALLATION

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INTRODUCTION

SECTION 4 - OPERATING PROCEDURES

This section contains information regarding modular power
system operation. This section includes information on status
LEDS for the AC transfer, bus monitor and power modules. It
explains how to start up the power module and how to remove
it during operation.

LED INDICATORS

AC Transfer Module

NOTE:

components are factory calibrated.

When the modular power system is operating, observe the sta­tus LEDs. The following paragraphs explain how to interpret
these LEDs. Also, refer to Tables 4-1 and 4-2.

The AC transfer module (IEPEP03 Power Entry Panel only) has
three status LEDs: a module status LED, line one and line two
AC input status LEDs. All LEDs are red/green LEDs. When the
system is receiving power and operating normally, the module
status LED is green. Also, the line one and two AC input status
LEDs are green under normal operation. The only time the
module status LED turns red is if the module fails. A failure
means that the internally generated supply voltages or refer­ences have fallen below the minimum acceptable level. In a
redundant supply line configuration, a failure in the primary
input turns line one AC input status LED red; a failure in the
secondary input turns line two AC input status LED red. Refer
to Table 4-1 for a listing of status LED conditions.

The modular power system requires no user calibration; all

Bus Monitor Module

The bus monitor module has two LEDs: module status and
system status. The module status LED is green when the mod­ule is operating properly. It turns red if the module fails. A fail­ure means that the internally generated supply voltages or
references have fallen below the minimum acceptable level.

The system status LED is green when everything in the system
is satisfactory (refer to Table 4-1). 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
AC transfer module (ATM) fails, the LED turns red.

INTRODUCTION

I-E96-506B1 4 - 1

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OPERATING PROCEDURES

Table 4-1. Status LEDs, AC Transfer and Bus Monitor Modules

AC transfer
module

Bus monitor
module

Power Module

The power module has one LED, module status. This LED is
green when the module is operating normally. This LED has
five possible states that describe the status of the power mod­ule. Refer to Table 4-2 for a list of power supply faults, the LED
states, priority level and associated power module status
signal.

Module LED/Condition Condition

Status Green Normal

Red Module has failed

Line 1 Green Line 1 input is good

Red Line 1 input has failed

Line 2 Green Line 2 input is good

Red Line 2 input has failed

Status Green Normal

Red Module has failed

System
Status

Green Normal
Red Bad power system status

®

Table 4-2. Status LEDs, Priority Level and Status Signal

for IEPAS02 and IEPAF02 Power Modules

LED

State

Fault

Priority

Level

Red 5 V DC/DC converter failure 1 Low

24 V DC/DC converter failure
+15 V DC/DC converter failure

-15 V DC/DC converter failure

Alternating red
and green

2

5 V DC/DC converter over-temperature
[85°C (192°F)]

2Low

24 V DC/DC converter over-temperature
[85°C (192°F)]

Blinking green 5 V DC/DC converter overcurrent (13 A typical) 3 Low

24 V DC/DC converter overcurrent (4 A typical)

3

Blinking red

5 V DC/DC converter undercurrent (<0.5 A typical) 4 Low
24 V DC/DC converter undercurrent (<0.3 A typical)

Green No faults 5 High

NOTES:

1. Faults with the highest priority will override faults with a lower pr iority. A 1 represents the highest priority an d a 5 represents the
lowest priority.

2. If the 5 V or 24 V DC/DC converter temperature reaches 90°C (203°F) it will shut down and the status LED will show a failure (red).

3. A converter undercurrent condition (blinking red LED) indicates that the power module is not supplying current to the system. It may
be desirable to disable the sta tus LED for conve rter u ndercu rrent wh en cer tain c ondition s exist s uch as a sm all o r no 24 VDC load .
Disable the undercurrent status LED by referring to Table 3-3 for the power module jumper settings.

Power Module

1

Status Signal

LED INDICATORS
4 - 2 I-E96-506B1

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REMOVING ATM OR BMM MODULES DURING OPERATION

While the power system is in operation, do not remove the AC
transfer module (IEPEP03 Power Entry Panel only) without first
verifying that line one is operational. Removing the ATM mod­ule causes the system to transfer to line one. If the ATM mod­ule transfers from line one to line two because of a problem,
the whole system will go down when the ATM module is
removed. Before removing the ATM module, line one must be
operational. Additionally, removal of the ATM module takes the
bus monitor module off-line because it receives its power from
the ATM module.

To avoid unintentional triggering of the PFI signal when han­dling the bus monitor module or the AC transfer module, insert
or remove the bus monitor module only when the AC transfer
module is in its designated slot.

RECOMMENDED START-UP PROCEDURES

Follow the procedures in Steps 1 through 9 before applying
power to the system.

OPERATING PROCEDURES

1. Verify that all connections are secure.

2. Insure that all input power bus bar receptacles are covered
with insulated receptacles.

3. Install the power modules only (refer to Section 3 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 DC com­mon; +24 is VDC with respect to I/O COM). Table 4-3 shows
the maximum and minimum unloaded DC bus voltage levels
required to begin installing modules.

6. When the bus voltages are at acceptable levels, start adding
process control modules.

7. Continue adding process control modules until the system
cabinet is filled.

8. Verify that the system voltages are within specification.
Refer to Table 1-4 for system specifications.

9. Put a blank faceplate (Bailey part number 6636586_1) over
any unused PMU slots. If your MMU card cages have any
unused slots, place the cap (Bailey part number 6638748_1)
on the backplane by snapping in the top then the bottom.

REMOVING ATM OR BMM MODULES DURING OPERATION

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OPERATING PROCEDURES

®

Table 4-3. Unloaded DC Bus Output Voltage Requirements

5 VDC 24 VDC +15 VDC -15 VDC

Min Max Min Max Min Max Min Max

5.1 5.3 25.7 26.0 15 15.75 -15 -15.75

RECOMMENDED START-UP PROCEDURES
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INTRODUCTION

This section provides troubleshooting tools to help you locate
and correct modular power system problems. These are gen­eral troubleshooting procedures and are not exhaustive of all
possible causes.

TROUBLESHOOTING FLOWCHARTS

The flowcharts in Figures 5-1 and 5-2 represent basic trouble-
shooting procedures for the IEPEP01, IEPEP02 and IEPEP03
Power Entry Panels.

IEPEP01 and IEPEP02 Systems

Systems with an IEPEP01 or IEPEP02 Power Entry Panel only
monitor the AC power input. There are no bus voltage or other
power system status indicators on the power entry panel. If AC
input power is lost or goes low, a power fail interrupt (PFI) sig­nal is sent to the process control modules. Figure 5-1 shows a
troubleshooting flowchart for IEPEP01 and IEPEP02 systems.

SECTION 5 - TROUBLESHOOTING

IEPEP03 Systems

To troubleshoot the system:

1. Check system and I/O power. If system and I/O power are
good, an overload condition may exist in the power modules.

2. Check for red status LEDs on the power modules.

3. If there are power modules with red LEDs, install additional
power modules.

4. Check power modules that had red LEDs. If they are still
red, they have failed. Remove and replace them.

5. Check the PFI signal. If it is good, there is a power entry
panel failure. Replace the power entry panel. This should be
done by a qualified service technician.

Any power system problem will cause a bad status flag at the
operator interface. This alarm appears under the S group on
the system status display of an operator interface station (OIS),
management command system (MCS), or LAN-90 process con­trol view computer. Additionally, the LEDs on the power sup­ply, bus monitor or AC transfer module go red to indicate bad

INTRODUCTION

I-E96-506B1 5 - 1

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TROUBLESHOOTING

®

START

SYSTEM

AND I/O POWER

GOOD?

NO

POWER

MODULE STATUS

GOOD?

NO

REPLACE POWER
SUPPLY MODULE.

REFER TO REPAIR/

REPLACEMENT
PROCEDURES.

YES

YES

PFI SIGNAL

LOW LEVEL?

NO

DONE

ADD POWER SUPPLY

MODULES. REFER TO

INSTALLATION.

YES

REPLACE PEP.

REFERTO

REPAIR/REPLACEMENT

PROCEDURES.

TP55170B

Figure 5-1. Troubleshooting Flowchart, IEPEP01 and IEPEP02

Power Entry Panels

status. Figure 5-2 shows a troubleshooting flowchart for an
IEPEP03 system.

Another way to detect bad power system status is to hard wire
alarms to the customer alarm outputs. These outputs turn off
to indicate a low bus voltage and other power system problems.

If bad status is detected:

1. Check the LEDs on the AC transfer and bus monitor mod­ules.

2. If the AC transfer module status LED is red, the module
has failed and must be replaced. Note that a defective AC
transfer module may cause the bus monitor module to show
bad status.

NOTE:

to verify that it is operational and within tolerance (+102 to
+132 VAC for 120 VAC input; +204 to +26 4 VAC for 240 VAC i nput).

Before remo ving the A TM module , measure AC input li ne 1

3. If the bus monitor module status LED is red, the module
has failed and must be replaced.

NOTE:

replacement.

Refer to Section 7 for details on module removal and

TROUBLESHOOTING FLOWCHARTS
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TROUBLESHOOTING

4. If the LEDs on both modules are green, check the AC input
line 1 and line 2 LEDs on the AC transfer module.

5. If either of the AC input line LEDs are red, this means a
loss of AC input power, or bad quality. If both LEDs are red,
switch S1 may have been moved when the ATM module was
installed. Check switch setting for 120/240 VAC and set to the
appropriate setting.

6. Verify that the circuit breakers are in the on position.

7. If the circuit breakers are on and the AC input line LEDs
are still red, the power entry panel has failed. Replace the
power entry panel.

8. If all AC transfer module LEDs are green, look at the bus
monitor module LEDs.

9. If the bus monitor module status LED is red, the module
has failed and must be replaced. If it is green, proceed.

10. If the system status LED is red, measure the bus voltages
at the test jacks on the module front panel. If the system status
LED is green there is no problem.

11. Install additional power modules if the bus voltages mea­sured in Step 10 are low.

12. If the measurements made in Step 10 are good, check the
power module LEDs. If any LEDs are red, that power module
has failed. Install a good power module before removing the
failed power module.

13. If any power modules have blinking red and green LEDs,
those modules are over temperature. Check the fan assembly
for proper operation. Check the condition of cabinet air filter
and clean or replace if dirty.

14. Check the power modules for blinking green LEDs. Blink­ing green LEDs indicate an overcurrent condition. Install addi­tional power modules.

15. If any power module LEDs are blinking red, an undercur­rent condition may exist because of low 5 or 24 VDC loads on
the system. If the 5 and 24 VDC loads are normal, insert a good
power module then remove the power module with the blinking
red LED.

16. Disable the 5 or 24 VDC undercurrent detection on all
power modules if the system load for those voltages is low.

TROUBLESHOOTING FLOWCHARTS

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TROUBLESHOOTING

17. If the system status LED is red, the bus voltages check
good and there are no LED conditions on the power modules,
the problem is caused by the external inputs being monitored
by the bus monitor module.

18. If customer external power supply voltages are being moni­tored at the AUX BUS MONITOR inputs to the power entry
panel, verify the jumper settings on the bus monitor module
are correctly set for the voltage levels being monitored (refer to
Table 3-2 for jumper settings).

19. If switch settings are okay, measure the voltages between
terminals 1 and 2 and terminals 3 and 4 of TB4 on the PEP
rear panel. Voltages should be:

•

Greater than 22 VDC if 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 is a problem in one of the aux­iliary status inputs (STATUS IN) at terminal block TB3 on the
power entry panel.

®

20. Measure the voltage from terminal 1 and terminal 3 with
respect to terminal 2 of TB3. The voltages at these terminals
will depend on how J4 and J5 are set on the bus monitor mod­ule.

If J4 and J5 are set for normally open (NO) and the voltage
measures less than 3.1 VDC, the input status is bad. If J4 and
J5 are set for normally closed (NC) and the voltage measures
more than 3.1 VDC, the input status is bad. To verify that the
external device is causing the bad status, remove the suspect
input wire. The system status LED should turn green if the
external device was pulling the input low or high, causing the
status. Otherwise, the bus monitor module is defective.

TROUBLESHOOTING FLOWCHARTS
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START

CHECK PEP

IN SYSTEM

CABINET

TROUBLESHOOTING

ATM STATUS

LED RED?

NO

LINE 1/2 LED

RED?

YES

VOLTAGE AT

TB1 WITHIN

RANGE?

YES

CB1/CB2

ON?

NO

TURN CB1/CB2 ON

YES

NO

NO

YES

REPLACEATM.

REFER TO REPAIR/

REPLACEMENT

PROCEDURES.

CHECK BUS MONITOR

LEDs.REFERTO

OPERATING

PROCEDURES.

RESTORE LINE

POWER. REFERTO

SITE PLANNING AND

PREPARATION.

REPLACE PEP.REFER

TO REPAIR/

REPLACEMENT

PROCEDURES.

CONTINUED
NEXT PAGE

2

DONE

TP55171A

Figure 5-2. Troubleshooting Flowchart, IEPEP03 Power Entry

Panel (Page 1 of 3)

TROUBLESHOOTING FLOWCHARTS

I-E96-506B1 5 - 5

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TROUBLESHOOTING

CONTINUED

FROM

NEXT PAGE

4

CONTINUED FROM

PREVIOUS PAGE

2

IS

BMM STATUSLED

RED?

NO

IS

SYSTEM STATUS

LED RED?

YES

YES

NO

REPLACE BMM.

REFER TOREPAIR/

REPLACEMENT

PROCEDURES

NO

IS SYSTEM

STATUS LED

GREEN?

YES

CONTINUED

FROM

NEXT PAGE

5

DONE

®

ADD POWER

MODULES.
REFER TO

INSTALLATION

REPLACE

POWER MODULE.

REFER TO REPAIR/

REPLACEMENT

PROCEDURES

MORE CABINET

COOLING

REQUIRED

ADD POWER

MODULES.

REFER TO

INSTALLATION

NO

OUTPUT VOLTAGES

YES

YES

YES

MODULE BLINKING

ARE

GOOD?

YES

IS

POWER

MODULE STATUS

LED RED?

NO

POWER

MODULE LED

BLINKING RED &

GREEN?

NO

IS

POWER MODULE

LED BLINKING

GREEN?

NO

IS

POWER

RED?

NO

YES

CONTINUED
NEXT PAGE

3

DONE

TP55172C

Figure 5-2. Troubleshooting Flowchart, IEPEP03 Power Entry Panel (Page 2 of 3)

TROUBLESHOOTING FLOWCHARTS
5 - 6 I-E96-506B1

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CONTINUED FROM

PREVIOUS PAGE

3

TROUBLESHOOTING

LOW 5VDCOR

24VDCLOADON

SYSTEM?

YES

LOW 5 VDC LOAD

ON SYSTEM?

NO

LOW 24 VDC LOAD

ON SYSTEM?

NO

USER INPUTS

GOOD?

YES

NO

YES

YES

NO

REMOVEPOWER

MODULE,THEN INSERT

POWER MODULE

POWER MODULE

LED BLINKING

RED?

NO

DISABLE 5 V

UNDERCURRENT

DETECTION ON ALL

IEPAS02s.REFERTO

INSTALLATION

DISABLE 24 V

UNDERCURRENT

DETECTION ON ALL

IEPAS02s AND IEPAF02s.

REFER TO INSTALLATION

CHECK AUXILIARY

SYSTEM

YES

REPLACE POWER

MODULE. REFER TO

REPAIR/REPLACEMENT

PROCEDURES.

544

CONTINUED

PREVIOUS PAGE

CONTINUED

PREVIOUS PAGE

CONTINUED

PREVIOUS PAGE

TP25406A

Figure 5-2. Troubleshooting Flowchart, IEPEP03 Power Entry

Panel (Page 3 of 3)

TROUBLESHOOTING FLOWCHARTS

I-E96-506B1 5 - 7

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INTRODUCTION

WARNING

AVERTISSEMENT

SECTION 6 - MAINTENANCE

There are exposed AC and DC connections inside the cabinet.
These exposed electrical connections present a shock hazard
that can cause injury or death.

Cette armoire comporte des connexions c.a. e t c.c. dénudées.
Ces connexions électriques présentent un danger d'électrocu­tion pouvant entraîner des blessures ou la mort.

WARNING

AVERTISSEMENT

WARNING

AVERTISSEMENT

WARNING

Never clean electrical parts or components with the AC power
on. Doing so exposes you to a fatal electrical shock hazard.

Il ne faut jamais nettoyer des piècesou des composants élec­triques lorsqu'ils sont sous tension. Cedi présente un risque
d'électrocution fatale.

If input or output circuits are a shock hazard after disconnect­ing system power at the power entry panel, then the door of the
cabinet containing these externally powered circuits must be
marked with a warning stating that multiple power sources
exist.

Si des circuits d'entrée ou de sortie sont alimentés à partir de
sources externes, ils présentent un risque de choc électrique
même lorsque l'alimentation du système est débranchée du
panneau d'entrée l'alimentation. Le cas échéant, un avertisse­ment signalant la présence de sources d'alimentation multiples
doit être apposé sur la porte de l'armoire.

Wear eye protection wheneve r wor king with cleani ng solve nts.
When removing solvents from printed circuit boards using
compressed air, injury to the eyes could result from splashing
solvent as it is blown off the printed circuit board.

Portez toujours des lunettes de protection lorsque vous uti-

AVERTISSEMENT

I-E96-506B1 6 - 1

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lisez des solvants de nettoyage. L'aircomprimé servant à
enlever le solvant des cartes de circuits imprimés provoque
des éclaboussures qui risquent d'atteindre les yeux.

This section contains a modular power system preventive
maintenance schedule and procedures. Doing the preventive
maintenance procedures as scheduled maintains good,
dependable modular power system operation.

INTRODUCTION

MAINTENANCE

This section presents procedures that the customer should be
able to perform on site. These preventive maintenance proce­dures should be used as a guideline to assist in establishing
good preventive maintenance practices. Select the minimum
steps required to meet the cleaning needs of your system.

Personnel performing preventive maintenance should meet the
following qualifications.

•

Maintenance personnel should be qualified electrical tech­nicians or engineers that know the proper use of test equip­ment such as digital multimeters.

•

Maintenance personnel should be familiar with the INFI 90
modular power system, have experience working with pro­cess control systems, and know what precautions to take
when working on live AC systems.

PREVENTIVE MAINTENANCE SCHEDULE

Table 6-1 is the preventive maintenance schedule for the mod­ular power system. The table lists the preventive maintenance
tasks in groups according to their specified maintenance inter­val. Some tasks in Table 6-1 are self explanatory. Instructions
for tasks that require further explanation are covered in PRE-

VENTIVE MAINTENANCE PROCEDURES in this section.

®

NOTE:

poses only. Your applicat ion may requ ire special attention.

The preventive maintenance schedule list is for general pur-

Table 6-1. Preventive Maintenance Schedule

Task Frequency

Check the cabinet air filters. Clean or replace them as necessary. Check the air filter
more frequently in excessively dirty environments. Refer to procedure.

Check cabinet, power entry panel and power modules for dust. Clean as necessary
using an antistatic vacuum.

Check all signal, power and ground connections within the cabinet and verify that they
are secure. Refer to procedure.

Check modular power supply outputs. Refer to procedure. 6 months
Do a visual inspection of the fan assembly. Verify that all fans are rotating and replace

if necessary. Refer to the appropriate INFI 90 power system manual for replacement
instructions.

Check the quality of the plant power and grounding system. Follow the power and
grounding system verification procedures in the INFI 90 site preparation and planning
instruction.

Inspect all control, I/O modules and power module s, giving pa rticular atten tion to powe r
supply contacts and heat sinks. Clean as necessary. Refer to procedure.

Inspect and chec k the power en try panel. In high vib ration e nvironments testing m ay be
necessary at shorter intervals. Refer to procedure.

3 months

12 months

^

2 years

PREVENTIVE MAINTENANCE SCHEDULE
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MAINTENANCE

Table 6-1. Preventive Maintenance Schedule

Task Frequency

Replace power modules. Call Bailey sales and service for information. 5 years
Complete all checks and inspections in this table. Replacement tasks should be done

at the scheduled frequency.

(continued)

Shutdown

EQUIPMENT REQUIRE D

Following is a list of tools and equipment required for the
maintenance procedures.

•

Antistatic vacuum.

•

Digital multimeter.

•

Flathead torque screwdriver (Newton meters/inch-pounds).

•

Four-inch flathead screwdriver.

•

16-inch flathead screwdriver.

•

Isopropyl alcohol (99.5% electronic grade).

•

Foam-tipped swab.

•

Eberhard Faber (400A) pink pearl eraser or equivalent.

•

Fiberglass burnishing brush.

•

Lint-free cloths.

•

Small needle nose pliers.

PREVENTIVE MAINTENANCE PROCEDURES

This section covers tasks from Table 6-1 that require specific
instructions or further explanation. The tasks and instructions
covered are:

•

Cabinet air filter cleaning or replacement.

•

How to check signal, power and ground connections.

•

Checking modular power supply outputs.

•

The power entry panel preventive maintenance procedure.

•

Specific instructions on cleaning printed circuit boards and
edge connectors.

Refer to Section 7 for instructions on how to replace the fan
assembly.

Cabinet Filter Cleaning/Replacement

The cabinet air filter mounts over the lower air vent, inside the
cabinet front door. To replace the air filter:

1. Use a flathead screwdriver to remove one screw securing
the mounting plate at the top of the air filter mounting bracket.

EQUIPMENT REQUIRED

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MAINTENANCE

®

2. Pull the mounting bracket (and air filter) off the cabinet
door.

3. Remove the air filter from its mounting bracket.

4. Either clean or replace the air filter.

5. If the air filter stays dry and relatively clean, use com­pressed air to blow dust and dirt free from the filter.

6. Clean a dirty filter in water and a mild detergent (i.e., dish
washing soap). Agitate the filter or squeeze the soapy water
through the filter to remove dirt.

7. When the filter is clean, rinse the filter thoroughly with
water.

8. Air dry the filter before replacing it.

9. Wipe any dust or dirt from the mounting bracket.

Checking Connections

10. Return the dry filter to its mounting bracket.

11. Place the mounting bracket into position on cabinet door
and tighten the screw that holds the mounting plate over the
air filter mounting bracket.

NOTE:

ventive maintenance task.

Power to the cabinet should be off while performing this pre-

Check all signal wiring, power and ground connections within
the cabinet to verify their integrity. When checking connec­tions, always turn a screw, nut or other fastening device in the
direction to tighten only. If the connection is loose, it will be
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 phase, neutral and grounding conductor
connections on the power entry panel are secure.

2. Verify that all other power connections within the cabinet,
including bus bars and connections to the power supplies are
secure.

3. Verify that all field wiring connections to the termination
units or termination modules are secure.

PREVENTIVE MAINTENANCE PROCEDURES
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Checking Power Module Outputs

To check modular power supply outputs on IEPEP01 and
IEPEP02 power entry panel systems, check the bus voltages on
the system power bus bar. There are test jacks on the bus
monitor module for checking bus voltages on IEPEP03 power
entry panel systems. Appendix C contains complete modular
power system wiring diagrams.

CHECKING BUS VOLTAGES ON IEPEP01 AND IEPEP02
SYSTEMS

1. Verify all power module status LEDs are green.

2. If any of the status LEDs are not green, refer to Section 5 to
troubleshoot and correct the problem before proceeding.

3. Measure the bus voltages at the system power bus bar.

Appendix C shows wiring diagrams of the IEPEP01 and

IEPEP02 power entry panels and bus bars. This test should be
done with the system loaded.

MAINTENANCE

4. Use a digital voltmeter to measure +5, +15, and -15 VDC
with respect to DC common.

5. Measure 24 VDC with respect to I/O common using a digi­tal voltmeter.

6. The measured voltages should be within the specifications
under module voltage requirements in Table 1-4.

7. If the module bus voltages are not within specification, ver­ify that the system is properly sized. Refer to Appendix B for
the power system sizing procedure.

CHECKING BUS VOLTAGES ON IEPEP03 SYSTEMS

1. Verify all power module status LEDs are green.

2. If any of the status LEDs are not green, refer to Section 5 to
troubleshoot and correct the problem before proceeding.

3. Measure the bus voltages at the test jacks on the bus mon­itor module. This test should be done with the system loaded.

4. Use a digital voltmeter to measure +5, +15, and -15 VDC
with respect to DC common.

5. Measure 24 VDC with respect to I/O common using a digi­tal voltmeter.

PREVENTIVE MAINTENANCE PROCEDURES

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MAINTENANCE

6. The measured voltages should be within the specifications
under module voltage requirements in Table 1-4.

7. If the module bus voltages are not within specification, ver­ify that the system is properly sized. Refer to Appendix B for
the power system sizing procedure.

Power Entry Panel Inspection and Check

This procedure applies to IEPEP01, IEPEP02 and IEPEP03
Power Entry Panels. The system must be shut down to perform
this maintenance task.

®

NOTE:

Removal of the power entry panel may require two people.

1. Turn off power at the external circuit breakers that feed
power to the power entry panel.

2. Use the 4-inch screwdriver to disconnect all wires and
cables from the rear of the power entry panel. Label the wires
according to their terminal assignments.

3. Use the 16-inch flathead screwdriver to remove the
4 screws (2 on each side) that hold the power entry panel in
position.

4. Remove the power entry panel by sliding it out the back of
the cabinet.

5. Remove the top cover from the power entry panel by remov­ing the 3 screws securing it at the rear of the power entry
panel.

6. Check the tightness of all power wiring screws within the
power entry panel. Torque all No. 6 screws to 0.90 Newton
meters (8 in-lbs). Torque all No. 8 screws to 1.58 Newton
meters (14 in-lbs).

7. Inspect and clean the power entry panel, AC transfer mod­ule and bus monitor module.

8. Replace the power entry panel top cover and install the
power entry panel.

9. Connect all wires and cables removed from the power entry
panel in Step 2.

Printed Circuit Board Cleaning

There are several circuit board cleaning procedures in this sec­tion. These procedures cover circuit board cleaning and wash­ing, cleaning edge connectors and circuit board laminate
between edge connectors. Use the procedures that meet the

PREVENTIVE MAINTENANCE PROCEDURES
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MAINTENANCE

needs of each circuit board. Remove all dust, dirt, oil, corrosion
or any other contaminant from the circuit board.

Do all cleaning and handling of the printed circuit boards at
static safe work stations. Always observe the steps in Special

Handling in Section 3 when handling printed circuit boards.

GENERAL CLEANING AND WASHING

If the printed circuit board needs minor cleaning, remove dust
and residue from the printed circuit board surface using clean,
dry, filtered compressed air or an antistatic field service vac­uum cleaner.

An alternate method of washing the printed circuit board is:

1. Clean the printed circuit board by spraying or wiping the
board with isopropyl alcohol (99.5% electronic grade). Use a
foam tipped swab to apply the alcohol when wiping the board.

2. When the circuit board is clean, remove excess solvent by
using compressed air to blow it free of the circuit board.

EDGE CONNECTOR CLEANING

1. Use a solvent mixture of 80% isopropyl alcohol (99.5% elec­tronic grade) and 20% distilled water.

2. Soak a lint free cloth with the solvent mixture.

3. Work the cloth back and forth parallel to the edge connec­tor contacts.

4. Repeat with a clean cloth that is soaked with the solvent
mixture.

5. Dry the edge connector contact area by wiping with a clean
lint free cloth.

To clean tarnished or deeply stained edge connector contacts:

1. Use an Eberhard Faber (400A) pink pearl eraser or equiva­lent to remove tarnish or stains. Fiberglass or nylon burnish­ing brushes may also be used.

2. Minimize electrostatic discharge by using the 80/20 iso­propyl alcohol/water solution during burnishing.

3. Do not use excessive force while burnishing. Use only
enough force to shine the contact surface. Inspect the edge
connector after cleaning to assure no loss of contact surface.

4. Wipe clean with a lint-free cloth.

PREVENTIVE MAINTENANCE PROCEDURES

I-E96-506B1 6 - 7

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MAINTENANCE

®

CLEANING FEMALE EDGE CONNECTORS

1. Use a foam tipped swab or a lint free cloth wrapped over a
piece of scrap circuit board. Soak the swab or cloth in elec­tronic grade isopropyl alcohol.

2. Insert the swab of cloth covered circuit board into edge
connector and work it back and forth to clean the contacts.

3. Rinse the edge connector contacts by spraying with isopro­pyl alcohol.

4. Remove excess alcohol and dry using compressed air.

PREVENTIVE MAINTENANCE PROCEDURES
6 - 8 I-E96-506B1

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SECTION 7 - REPAIR/REPLACEMENT PROCEDURES

INTRODUCTION

Although the modular power system is designed to give long,
troublefree service, some components may need to be replaced
periodically. This section explains the replacement procedures
and lists spare part numbers.

SPARE PARTS

Table 7-1 lists a description and Bailey part number of spare
parts that can be stocked. It is impractical to specify a recom­mended quantity of spare parts because Bailey Controls Com­pany custom designs every system. Contact Bailey Controls
Company for help determining the quantity of spare parts to
keep on hand for your particular system.

Table 7-1. Spare Part Numbers and Description

Description Part No./Nomenclature Remarks

AC field power module IEPAF02 Can replace an IEPAF01 module
AC power cables 6637814_2 Connects PEP to PMU or to inp ut power bus

bar

6637818_2 Connects input power bus bar to MMU
AC system power module IEPAS02 Can replace an IEPAS01 module
AC transfer module 6637827_1 Used in IEPEP03
Bus monitor module 6637830_1 Used in IEPEP03
Cabinet filter 199914_20 IECAB01and IECAB03
DC power cable 1948509_5 Connects MMU to system power bus bar

®

Fuse, 1 A Bussman

or equivalent

194776A11001
Fuse, 2 A Bussman AGC2

or equivalent

194776A12001
Fuse, 3 A Bussman GMA-3 fast act-

ing or equivalent

1948182_23001
IEFAN01 assembly (120 VAC) 1947419_1 —
IEFAN02 assembly (240 VAC) 1947419_2 —
Insulated quick conn ect

receptacle
PFI cable 6638084_1 Connects IEPEP01/02 to system power bus

1948529_1 —

AGC1

Fuse in IEFAN02 assembly

Fuse in IEFAN01 assembly

Fuse in IEPAS02 and IEPAF02 modules

bar

® Bussman is a registered trademark of McGraw Edison Company.

INTRODUCTION

I-E96-506B1 7 - 1

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REPAIR/REPLACEMENT PROCEDURES

®

Table 7-1. Spare Part Numbers and Description

Description Part No./Nomenclature Remarks

PFI cable

(cont.)

Power entry panel IEPEP01 Single AC feed with no circuit breaker

Node status output cable 66334205_1 Connects IEPEP01/02/03 to INBIM02 or

6637813_1 Connects IEPEP03 to system power bus bar

IEPEP02 Single AC feed with circuit breaker
IEPEP03 Redundant AC feed with circuit breakers

INPTM01

(continued)

AC TRANSFER MODULE REPLACEMENT

NOTES:

1. The AC trans fer module can be remo ved under power if li ne
one is verified operational and within tolerance.

2. The bus monitor module goes off-line when the AC transfer
module is removed. The bus monitor module

. Then remove the AC transfer module.

first

must be

removed

To replace the AC transfer module:

1. Turn the 2 thumbscrews 1/2-turn to release the bus moni­tor module faceplate. Pull on the faceplate to slide the module
out.

2. Turn the 2 thumbscrews 1/2-turn to release the AC trans­fer module faceplate. Pull on the faceplate to slide the module
out.

3. Set switch S1 on the replacement to match the setting of
the ATM module just removed.

4. Insert the replacement AC transfer module. Grasp it by the
faceplate. Align the top and bottom edges of the circuit board
with the guides in the panel.

5. Hold the module by the faceplate and slide it into the slot;
push until the rear edges are firmly seated in the backplane
connectors.

6. Reinsert the bus monitor module. Grasp it by the faceplate.
Align 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 into the slot;
push until the rear edges are firmly seated in the backplane
connectors.

8. Latch both modules in place by turning the faceplate
thumbscrews 1/2-turn.

AC TRANSFER MODULE REPLACE MEN T
7 - 2 I-E96-506B1

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BUS MONITOR MODULE REPLACEMENT

REPAIR/REPLACEMENT PROCEDURES

FAN ASSEMBLY

NOTE:

Replace with another bus monitor module as soon as possible.

The bus monitor module can be removed under power.

To replace the bus monitor module:

1. Turn the 2 thumbscrews on the module faceplate 1/2-turn
in either direction to release the module. Slide the module out.

2. Set switch S1 and jumpers J1 through J8 on the replace­ment to match the settings of the BMM module just removed.

3. Grasp the replacement module by the faceplate.

4. Align the top and bottom edges of the circuit board with the
guides in the panel.

5. Hold the module by the faceplate and slide it into the slot;
push until the rear edges are firmly seated in the backplane
connectors.

6. Turn the 2 thumbscrews on the module faceplate 1/2-turn
to lock the module in place.

Fuse Replacement

Fan Assembly Replacement

1. Disconnect power from the fan assembly by unplugging it
from J4 on the IEPEP01 or IEPEP02 power entry panel or J1 on
the IEPEP03 power entry panel.

2. Remove the fuse by turning the fuse holder cap counter­clockwise until it releases.

3. Use the fuse holder cap to pull the fuse from its holder.

4. Put an identically rated replacement fuse in the fuse holder
cap.

5. Touching only the fuse holder cap, insert the fuse into the
fuse holder and turn the fuse holder cap clockwise until
secure.

6. Connect the fan assembly to power by connecting it to J4
on IEPEP01 and IEPEP02 power entry panels or J1 on
IEPEP03 power entry panels.

1. Unplug the fan assembly.

BUS MONITOR MODULE REPLACEMENT

I-E96-506B1 7 - 3

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REPAIR/REPLACEMENT PROCEDURES

2. Remove and save the 4 screws on the front of the assembly
that attach it to the cabinet frame.

3. Carefully slide the assembly out of its mounting position.
Be careful not to disturb other cabinet wiring.

4. Verify that the replacement assembly has the same AC
power requirements as the one just removed.

5. Slide the replacement assembly into the same spot vacated
by the faulty fan assembly.

6. Secure the fan assembly into its mounting position with
the 4 screws removed in Step 2.

7. Plug the power cord into the connector labeled J1 on the
power entry panel.

8. Listen for fan rotation to verify that the replacement assem­bly is operating.

®

POWER MODULE

Power Module Replacement

Before replacing IEPAS01 or IEPAF01 power module with
IEPAS02 or IEPAF02 power module read the information in

Appendix E. Power modules can be removed under power.

Always insert a replacement power module before removing a
power module.

1. Set the jumper settings on the replacement power module.

2. Grasp the replacement module by its faceplate handle.

3. Align the top and bottom edges of the circuit board with the
guides of its slot in the power mounting unit or module mount­ing unit.

4. Hold the module by the faceplate handle and slide it into
the slot; push until the rear edges are firmly seated in the
backplane connectors.

5. Firmly press the module handle while using a flat blade
screwdriver to push and turn the 2 concentric screws 1/2-turn
clockwise to lock the module in place.

POWER MODULE
7 - 4 I-E96-506B1

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WARNING

AVERTISSEMENT

REPAIR/REPLACEMENT PROCEDURES

6. Verify the status LED turns green.

7. Use a flat blade screwdriver to turn the 2 concentric screws
1/2-turn in either direction on the power module being
replaced.

Allow five seconds for the line filter capacitors to discharge
before handling the module after removal. Failure to do so
could result in severe or fatal shock.

Après avoir retiré le modle, laissex les condensateurs de filtres
antiparasites se décharger pendant cinq secondes avant de
manipuler celui-ci, afin d'éviter les chocs sérieux et même mor­tels.

WARNING

Handle the module by surfaces other than the heat sink. The
heat sink may be hot and may cause severe burns.

Le module doit être manipulé à l'aide de surfaces autres que le

AVERTISSEMENT

dissipatour thermique. Ce dernier resque d'être chaud et de
provoquer des brûlures sérieuses.

8. Grasp the faceplate handle and partially pull out the mod­ule.

9. Allow at least 5 seconds for the line filter capacitors to dis­charge then remove it completely from power mounting unit or
module mounting unit.

Power Module Fuse Replacement

Do the steps in Power Module Replacement in this section to
remove the power module from its mounting unit. To replace
the power module fuse:

1. Lay the module on an antistatic mat.

2. Locate fuse F1 at the rear of the module by the P1 edge
connector (see Figure 3-6).

3. Use a fuse removal tool to extract fuse F1.

4. Insert a new 3 A slow blow fuse.

5. To install the power module after changing its fuse, repeat
the steps in Power Module Replacement in this section.

POWER MODULE

I-E96-506B1 7 - 5

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REPAIR/REPLACEMENT PROCEDURES

POWER ENTRY PANEL REPLACEMENT

Verify the main power and power entry panel circuit breakers
are turned off before starting installation, retrofit, upgrade, or

WARNING

AVERTISSEMENT

wiring procedures. Failure to do so could result in severe or
fatal shock. Do not turn the power on until the installation, ret­rofit, upgrade, or wiring procedures are complete.

Assurez-vous que le disjoncteur d'alimentation principal et le
disjoncteur de panneau d'entrée des alimentations sont éteints
avant de procéder à l'installation, à la mise à jour, à l'extension
ou au câblage, dans le but d'éviter les chocs sérieux et même
mortels. Ne rétablissez pas l'aliment ation tant que ces procé­dures ne sont pas terminées.

1. Turn off power to the cabinet at the AC power source.

2. Open the rear door of the cabinet to gain access to the rear
of the power entry panel.

®

3. Remove all wiring from the power entry panel. Label the
wires as you remove them.

4. From the rear of the cabinet, use a 16-inch bladed screw­driver to remove the 4 mounting screws.

5. Pull the power entry panel out of the cabinet.

6. From the rear of the cabinet, insert the replacement power
entry panel in the same mounting space.

7. Secure the power entry panel to the cabinet with the 4
mounting screws.

8. With power entry panel circuit breakers off, connect the
wiring that was removed in Step 3. Appendix C contains power
entry panel wiring diagrams.

9. If it is an IEPEP01 or IEPEP02 panel, check the 120/
240 VAC switch to verify that it is set for the correct line volt­age.

10. If it is an IEPEP03 panel, set the jumpers and dipswitches
on the bus monitor module for the desired operation. Verify
that the switch on the AC transfer module is set for the correct
line voltage.

11. Turn on the power to the power entry panel at the AC
source.

12. Turn on the power to the cabinet at the power entry panel
circuit breakers and check for proper operation.

POWER ENTRY PANEL REPLACEMENT
7 - 6 I-E96-506B1

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SECTION 8 - SUPPORT SERVICES

INTRODUCTION

Bailey Controls Company is ready to help in the use and repair
of its products. Contact your nearest sales office to make
requests for sales, applications, installation, repair, overhaul
and maintenance contract services.

REPLACEMENT PARTS AND ORDERING INFORMATION

When making repairs at your facility, order replacement parts
from a Bailey sales office. Provide this information:

1. Part description, part number and quantity.

2. Model and serial numbers (if applicable).

3. Bailey Controls Company instruction manual number,
page number and reference figure that identifies the part.

When ordering standard parts, use Bailey Controls Company
part numbers and descriptions. Order parts without commer­cial descriptions from the nearest Bailey Controls Company
sales office.

TRAINING

Bailey Controls Company has a modern training facility avail­able for training your personnel. On-site training is also avail­able. Contact a Bailey Controls Company sales office for
specific information and scheduling.

TECHNICAL DOCUMENTATION

Additional copies of this manual, or other Bailey Controls Com­pany manuals, can be obtained from the nearest Bailey Con­trols Company sales office at a reasonable charge.

INTRODUCTION

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INTRODUCTION

APPENDIX A - QUICK REFERENCE GUIDE

Use Table A-1 as a quick reference to check jumper and switch
settings for the IEPAS02 and IEPAF02 Power Modules, bus
monitor module and AC transfer module.

Table A-1. Switch and Jumper Setting Reference Guide

Device

AC transfer
module

Bus monitor
module

Switch

Position

S1 - 120
S1 - 240

S1 = 0011 Factory default setting, 5, ±15, 24 VDC monitoring enabled.

Jumper

Position

120 VAC operation
240 VAC operation

External monitoring disabled.

J1

1-2
2-4
2-3

J2

1-2
2-4
2-3

J3

1-2
2-3

J4

1-2
2-3
3-4

J5

1-2
2-3

J6

1-2 Must be set as shown

J7

1-2
2-3

J8

2-3 Must be set as shown

Auxiliary bus monitor, channel 1:

Selects 24 VDC external power
Selects 48 VDC external power
Selects 125 VDC external power

Auxiliary bus monitor, channel 2:

Selects 24 VDC external power
Selects 48 VDC external power
Selects 125 VDC external power

AC input voltage, line 2:

Selects 120 VAC input
Selects 240 VAC input

Auxiliary status input 1:

Normally open status input
Normally closed status input
Not used

Auxiliary status input 2:

Normally open status input
Normally closed status input

AC input voltage, line 1:

Selects 120 VAC input
Selects 240 VAC input

Function

INTRODUCTION

I-E96-506B1 A - 1

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QUICK REFERENCE GUIDE

®

Table A-1. Switch and Jumper Setting Reference Guide

Device

IEPAS02
Power Module

IEPAF02 Power
Module

Switch

Position

Jumper

Position

J1

1-2
2-3

J2

1-2
2-3

J3

1-2
2-3

J1

1-2
2-3

J2

1-2
2-3

(continued)

Function

AC input voltage:

120 VAC
240 VAC

Enable 24 VDC undercurrent monitoring
Disable 24 VDC undercurrent monitoring

Enable 5 VDC undercurrent monitoring
Disable 5 VDC undercurrent monitoring

AC input voltage:

120 VAC
240 VAC

Enable 24 VDC undercurrent monitoring
Disable 24 VDC undercurrent monitoring

INTRODUCTION
A - 2 I-E96-506B1

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APPENDIX B - MODULE POWER REQUIREMENTS

INTRODUCTION

This section lists the power requirements of INFI 90 modules,
termination units and termination modules. Use this informa­tion to calculate the +5, +15, -15 and +24 VDC module current
requirements for each INFI 90 cabinet. The procedure for cal­culating current requirements includes a worksheet for calcu­lating any current requirements for system powered I/O.

After calculating the current requirements for each cabinet,
calculate the number of modular power supplies needed for
each cabinet by following the instructions in SIZING THE

MODULAR POWER SYSTEM in this section. Finally, follow the

procedure to verify that the total current draw of the power
cabinet is within the power entry panel specifications.

CALCULATING CURRENT REQUIREMENTS

Tables B-1 and B-2 contain a list of all INFI 90 modules, termi­nation units and termination modules, and their operating
current requirements. Use Table B-3 to calculate system pow­ered I/O current requirements. To use the information in these
tables:

NOTE:

module. Multipl y the valu e of cu rrent consu mptio n per mo dule b y the
number of those modules in the cabinet. For example, if a cabinet
contains four IMASI02 modules, the total +5 VDC current consump­tion of these modules is 4 x 85 mA = 340 mA.

Current consumption values listed in the tables apply to one

1. Make a list of modules contained in the cabinet you are siz­ing for modular power supplies.

2. Calculate the +5 VDC current requirement for each
cabinet.

a. Refer to Table B-1 for the +5 VDC current requirement
of each module.

b. Total the +5 VDC current requirement per cabinet.

3. Calculate the +15 VDC current requirement for each
cabinet.

a. Refer to Table B-1 for the +15 VDC current requirement
of each module.

b. Total the +15 VDC current requirement per cabinet.

INTRODUCTION

I-E96-506B1 B - 1

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MODULE POWER REQUIREMENTS

4. Calculate the -15 VDC current requirement for each
cabinet.

a. Refer to Table B-1 for the -15 VDC current requirement
of each module.

b. Total the -15 VDC current requirement per cabinet.

5. Calculate the +24 VDC current requirement.

a. Refer to Table B-1 for the +24 VDC current requirement
for each module.

b. Table B-2 lists +24 VDC current requirements of termi­nation units and termination modules.

c. Total the +24 VDC current requirement per cabinet.

6. Add the current requirement of any system powered I/O
using +24 VDC to the total from Step 5c. Table B-3 gives an
overview of how to calculate the system powered I/O current
requirement.

®

Table B-1. DC Current Consumption for INFI 90 Modules

INFI 90

Modules

IISAC01 0 0 0 530
IMAMM03 725 125 30 0
IMAOM01 1045000
IMASI02 95 30 25 0
IMASI03 330 140 40 0
IMASM01 1208545 0
IMASM02

IMASM03
IMASM04 5504530 0
IMASO01 530 220 225 50
IMCIS02 300 30 25 7
IMCOM03

IMCOM04
IMCPM01 0000
IMCPM02 825000
IMDSI02 60000
IMDSM04 1500 0 0 65
IMDSM05 600000

Total for page

No. of

Modules/

Cabinet

5 V

4008040 6

6605550 7

Current Consumption Per Module (mA)

Total

5 V

+15 V

Total

+15 V

-15 V

Total

-15 V

24 V

Total

24 V

CALCULATING CURRENT REQUIREMENTS
B - 2 I-E96-506B1

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MODULE POWER REQUIREMENTS

Table B-1. DC Current Consumption for INFI 90 Modules

INFI 90

Modules

IMDSO01
IMDSO02
IMDSO03

IMDSO04 165000
IMFBS01 100 30 20 0
IMFCS01 220 7 10 0
IMHSS01

IMHSS02
IMLMM02 660000
IMMFC03 4200 40 20 0
IMMFC04 1400000
IMMFC05 1000000
IMMFP01

IMMFP02
IMMFP03 2000000
IMMPC01 4200 40 20 0
IMMPI01 415000
IMMPI02 700000
IMQRC01 660 55 50 7
IMQRS01

IMQRS02
IMRIO02 1600 20 90 0
IMSPM01 1330 30 25 0
INBIM01

INBIM02
INBTM01

INICT01 4200 40 20 0
INICT03 1958000
INIIT01 4200 40 20 0
INIIT02

INIIT03
INIPT01 4200 40 20 0
INLIM03 2 20 0 90 90 0
INNIS01 900 5 200 0
INNPM01 2000000
INPCT01

INPPT01
INPTM01 1100000

Total for page

No. of

Modules/

Cabinet

5 V

150000

180807020

2000000

300 30 25 7

1100000

2000000

4200 40 20 0

Current Consumption Per Module (mA)

Total

5 V

+15 V

Total

+15 V

-15 V

(continued)

Total

-15 V

24 V

Total

24 V

CALCULATING CURRENT REQUIREMENTS

I-E96-506B1 B - 3

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MODULE POWER REQUIREMENTS

®

Table B-1. DC Current Consumption for INFI 90 Modules

INFI 90

Modules

INSIM01 15003025 0
NCTM01 1500000
NDCS03 0 0 0 510
NDIS01 0 0 0 360
NDLS02 0 0 0 320
NLIS01 900 5 200 0
NLSM01

NLSM02
NMFC01

NMFC02
NSBM01 1000000
NSSM01 4200000

Total for page
Cabinet total

No. of

Modules/

Cabinet

5 V

4200 40 20 0

4600 40 20

Current Consumption Per Module (mA)

Total

5 V

+15 V

Total

+15 V

-15 V

(continued)

Total

-15 V

24 V

Total

24 V

Table B-2. 24 VDC Current Consumption of Termination

Units and Termination Modules

Termination
Unit/Module

NTCL01
NICL01

NTDO02 90
NTFB01 65
NTMF01

NIMF01
NIMF02

NTMP01
NIMP01
NIMP02

NTRL03
NIRL01
NIRL02
NIRL03

NTRL02 190

Total

TU/TMs Using System

Power per Cabinet

24 VDC Current

Consumption per

TU/TM (mA)

40

130

230

130

24 VDC TU/TM

Current Consumption

per Cabinet

CALCULATING CURRENT REQUIREMENTS
B - 4 I-E96-506B1

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MODULE POWER 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 cur­rent per input or output). For digital outputs, specify the cur­rent requirements for the digital outputs in your system.
Complete the calculation to determine the current require­ments by filling in all five rows as necessary then totaling the
current requirements in column four.

Table B-3. System Powered I/O Current Consumption

Type of

Input/Output

Analog outputs 20
Analog inputs 20
TC inputs 20
Digital inputs 5
Digital outputs NOTE 1

Total I/O current
consumption

NOTE:

1. Use the typical current requirements of your particular digital outputs.

No. of

Inputs/Ouputs

SIZING THE MODULAR POWER SYSTEM

The following text and equations explain how to calculate the
number of IEPAS02 and IEPAF02 power supply modules
needed for a particular system.

Cabinet requirements for 5 VDC, +15 VDC, -15 VDC and
24VDC power are calculated by adding the individual module
current requirements. Refer to CALCULATING CURRENT

REQUIREMENTS in this section to determine the current

requirements of your system. Refer to product specifications
for current requirements of new modules not listed.

Current

Consumption per

Input/Output (mA)

Total Current

Consumption for

System Power I/O

Sizing Systems with IEPAS02 Modules Only

A

B

C

Total 5 VDC current requirements for system cabinet.

Total 24 VDC current requirements for associated I/O.

Total +15 VDC current requirements for system cabi­net.

D

Q1

Total -15 VDC current requirements for system cabinet.

Number of IEPAS02 power modules needed to meet
5 VDC current requirements.

SIZING THE MODULAR PO WER SYSTEM

I-E96-506B1 B - 5

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MODULE POWER REQUIREMENTS

®

Q2

Number of IEPAS02 power modules needed to meet
24 VDC current requirements.

Q3

Number of IEPAS02 power modules needed to meet
+15 VDC current requirements.

Q4

Number of IEPAS02 power modules needed to meet

-15 VDC current requirements.

Q5

QS

Total power needed.

Total number of IEPAS02 power modules needed to
power the system.

Then solve the following equations:

A

Q1

------=

13

B

Q2

--- -=

4

C

Q3

--------=

0.8

D

Q4

--------=

0.8

5.225

A

Q5

QS

×〈〉

-------------------------------------------------------------------------------------------------------------------------------------=

= Largest of Q1, Q2, Q3, Q4 and Q5.

25.8

B

×〈〉

130

Round the value of QS to the next highest integer. This number
represents the number of IEPAS02 power modules needed to
satisfy system requirements. If using N+1 redundancy, add 1
to the value of QS.

System Calculation Example Using IEPAS02 Modules Only

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
was calculated. The results are:

A

= 26.5 A (5 VDC current requirement)

B

= 3.1 A (24 VDC and associated I/O current)

C

= 0.9 A (+15 VDC current requirement)

15.3

C

×〈〉

15.3

D

+〈〉+++

D

= 0.4 A (-15 VDC current requirement)

SIZING THE MODULAR POWER SYSTEM
B - 6 I-E96-506B1

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MODULE POWER REQUIREMENTS

Substitute these values into the equations and solve for Q.

26.5

Q1

-----------

==

3.1

Q2

--------

==

0.9

Q3

--------

==

0.8

0.4

Q4

--------

==

0.8

13

4

2.038

0.775

1.125

0.5

26.5 5.225

Q5

==

= Largest of Q1, Q2, Q3, Q4 and Q5 = 2.038

QS

×〈〉

---------------------------------------------------------------------------------------------------------------------------------------------------------=

〈〉

138.46 79.98 13.77 6.12

------------------------------------------------------------------------------------

+++

130

3.1 25.8

×〈〉

Number of power modules required for system.

= 2.038

QS

Round the value of QS to the next highest integer.

= 3 IEPAS02 modules

QS

With N+1 redundancy where N = QS.

QS

= 3 + 1 = 4 IEPAS02 modules

(N+1)

For Systems Using Both IEPAS02 and IEPAF02 Modules

Let:

A

Total 5 VDC current requirements for system cabinet.

130

0.9 1 5.3

×〈〉

1.833

0.4 15.3

+〈〉+++

B

C

Total 24 VDC current requirements for associated I/O.

Total +15 VDC current requirements for system cabi­net.

D

Q1

Total -15 VDC current requirements for system cabinet.

Number of IEPAS02 power modules needed to meet 5 V
current requirements.

Q2

Number of IEPAS02 power modules needed to meet 24
V current requirements.

Q3

Number of IEPAS02 power modules needed to meet +15
V current requirements.

SIZING THE MODULAR PO WER SYSTEM

I-E96-506B1 B - 7

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MODULE POWER REQUIREMENTS

®

Q4

Number of IEPAS02 power modules needed to meet

-15 V current requirements.

Q5

PS

PF

QS

Total power needed.

Total 5, +15, and -15 V power requirements.

Total 24 V power requirement.

Total number of IEPAS02 power modules needed to
power the system.

QF

Total number of IEPAF02 power modules needed to
power associated I/O.

Then solve the following equations:

A

Q1

------=

13

B

Q2

----=

4

C

Q3

--------=

0.8

D

Q4

--------=

0.8

5.225

A

Q5

QN

×〈〉

------------- ------ ------- ------ ------- ------ ------ ------- ------ ------ ------- ------ ------- ------ ------ ------- ------ ------ ------- -----=

= Largest of Q1, Q2, Q3, Q4 and Q5.

25.8

B

×〈〉

130

15.3

C

×〈〉

15.3

D

+〈〉+++

Round up the value of QN to the next highest integer.

= (

PS
PF

Q6

Q7

QS

5.225) + (

A

×

=

25.8

B

×

PF

130

---------–=

QN

PS

--------=

Q6

= Largest of Q1, Q3, Q4 and Q7.

15.3) + (

C

×

(if Q6 > 92 then set Q6 = 92)

D

×

15.3)

Round the value of QS to the next highest integer. This number
represents the number of IEPAS02 power modules needed to
satisfy system requirements.

= QN -

QF

QS

QF represents the number of IEPAF02 power modules needed
to satisfy associated I/O requirements. If using N+1 redun-

SIZING THE MODULAR POWER SYSTEM
B - 8 I-E96-506B1

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MODULE POWER REQUIREMENTS

dancy, add 1 to the value of QS. The IEPAS02 can supply all
the system voltages.

System Calculation Example Using IEPAS02 and IEPAF02 Modules

Assume that the current requirements for a set of modules
residing in a system cabinet has been calculated.

Additionally, the current requirement for 24 VDC I/O power
was calculated. The results are:

A

= 26.5 A (5 VDC current requirement)

B

= 16 A (24 VDC and associated I/O current requirement)

C

= 0.9 A (+15 VDC current requirement)

D

= 0.4 A (-15 VDC current requirement)

Substitute these values into the equation and solve for Q.

26.5

Q1

-----------

==

13

2.038

16

Q2

------4==

4

0.9

Q3

==

Q4

==

Q5

==

= Largest of Q1, Q2, Q3, Q4 and Q5 = 4.39

QN

1.125

--------

0.8

0.4

0.5

--------

0.8

26.5 5.225

×〈〉

------------------------------------------------------------------------------------------------------------------------------------------------------- -

16 25.8

×〈〉

130

0.9 1 5.3

×〈〉

Round QN up to the next highest integer.

= 5

QN

= (

PS

= (26.5

PF = B

Q6

5.225) + (

A

×

25.8 = (16

×

130

5.225) + (0.9

×

PF

-------- -

QN

15.3) + (

C

×

×

25.8) = 412.8

×

412.8

130

-------------- -–=–=

5

15.3)

D

×

15.3) + (0.4

(if Q6 > 92 then set Q6 = 92)

15.3) = 158.35

×

0.4 15.3

+〈〉++ +

= 47.44

4.39

158.35

PS

Q7

--------

Q6

----------------- -

47.44

== =

= Largest of Q1, Q3, Q4 and Q7 = 3.33

QS

3.33

SIZING THE MODULAR PO WER SYSTEM

I-E96-506B1 B - 9

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MODULE POWER REQUIREMENTS

Round the value of QS to the next highest integer. This number
represents the number of IEPAS02 power modules needed to
satisfy system requirements.

= 4

QS

®

QF

=

QN - QS

= 5 - 4 = 1 IEPAF02 module

Number of IEPAS02 power modules required for the system.

= 4 IEPAS02 modules

QS

With N+1 redundancy where N = QS.

QS

= N + 1 = 5 IEPAS02 modules

(N+1)

MAXIMUM POWER ENTRY PANEL CURRENT DRAW

Use the value of Q5 × 30 (total power from the modular power
system sizing procedure) to determine if your system is within
specification of the power entry panel. The following equations
show how to determine the current draw on the power entry
panel.

130

×

Q5

----------------------- -

47.25

Q5

----------------------- -

94.5

for 120 VAC systems.

130

×

for 240 VAC systems.

The resulting quotient is the maximum current draw on the
power entry panel. The specified current limits on the power
entry panel are:

•

20 amps for 120 VAC systems.

•

10 amps for 240 VAC systems.

MAXIMUM POWER ENTRY PANEL CURRENT DRAW
B - 10 I-E96-506B1

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INTRODUCTION

APPENDIX C - WIRING DIAGRAMS

Appendix C contains system cabinet wiring diagrams for the

module mounting unit and power mounting unit. Figure C-1
shows how to wire the IEPEP03 Power Entry Panel to module
mounting units. Figure C-2 shows how to wire the IEPEP03
Power Entry Panel to power mounting units. Figures C-3 and

C-4 show how to wire the IEPEP01 and IEPEP02 Power Entry

Panels to module mounting units and power mounting units
respectively.

INTRODUCTION

I-E96-506B1 C - 1

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WIRING DIAGRAMS

®

CUSTOMER AUXBUS

MONITORINPUTS

24/48/125 VDC

STATUS INPUTS

NODE STATUSTO BI M/PTM

USER ALARM OUTPUT

POWER SYSTEM STATUS

USER ALARM OUTPUT

BUS VOLTAGE STATUS

STAT US

I/O COM

RED

+5 V

WHT

MCOM

ORN

+15 V

BLK

–15 V

STAT US

I/O COM

YEL

PFI

ORN

WHT/BLU

WHT/ ORN

STATUS
I/O COM
+24 V

STAT US

I/O COM

SYSTEM POWER

BUS BAR

+5 V

MCOM

+15 V
–15 V

+24 V

+5 V

MCOM

+15 V
–15 V

+24 V

+24 V

MCOM

PFI

PFI

CH1

CH2

COM

(+)
(–)
(+)
(–)

1

2

(+)
(–)
(+)
(–)

CABLE P/N 6637813C1
(SUPPLIEDWITHPEP)

CABLE P/N
1948509 5

CABLE P/N
1948509 5

CABLE P/N
1948509 5

CABLE P/N
1948509 5

WHT/ORN
GRAY
GRAY
GRAY
GRAY

CABLE P/N



6634205 1





ORN

YEL

WHT





ORN

YEL YEL

WHT WHT

AUX BUS
MONITOR

CH1

J2

TB3115

+5 V

MCOM
+15 V

–15 V
PFI
STATUS
I/O COM
+24 V

MBUS
MBUS
MCOM

+5 V

MCOM
+15 V

–15 V
PFI
STATUS
I/O COM
+24 V

MBUS
MBUS
MCOM

+–

TB4

ALARMS

STATUS

PWR

IN

SYS

1COM2

+–

37

26

48

FAN ASSEMBLY
IEFAN01/02
ROW 1

ORN

TO NEXT MMU

NO. 14 AWG

NO. 10 AWG

ISOLATED SYSTEM COMMO N BUS

MAIN POWER INPUT

120/240 VAC 50/60 HZ

CH2
+–

3

2

4

POWER E NT RY PANEL
IEPEP03

BUS

ROW 0

VOLT

+–

MODULE MOUNTING UNIT
IEMMU01/02
ROW 2

NO. 18 AWG (3-WIRE TWISTED)

MODULE MOUNTING UNIT
IEMMU01/02
ROW 3

USER +24 V
OUTPUT

GND

N(L2)

L(L1)

FAN
OUT

MAIN POWER
INPUT
120/240VAC
50/60HZ

(VIEW A)

1

2

TB1

L

L

N

120 VAC

L1

240 VAC

120 VAC

J1

240 VAC

1

TB2

NO.6AWGGRN/YEL

CABLE P/N 6637814 2
(SUPPLIED W ITH PEP)

N(L2)
L(L1)

FOR SYSTEMS WITH SINGLE LINE POWER ENTRY

N

L1

L2

L2

AC OUT

L

N

L1

L2

BRN

BLU

(–)
(+)

(+)

TB1 1 2 3 4 5 6

120 VAC

L

240 VAC

L1

665544332

GRN/YEL

N
L2

L(L1)
N(L2)



GRN/YEL

GRN/YEL

L
L1

VIEW A

AUX. POWER INPUT
120/240 VAC 50/60 HZ

SAFETY GND.
CONN.TO CAB.

CABLE P/N



6637818 2

BRN

BLU

CABLE P/N
6637818 2

BLU

N
L2



BRN
BRN
BLU

BLU
GRN/YEL
GRN/YEL

BRN

BLU
GRN/YEL

BRN

BRN

BLU

BLU

BRNBRN

BLU
GRN/YEL

+/L1

–/L2

+/L1
–/L2

+/L1

–/L2

+/L1
–/L2(–)

+/L1
–/L2

INPUT POWER

BUS BAR

TP25161B

Figure C-1. IEPEP03 Power Entry Panel and Module Mounting Unit Wiring Diagram

INTRODUCTION
C - 2 I-E96-506B1

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CUSTOMER AUX BUS

MONITOR INPUTS

24/48/125 VDC

STATUS
INPUTS

NODE STATUS TO BIM/PTM

USER ALARM OUTPUT

POWER SYSTEM STATUS

USER ALARM OUTPUT
BUS VOLTAGE STATUS

CH1

CH2

(+)
(-)
(+)
(-)

COM

(+)
(-)
(+)
(-)

1

2

CABLE P/N
6637813C1
(SUPPLIED WITH PEP)

6632285A45
(BRAIDED WIRE)

CABLE P/N

J2

6634205-1

STATUS

IN

1COM 2

12

AUX BUS
MONITOR

CH1 CH2

+-

1234

TB4

ALARMS

PWR
SYS

+- +-

3

45678

MAIN POWERINPUT

120/240 VAC50/60 Hz

+-

BUS
VOLT

GND

N(L2)

L(L1)

123456

TB1

120 VAC

LN
L1 L2

240 VAC

FAN
OUT

123456

TB2

J1TB3

LN

L1 L2

AC OUT

120 VAC

LN

240 VAC

L1 L2

NO. 10 AWG GRN/YEL

WIRING DIAGRAMS

L(L1)

AUX.POWERINPUT

N (L2)

120/240 VAC50/60 Hz

(SEE VIEW A)

POWER ENTRYPANEL
IEPEP03 ROW 0

SAFETY GND.
CONN. TO CAB.

CABLE P/N
6637814-2

FANASSEMBLY
IEFAN01/02 ROW 1

YEL
ORN
WHT/BLU
WHT/ORN

MCOM

STATUS
I/O COM

RED

+5 V

WHT

MCOM

ORN

+15 V

BLK

-15 V

MCOM

STATUS
I/O COM
+24 V

PFI
STATUS
I/O COM
+24 V

STATUS

I/O COM

MCOM

SYSTEM POWER

BUS BAR

+5 V

+15 V

-15 V

+24 V

+5 V

+15 V

-15 V

+24 V

NO. 10 AWG

PFI

CABLE P/N
1948509-5

PFI

WHT/ORN
GRAY
GRAY
GRAY
GRAY

CABLE P/N
1948509-5

TO NEXT MMU

+15 V

-15 V
STATUS

MCOM
+5 V

I/O COM

+24 V

NO. 10 AWG (USE ADDITIONAL CONNECTORS IF
GREATER THAN 10 AMPS)

+5 V

MCOM
+15 V

-15 V
PFI
STATUS
I/O COM
+24 V

ORN

MBUS

YEL

MBUS

WHT

MCOM

NO. 18 AWG (3-WIRE TWISTED)

NO. 14 AWG

NO. 10 AWG

CUSTOMER +24V OUTPUT

GRN/YEL

N (L2)

L(L1)

DC IN/COM
24V/48V IN

MAIN POWER
INPUT
120/240 VAC
50/60 Hz

FOR SYSTEMS WITH SINGLELINE POWER ENTRY

BLU
BRN

POWER MOUNTING UNIT
PMU ROW 2

MODULEMOUNTING UNIT
IEMMU01/02 ROW 3

N (L2)

L(L1)

123456

TB1

LN

120 VAC
240 VAC

L1 L2LNL1 L2

VIEW A

ISOLATEDSYSTEM COMMON BUS

TP25160B

Figure C-2. IEPEP03 Power Entry Panel and Power Mounting Unit Wiring Diagram

INTRODUCTION

I-E96-506B1 C - 3

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WIRING DIAGRAMS

CABLE P/N 6638084 1
(SUPPLIED WITH PEP)

+5 V

MCOM

+15 V
–15 V

PFI
STATUS
I/OCOM

+24 V

RED

+5 V

WHT

MCOM
+15 V
–15 V

+5 V

MCOM

+15 V
–15 V

PFI
STATUS
I/OCOM

+24 V

YEL

PFI
STATUS
I/O COM
+24 V

CABLE P/N
1948509 5

CABLE P/N
1948509 5

CABLE P/N
1948509 5

CABLE P/N
1948509 5







ORN

YEL

WHT





ORN ORN

YEL YEL

WHT WHT

PFI

FAN A SSEMBLY
IEFAN01 /02
ROW 1

+5V

MCOM
+15 V

–15V
PFI

STATUS
I/O COM
+24 V

MBUS
MBUS
MCOM

+5V

MCOM
+15 V

–15V
PFI
STATUS
I/O COM
+24 V

MBUS
MBUS
MCOM

POWERENTRY PANEL
IEPEP01_
ROW 0

MODULE MOUNTING UNIT
IEMMU01/02
ROW 2

NO. 18 AWG (3-WIRE TWISTED)

MODULE MOUNTING UNIT
IEMMU01/02
ROW 3

TO NEXTMMU

GND

FAN
OUT

J4

2

TB1

L

120VAC

N

L1

240VAC

L2

AC OUT

L

120 VAC
240 VAC

CABLEP/N 6637814 1
(SUPPLIED WITH PEP)

N(L2)

N(L2)

L(L1)

L(L1)

TB3

N

L1

L2

11332

BRN

BRN

BLU

BLU



GRN/YEL

GRN/YEL

L(L1)

AUX. POWER INPUT

N (L2)

120/240 VAC 50/60 HZ

NO. 10 AWG

GRN/YEL

SAFETYGND.
CONN.TO CAB.

CABLE P/N
6637818 1

CABLE P/N
6637818 1

®

BRN

L1

BRN

BLU

L2

BLU
GRN/YEL
GRN/YEL



BRNBRN

L1

BLUBLU

L2

GRN/YELGRN/YEL



BRNBRN

L1

BLUBLU

L2

GRN/YELGRN/YEL

L1

+24 V

I/OCOM

MCOM

SYSTEMPOWER

BUS BAR

WHT/ORN
GRAY
GRAY
GRAY
GRAY

NO. 14 AWG

CUSTOMER +24 V OUTPUT

NO.10 AWG

ISOLATED SYSTEM COMMON BUS

L2

INPUT POWER

BUS BAR

TP50310B

Figure C-3. IEPEP01/IEPEP02 Power Entry Panel and Module Mounting Unit Wiring Diagram

INTRODUCTION
C - 4 I-E96-506B1

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RED
WHT

+5 V

MCOM

+15 V

-15 V

STATUS

I/O COM

+24 V

+5 V
MCOM
+15 V

-15 V

CABLE P/N
6638084_1
(SUPPLIEDWITHPEP)

(TWISTEDPAIR)

NO. 10 AWG

PFI

6632285A45

PFI

+15 V

-15 V
STATUS

MCOM
+5 V

I/O COM

+24 V

GND

FAN
OUT

J4

CABLE P/N
6637814_2
(SUPPLIED WITH PEP)

DC IN/COM

24V/48VIN

120 VAC
240 VAC

120 VAC
240 VAC

TB3

N(L2)
L(L1)

WIRING DIAGRAMS

L(L1)

AUX. POWER INPUT

N(L2)

120/240VAC
50/60 HZ

123TB1

LN
L1 L2

POWER ENTRY PANEL
IEPEP01__ ROW 0

AC OUT

LN
L1 L2

123

NO. 10 AWG
GRN/YEL

SAFETY GND.
CONN. TO CAB.

FAN ASSEMBLY
IEFAN01/02 ROW 1

GRN/YEL

BLU
BRN

POWER MOUNTING UNIT
IEPMU01/02 ROW 2

L (L1)
N(L2)

MODULE MOUNTING UNIT
IEMMU01/02 ROW 3

MCOM

STATUS
I/O COM

YEL

PFI
STATUS
I/O COM
+24 V

I/O COM

MCOM

SYSTEM POWER

BUS BAR

+5 V

+15 V

-15 V
PFI

+24 V

+24 V

CABLE P/N
1948509-5

WHT/ORN
GRAY
GRAY
GRAY
GRAY

CABLE P/N
1948509-5

+5 V

MCOM
+15 V

-15 V
PFI
STATUS
I/O COM
+24 V

ORN

MBUS

YEL

MBUS

WHT

MCOM

NO. 14 AWG

TO NEXT MMU

CUSTOMER +24V OUTPUT

NO. 10 AWG

ISOLATED SYSTEM COMMONBUS

TP25396B

Figure C-4. IEPEP01/IEPEP02 Power Entry Panel and Power Mounting Unit Wiring Diagram

INTRODUCTION

I-E96-506B1 C - 5

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APPENDIX D - RETROFITTING THE MODULAR POWER SYSTEM

INTRODUCTION

Verify the main power and power entry panel circuit breakers
are turned off before starti ng installation, retrofit, upgrade, or

WARNING

AVERTISSEMENT

wiring procedures. Failure to do so could result in severe or
fatal shock. Do not turn the power on until the installation, ret­rofit, upgrade, or wiring procedures are complete.

Assurez-vous que le disjoncteur d'alimentation principal et le
disjoncteur de panneau d'entrée des alimentations sont éteints
avant de procéder, à la mise à jour, à l'extension ou au câblage,
dans le but d'éviter les chocs sérieux et même mortels. Ne
rétablissez pas l'alimentation tant que ces procédures ne sont
pas terminées.

Network 90 systems can be retrofitted with the INFI 90
AC Modular Power System. This appendix addresses only one
of several possible power system and cabinet combinations. It
describes the retrofitting procedures for one specific configura­tion that requires +5, ±15 and +24 VDC for system and I/O
power. If these procedures do not match your particular config­uration, please call your Bailey Controls Company sales
engineer.

Regardless of your present configuration, you must have the
following hardware in addition to the IEPMU01 or IEPMU02
power mounting unit to retrofit your system:

1. IEPEP01, IEPEP02 or IEPEP03 power entry panel.

2. IEFAN01 or IEFAN02 fan assembly.

3. IEFAS01 fastener kit (mounting hardware).

4. Rectangular spacer (if required). Consult with your Bailey
representative to custom make the spacer.

NOTES:

1. Bailey suggests that 2 people do the removal and retrofitting
tasks.

2. When removing Network 90 power supply hardware, save all
screws. You can use these screws to install the INFI 90 modular
power system hardware. If you require more hardware, get it from
the IEFAS01 mounting hardware kit.

3. Label all wires and cables while disconnecting them from the
system.

4. The complete procedure from removing the old system to pow­ering up the new system should take approximately 3 hours.

INTRODUCTION

I-E96-506B1 D - 1

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RETROFITTING THE MODULAR POWER SYSTEM

NETWORK 90 POWER SYSTEM REMOVAL

Required Tools

The following tools are needed for the retrofitting procedure:

•

16-inch blade screwdriver.

•

1/2-inch nut driver.

•

Pliers.

•

Volt/ohmmeter.

•

Heat gun.

Power Entry Panel Removal

1. Turn the main power feed to the cabinet and circuit break­ers off.

2. Use a voltmeter to test TB5. Verify that no power is present.

3. Disconnect the wiring from TB5 (AC IN).

®

4. Disconnect the AC wiring from TB2, TB3 and TB4.

5. Disconnect the chassis ground wire from the power entry
panel, but leave it attached to the cabinet and label it. It will be
used with the new power entry panel (PEP).

6. Disconnect the 2 monitor connectors from J1 and J2.

7. Disconnect status and cascade connections from TB1 and
label them.

NOTE:

them with colored ta pe o r la bel s. T his w il l he lp in c on nec ting them to
the new PEP panel.

When removing status and cascade connections, identify

8. Remove the 4 screws securing the PEP panel to the mount­ing rails.

9. Remove the 2 screws that attach the front of the PEP panel
to the support bracket.

10. Remove the plastic nipples (if present) on both sides of the
PEP mounting brackets.

11. Push the power entry panel from the front while another
person pulls from behind.

NETWORK 90 POWER SYSTEM REMOVAL
D - 2 I-E96-506B1

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I/O Power Panel Removal

RETROFITTING THE MODULAR POWER SYSTEM

NOTE:

the individual power supplies from the panel first.

If you are removing the I/O power panel by yourself, remove

1. Disconnect E1 and E2 wires. Remove E2 connection.

2. Disconnect I/O monitor connector from J1.

3. Disconnect 24 VDC and common wiring from TB1, TB2 and
TB3. Remove wiring from TB1. Mark wires removed from TB2
and TB3.

4. Disconnect and remove AC wiring from TB5.

5. Disconnect cascade and alarm wiring from TB4. Remove
wiring from TB4-2, TB4-3 and TB4-4.

6. Disconnect and remove all wiring from NPSI03 and NPSI04
power supplies.

7. Remove the 4 screws securing the I/O power panel to the
mounting rails.

8. Pull the I/O power panel out.

Module Power Panel Removal

1. Disconnect and remove heavy strap cables from 5 V and
COMM (E1 through E4) for both power supplies.

2. Disconnect DC wiring from TB1, TB2, TB3, TB4 and TB5.
Remove wiring from TB2. Label wires disconnected from TB4
and TB5.

3. Disconnect and remove sense (J1, J2) and module monitor
out (J3) connectors.

4. Disconnect connections from J4 and J5 and label the
cables.

5. Disconnect connections E5 and E6. Disconnect and
remove power wiring from supplies.

6. Remove the 4 screws securing each module power supply.
Remove power supply.

7. Remove the 4 screws securing the module power panel to
the mounting rails.

8. Pull the module power panel out.

NETWORK 90 POWER SYSTEM REMOVAL

I-E96-506B1 D - 3

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RETROFITTING THE MODULAR POWER SYSTEM

Fan Assembly Removal

1. Disconnect and remove AC wiring from TB1.

2. Disconnect and remove fan status wiring from TB2.

3. Remove the 4 screws securing the fan assembly to the
mounting rails.

4. Pull the fan assembly out.

®

NOTE:

mon cable from the Network 90 installation. Remove the other wiring
by cutting the tie wraps that secure it to the sides of the cabinet.

Installing the INFI 90 Power System

Install the INFI 90 power system hardware from the bottom up
as explained in Steps 1 through 11.

NOTE:

nuts will go. Use a pair of pliers to crimp them onto the mounting
rails. All hardware requires 4 screws (2 screws in front, 2 screws in
back).

1. Install the row 4 spacer (if required) directly above the first
MMU in your cabinet.

2. Install the power mounting unit (PMU) above the spacer
installed in Step 1.

3. If a terminal block is present at the top of the cabinet, do
the appropriate wiring.

4. Shape the heavy 0 AWG (MCOM and +5 V) strap cables
(part number 6632285_45) in a [ fashion.

You will be able to use the +24 VDC wiring and the I/O com-

Before mounting the hardware, determine where the speed

5. Attach one end of each cable to its respective cabinet bus
bar first so as not to stress the PMU bus (see Figures D-1 and

D-2).

6. Attach the other ends to the MCOM and +5 VDC bus bars
of the power mounting unit.

7. Slide heat shrink tubing over PMU connection (see
Figure 3-8).

8. Insure that connections are properly covered, then use a
heat gun to shrink the tubing into place.

9. Install the fan assembly directly above the PMU.

NETWORK 90 POWER SYSTEM REMOVAL
D - 4 I-E96-506B1

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10. Install the power entry panel directly above the fan
assembly.

11. Install row 0 spacer.

Wiring the INFI 90 Power System

RETROFITTING THE MODULAR POWER SYSTEM

NOTE:

bus monitor module switch and jumper settings are correct. Refer to

Section 3 for switch and jumper setting information; see Figures D-1

and D-2 for wiring diagrams of the INFI 90 modular power system in
a Network 90 cabinet.

Before wiring the system, verify the AC transfer module and

1. Attach one end of the 6 AWG wire assembly to PMU I/O
COM. Attach the other end to the isolated system common
bus.

2. Connect the +24 VDC, originally from TB2 and TB3 of the
I/O power panel, to the +24 VDC bus bar on the PMU back­plane by stacking all wires onto a 6 AWG lug (or connect each
wire [6 total] separately).

3. Slide heat shrink tubing over the PMU connection (see
Figure 3-9).

4. Wire the auxiliary status input to TB3 (IEPEP03 panel
only). Refer to the IEPEP03 installation procedure in Section 3
for more details.

5. Attach the AC cable (part number 6637814_2) from TB2 on
the IEPEP03 panel or TB3 on the IEPEP01 and IEPEP02 panels
to the AC terminal block on the PMU backplane.

6. Attach the J2 molex connector (part number 6637813_1) to
the J2 socket on the IEPEP03 panel. Attach part number
6638084_1 to PFI on the IEPEP01 or IEPEP02 panel.

7. Attach the other ends of the J2 connector (or PFI) as shown
in the wiring diagrams (see Figures D-1 and D-2).

8. Connect the status signal wires removed in Step 7 of Power

Entry Panel Removal in this section to TB3-4. Wire COM on

TB3-2 to the isolated system common bus bar (IEPEP03 panel
only).

9. Attach any auxiliary bus monitor (24, 48, 125 VDC) input
wires to TB4 (IEPEP03 panel only).

10. Attach fan cable to J4 on IEPEP01 and IEPEP02 panels, or
J1 on IEPEP03 panel.

11. Connect the cabinet ground wire to the ground stud on the
PEP panel.

NETWORK 90 POWER SYSTEM REMOVAL

I-E96-506B1 D - 5

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RETROFITTING THE MODULAR POWER SYSTEM

12. Connect the source wiring to TB1.

13. Use an ohmmeter to verify continuity between TB2 (or TB3)
on the power entry panel and the AC terminal connections on
the PMU backplane.

14. Verify the circuit breakers on the PEP panel are in the off
position.

15. Unplug all process and I/O modules from the MMU back­plane.

®

NOTE:

ber 6638748_1) on the backplane by snapping in the top then the
bottom. Install a blank faceplate (part number 6636586_1) in any
unused PMU slots.

If your MMU has any unused slots, place the cap (part num-

16. Determine the number of IEPAS02 and IEPAF02 modules
the cabinet will require by following the sizing procedures in

Appendix E.

17. Verify that switch and jumper settings on the power supply
modules are correct. Refer to Section 3 for settings.

18. Refer to RECOMMENDED START-UP PROCEDURES in
Section 4 and follow the procedure for applying power to the
system.

NETWORK 90 POWER SYSTEM REMOVAL
D - 6 I-E96-506B1

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RETROFITTING THE MODULAR POWER SYSTEM

CUSTOMER AUX BUS

MONITOR INPUTS

24/48/125 VDC

STATUS
INPUTS

NODE STATUSTO BIM/PTM

USER ALARM OUTPUT

POWER SYSTEM STATUS

USER ALARM OUTPUT

BUS VOLTAGESTATUS

RED

+5 V

WHT

GND

CABLE P/N
6637813C1

CH1

CH2

6632285A45
(BRAIDEDWIRE)

(+)
(-)
(+)
(-)

COM

(+)

(+)

MAIN POWER INPUT

120/240 VAC 50/60 Hz

AUX BUS
MONITOR

J2

TB3

1

2

(-)

(-)

CABLE P/N
6634205-1

+15 V

-15 V
STATUS

CH1 CH2

+- + -

TB4

1234

ALARMS

STATUS

PWR

IN

1COM2

12345678

MCOM
+5 V

I/O COM

+24 V

BUS

SYS

VOLT

+-+-

GND

N(L2)
L(L1)

123456

TB1

LL1L

120 VAC
240 VAC

FAN

OUT

123456

TB2

J1

N (L2)
L (L1)

24V/48V IN

L1

L
L1

N

L2

AC OUT

N
L2

N
L2

120 VAC
240 VAC

NO. 10 AWG GRN/YEL

DC IN/COM

L(L1)

AUX. POWER INPUT

N(L2)

120/240 VAC 50/60 Hz

(SEE VIEW A)

POWER ENTRY PANEL
IEPEP03 ROW 0

SAFETY GND.
CONN. TO CAB.

CABLE P/N
6637814-2

FANASSEMBLY
IEFAN01/02 ROW 1

GRN/YEL

BLU
BRN

POWER MOUNTING UNIT
IEPMU01/02 ROW 2

CUSTOMER 24 VDC OUTPUT
NO. 12 AWG

+5 V

GND

GND

NETWORK 90

SYSTEMPOWER

BUS BAR

YEL

WHT/BLU
WHT/GRN

+5 V
GND
+15 V

-15 V
PFI
MOD BUS

MOD BUS COM

TO NEXT NMMU
NO. 14 AWG

ISOLATED SYSTEM COMMON BUS

MODULE MOUNTING UNIT
NMMU01, NMMU02 ROW 3

I/O COM

MAIN POWER
INPUT
120/240 VAC
50/60 Hz

N (L2)
L (L1)

123456

TB1

LN

120 VAC
240 VAC

L1 L2LNL1 L2

FOR SYSTEMS WITH SI NGLE LINEPOWER ENTRY

VIEW A

NO. 6 AWG

TP25397B

Figure D-1. Wiring Diagram of IEPEP03 Power Entry Panel and Power Mounting Unit,

Network 90 Cabinet

NETWORK 90 POWER SYSTEM REMOVAL

I-E96-506B1 D - 7

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RETROFITTING THE MODULAR POWER SYSTEM

+5 V
GND

CABLE P/N
6638084_1

RED
WHT

6632285A45
(BRAIDED WIRE)

BLK

ORN

YEL

PFI

+15 V

-15 V
STATUS

MCOM
+5 V

I/O COM

+24 V

GND

FAN
OUT

J4

TB1

120 VAC
240 VAC

120 VAC
240 VAC

CABLE P/N
6637814_2
(SUPPLIED WITH PEP)

N(L2)
L (L1)

DC IN/COM
24V/48V IN

123

LN

L1

L2

AC OUT

LN

L2

L1

123TB3

L(L1)

AUX. POWER INPUT

N(L2)

120/240 VAC
50/60 HZ

POWER ENT RY PANEL
IEPEP01__ ROW 0

NO. 10 AWG
GRN/YEL

SAFETY GND.
CONN. TO CAB.

FAN ASSEMBLY
IEFAN01/02 ROW 1

GRN/YEL

BLU

BRN

POWER MOUNTING UNIT
PMU ROW 2

CUSTOMER 24 V OUTPUT
NO. 14 A WG

®

+5 V
GND

GND

NETWORK 90

SYSTEM POWER

BUS BAR

YEL

WHT/BLU
WHT/GRN

+5 V
GND
+15 V

-15 V
PFI
MOD BUS

MOD BUS COM

TO NE XT NMMU
NO. 14 A WG

ISOLATED SYSTEM COMMON BUS

L (L1)
N (L2)

MODULEMOUNTING UNIT
NMMU01, NMMU02 ROW 3

TP25398B

Figure D-2. Wiring Diagram of IEPEP01 and IEPEP02 Power Entry Panel and Power

Mounting Unit, Network 90 Cabinet

NETWORK 90 POWER SYSTEM REMOVAL
D - 8 I-E96-506B1

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APPENDIX E - IEPAS01/IEPAF01 POWER MODULE

INTRODUCTION

The IEPAS02 and IEPAF02 power modules are compatible
replacements for the IEPAS01 and IEPAF01 power modules
respectively. The IEPAS02 and IEPAF02 modules have design
enhancements and features that are not available in the previ­ous power modules. The information in this appendix pertains
to replacing IEPAS01 and IEPAF01 power modules with
IEPAS02 and IEPAF02 power modules.

REPLACING POWER MODULES

The IEPAS02 module can directly replace the IEPAS01 power
module in all applications. Because the IEPAS02 can supply
more power, there is no power deficiency when replacing an
IEPAS01 module with an IEPAS02 module.

The IEPAF02 module can directly replace the IEPAF01 module
in all applications. The power output of these modules is equal.

REPLACEMENT

POWER SYSTEM SIZING

LOAD SHARING

The IEPAS02 power module can deliver more power than the
IEPAS01 module. Refer to Table E-1 to compare total power and
current outputs of each module. Because of the difference in
load capability, systems using both IEPAS01 and IEPAS02 mod­ules must use the power system sizing procedures for IEPAS01
modules (i.e., based on 102 watts output per power module).

Table E-1. IEPAS01/IEPAS02 Modules Power

and Current Outputs

Module

IEPAS01 102 10 0.5 4.0
IEPAS02 130 13 0.8 4.0

NOTE: The power output capabilities of the IEPAF01 power module and the IEPAF02 power mod­ules are equal.

Maximum

Power (W)

Maximum Current Outputs (A)

5 VDC

±

15 VDC 24 VDC

All power modules share the same load buses. The load sharing
scheme relies on power module voltage outputs being equal.
Equal load sharing on a particular bus depends upon the power
module voltage outputs being equal. A power module with a
higher voltage output will tend to supply more of the load on a
particular bus than its lower voltage output counterparts.

INTRODUCTION

I-E96-506B1 E - 1

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IEPAS01/IEPAF01 POWER MODULE REPLACEMENT

The IEPAS01 module output voltages are factory adjusted at
full load conditions. These output voltages can show minor
changes because of loading, temperature, component aging,
and environment. The IEPAS02 power module does not require
factory calibration, and will automatically adjust its outputs to
compensate for changes that affect the output voltages. The
IEPAS01 module outputs tend to output a higher voltage than
the IEPAS02 modules in systems with a light load. Therefore,
the remaining IEPAS01 modules will share more of the load as
IEPAS02 modules replace them. The IEPAF01 power module
and IEPAF02 power module exhibit these same characteristics.

SYSTEM EFFECTS ON MOD ULE LEDS

Replacing an IEPAS01 or IEPAF01 power module with an
IEPAS02 or IEPAF02 power module should have no effect on
system operation. Nevertheless, in some cases replacing an
IEPAS01 or IEPAF01 power module with an IEPAS02 or
IEPAF02 power module may cause a remaining IEPAS01 or
IEPAF01 power module status LED to turn red or blinking
green. A red LED may indicate that an output voltage is too low
or an output voltage is too high resulting in an overload condi­tion (earlier versions of the IEPAS01 or IEPAF01 power mod­ule). A blinking green LED on an IEPAS01 or IEPAF01 power
module indicates an overload condition because the output is
too high. If one of these effects occurs from replacing an
IEPAS01 or IEPAF01 power module with an IEPAS02 or
IEPAF02 power module, there are two courses of action.

®

1. Replace the IEPAS01 or IEPAF01 power module with a new
IEPAS01 or IEPAF01 power module. Return the overloading
IEPAS01 or IEPAF01 power module to the factory for testing
and calibration.

2. Replace the IEPAS01 or IEPAF01 power module with an
IEPAS02 or IEPAF02 power module.

NOTE:

net power occurs when replacing an IEPAS01 or IEPAF01 power
module with an IEPAS02 or IEPAF02 power module. Always install
a replacem ent p ower module a nd ve rify that i t is oper ating p rope rly
before removing a power module.

System int egratio n test ing show s that n o disrup tion of cabi-

Refer to Appendix A for IEPAS02 and IEPAF02 power module
jumper settings. Refer to Section 7 for power module replace­ment procedures. Enhancements to the IEPAS02 and IEPAF02
power modules give the module LEDs additional functionality.
Refer to Table 4-2 for a description of IEPAS02 and IEPAF02
power module LED states.

SYSTEM EFFECTS ON MODULE LEDS
E - 2 I-E96-506B1

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Index

A

AC transfer module ....................................................2-3

Installation............................................................. 3-5

LEDs..................................................................... 4-1

Removal................................................................ 4-3

Replacement.........................................................7-2

Switch S1.............................................................. 3-5

Alarm outputs............................................................. 2-7

B

Bus monitor module ...................................................2-3

Installation............................................................. 3-7

Jumper settings.................................................... 3-8

LEDs..................................................................... 4-1

Removal................................................................ 4-3

Replacement.........................................................7-3

Switch settings...................................................... 3-7

Bus voltage status......................................................2-6

C

Checking connections................................................ 6-4

Cleaning

Cabinet filter.......................................................... 6-3

Edge connectors....................................... ...... ..... .6-7

Printed circuit boards............................................6-6

Customer alarm outputs.............................................2-7

D

IEPEP03 power entry panel

Description............................................................2-2

Troubleshooting ....................................................5-5

Wiring............................................................3-2, C-1

IEPMU01/02 power mounting unit

Description............................................................2-4

Installation...........................................................3-14

Wiring...................................................................C-1

Installation...................................................................3-1

AC transfer module...............................................3-5

Bus monitor module..............................................3-7

Fan assembly........................................................3-9

Power module.......................................................3-9

Power mounting unit ...........................................3-14

J

Jumper setting reference ........................................... A-1

M

Maintenance ...............................................................6-1

Module current requirements..................................... B-1

Module mounting unit

Description............................................................2-4

Wiring...................................................................C-1

O

Operating procedures...................................... ...... .....4-1

Ordering replacement parts........................................8-1

Documentation........................................................... 8-1

F

Fan assembly.............................................................2-4

Fuse...................................................................... 7-3

Installation............................................................. 3-9

Replacement.........................................................7-4

I

IEMMU01/02 module mounting unit

Description............................................................ 2-4

Wiring....................................................................C-1

IEPEP01/02 power entry panel

Description............................................................ 2-2

Troubleshooting....................................................5-1

Wiring...........................................................3-12, C-1

Part numbers ..............................................................7-1

Power

Distribution............................................................2-2

Requirements.......................................................B-1

Power entry panel

Description............................................................2-2

Maximum current ............................................... B-10

Troubleshooting ....................................................5-1

Wiring...........................................................3-2, 3-12

Wiring diagram.....................................................C-1

Power module

Description............................................................2-4

Fuse replacement.................................................7-5

Installation.............................................................3-9

Jumpers ..............................................................3-10

P

I-E96-506B1 Index - 1

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®

Index

Power mounting unit

Power system

Preventive maintenance.............................................. 6-2

(continued)

LEDs......................................................................4-1

Mounting................................................................3-9

Operation...............................................................2-1

Output verification.................................................6-5

Replacement.................................................7-4, E-1

Sizing procedures.............. ...... ..... ........................ B-1

Start-up..................................................................4-3

Status........................................... .........................2-6

Status LEDs..........................................................4-2

Troubleshooting.....................................................5-1

Description............................................................2-4

Installation...........................................................3-14

Wiring..........................................................3-14, C-1

Retrofitting procedures.........................................D-1

Sizing.................................................................... B-5

Status....................................................................2-5

Troubleshooting.....................................................5-1

Procedures............................................................6-3

Required tools.................................... ..... ...... ...... ..6-3

Schedule............................................................. ..6-2

Q

Quick reference guide................................................A-1

R

Repair/replacement procedures .................................7-1

Replacement modules................................................E-1

Retrofitting Network 90 systems.................................D-1

S

Special handling.........................................................3-1

Status LEDs................................................................4-1

Status signals.............................................................2-5

Switch setting reference.............................................A-1

T

Training.......................................................................8-1

Troubleshooting.......................................................... 5-1

Flowcharts ............................................................5-1

Power entry panels...............................................5-1

U

Unpacking and inspection..........................................3-1

W

Wiring

Diagrams ............................. ..... ...... ..... .................C-1

IEPEP01/02 panel ..............................................3-12

Power mounting unit...........................................3-14

Index - 2 I-E96-506B1

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ile

y

ion

For prompt, personal attention to your instrumentation and control needs or a full listing of

Bailey representatives in principal cities around the world, contact the Bailey location nearest you.

Australia

Elsag Bailey Pty. Limited
Regents Park, NSW
Phone: [phone]
Telefax: 61-2-645-2212

Brazil

Bailey do Brasil
São Paulo
Phone: [phone]
Telefax: 55-11-547-0315

Canada

Elsag Bailey (Canada), Inc.
Burlington, Ontario
Phone: [phone]
Telefax: 1-905-639-8639

France

Elsag Bailey S.A.
Massy
Phone: [phone]
Telefax: 33-1-64-47-2016

Japan

Bailey Japan Company, Ltd.
Tagata-Gun, Shizuoka-Ken
Phone: [phone]
Telefax: 81-559-49-1114

Jordan

Bailey Controls Jordan
Amman
Phone: [phone]
Telefax: 962-6-756-908

Mexico

Bailey Mexico S.A. de C.V.
Naucalpan
Phone: [phone]
Telefax: 52-5-557-7022

Norway

Bailey Norge A.S.
Bergen
Phone: [phone]
Telefax: 47-55-222-010

United Kingdom

Bailey Automation plc
Telford, Shropshire
Phone: [phone]
Telefax: 44-1952-670-455

United States

Bailey Controls Company
Wickliffe, Ohio
Phone: [phone]
Telefax: 1-216-585-8756

Venezuela

Bailey de Venezuela SA
Valencia
Phone: [phone]
Telefax: 58-41-327-632

Germany

Bailey-F & P Automation GmbH
Overath
Phone: [phone]
Telefax: 49-220-473-979

Italy

Elsag Bailey
Genoa
Phone: [phone]
Telefax: 39-10-658-2941

Form I-E96-506B1 Litho in U.S.A. 194
Copyright © 1994 by Elsag Bailey Process Automation, As An Unpublished Work
® Registered Trademark of Elsag Bailey Process Automation
™ Trademark of Elsag Bailey Process Automation

People’s Republic of China

Bailey Beijing Controls
Beijing
Phone: [phone]
Telefax: 86-10-401-1643

Singapore

Elsag Bailey Pte. Ltd.
Singapore
Phone: [phone]
Telefax: 65-442-2700

Elsag B a

Process Automat

29801 Euclid Avenue • Wickliffe, Ohio 44092 • (216) 585-850 0

Telex: 980621

•

Telefax: [phone] or [phone]

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