Preventive Maintenance Tips: xPM Power Systems
Contents
1. Additional Power System Information Additional details on proper maintenance procedures such as load testing and specifics on the power supplies and batteries may be found in the Honeywell Customer Resource Manual This is located in the Process Manager section of the CRM under TAB 22 As always you may also contact your local Honeywell account manager or service technician for further details Honeywell 2012 Honeywell International Inc2. The batteries in the standard power system are periodically tested by the charging circuit If the voltage falls below the allowed limit a battery failure alarm will be generated and the batteries should be replaced Regardless of alarms Honeywell recommends that new batteries be installed every two years All three batteries should be replaced at one time Description Replacement Part 51190422 100 Size AA Ni Cad CMOS Battery Size C Ni Cad CMOS Battery 51192060 100 Preventive Maintenance Tips Preventive Maintenance Tips Power Systems 2 48 Volt Battery Backup The battery backup is designed to maintain a fully loaded xPM for a minimum of 20 minutes It will shutdown when the voltage reaches 38 volts to prevent the power supply from going out of regulation and an alarm will be generated Rechargeable batteries will lose their full charging capabilities over time and will need to be tested and replaced when they fall below 60 percent of their original capacity The battery backup has been designed to operate in standby float service for approximately five years The five years is based on the battery being kept at 20C 68F and the float charge voltage being maintained between 2 25 and 2 30 volts per cell This includes the battery being fully discharged once every three months No battery should be left in service over five years and if no maintenance is done it should be replaced every three years
3. The service life is directly affected by the number of discharges the depth of discharge ambient temperature and the charging voltage The expected service life can be shorted by 20 for each 10C that the ambient is above 20C The batteries should never be left in a discharged state This allows sulfating to occur which will increase the internal resistance of the battery and lower its capacity The self discharge rate is about 3 per month at an ambient of 20C The self discharge rate doubles for each 10C in ambient above 20C The discharged voltage of the battery should never go below 1 30 volts to maintain the best battery life With this in mind it is recommended to periodically load test the batteries to ensure they have sufficient capacity to maintain the system during a power outage Tests should be done on an annual basis and more frequently as they become older and begin to lose capacity The load test is recommended off process if possible as there will be no battery backup available while performing the test and recharging of the battery pack can take up to 16 hours Having a spare available to swap especially if doing on process is a wise option leading to minimal time without battery backup and allowing the tested battery to be recharged on a bench outside the system for future swap with the next test If regular maintenance is not performed the recommendation is to change at least every three years rather than every five P
4. power source However as with any electrical component they do not last forever and there is the potential for failure modes Issues such as foreign particles introduced have already been discussed In addition even clean environments are susceptible to whiskers which have the potential to short out active circuits Whiskers are a real issue and further details may be found in the Customer Resource Manual CRM in the Process Manager section PD22_G97 G The new power supply available through the power system maintenance kit includes design improvements specifically done to address some of these possible failure modes to make a robust power supply even better Remember that the power supply is a critical component to your system and regular maintenance as well as having spares available is highly recommended to keep your site running without problems Monitor the power system alarms and take action when they do occur Replacement Part 51198651 100 Description Power Supply Preventive Maintenance Tips Power Systems 4 Importance of Power System Alarms Always ensure that all power supply alarm contacts are properly implemented working and are being monitored Failure to monitor these alarms and take appropriate action in a timely manner can lead to failures of the power system that could have otherwise been prevented There are DC Out Battery Fan Temp AC In and Charging LED indicators for each Power Supply module
5. for changing out each component are every 10 years for the power supply every five years for the battery backup and possibly every three and every two years for the CMOS batteries Honeywell now offers an upgrade kit MC ZPSUGz2 which provides all of these components packaged together The power supply provided is the current version with improved characteristics Any failures of these power system components should be changed immediately Description CMOS Memory Battery Backup The xPM power systems are designed to provide battery backup to all the CMOS memory The CMOS battery backup prevents the loss of the data base during a power outage after the battery backup Size AA Ni Cad CMOS Battery Size C Ni Cad CMOS Battery has been depleted or if no battery backup module is present There are two different power system chassis out in the field with CMOS batteries The older style power system introduced with PM APM requires three specific AA size Ni Cad batteries For the current back panel introduced for HPM the CMOS memory requires three specific C size Ni Cad batteries The size C batteries are required if the full 50 hours of CMOS memory backup is desired for HPM due to the larger memory available in HPM In either scenario the incorrect usage of other batteries than what have been tested and qualified by Honeywell may result in the battery overheating and could possibly cause the battery to rupture
6. If the Power system is fully functional all five of the indicators are illuminated In addition each of these conditions plus a CMOS Memory is available as a digital input for each supply DC Out Indicator If a DC Out LED is off AC line power has been lost check the AC In LED or the Power Supply Module has failed If the Power System is non redundant or if both DC Out LEDs are off the HPM has lost 24 VDC The CMOS backup system maintains power to the CMOS memory so subsystem programs are not lost See the Battery LED description below The annunciator contact illustrated in the following figure will open when these conditions occur Battery Indicator If the Battery LED is off and the Charging LED is on the 48 Volt Battery switch is in the off position or the 48 V Battery Backup system has failed The annunciator contact illustrated in the following Figure will open when these conditions occur If the Power System does not have the battery pack option the Battery LED will normally be on and the Charging LED will normally be on Coo ok OC OUTPUT BATTERY FAN TEMP AC IN CHARGING ON SILVER CASE POWER SUPPLY OFF COMMON Fan Temp Indicator If the Fan Temp LED is off the fan in the Power Supply Module has failed or the temperature of the supply has exceeded a safe value The annunciator contact discussed below is activated AC In Indicator If the AC In LED is off AC power to the HPM has been lost or
7. Lifecycle Solutions amp Services Honeywell Preventive Maintenance Tips TW Power Systems for PM APM HPM Remote I O and PMIO Preventive Maintenance Tips Power Systems 1 It Doesn t Run Without Power Proper Maintenance of Power Systems Maintaining the power system is critical for any of your systems and that is definitely true when dealing with the PM APM HPM xPM family Depending on your configuration and process the failure of proper maintenance practices and ignoring alarms from the power system could lead to failures that have the potential to bring a process or plant to a standstill This includes loss of view loss of control or even loss of the process How Proper Power System Maintenance Can Help You e Reassurance that your power system and battery back ups are running properly e Reduced risk of downtime due to power system issues e Allows you to be proactive in your maintenance approach e Simplified ordering for maintenance items available in a kit versus individual components e Lower cost of replacement to mitigate costly unplanned system downtime e Current version of Power Supply has multiple improved characteristics Proper maintenance of the power system includes addressing the power supplies battery backup and the CMOS memory backup batteries The expected lifespan of each of these components is different and the lifespan of each is also affected by the environment in which they are used Benchmarks
8. ower Supplies The power supply is the heart of the xPM power system and the recommendation is for a redundant power supply configuration having each power supply fed by its own dedicated power source Honeywell has introduced the next generation power supply for this family which increases the robustness of the power system Even with redundant power supplies one must be careful when changing out a failed power supply This is to minimize disturbance of the environment and to reduce the introduction of particles into the area around and near the power supplies Those particles can be pulled through the airflow of the working power supply and result in the second power supply failing For this reason Honeywell does not recommend replacing a working power supply on process other than the black colored version However power supplies do not last forever and you should consider upgrading older power supplies or prepare to do so when the opportunities arise The recommendation for changing out the power supplies is every ten years and this replacement should be included during a scheduled down time if possible The power supply replacement procedure listed in the Honeywell xPM Service manual should be followed at all times Recommend Change of Original Black Power Supplies In October of 1996 Honeywell issued a customer priority notification PN 1986 about a possible over voltage issue with the black colored 51109456 200 power supplies
9. that were sold from 1988 through 1994 The Honeywell recommendation was to change out those black power supplies with the new silver version Honeywell still recommends and strongly suggest that these black power supplies be replaced with the current power supply under part number 51198651 100 regardless of when they were put into service Silver Power Supplies There have been three part number versions of the silver power supplies The first 51109684 100 300 was sold from 1993 through 1997 The second 51198947 100 sold from 1997 through today The next generation power supply was released in early 2009 and was introduced initially through the power system maintenance upgrade kit If a site is running the original silver version they have now been in service for over 10 years and sites should consider the need to replace before they are forced to do so by failure of the power supply Note that there is always risk involved when powering down equipment and possible issues when the equipment is powered back up As stated previously it is recommended to change these out off process if possible Replacements on process should be done only when a power supply fails and replacement is then required immediately Description 51303948 100 Replacement Part 48V Battery Backup Preventive Maintenance Tips Preventive Maintenance Tips Power Systems 3 Power Supply Issues The xPM power supplies have proven to be a reliable and robust
10. the switch on the Power Supply Module is off Backup systems if operating are maintaining the unit Check the DC Out and Battery indicators to determine the state of the system Many installations may have the Power Supply Modules connected to separate AC power sources to minimize outage caused by a power loss The Annunciator contact signifying power loss from either supply are opened independently Charging Indicator When the Charging LED is off the charging circuit that maintains the optional 48 V Battery Backup system has failed Check the batteries their corresponding connections and the charging circuits in the Power Supply Module s The annunciator contact output is opened by this condition Preventive Maintenance Tips Alarms The primary Power Supply Module alarm and secondary Power Supply Module alarm contacts monitor five functions within each Power Supply Module The appropriate contact will open when any of the following occur e The DC output voltage is not within normal limits e AC input power to the supply has failed e The Power Supply Module electronics have overheated or the Power Supply Module fan has failed e The 48 V backup battery system has failed because the batteries have discharged or they have been disconnected e The battery charger in the Power Supply Module has failed Servicing the Power System The power system is critical to your process Loss of the power system may lead to loss of con
11. trol loss of view or loss of process Honeywell strongly recommends regular maintenance to the power system and service checks with regular component replacements performed by Honeywell trained service technicians e Options for Power System Upgrade Maintenance e Order the power system upgrade kit e Order replacement parts for immediate installation e Order spares to have in stock as needed e Add power system components to a parts contract For More Information Learn more about how Honeywell s Preventive Maintenance Tips can limit downtime and assure system power supplies and battery backups are working properly visit our website www honeywellprocess com or contact your Honeywell account manager Honeywell Process Solutions Honeywell 1250 West Sam Houston Parkway South Houston TX 77042 Honeywell House Arlington Business Park Bracknell Berkshire England RG12 1EB Shanghai City Centre 100 Junyi Road Shanghai China 20051 SV 12 37 ENG May 2012 www honeywellprocess com Preventive Maintenance Tips Power Systems 5 Orderable Power System Components e CMOS Batteries e 48V Battery Backup e Power Supply e Power System Chassis Assembly Benefits of New Power Supply e Improved airflow handling e Conformal coating of all metallic components e Enhanced mechanical design e Extended temperature range e Added thermal shutdown capability e More reliable power switch design e More consistent alarm handling
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