WBPEEUI210509A4 en Harmony Modular Power System III User Manual

ControlIT
Modular Power System III

Preface
The Modular Power System III (MPSIII) supplies 5 VDC,

±15 VDC, 24 VDC, 48 VDC, and 125 VDC power to Harmony
Rack components of the Symphony Enterprise Management
and Control System. The power system is designed to operate
with 2N redundancy. This power system can operate with 120
VAC, 240 VAC, or 125 VDC input power.
This instruction provides specific hardware installation, trou-

bleshooting, maintenance, and replacement information nec-
essary for the MPSIII system. The information in this
instruction applies to MPSIII systems installed in ABB
cabinets.
This instruction can be used as a guide by system engineers. It

is not a tutorial and assumes the reader has a general knowl-
edge of installing and maintaining process control systems.
Some sections of this instruction have been prepared in proce-

dure format. There is a sequence flowchart that follows the
introduction to the section and any nonprocedural informa-
tion. This flowchart directs personnel to the appropriate proce-
dure located in the back of this instruction. By treating each
task as a separate entity, the procedures provide an easy
method for finding the information needed to perform each
task. The procedures can be removed and placed in separate
folders or notebooks, or carried to the job site.
The procedures have check boxes in the margin by each step.

When performing a procedure, check each box as each step is
completed. Some procedures have numbered warnings and /
or cautions under Safety Considerations. A triangle with a
warning or caution reference number appears in the margin by
the part of the procedure to which the warning or caution
applies.
Do not perform any procedures related to installation, mainte-

nance, or repair until reading and understanding this
instruction.
WBPEEUI210509A4 August 2011

List of Effective Pages
Total number of pages in this instruction is 104, consisting of the following:
Page No. Change Date Page No. Change Date

Preface Original PR5-1 through PR5-4 Original
List of Effective Pages August 2011l PR6-1 through PR6-2 Original
iii through xiv Original PR7-1 through PR7-2 Original
1-1 through 1-10 Original PR8-1 through PR8-4 Original
2-1 through 2-10 August 2011 PR9-1 through PR9-8 Original
4-1 through 4-2 August 2011 PR11-1 through PR11-2 Original
PR1-1 through PR1-4 Original PR15-1 through PR15-2 Original
PR2-1 through PR2-4 Original PR16-1 through PR16-2 Original
PR3-1 through PR3-2 Original
PR4-1 through PR4-4 Original
August 2011 WBPEEUI210509A4

Table of Contents
Section 1 Introduction ..................................................................................................1-1

Overview .................................................................................................................. 1-1
Intended User .......................................................................................................... 1-1
Applications ............................................................................................................. 1-2
Features .................................................................................................................. 1-2
Instruction Content.................................................................................................. 1-2
How to use this Instruction ...................................................................................... 1-3
Document Conventions ............................................................................................ 1-3
Glossary of Terms and Abbreviations ....................................................................... 1-4
Reference Documents .............................................................................................. 1-4
Nomenclature .......................................................................................................... 1-4
Specifications........................................................................................................... 1-6
Section 2 Description and Operation .........................................................................2-1

Introduction............................................................................................................. 2-1
Description .............................................................................................................. 2-1
Power Chassis ...................................................................................................... 2-1
Power Supply Trays.............................................................................................. 2-5
............................................................................................................................ 2-6
Power Entry Panel (PEP) ....................................................................................... 2-6
Fan Assembly....................................................................................................... 2-7
DC Bus Monitoring Assembly ............................................................................... 2-7
Section 3 Installation ....................................................................................................3-1

Introduction............................................................................................................. 3-1
Special Handling ...................................................................................................... 3-1
Unpacking and Inspection........................................................................................ 3-2
Safety Considerations .............................................................................................. 3-3
Wiring Considerations.............................................................................................. 3-3
Grounding ............................................................................................................... 3-3
Installation Sequence............................................................................................... 3-4
Section 4 Troubleshooting ..........................................................................................4-1

Introduction............................................................................................................. 4-1
Troubleshooting Procedures ..................................................................................... 4-1
Testing Voltage Output......................................................................................... 4-2
Section 5 Maintenance .................................................................................................5-1

Introduction............................................................................................................. 5-1
Preventive Maintenance Schedule ............................................................................ 5-2
WBPEEUI210509A4 August 2011 iii

Table of Contents (continued)
Section 6 Replacement Procedures ...........................................................................6-1

Introduction .............................................................................................................6-1
Replacement Sequence .............................................................................................6-1
Section 7 Spare Parts ...................................................................................................7-1

Spare Parts ..............................................................................................................7-1
Purpose/Scope .................................................................................................... PR1-1
Procedure ............................................................................................................ PR1-1
Purpose/Scope .................................................................................................... PR2-1
Safety Considerations .......................................................................................... PR2-1
Procedure ............................................................................................................ PR2-1
Front Mounting Brackets ................................................................................. PR2-2
Rear Mounting Brackets .................................................................................. PR2-2
Single Power Chassis ................................................................................... PR2-2
Dual Power Chassis ..................................................................................... PR2-2
Purpose/Scope .................................................................................................... PR3-1
Procedure ............................................................................................................ PR3-1
Purpose/Scope .................................................................................................... PR4-1
Procedure ............................................................................................................ PR4-1
Purpose/Scope .................................................................................................... PR5-1
Safety Considerations ...................................................................................... PR5-2
Procedure ............................................................................................................ PR5-2
Initial Installation ............................................................................................ PR5-2
Field Installation.............................................................................................. PR5-3
....................................................................................................................... PR5-4
Purpose/Scope .................................................................................................... PR6-1
Procedure ............................................................................................................ PR6-1
Purpose/Scope .................................................................................................... PR7-1
Procedure ............................................................................................................ PR7-1
Purpose/Scope .................................................................................................... PR8-1
Procedure ............................................................................................................ PR8-1
Purpose/Scope .................................................................................................... PR9-1
Safety Considerations ....................................................................................... PR9-1
Procedure ............................................................................................................ PR9-1
Wiring and Cabling Diagrams .......................................................................... PR9-1
Wiring and Cabling Guidelines......................................................................... PR9-6
Purpose/Scope .................................................................................................. PR10-1
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List of Figures (continued)
No. Title Page
Safety Considerations .................................................................................... PR10-1
Procedure .......................................................................................................... PR10-1
Power Disconnected at Source........................................................................ PR10-2
Power Disconnected from Single Power Supply Tray ....................................... PR10-3
Purpose/Scope .................................................................................................. PR11-1
Safety Considerations ........................................................................................ PR11-1
Procedure .......................................................................................................... PR11-1
Purpose/Scope .................................................................................................. PR12-1
Procedure .......................................................................................................... PR12-1
Purpose/Scope .................................................................................................. PR13-1
Procedure .......................................................................................................... PR13-1
Purpose/Scope .................................................................................................. PR14-1
Procedure .......................................................................................................... PR14-1
Purpose/Scope .................................................................................................. PR15-1
Procedure .......................................................................................................... PR15-1
Purpose/Scope .................................................................................................. PR16-1
Procedure .......................................................................................................... PR16-1
List of Procedures
No. Title
PR1 Component Arrangement

PR2 Mounting Bracket Installation
PR3 Filler Panel Installation
PR4 Power Chassis Installation
PR5 Power Supply Tray Installation
PR6 PEP Installation
PR7 Fan Assembly Installation
PR8 DC Bus Monitoring Assembly Installation
PR9 Wiring and Cabling
PR10 Power Supply Tray Removal
PR11 DC Bus Monitoring Assembly Removal
PR12 Power Chassis Removal
PR13 PEP Removal
PR14 Fan Assembly Removal
WBPEEUI210509A4 August 2011 v

PR15 Cabinet Air Filter Cleaning
PR16 Checking Connections
List of Figures
No. Title Page
2-1. MPSIII System Architecture .......................................................................2-2

2-2. MPSIII System (Single Power Chassis)........................................................2-3
2-3. Power Chassis (Power Supply Trays Installed)............................................2-4
2-4. Power Supply Tray ....................................................................................2-5
2-5. Power Entry Panel .....................................................................................2-7
2-6. Fan Assembly ............................................................................................2-7
2-7. DC Bus Monitoring Assembly ....................................................................2-8
3-1. Installation Sequence ................................................................................3-5
6-1. Replacement Sequence ..............................................................................6-2
PR1-1. Component Arrangements and Dimensions .......................................... PR1-2
PR1-2. Rack Mount Rail Locations for Nonstandard Cabinets .......................... PR1-3
PR2-1. Mounting Bracket Installation .............................................................. PR2-3
PR3-1. Filler Panel Installation......................................................................... PR3-2
PR4-1. Power Chassis Installation.................................................................... PR4-3
PR5-1. Power Supply Tray Installation ............................................................. PR5-3
PR6-1. PEP Installation.................................................................................... PR6-2
PR7-1. Fan Assembly Installation .................................................................... PR7-2
PR8-1. DC Bus Monitoring Assembly Jumper Access ....................................... PR8-2
PR8-2. DC Bus Monitoring Assembly Jumper Settings ..................................... PR8-3
PR8-3. DC Bus Monitoring Assembly Installation ............................................. PR8-4
PR9-1. Single Chassis Wiring and Cabling Diagram - Front of Cabinet ............. PR9-2
PR9-2. Single Chassis Wiring and Cabling Diagram - Rear of Cabinet .............. PR9-3
PR9-3. Dual Chassis Wiring and Cabling Diagram - Front of Cabinet ............... PR9-4
PR9-4. Dual Chassis Wiring and Cabling Diagram - Rear of Cabinet ................ PR9-5
PR10-1. Power Supply Tray Removal................................................................ PR10-2
PR11-1. DC Bus Monitoring Assembly Removal ............................................... PR11-2
PR12-1. Power Chassis Removal ...................................................................... PR12-2
PR13-1. PEP Removal ...................................................................................... PR13-2
PR14-1. Fan Assembly Removal ....................................................................... PR14-2
vi August 2011 WBPEEUI210509A4

List of Tables
No. Title Page
1-1. Glossary of Terms and Abbreviations ........................................................ 1-4

1-2. Reference Documents ............................................................................... 1-4
1-3. Nomenclature ........................................................................................... 1-5
1-4. Specifications............................................................................................ 1-6
2-1. Power Entry Panel Kit ............................................................................... 2-6
4-1. Power Supply Tray LED ........................................................................... 4-1
4-2. Fan Assembly Status LEDs ...................................................................... 4-1
5-1. Preventive Maintenance Schedule ............................................................. 5-2
7-1. Spare Parts ............................................................................................... 7-1
PR16-1. Torque Values..................................................................................... PR16-2
WBPEEUI210509A4 August 2011 vii

viii August 2011 WBPEEUI210509A4

Safety Summary
Electrostatic Sensitive Device

Devices labeled with this symbol require special handling precau-
tions as described in the installation section.
GENERAL Equipment Environment

WARNINGS All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
SPECIFIC Disconnect power before attempting these procedures. Failure to do

WARNINGS so could result in severe or fatal shock, or equipment damage. (p.
PR2-1, PR3-1, PR4-1, PR5-2, PR6-1, PR7-1, PR8-1, PR9-1,
PR10-1, PR11-1, PR12-1, PR13-1, PR14-1, PR16-1)
SPECIFIC Do not use the same power level from two power chassis. Doing so
CAUTIONS will disrupt the active power sharing scheme and damage the power
system. (p. PR5-2, PR9-1)
Turn off the circuit breaker on the power entry panel (PEP) corre-
sponding to the line (LINE 1 or LINE 2) that powers the power sup-
ply tray to be removed or installed. Process upset may occur if a
power supply tray is removed or installed with power applied.
(PR5-2, PR10-1)
ix August 2011 WBPEEUI210509A4

Safety Summary (continued)
x August 2011 WBPEEUI210509A4

Support Services
ABB will provide assistance in the operation and repair of its

products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also pro-
vide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and

part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available though the nearest sales or service office.
ABB has modern training facilities available for training your

personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and schedul-
ing.
Additional copies of this instruction, or other instructions, can

be obtained from the nearest ABB sales office at a reasonable
charge.
WBPEEUI210509A4 August 2011 xi

Support Services
xii August 2011 WBPEEUI210509A4

Trademarks and Registrations
Registrations and trademarks used in this document include:

® INFI 90 Registered trademark of ABB.
® INFI-NET Registered trademark of ABB.
xiii August 2011 WBPEEUI210509A4

Trademarks and Registrations
xiv August 2011 WBPEEUI210509A4

Introduction Section 1
Overview
The Modular Power System III (MPSIII) supplies 5 VDC,
15 VDC, -15 VDC, 24 VDC, 48 VDC, and 125 VDC power to
Harmony Rack components of Symphony Enterprise Manage-
ment and Control Systems. A single power chassis system
consists of a power chassis, two power supply trays, a power
entry panel (PEP), a fan assembly, and a DC bus monitoring
assembly. A dual power chassis system consists of two power
chassis, four power supply trays, a PEP, a fan assembly, and a
DC bus monitoring assembly.
NOTE: The 24 VDC supply is nominally 25.5 VDC; however, throughout this
instruction it is referred to as the 24 VDC supply.
The MPSIII system is designed to operate with 2N power

redundancy. It directly accepts 120 VAC, 240 VAC, and
125 VDC inputs with no switches or jumpers to set.
Intended User
This instruction is intended for engineers, technicians, and
system designers as a source of technical information on the
MPSIII system. It should be used by those installing, operat-
ing, troubleshooting, maintaining, and replacing the system or
system components.
Personnel working with the power system should:
• Have experience working with AC and DC power.
• Know what safety precautions to take when working with

AC and DC power.
• Have experience and knowledge of working with basic elec-

tronic test equipment.
• Have training in and experience working with electrical

and electronic principles.
WBPEEUI210509A4 August 2011 1-1

Applications
Applications
The MPSIII system is compatible with Harmony Rack systems
and INFI 90 ® OPEN systems.
It is a direct replacement for MPSII systems, used in Harmony

Rack systems, in their entireties. Components of the previous
power systems are not compatible with this power system. The
MPSIII system fits in the same cabinet space as the MPSII sys-
tem, but may require additional mounting provisions.
NOTE: The MPSIII system incorporates an optional rear cabinet door fan for
supplemental cooling. Most MPSII systems do not have this fan.
Features
Features of the MPSIII system include:
• Power Factor Correction. AC inputs have active power

factor correction to greater than 0.95.
• Online Replaceable Components. Power supply trays

may be replaced while system is operating.
• Monitoring Functions. Monitors supplies, fans, and cabi-

net temperature.
• Directly Accepts 120 VAC, 240 VAC, or 125 VDC Inputs.

No switches or jumpers to set.
Instruction Content
This instruction contains information on the MPSIII system. It
is organized into seven sections and a set of procedures. After
becoming completely familiar with it and the equipment it
describes, it may be used as a reference.
Introduction Contains general information, nomenclature, and product
specifications.
Description and Provides detailed descriptions of the components of the MPSIII
Operation system.
Installation Provides an introduction into the procedures involved in plac-
ing the MPSIII system into operation. Provides installation
1-2 August 2011 WBPEEUI210509A4

How to use this Instruction
sequence flowcharts that direct installation personnel to the

appropriate procedures.
Troubleshooting Provides information on the status indicators on the power
supply trays and fan assembly.
Maintenance Provides an introduction into the routine maintenance of the
power system. Includes a preventive maintenance schedule
that includes references to applicable procedures.
Replacement Provides an introduction into the procedures involved in
Procedures replacing power system components. Includes a repair and
replacement sequence flowchart that directs repair personnel
to the appropriate procedures.
Spare Parts Includes a spare parts list.
Procedures PR1 Provide procedures for each task.
through PR16
How to use this Instruction

Read this entire instruction carefully before attempting to
install, maintain, or repair the power system. After gaining a
complete understanding of this instruction and the power sys-
tem, it can be used as a reference.
Some sections of this instruction have been prepared in proce-

dure format. There are flowcharts that follow the introduction
to the section and any nonprocedural information. These flow-
charts direct personnel to the appropriate procedure. By treat-
ing each task as a separate entity, the procedures provide an
easy method for finding the information needed to perform
each task. The procedures can be removed and placed into
separate folders or notebooks, or carried to the job site.
Each procedure lists the recommended tools to perform that

procedure.
Document Conventions
This document uses standard text conventions:
Revision variable A ? indicates a value that may change depending on the ver-
sion of an item. Example:

Glossary of Terms and Abbreviations
Part number: 1234567?0

Part number: 1234567??
Glossary of Terms and Abbreviations

Table 1-1 contains those terms and abbreviations that are
unique to ABB or have a definition that is different from stan-
dard industry usage.
Table 1-1. Glossary of Terms and Abbreviations
Term Definition
Installation location The specific area within the installation site in which equipment is, or will
be positioned. There may be several installation locations within an instal-
lation site.
Installation site The facility on site that includes the area occupied, or to be occupied, by a
structure or set of structures.
PEP Power entry panel.
PFI Power fail interrupt. A signal that causes active controllers to reset and
the communication system to be bypassed, when generated in the sys-
tem by an out of tolerance bus voltage.
Reference Documents
Table 1-2 lists ABB documents directly referred to in this
instruction.
Table 1-2. Reference Documents
Number Title
WBPEEUI200505?? Site Planning
WBPEEUI210503?? Symphony Enclosures
Nomenclature
Table 1-3 contains the nomenclatures used in this instruction.

Nomenclature
Table 1-3. Nomenclature

Position
Modular Power System III
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Power Supply Trays1

P - HA - RP S - 0 0 0 1 0 0 0 0 125 VDC at 2.3 A
- 0 0 2 0 0 0 0 0 48 VDC at 8.5 A
- 0 2 0 1 0 0 0 0 24 VDC at 17 A, 125 VDC at 2.3 A
- 0 2 2 0 0 0 0 0 24 VDC at 17 A, 48 VDC at 8.5 A
- 0 3 0 0 0 0 0 0 24 VDC at 17 A (dual output, 34 A total)
- 1 1 0 0 0 0 0 0 5 VDC at 14 A, ±15 VDC at 1 A each, 24 VDC at 6 A
- 1 1 0 1 0 0 0 0 5 VDC at 14 A, ±15 VDC at 1 A each, 24 VDC at 6 A,
125 VDC at 2.3 A
- 1 1 1 0 0 0 0 0 5 VDC at 14 A, ±15 VDC at 1 A each, 24 VDC at 6A,
48 VDC at 3 A
125 VDC at 2.3 A
48 VDC at 8.5 A
125 VDC at 2.3 A2
48 VDC at 8.5 A2
- 4 0 0 0 0 0 0 0 5 VDC at 100 A, ±15 VDC at 8 A each
P - HA - RP S - C H 1 0 0 0 0 0 Power Chassis
P - HA - RP S - F A N 0 3 0 0 0 Fan Assembly
Power Entry Panel 3
P - HA - RP S - P E P 1 1 0 1 2 Single chassis, 120/240 VAC main, 120/240 VAC aux,
Category II
1 1 0 2 2 Single chassis, 120/240 VAC main, 125 VDC aux, Category II
1 2 0 0 2 Single chassis, 125 VDC main, 125 VDC aux, Category II
1 1 0 1 3 Single chassis, 120/240 VAC main, 120/240 VAC aux,
Category III
1 1 0 2 3 Single chassis, 120/240 VAC main, 125 VDC aux, Category III
1 2 0 0 3 Single chassis, 125 VDC main, 125 VDC aux, Category III
2 1 0 1 2 Dual chassis, 120/240 VAC main, 120/240 VAC aux,
Category II
2 1 0 2 2 Dual chassis, 120/240 VAC main, 125 VDC aux, Category II
2 2 0 0 2 Dual chassis, 125 VDC main, 125 VDC aux, Category II
2 1 0 1 3 Dual chassis, 120/240 VAC main, 120/240 VAC aux,
Category III
2 1 0 2 3 Dual chassis, 120/240 VAC main, 125 VDC aux, Category III
2 2 0 0 3 Dual chassis, 125 VDC main, 125 VDC aux, Category III
NOTES:
1. Voltage and amperage ratings are at 50°C (122°F). At temps above 50°C (122°F), the amperage rating is reduced 2.5% per
°C rise to a max. of 70°C (158°F) where only 50% of the amperage rating is available.
2 The max. output power for these power supply trays is 816 W.
3. Category III power entry panels have 2 transient suppressors; Category II panels are without transient suppressors.

Specifications
Specifications
Table 1-4 lists the specifications for the MPSIII system.
Table 1-4. Specifications
Property Characteristic/Value
General
Power input
Voltage 102 to 265 VAC, 102 to 144 VDC
Current 12.5 A per power supply max.
Peak inrush current 40 A peak
Frequency 47 to 63 Hz
Total harmonic distortion Less than 5%
Efficiency 70% at full load
Power factor Actively corrected to 0.95 min at input currents greater than 5 A
Power module chassis
Output bus capacity 100 A at 5.1 VDC max.
8 A at ±15.1 VDC max.
35 A at 25.5 VDC max.
Power entry disconnect device Separate disconnect switch/circuit breaker provided for each
power supply
Circuit Breaker Rating 25 A
System fans
Input power Fan assembly: 0.75 A nominal at 24 VDC
Door fan (optional): 0.70 A nominal at 24 VDC
Weight and dimensions P-HA-RPS-CH100000: 431.8-mm wide x 431.8-mm deep x
88.9-mm high (17.00 x 17.00 x 3.50 in.), 16.1 kg (35.5 lbs)
with 2 power supplies installed
P-HA-RPS-PEP?????: 431.8-mm wide x 152.4-mm deep x
P-HA-RPS-FAN03000: 439.4-mm wide x 330.2-mm deep x
Electromagnetic/radio Meets IEC 1000-4-3, level 3, 80 MHz to 1 GHz and
frequency interference IEC 1000-4-8, level 4, 30 A/m, 50 Hz with no loss of function
or false status information.

Specifications
Table 1-4. Specifications (continued)
Fast transient/burst Meets IEC 1000-4-4, level 3, mains 2 kV at 5 kHz, outputs
susceptibility 1 kV at 5.0 kHz with no degradation or loss of function.
Transient surge Meets IEC 1000-4-5, level 3, 2 kV with no degradation or loss
of function.
Electrostatic discharge Meets IEC 1000-4-2, level 3 with no degradation or loss of
function.
Environmental
Temperature
Operating enclosure (int) 0° to 70°C (32° to 158°F) with derating from 50°C (-2.5% per °C)
Operating enclosure (ext) 0° to 55°C (32° to 131°F) with derating from 50°C (-2.5% per °C)
Storage and transport -40° to 85°C (-40° to 185°F)
Relative humidity
Operating 20% to 90% up to 55°C (131°F) noncondensing
20% to 45% at 55° to 70°C (131° to 158°F) noncondensing
Altitude
Operating Sea level to 3,048 m (10,000 ft)
Storage and transport Up to 9,144 m (30,000 ft)
Air quality Noncorrosive per ISA S71.04 class LA, LB, LC Severity Level 1
Overvoltage category IEC 1010-1, Category II or III, for mains
Vibration 13.2 to 100 Hz, 0.7 G
2 to 13.2 Hz, 12 mm (0.47 in.) peak-to-peak displacement
Certifications
Canadian Standards Certified for use as process control equipment in an ordinary
Association (CSA) (nonhazardous) location.
Factory Mutual (FM) Nonincendive for Class I; Division 2; Groups A,B,C,D T4
CE mark, low voltage directive, EMC Directive when used in
appropriate cabinet
WBPEEUI210509A4 1-7
Specifications
Power output
Module Rated Voltages (VDC)
Voltage/current
Outputs 5 +15 -15 24 48 125
Nominal VDC 5.09 15.10 -15.10 25.50 49.1 125.6
Minimum VDC 5.04 14.95 -14.95 24.35 48.5 123.1
Maximum VDC 5.25 15.75 -15.75 26.80 49.6 128.1
Maximum ripple 100 150 150 300 600 1,000
and noise (mVpp)
Load sharing Current shared equally between modules within 10% (highest
current load to lowest current load) at full load for +5 VDC and
+24 VDC outputs
Line regulation ±0.5% of nominal output voltage over input voltage range
Load regulation Within specified min and max. outputs from 0% to 100% load
Hold up time 20 msecs following loss of power
Power Consumption and
Heat Dissipation (max. values) Power
Heat Dissipation
Power Supply Consumption
(BTU/Hr1)
(Watts)
P-HA-RPS-00010000 411 421
P-HA-RPS-00200000 583 597
P-HA-RPS-02010000 994 1,018
P-HA-RPS-02200000 1,166 1,194
P-HA-RPS-03000000 1,166 1,194
P-HA-RPS-11000000 349 357
P-HA-RPS-11010000 760 778
P-HA-RPS-11100000 554 568
P-HA-RPS-21000000 477 489
P-HA-RPS-21010000 888 909
P-HA-RPS-21200000 1,060 1,086
P-HA-RPS-32000000 1,140 1,168
P-HA-RPS-320100002 1,166 1,194
2
P-HA-RPS-32200000 1,166 1,194
P-HA-RPS-40000000 1,057 2,251
NOTES:
1. 70% of input power converted to output power. 30% of input power
converted to heat dissipated into cabinet.
2. The max. output power for these power supply trays is 816 W.

Specifications
Monitoring functions
System bus voltage monitor trip 4.75 VDC for 5 VDC bus
points 14.75 VDC for +15 VDC busses
Power fail interrupt (PFI) 1 output, open collector driven (nonisolated), logic 0 = power
failure
Logic 0  0.8VDC at 10 mA sink current
Logic 1 4.75 to 5.25 VDC at 80 µA source current
Status out 1 output, open collector driven (nonisolated), logic 0 = fault
Logic 0: 0.8VDC at 10 mA sink current
Logic 1: 4.75 to Vcc at 80 µA source current
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Description and Operation Section 2
Introduction
The MPSIII system supplies 5 VDC, 15 VDC, -15VDC, 24VDC,
48 VDC, and 125 VDC power to Harmony rack components of
the Symphony control system. The MPSIII system can also be
used to power INFI 90 OPEN system components.
The MPSIII system is designed to entirely replace the MPSII

system used in Harmony Rack systems. Components of the
MPSII and the MPSIII system are not interchangeable. The
MPSIII system fits in the same cabinet space as the MPSII sys-
tem, but some cabinet arrangements and types may require
that additional mounting provisions be used.
NOTE: The MPSIII system has provisions for a supplemental rear door
mounted fan for proper cooling. Cabinets using the MPSII system may not have
had this fan.
Description
The MPSIII system consists of a power chassis, PEP, fan
assembly, DC bus monitoring assembly, and power supply
trays. Figure 2-1 shows the system architecture of the MPSIII
system.
At the right side of the Figure 2-1, the 5 VDC, 15 VDC, and
-15 VDC lines shown entering the system power bus bar are
the operating voltages for the rack devices. MCOM (module
common) is the return line for these voltages. The 25.5 VDC
line shown entering the system power bus bar is I/O power for
field devices and I/O COM is its return line.
The physical arrangement of the MPSIII system components is

shown in Figure 2-2.
Power Chassis
The power chassis provides mounting slots for two redundant
power supply trays, cooling fans, power output terminals, a
DIN rail for the DC bus monitoring assembly, and a status
WBPEEUI210509A4 2-1
Description
IN P U T P O W E R
1 20 /2 40 VAC
12 5 V D C
48 VDC 2 N R E D U N DA N T
OR LIN E 1 L IN E S . L IN E 1 L IN E 2
1 25 V D C IS IS O L AT E D
F O R I/O F R O M LIN E 2
C IR C U IT C IR C U IT
B R E A K E R /S W IT C H B R E A K E R /S W IT C H
A N D LIN E F ILT E R IN G A N D LIN E F ILT E R IN G
AC /D C P O W E R E N T RY PA N E L AC /D C
IN P U T IN P U T
P OW E R POW ER
P O W E R S U P P LY P O W E R S U P P LY
T R AY T R AY
+15 VD C +5 VDC
–15 VDC +15 VDC
BUS
– 15 V D C
M O N ITO R IN G
5 VDC MCOM A S S E M B LY
P O W E R C H A S S IS
2 5.5 V D C P FI
MCOM
I/O C O M
N O D E S TAT U S
TO IN F I-N E T
T E R M IN AT IO N
S TAT U S
POW ER AND
DOOR
S TAT U S
FA N
FA N A S S E M B LY (O P T IO N A L )
2 5.5 V D C
I/O C O M
M O D U LE M O U N T IN G U N IT
5 VDC
+15 VDC SYSTEM
POW ER
M O D U LE S – 15 V D C
BU S BAR
MCOM
P FI
5 VDC
+15 VD C
M O D U LE S –15 VDC
MCOM
PFI
25 .5 V D C F O R I/O
I/O C O M
T 04 478 A
Figure 2-1. MPSIII System Architecture
output terminal connection. Cables connect the power termi-

nals for 5 VDC, ±15 VDC, and 24 VDC to the power bus bar for
distribution to the cabinet. The 48 VDC and 125 VDC termi-
nals are for field I/O devices. Power supply trays can be
removed from the power chassis and replaced while the system
2-2 WBPEEUI210509A4
Description
D O O R FA N
(O P T IO N A L)
S M A L L F IL LE R
PA N E L (2)
L A R G E F ILL E R PA N E L
(O N LY IF S E C O N D
F RO N T M O U N T IN G N OT IN S TA LL E D )
B R AC K E T (2)
P O W E R S U P P LY
T R AY S
P O W E R E N TRY
PA N E L (P E P )
F R O N T D O O R R E M OV E D
D C B U S M O N ITO R
A S S E M B LY
R E A R M O U N T IN G
B R AC K E T (2)
FA N A S S E M B LY
R E A R D O O R R E M OV E D T 04 456 A
Figure 2-2. MPSIII System (Single Power Chassis)

Description
is online. Prior to removing a power supply tray, power to that

power supply tray must be switched off at the PEP. Failure to
do so may generate a PFI signal and cause a process upset.
In some cases, one redundant pair of power supply trays may

not provide all the power needs of the cabinet, thus requiring
the installation of two power chassis; however, each voltage
must be provided by only one power chassis. Do not attempt
to connect like voltages from two power chassis, as it will
result in equipment damage. A typical use for two power
chassis has the lower power chassis providing system voltages
(5 VDC, ±15 VDC) and the upper power chassis providing
power for field I/O (24 VDC, 48 VDC, or 125 VDC). Figure 2-3
shows the power chassis with redundant power supply trays
installed.
OUTPUT O UTPU T
T E R M IN A L B L O C K T E R M IN A L S
2 5 .5 V
2 5 .5 V R E T
S TAT U S O U T
+15V
– 15V
48V
125V
15V RTN
4 8 V /1 2 5 V R T N
5V RET
5V
R E A R V IE W
D IN R A IL F O R
M O U N T IN G D C B U S
M O N ITO R IN G A S S E M B LY
POW ER
C H A S S IS
S TAT U S O K S TAT U S O K
F R O N T V IE W
P O W E R S U P P LY P O W E R S U P P LY
T R AY T R AY T04459A
Figure 2-3. Power Chassis (Power Supply Trays Installed)
2-4 WBPEEUI210509A4
Description
Power Supply Trays

Power supply trays slide into the power chassis and are
secured with thumb screws. There are 15 different power
supply trays available. Refer to Nomenclature in Section 1 for
the full listing. Power supply trays installed in a power chassis
must be of the same type. Power supply trays can provide
combinations of 5 VDC, 15 VDC, or -15 VDC system operating
voltages, and 24 VDC, 48 VDC, or 125 VDC field power. Each
power supply tray can accept 120 VAC, 240 VAC, or 125 VDC
input power. Input voltages to a redundant pair of power sup-
ply trays may be from different sources and of different volt-
ages. AC inputs have active power factor correction to greater
than 0.95. Sharing circuitry allows the power supply trays to
equally share output current. The power supply tray monitors
its output and internal temperature and displays the status
with an LED. Input power to each power supply tray is pro-
vided by a cord that connects to the PEP. Figures 2-4 and 2-5
show front views of the power supply trays. Note: Earlier ver-
sions of power supply trays did not have voltage test jacks.
S TAT U S LE D
S TAT U S O K
F R O N T V IE W
POW ER CORD T 0 4 45 8 A
Figure 2-4. Power Supply Tray
WBPEEUI210509A4 2-5
Description
Figure 2-5. Power Supply Tray with Voltage Test Jacks
Power Entry Panel (PEP)

There are twelve available power entry panel kits. They differ
in the number of chassis supported, transient surge suppres-
sors (required for Overvoltage Category III), and circuit break-
ers depending on input voltages. Refer to Nomenclature in
Section 1 for a detailed listing of the power entry panels avail-
able.
Each PEP comes with the components listed in Table 2-1.
Table 2-1. Power Entry Panel Kit
Part No. Qty Description

6644403?1 1 or 2 Mounting bracket, right rear (1 for single power chas-
sis, 2 for dual power chassis)
6644403?2 1 or 2 Mounting bracket, left rear (1 for single power chassis,
2 for dual power chassis)
6644417?1 2 Mounting bracket, front
6644418?1 2 Filler panel, 1.7 in.
6644418?2 0 or 1 Filler panel, 3.5 in. (included for single power chassis
only)
6644423?1 2 Cable, 5 VDC
6644423?2 2 Cable, 12 in., 24 VDC
6644423?3 0 or 1 Cable, 21 in., 24 VDC (included for dual power chas-
sis only)
2-6 WBPEEUI210509A4
Description
Table 2-1. Power Entry Panel Kit
Part No. Qty Description

6644424?1 1 DC bus monitoring assembly
6644463?? 1 PEP
Power entry panels include connection points for two input

power sources, two 25-Ampere disconnect switch/circuit
breakers, two optional surge suppressors, connection points
for four power tray cords, chassis ground studs, and a wrist
strap grounding jack. The input terminals accept 16-square
millimeter (six-AWG) to four-square millimeter (12-AWG) wires
for customer input power. Figure 2-6 shows a typical PEP face-
plate.
Fan Assembly
The fan assembly provides cooling for rack modules mounted
in the cabinet. The fan assembly includes three fans, select-
able cabinet temperature monitoring, status output connec-
tion, status LEDs, a door fan power connection, and status
connection terminals. 24 VDC power for the fan assembly is
derived from the DC power bus bar via a cable connection. An
optional 24 VDC door fan mounted on the upper portion of the
rear door is used to draw air out of the top of the cabinet.
Power must be removed from the fans before attempting to ser-
vice them. Figure 2-7 shows the module cooling fan assembly
layout.
DC Bus Monitoring Assembly

The DC bus monitoring assembly is used to generate a PFI sig-
nal to shut down control modules in the event of a loss of
power. The assembly mounts to the DIN rails on the rear of the
power chassis. The DC bus monitoring assembly cable con-
nects to the 5 VDC, +15 VDC, -15 VDC, MCOM, and PFI
connectors on the DC power bus bar. It monitors each of these
voltages and generates a PFI on failure of any of them. Moni-
toring of +15 VDC and -15 VDC may be disabled by a jumper.
Figure 2-8 shows a view of the DC bus monitoring assembly.
WBPEEUI210509A4 2-7
Description
C IR C U IT
BREAKERS
LIN E 1 IN P U T LIN E 1 O U T P U T
OFF
L L1 + BRN BRN
N L2 – CB1 R P S P O W E R E N T RY PA N E L B LU BLU
OFF
G R N /Y E L G R N /Y E L
TB1 TB3
OFF
L L1 + BRN BRN
N L2 – CB2 B LU BLU
W R IS T S T R A P G R N /Y E L G R N /Y E L
OFF
TB2 TB4
CAUTION: SYSTEM MAY HAVE
MULTIPLE SOURCES OF POWER. SWITCH OFF
ALL DISCONNECTS BEFORE SERVICING.
F R O N T V IE W
W R IS T S T R A P
G ROUND T 04 4 57 A
Figure 2-6. Power Entry Panel
24V D C IN P U T W H IT E = +
POW ER CORD B LAC K = –
T E M P E R AT U R E S TATU S
OUTPUT D O O R FA N
SELECT D O O R FA N POW ER
TE M P E R AT U R E FA N
M O N ITO R
S TATU S S TAT U S
50 60 70 OFF ON
RPS1
R E A R V IE W T 04 460 A
Figure 2-7. Fan Assembly
2-8 WBPEEUI210509A4
Description
POW ER D C B U S M O N ITO R IN G
C H A S S IS A S S E M B LY
2 5.5V
2 5.5V R E T
S TAT U S O U T
+15V
– 15V
48V
125V
15V RT N
48V /125V RT N
J1
J2
5V RET
5V
RED
+5 VDC
ORN
R E A R V IE W
+ 15 V D C
B LK
– 15 V D C
WHT
M C O M (+ 5 V D C R T N )
YEL
PFI T04 46 1B
Figure 2-8. DC Bus Monitoring Assembly

Description
2 - 10 August 2011 WBPEEUI210509A4

Installation Section 3
Introduction
This section contains information needed when installing the
MPSIII system. It includes information on special handling,
unpacking and inspection, safety considerations, and wiring
considerations.
Following these topics is an installation sequence flowchart

that guides personnel, seeking to perform a specific installa-
tion task, to the proper procedure needed to perform that task.
Special Handling
The MPSIII system contains sensitive electronic circuitry. This
circuitry contains semiconductor devices that are subject to
damage by static electricity.
A static field kit is available for personnel working on compo-

nents containing semiconductor devices. It contains two wrist
straps, a ground cord assembly, an alligator clip, and a static
dissipating work surface. The intention is to connect the tech-
nician and the static dissipating work surface to the same
ground point to prevent electrostatic discharge damage to the
static sensitive devices.
When handling static sensitive devices:
1. Most assemblies with semiconductor devices come in a

special antistatic bag. Keep the assembly in the bag as much
as possible whenever the assembly is not installed.
2. Remove assemblies containing semiconductor devices from

their antistatic container only under certain conditions:
a. When at a static-free workstation or when the bag is

grounded at a field test sight.
b. Only after neutralizing the conductive area of the

container.

Unpacking and Inspection
c. Only after firm contact with an antistatic mat and/or

firmly gripped by grounded personnel.
3. Personnel handling assemblies with semiconductor devices

should be neutralized to a static-free workstation by a ground-
ing wrist strap connected to the station or to a good ground
point at the field sight.
4. Do not allow clothing to contact semiconductor devices.

Most clothing generates static electricity.
5. Avoid touching connectors or components.
6. Avoid partial connection of semiconductor devices. Most

devices can be damaged by floating leads, especially the power
supply connector. If an assembly must be placed in a live sys-
tem, it should be done quickly. Do not cut leads or lift circuit
paths when troubleshooting.
7. Be sure to ground any test equipment.
8. Avoid static charges during removal and replacement.

Make sure the assembly is fully clean around its leads, but do
not rub or clean with an insulating cloth.
9. Remove dust from components using an antistatic field

service vacuum.
Unpacking and Inspection

When the MPSIII system is received it should be unpacked and
inspected.
1. Check for any obvious damage to the crate or its contents.

If damage is evident, notify the carrier and an ABB sales repre-
sentative.
2. Remove any loose packing from the crate.
3. Inspect the nameplate and verify the unit received matches

the desired function.
4. If storing the MPSIII system prior to installation, leave it in

the original crate, if possible. Store in an area free from corro-
sive vapors and extremes in temperature and humidity.
5. Do not store the MPSIII system in an area that would take

it out of the specifications listed in Table 1-4.

Safety Considerations
It is critical to read, understand, and heed all instructions,
warnings, and cautions located throughout this instruction
and on the equipment itself. Only qualified personnel must be
allowed to install, operate, maintain, and repair this
equipment.
Do not remove or install printed circuit boards, or modules or

components containing them, unless otherwise indicated in
this instruction, with power applied. This could damage the
equipment. Remove power to all AC wiring when removing or
connecting AC wires to prevent injury to personnel and equip-
ment damage. To prevent equipment damage, remove DC
power to all DC wiring when removing or connecting DC wires,
circuit boards, or modules or components connected to them.
Wiring Considerations
This section discusses AC power wiring and grounding for the
MPSIII system. For the procedures to accomplish these tasks,
refer to the installation sequence flowcharts at the end of this
section for the path to the proper procedure.
For detailed information on AC power distribution and system

grounding, refer to:
• Site Planning.
• Recommended Practice for Powering and Grounding

Sensitive Electronic Equipment (IEEE Emerald Book),
ANSI/IEEE 1100.
• Recommended Practice for Grounding of Industrial and

Commercial Power Systems (IEEE Green Book),
ANSI/IEEE 142.
Do not attempt to install any system or related equipment

before consulting and understanding these documents as well
as any other applicable international standards.
Grounding
The PEP provides grounding of the AC input to the MPSIII sys-
tem chassis.

Installation Sequence
This instruction does not discuss the details of grounding sys-

tems. Good grounding practices prevent problems and reduce
system downtime. A complete and properly grounded electrical
system is vital for personnel safety, equipment protections,
and normal process system operation. Digital process control
systems require a single-point grounding system that has two
paths: one path for an alternating current ground (safety
ground) and one path for a direct current ground (system
common).
For detailed information on system grounding, refer to the Site

Planning instruction.
Refer to Figure 3-1 for the installation sequence for the main
components of the MPSIII system. Each block of the flow rep-
resents a single task that must be completed before continuing
with the sequence.
Some blocks contain alphanumeric codes. These codes identify

the procedure that describes the steps to complete an indi-
cated task. Complete all of the steps given in a procedure
before continuing to the next procedure.
The procedures have check boxes in the margin by each proce-

dural step. When performing a procedure, check each box as
each step is completed. Some procedures have numbered
warnings and /or cautions under Safety Considerations. A tri-
angle with a warning or caution reference number appears in
the margin by the part of the procedure to which the warning
or caution applies.
By treating each task as a separate entity, the procedures pro-

vide an easy method for finding the information needed to per-
form each task in the installation sequence.

S TA RT
COMPONENT PEP
ARRANGEMENT IN S TA L LAT IO N
PR1 PR6
M O U N T IN G FA N
B R AC K E T A S S E M B LY
IN S TA LL AT IO N IN S TA L LAT IO N
PR2 PR7
F IL L E R D C B U S M O N ITO R IN G
PA N E L A S S E M B LY
IN S TA LL AT IO N IN S TA L LAT IO N
PR3 PR8
POW ER W IR IN G
C H A S S IS AND
IN S TA LL AT IO N C A B L IN G
PR4 PR9
P O W E R S U P P LY DONE
T R AY
IN S TA LL AT IO N
PR5
T 04 463 A
Figure 3-1. Installation Sequence

Troubleshooting Section 4
Introduction
This section provides troubleshooting tables containing trou-
bleshooting procedures to help locate and correct MPSIII sys-
tem problems. These are general troubleshooting guidelines
and are not exhaustive of all possible causes.
Troubleshooting Procedures
Tables 4-1 and 4-2 contain troubleshooting procedures that
are listed by LED state, cause, and corrective action. Use these
tables to correct power system problems that are revealed by
LEDs on the power supply tray (Table 4-1) and the fan assem-
bly (Table 4-2).
Table 4-1. Power Supply Tray LED
LED LED State Cause Corrective Action

Status Green Normal Operation. None.
Off Output voltage under 1. If the cabinet temperature is over 70°C
threshold or temperature (144°F), reduce cabinet temperature.
over threshold.
2. If cabinet temperature is OK, replace power
supply tray (refer to Section 6).
3. Verify voltage levels are within tolerances
using voltage test jacks. Refer to the specifica-
tions section for Rated Voltages (VDC) located
in Table 1-4 and the Testing Voltage Output
section below.
Table 4-2. Fan Assembly Status LEDs
LED
LED Problem Corrective Action
State
Temperature Off Normal operation. None.
Red Fan assembly over Reduce cabinet temperature.
selected temperature

Table 4-2. Fan Assembly Status LEDs (continued)
LED
LED Problem Corrective Action
State
Fan status Off Normal operation. None.
Red One or more fan assem- Disable door fan monitor. If fan status LED
bly fans are under speed. is still red, replace fan assembly (refer to
Section 6). If fan status LED turns off,
replace optional door fan.
Testing Voltage Output

The latest revision of power supply trays from ABB now
include voltage test jacks (see Figure 2-5). These jacks provide
test points from which voltage output measurements may be
made. There are test points to measure +5V, +15V, -15V, 24V,
48V and 125V.
NOTE: There are multiple power supply tray models and not all power supply
trays provide all output voltages. Test points will only be active if the power sup-
ply tray supports the output voltage.
Connect a volt meter between the voltage test point and RTN 1
or RTN 2 to verify proper voltage. See Section 1 for power tray
voltage specifications.
Power supply trays with test jacks are fully compatible with
power supply trays that do not have test jacks, i.e. they may be
used together in redundant pairs.

Maintenance Section 5
Introduction
This section contains a preventive maintenance schedule for
the power system (Table 5-1). This table has a procedure refer-
ence next to the task when applicable. The reference indicates
the procedure number where the procedure for that task can
be found.
Be sure to follow all warnings, cautions, and notes. Put boards

containing semiconductors into antistatic bags when stored or
shipped back to the factory. Do not repair printed circuit
boards in the field. All repairs and adjustments should be per-
formed by qualified personnel.
The maintenance of any stand-alone product or control system

affects the reliability of that product. All equipment users
should practice a preventive maintenance program that will
keep the equipment operating at an optimum level.
The procedures referred to in this section contain instructions

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 mainte-
nance practices. Select the minimum steps required to meet
the needs of the system.
Personnel performing preventive maintenance should meet the

following qualifications:
• Maintenance personnel should be qualified electrical tech-

nicians or engineers that know the proper use of test
equipment.
• Maintenance personnel should be familiar with the equip-

ment, have experience working with process control sys-
tems, and know what precautions to take when working
with live AC power.

Preventive Maintenance Schedule
Preventive Maintenance Schedule

Table 5-1 is the preventive maintenance schedule for the
MPSIII system. The table lists the preventive maintenance
tasks in groups according to their specified maintenance inter-
val. Some tasks in Table 5-1 are self-explanatory. Instructions
for tasks that require further explanation are found in the
procedures.
NOTE: The preventive maintenance schedule is for general purposes only.

Each application may require special attention.
Table 5-1. Preventive Maintenance Schedule
Task Procedure Frequency

Check cabinet air filters. Clean or replace them as necessary. Check PR15 3 months
the air filter more frequently in excessively dirty environments.
Check cabinet for dust. Clean as necessary using an antistatic vacuum. —
Check all signal, power, and ground connections within the cabinet and PR16
verify that they are secure.
Do a visual inspection of the fan assembly. Verify that all fans are rotat- — 6 months
ing. Refer to Section 6 for replacement sequence if fans need replaced.
Check the quality of the plant power and grounding system. Follow the — 12 months
power and grounding system verification procedures in the Site Plan-
ning instruction.
Inspect all control, I/O, and power modules, giving particular attention —
to power supply contacts and heat sinks. Clean as necessary.
Replace power supply. Call ABB sales and service for exchange infor- Section 6 5 years
mation. (Components such as electrolytic capacitors deteriorate over
time and need to be replaced.)
Complete all checks and inspections in this table. Replacement tasks — Shutdown
should be done at the scheduled frequency.

Replacement Procedures Section 6
Introduction
This section provides replacement procedures for the power
system. The power system components are not field replace-
able. If a component fails, it must be returned to the factory for
repair.
NOTE: Follow the procedures for working with static sensitive devices when
performing the replacement procedures.
Replacement Sequence
Refer to Figure 6-1 for the replacement sequence.
Each block of the flow represents a single task that must be

completed before continuing with the sequence. In some cases,
more than one path can be taken during replacement proce-
dures. For paths that are in parallel, either complete all of the
tasks in all of the paths before continuing or complete all of
the tasks in only those paths that apply before continuing. At
least one path must be completed.
Some blocks contain alphanumeric codes. These codes identify

the procedure that describes the steps to complete an indi-
cated task. Complete all of the steps given in a procedure
before continuing to the next procedure. By treating each task
as a separate entity, the procedures provide an easy method
for finding the information needed for each task in the replace-
ment sequence.
The procedures have check boxes in the margin by each proce-

dural step. When performing a procedure, check each box as
each step is completed. Some procedures have numbered
warnings and /or cautions under Safety Considerations. A tri-
angle with a warning or caution reference number appears in
the margin by the part of the procedure to which the warning
or caution applies.

Replacement Sequence
A
P O W E R S U P P LY T R AY
B
R E P LAC E
W H IC H PEP
S TA RT C
COM PO NENT?
FA N A S S E M B LY
D
D C B U S M O N ITO R IN G A S S E M B LY
E
A B C D E
TURN OFF PEP

T U R N O FF R E M OV E AC TURN OFF TURN OFF
C IR C U IT B R E A K E R
P O W E R AT P O W E R AT P O W E R AT P O W E R AT
FOR POW ER
PEP SOURCE PEP PEP
S U P P LY T R AY TO
B E R E M OV E D
P O W E R S U P P LY FA N D C B U S M O N ITO R IN G
T R AY PEP A S S E M B LY A S S E M B LY
P O W E R S U P P LY R E M OVA L
R E M OVA L T R AY R E M OVA L R E M OVA L
P R 10 R E M OVA L P R 13 P R 14 P R 11
P R 10
D C B U S M O N ITO R IN G FA N D C B U S M O N ITO R IN G
A S S E M B LY PEP A S S E M B LY A S S E M B LY
P O W E R S U P P LY IN S TA LLAT IO N
R E M OVA L T R AY IN S TA LLAT IO N IN S TA LLAT IO N
P R 11 IN S TA LLAT IO N PR6 PR7 PR8
PR5
POW ER A P P LY AC TURN ON TURN ON

C H A S S IS POW ER FRO M P O W E R AT P O W E R AT
R E M OVA L TURN ON
P E P C IR C U IT SOURCE PEP PEP
P R 12
BREAKER
POW ER
C H A S S IS
IN S TA LLAT IO N
PR4
T R AY
IN S TA LLAT IO N
PR5
D C B U S M O N ITO R IN G
A S S E M B LY
IN S TA LLAT IO N
PR8
TURN ON
P O W E R AT
PEP
DONE
T04464B
Figure 6-1. Replacement Sequence
6-2 WBPEEUI210509A4
Spare Parts Section 7
Spare Parts
Table 7-1 lists the spare parts. The quantities listed are those
recommended by ABB for each installation site.
Table 7-1. Spare Parts
Part Number Qty Description

Power Entry Panels
6644463?1 1 of 120/240 VAC, 25 A, without line filter
6644463?2 each 120/240 VAC, 25 A, with line filter
type
6644463?3 used 120/240 VAC, 25 A; 125 VDC, 25 A, without line filter
6644463?4 120/240 VAC, 25 A; 125 VDC, 25 A, with line filter
6644463?5 125 VDC, 25 A, without line filter
6644463?6 125 VDC, 25 A, with line filter
Power Supply Trays
P-HA-RPS-00010000 1 of 125 VDC at 2.3 A
P-HA-RPS-00200000 each 48 VDC at 8.5 A
type
P-HA-RPS-02010000 used 24 VDC at 17 A, 125 VDC at 2.3 A
P-HA-RPS-02200000 24 VDC at 17 A, 48 VDC at 8.5 A
P-HA-RPS-03000000 24 VDC at 17 A (dual output, 34 A total)
P-HA-RPS-11000000 5 VDC at 14 A, ±15 VDC at 1 A each, 24 VDC at 6 A
P-HA-RPS-11010000 5 VDC at 14 A, ±15 VDC at 1 A each, 24 VDC at 6 A, 125 VDC at 2.3 A
P-HA-RPS-11100000 5 VDC at 14 A, ±15 VDC at 1 A each, 24 VDC at 6A, 48 VDC at 3 A
P-HA-RPS-40000000 5 VDC at 100 A, ±15 VDC at 8 A each
P-HA-RPS-CH100000 1 Power chassis
P-HA-RPS-FAN03000 1 Fan assembly

Component Arrangement PR1
Purpose/Scope
This procedure explains the arrangement options available for
power system components.
Parts None.
Tools None
Procedure
This instruction covers installation of the power system into
standard ABB cabinets. Nonstandard cabinets require rack
mount rails positioned at the front of the cabinet to provide
secure mounting points for the power chassis, PEP, and filler
plates. Nonstandard cabinets and rack mount rails must com-
ply with Racks, Panels, and Associated Equipment, EIA
RS-310-B. Figure PR1-1 shows the height and physical
arrangement of each individual component, and Figure PR1-2
shows the location of the mounting rails.
This procedure describes the physical arrangement in which to

install the power system components. The arrangement is
slightly different for one or two power chassis systems. It is for
reference only and does not contain any installation or
replacement procedures.
Figure PR1-1 shows the two standard mounting schemes. The

front mounting brackets accommodate two power chassis.
When two power chassis are mounted in the same cabinet,
mount the I/O field power chassis in the upper position and
the module power chassis in the lower position. When only one
power chassis is used, mount it in the lower position. Each
power chassis requires its own set of rear mounting brackets.
When using one power chassis, three filler plates are required
to direct cabinet air flow for cooling. When using two power
chassis, two filler plates are required to direct cabinet air flow
for cooling.
WBPEEUI210509A4 August 2011 PR1 - 1

Procedure
Follow the order shown in Figure PR1-1 when mounting the

various power system components.
TO P O F C A B IN E T TO P O F C A B IN E T
43.2
S M A LL F ILLE R PA N E L S M A LL F ILLE R PA N E L
1.70
P O W E R C H A S S IS W IT H
88.9
LA R G E F ILLE R PA N E L R E D U N DA N T P O W E R S U P P LY
3.50
T R AY S F O R F IE LD I/O P O W E R
43.2
S M A LL F ILLE R PA N E L S M A LL F ILLE R PA N E L
1.70
P O W E R C H A S S IS W IT H R E D U N DA N T P O W E R C H A S S IS W IT H
88.9
P O W E R S U P P LY T R AY S F O R M O D U LE R E D U N DA N T P O W E R S U P P LY
3.50 48 6.5
A N D F IE LD I/O P O W E R T R AY S F O R M O D U LE P O W E R
19 .15
222.3
PEP 8.75 PEP
FA N A S S E M B LY (B E H IN D P E P ) FA N A S S E M B LY (B E H IN D P E P )
M O D U LE M O D U LE
M O U N T IN G M O U N T IN G
U N IT S U N IT S
D IM E N S IO N S
S IN G LE P O W E R C H A S S IS M ILLIM E T E R S D UA L P O W E R C H A S S IS
(F R O N T V IE W ) IN C H E S (F R O N T V IE W ) T 04 462 A
Figure PR1-1. Component Arrangements and Dimensions
PR1 - 2 August 2011 WBPEEUI210509A4

Procedure
TO P V IE W
(R E A R O F C A B IN E T )
685.8 R E A R R A IL
(M IN )
27.00
314.3 ± 3.2
12.38 ± 0.13
R E Q U IR E D
F R O N T R A IL
101.6
(M IN )
4.00 D IM E N S IO N S
M ILLIM E T E R S
482.6 IN C H E S
19.00
F U LL PA N E L W ID T H T 04 47 9A
Figure PR1-2. Rack Mount Rail Locations for Nonstandard Cabinets

Mounting Bracket Installation PR2
Purpose/Scope
60 min.
This procedure explains how to install the front and rear
mounting brackets into the cabinets.
Parts
Number Qty Description
1
6644403?1 1 or 2 Mounting bracket, left rear (when viewed
from rear of cabinet)
6644403?2 1 or 21 Mounting bracket, right rear (when viewed
from rear of cabinet)
6644417?1 2 Mounting bracket, front
NFWAB19008 8 Screw, Phillips, thread forming, pan head,
No. 12 x 0.500 long
NIDHA16008 4 or 81 Screw, sems ext pan head slot, 0.190-32
NMPCC16002 4 or 81 Nut, cage, 10-32
NTLAC25000 8 Lockwasher, ext, No. 25
NOTE:
1. Use lesser quantity for cabinets with 1 power chassis and greater quantity for cabinets with
2 power chassis.
Tools • Bladed screwdriver.

• Phillips screwdriver.
1. Disconnect power before attempting these procedures. Fail-

WARNING ure to do so could result in severe or fatal shock, or equipment
damage.
Procedure
h 1. Be sure power is removed at the source before starting this
W1 procedure.
h 2. Open the front and rear doors of the cabinet.

Procedure
Front Mounting Brackets

h 1. Align the top hole in one of the front mounting brackets
with the first round mounting hole from the top of the cabinet
on the frame as shown in Figure PR2-1.
h 2. Use the Phillips screwdriver, and four thread forming

screws and lockwashers to secure the front mounting bracket
to the cabinet.
h 3. Repeat Steps 1 and 2 for the other front mounting bracket.
Rear Mounting Brackets

Each cabinet can have two or four rear mounting brackets.
Two rear mounting brackets are used for single power chassis
installations and four rear mounting brackets are used for
dual power chassis installations.
NOTE: Figure PR2-1 shows a single power chassis installation.
Single Power Chassis

h 1. Install two cage nuts on the 13th and 18th holes on the left
(when viewed from the rear of the cabinet) vertical mounting
rail inside the cabinet as shown in Figure PR2-1.
h 2. Align the top hole of the left rear mounting bracket with
the top cage nut.
h 3. Use the bladed screwdriver, and two pan head screws and
lockwashers to secure the left rear mounting bracket to the
vertical mounting rail.
h 4. Repeat Steps 1 through 3 to install the right rear mounting

bracket, installing it on the right vertical mounting rail.
Dual Power Chassis

h 1. For dual power chassis installations, perform the steps
under Single Power Chassis to install the bottom rear
mounting brackets.
h 2. Install two cage nuts on the 4th and 9th holes on the left
(when viewed from the rear of the cabinet) vertical mounting
rail inside the cabinet.

Procedure
1S T R O U N D
M O U N T IN G H O L E
F R O N T M O U N T IN G
B R AC K E T
(1 E AC H S ID E )
LOCKWASHER,
S C R E W (E AC H
M O U N T IN G
B R AC K E T H O L E )
13 T H S Q UA R E
M O U N T IN G H O LE
B R AC K E T
(1 E AC H S ID E )
C AG E N U T, LO C K W A S H E R ,
S C R E W (E AC H M O U N T IN G
B R AC K E T H O LE )
R E A R D O O R R E M OV E D T 04 469A
Figure PR2-1. Mounting Bracket Installation

Procedure
h 3. Align the top hole of the left rear mounting bracket with
the top cage nut.
h 4. Use the bladed screwdriver, and two pan head screws and
lockwashers to secure the left rear mounting bracket to the
vertical mounting rail.
h 5. Repeat Steps 2 through 4 to install the right rear mounting

bracket, installing it on the right vertical mounting rail.

Filler Panel Installation PR3
Purpose/Scope
20 min.
This procedure explains how to install the filler panels into the
cabinets.
Parts
6644418?1 1 Filler panel, 1 U
1
6644418?2 0 or 1 Filler panel, 2 U
1
NMPCB16003 4 or 81 Nut, cage, 10-32
NOTE:
1. Use greater quantity for cabinets with 1 power chassis and lesser quantity for cabinets with 2
power chassis.
Tools Bladed screwdriver.

damage.
Procedure
W1 procedure.
h 2. Open the front door of the cabinet.
h 3. Keeping in mind the component arrangement discussed at

the beginning of this installation sequence, install cage nuts
on the proper locations on the front mounting brackets
(Fig. PR3-1).
NOTE: Figure PR3-1 shows a single power chassis configuration. In dual

power chassis configurations the top power chassis takes the place of the large
filler panel.

Procedure
a. For single power chassis installations, install the cage

nuts on the 1st, 3rd, 4th, 9th, 10th, and 12th holes from
the top of the cabinet.
b. For dual power chassis installations, install the cage

nuts on the 1st, 3rd, 10th, and 12th holes from the top of
the cabinet.
h 4. Use the bladed screwdriver, and appropriate number of

pan head screws and lockwashers to secure the filler plates to
the front mounting brackets.
C AG E N U T, S C R E W,
L O C K W A S H E R (4 F O R
L A R G E F ILL E R PA N E L,
2 F O R S M A L L F IL LE R
PA N E LS
S M A L L F IL LE R
PA N E L (2 ) L A R G E F ILL E R PA N E L
(O N LY IF S E C O N D
N OT IN S TA L LE D )
F R O N T D O O R R E M OV E D T 04 470 A
Figure PR3-1. Filler Panel Installation

Power Chassis Installation PR4
Purpose/Scope
20 min.
This procedure explains how to install the power chassis into
the cabinets.
Parts
1
200021A040S100 4 or 8 Screw, pan head phil, M4 x 10
1
200036A040A1008 4 or 8 Washer, flat, M4
1
200037A040A1009 4 or 8 Washer, lock, M4
200037A080A1020 4 or 81 Lockwasher, helical spring, M8
NMPCC16002 4 or 81 Nut, cage, 10-32
P-HA-RPS-CH100000 1 or 21 Power chassis
NOTE:
1. Use lesser quantity for cabinets with 1 power chassis and greater quantity for cabinets with
2 power chassis.


damage.
Procedure
W1 procedure.

the beginning of this installation sequence, install cage nuts

Procedure
on the proper locations on the front mounting brackets

(Fig. PR4-1).
NOTES:
1. This step does not apply if this procedure is part of the replacement
sequence.
2. Figure PR4-1 shows a single power chassis configuration. In dual power

chassis configurations the top power chassis takes the place of the large filler
panel.
a. For single power chassis installations, install the cage

nuts on the 14th and 17th holes from the top of the
cabinet.
b. For dual power chassis installations, install the cage

nuts on the 5th, 8th, 14th, and 17th holes from the top of
the cabinet.
h 4. Install the power chassis from the front of the cabinet until
the rear of the power chassis rests on the rear mounting
brackets while still manually supporting the front of the power
chassis.
h 5. Use the bladed screwdriver, and appropriate number of

pan head slotted screws and M8 lockwashers to secure the
power chassis to the front mounting brackets.
h 6. Use the Phillips screwdriver, and appropriate number of

pan head Phillips screws, M4 lockwashers, and M4 flat wash-
ers to secure to power chassis to the rear mounting brackets.
h 7. If this procedure is part of power chassis replacement

rather than an initial installation, duplicate the wiring and
cabling from the replaced power chassis to the new power
chassis. If this procedure is part of initial power chassis instal-
lation, continue with the next procedure in the installation
sequence.
PR4 - 2 WBPEEUI210509A4
Procedure
C AG E N U T,
LOC KWASHER,
S C R E W (4 P E R
P O W E R C H A S S IS )
B R AC K E T
B R AC K E T
B R AC K E T
S C R E W, F LAT W A S H E R ,
L O C K W A S H E R (E AC H S ID E
B O T TO M R E A R O F P O W E R
C H A S S IS )
R E A R D O O R R E M OV E D T 04 471 A
Figure PR4-1. Power Chassis Installation

Power Supply Tray Installation PR5
Purpose/Scope
5 min.
This procedure explains how to install the power supply trays
into the power chassis.
Parts
Number Description
P-HA-RPS-00010000 Power supply tray, 125 VDC at 2.3 A
P-HA-RPS-00200000 Power supply tray, 48 VDC at 8.5 A
P-HA-RPS-02010000 Power supply tray, 24 VDC at 17 A, 125 VDC at 2.3 A
P-HA-RPS-02200000 Power supply tray, 24 VDC at 17 A, 48 VDC at 8.5 A
P-HA-RPS-03000000 Power supply tray, 24 VDC at 17 A (dual output, 34 A total)
P-HA-RPS-11000000 Power supply tray, 5 VDC at 14 A, ±15 VDC at 1 A each,
24 VDC at 6 A
24 VDC at 6 A, 125 VDC at 2.3 A
24 VDC at 6A, 48 VDC at 3 A
24 VDC at 6 A
24 VDC at 6 A, 125 VDC at 2.3 A
24 VDC at 6 A, 48 VDC at 8.5 A
24 VDC at 17 A
24 VDC at 17 A, 125 VDC at 2.3 A
24 VDC at 17 A, 48 VDC at 8.5 A
P-HA-RPS-40000000 Power supply tray, 5 VDC at 100 A, ±15 VDC at 8 A each
Tools None.


damage.
1. Do not use the same power level from two power chassis.
Doing so will disrupt the active power sharing scheme and
damage the power system.
CAUTION 2. Turn off the circuit breaker on the power entry panel (PEP)
corresponding to the line (LINE 1 or LINE 2) that powers the
power supply tray to be removed or installed. Process upset
may occur if a power supply tray is removed or installed with
power applied.
Procedure
This procedure can be used for an initial installation or as part
of power chassis replacement with no power applied to the
cabinet (refer to Initial Installation), or as part of the power
supply tray replacement procedures with power applied to the
cabinet (refer to Field Installation).
Initial Installation
W1 procedure.

the beginning of this installation sequence, slide the appropri-
ate power supply tray into the appropriate power chassis and
push until it firmly connects with the power chassis.
h 4. Turn the two thumbscrews (Figure PR5-1) clockwise to

secure the power supply tray to the power chassis.
NOTE: Figure PR5-1 shows a single power chassis configuration. In dual

power chassis configurations the top power chassis takes the place of the large
filler panel.
Procedure
T H U M B S C R E W S (4)
T R AY S
F R O N T D O O R R E M OV E D T 0 447 2A
Figure PR5-1. Power Supply Tray Installation
h 5. Slide another power supply tray of the same type into the
other side of the power chassis and push until it firmly con-
nects with the power chassis.
h 6. Turn the two thumbscrews clockwise to secure the power

supply tray to the power chassis.
h 7. Repeat Steps 3 through 6 if for the second power chassis if

C1 this is a dual power chassis installation. Output voltages from
each power chassis must be kept isolated from each other to
avoid damage to the power system. This typically means that
one power chassis supplies module power (±15 VDC and
5 VDC) and the other supplies field I/O power (24 VDC,
48 VDC, and 125 VDC).
Field Installation
The power supply trays can be installed into an operational
control system. This procedure assumes that the remaining
WBPEEUI210509A4 PR5 - 3
Procedure
installed power supply tray is operational and that its status

light is on.
h 1. Open the front door to the cabinet.
h 2. Verify that the circuit breaker on the PEP to the line (LINE
C2 1 or LINE 2) that will power the power supply tray to be
installed is off.
h 3. Slide the new power supply tray into the power chassis and
push until it firmly connects with the power chassis.
h 4. Turn the two thumbscrews (Figure PR5-1) clockwise to

secure the power supply tray to the power chassis.
h 5. Plug the power cord into the front of the power supply tray
and secure it with the wire retaining clip.
h 6. Check the circulation vents on the power supply trays and

power chassis and make sure they are free of air flow
obstructions.
h 7. Turn the proper circuit breaker on the PEP to the on

position.
h 8. Verify that the status LED is lit.
PEP Installation PR6
Purpose/Scope
20 min.
This procedure explains how to install the PEP into the
cabinets.
Parts
200037A080A1020 4 Lockwasher, helical spring, M8
NIDHA16008 4 Screw, sems ext pan head slot, 0.190-32
NMPCC16002 4 Nut, cage, 10-32
6644463?1 1 PEP, 120/240 VAC, 25 A, without line filter
6644463?2 PEP, 120/240 VAC, 25 A, with line filter
6644463?3 PEP, 120/240 VAC, 25 A; 125 VDC, 25 A,
without line filter
6644463?4 PEP, 120/240 VAC, 25 A; 125 VDC, 25 A,
with line filter
6644463?5 PEP, 125 VDC, 25 A, without line filter
6644463?6 PEP, 125 VDC, 25 A, with line filter

damage.
Procedure
W1 procedure.
h 3. Install cage nuts on the 21st and 28th holes from the top
of the cabinet on the front mounting brackets (Fig. PR6-1).

Procedure
h 4. Use the bladed screwdriver, and four screws and lockwash-

ers to secure the PEP to the front mounting brackets.
h 5. If this procedure is part of PEP replacement rather than an

initial installation, duplicate the wiring and cabling from the
replaced PEP to the new PEP. If this procedure is part of initial
PEP installation, continue with the next procedure in the
installation sequence.
B R AC K E T
C AG E N U T,
LO C K W A S H E R ,
S C R E W (4)
PEP
F R O N T D O O R R E M OV E D T04473A
Figure PR6-1. PEP Installation

Fan Assembly Installation PR7
Purpose/Scope
20 min.
This procedure explains how to install the fan assembly into
the cabinets.
Parts
200037A080A1020 4 Lockwasher, helical spring, M8
NIDHA16008 4 Screw, sems ext pan head slot, 0.190-32
NMPCC16002 4 Nut, cage, 10-32
P-HA-RPS-FAN03000 1 Fan assembly

damage.
Procedure
W1 procedure.
h 2. Open the rear door of the cabinet.
h 3. Install cage nuts on the 28th and 30th holes from the top
of the cabinet on vertical mounting rail inside the cabinet
(Fig. PR7-1).
h 4. Slide the fan assembly into the cabinet from the rear until
the holes in the mounting bracket on the rear of the fan
assembly align with the cage nuts.
h 5. Use the bladed screwdriver, and four screws and lockwash-

ers to secure the fan assembly to the vertical mounting rail.

Procedure
h 6. If this procedure is part of fan assembly replacement

cabling from the replaced fan assembly to the new fan assem-
bly. If this procedure is part of initial fan assembly installation,
continue with the next procedure in the installation sequence.
2 8T H S Q UA R E
C AG E N U T,
LOCKWASHER,
FA N A S S E M B LY S C R E W (4)
R E A R D O O R R E M OV E D T 0 447 4A
Figure PR7-1. Fan Assembly Installation

DC Bus Monitoring Assembly PR8
Installation
Purpose/Scope
5 min.
This procedure explains how to install the DC bus monitoring
assembly onto the rear of the power chassis.
Parts
Tools • Phillips screwdriver.

damage.
Procedure
W1 procedure.
h 3. Refer to Figure PR8-1 and use the Phillips screwdriver to

remove the two screws that secure the right DIN rail mounting
bracket to the DC bus monitoring assembly and remove the
right DIN mounting bracket.
h 4. Slide the protective cover off of the DC bus monitoring

assembly.
h 5. Set the jumper on the DC bus monitoring assembly as

desired as shown in Figure PR8-2.
h 6. Slide the protective cover onto the DC bus monitoring

assembly.
Procedure
h 7. Install the right DIN mounting bracket and use the Phillips
screwdriver to install the two screws that secure the right DIN
rail mounting bracket to the DC bus monitoring assembly.
h 8. Attach the DC bus monitoring assembly to the DIN rail on

the rear of the power chassis and press the locking devices
into place as shown in Figure PR8-3.
h 9. Refer to Figure PR8-3 and connect the wires to the DC bus

bar and the cable connector to J1.
NOTE: Do not disconnect or connect the cable from the DC bus monitoring
assembly to the DC bus bar while the system is operating. Doing so could
cause a PFI to occur.
h 10. If this procedure is part of DC bus monitoring replacement

cabling from the replaced bus monitoring assembly to the new
DC bus monitoring assembly. If this procedure is part of initial
DC bus monitoring assembly installation, continue with the
next procedure in the installation sequence.
P R O T E C T IV E
C OV E R
SCREW S
(2)
J1 J2
R IG H T D IN R A IL
M O U N T IN G B R AC K E T T 0 449 7A
Figure PR8-1. DC Bus Monitoring Assembly Jumper Access
Procedure
J2
1 2 1 2
3 4 3 4
5 6 5 6
± 15V D C + 15V D C D IS A B LE D 1 2
D IS A B LE D – 15V D C E N A B LE D 3 4
5 6
P R O T E C T IV E 1 2 1 2 C U S TO M E R
C OV E R
3 4 3 4 S E T T IN G
5 6 5 6
+ 15V D C E N A B LE D ± 15V D C
– 15V D C D IS A B LE D E N A B LE D
J1 J2
T04475B
Figure PR8-2. DC Bus Monitoring Assembly Jumper Settings
Procedure
25.5V
25.5V R E T
S TAT U S O U T
+15V
– 15V
48V
125V
15V RT N
48V /125V RT N
J1
J2
5V R E T
5V
RED
+5 VDC R E A R V IE W
ORN
+15 VDC
B LK
– 15 VDC
W HT
M C O M (+ 5 V D C RT N )
YEL
PFI
T04480B
Figure PR8-3. DC Bus Monitoring Assembly Installation
Wiring and Cabling PR9
Purpose/Scope
4 hr
This procedure contains wiring diagrams and guidelines.
Parts None.
Tools Individual tools are not listed due to the many types of connec-
tions involved.

damage.
1. Do not use the same power level from two power chassis.
CAUTION Doing so will disrupt the active power sharing scheme and
damage the power system.
Procedure
W1 procedure.
Wiring and Cabling Diagrams

Figures PR9-1 and PR9-2 are the wiring and cabling diagrams
for single power chassis installations. Figures PR9-3 and
PR9-4 are the wiring and cabling diagrams for dual power
chassis installations. Wiring and cabling guidelines follow
those figures.

Procedure
P O W E R C H A S S IS W IT H P O W E R S U P P LY T R AY S IN S TA LLE D
P O W E R IN P U T P O W E R IN P U T
M A IN
POW ER
L IN E 1 IN P U T LIN E 1 O U T P U T
IN P U T
L L1 + BRN
BRN
N L2 – CB1 BLU
BLU
G R N /Y E L
G R N /Y E L
AU X ILIA RY
POW ER
L IN E 2 IN P U T LIN E 2 O U T P U T
IN P U T
L L1 + BRN
BRN
N L2 – CB2 BLU
W R IS T S T R A P BLU
G R N /Y E L
G R N /Y E L
PEP T 04 46 5A
Figure PR9-1. Single Chassis Wiring and Cabling Diagram - Front of Cabinet

Procedure
C H A S S IS
GRO UND
6 mm2 STUD
(10 AW G ) G R N /Y E L
N O D E S TAT U S TO
IN F I-N E T
W H T /V IO 6 m m 2 (10 AW G ) T E R M IN AT IO N
V IO 6 m m 2 (10 AW G ) 1 m m 2 (18 AW G )
G R AY
I/O 25.5V D C
M O D U LE A N D I/O P OW E R C H A S S IS
CO M +24V D C B U S M O N ITO R IN G
25.5V R T N A S S E M B LY
S TAT U S O U T
+15V
– 15V
48V
125V
15V RT N
48/125V RT N
J1
5V RT N J2
5V D C
6 m m 2 (12 AW G ) G R N /Y E L
S U P P LIE D W IT H P E P
LIN E 1 O U T P U T CB1 LIN E 1 IN P U T

L L1 +
N L2 –
LIN E F ILT E R LIN E F ILT E R
SURGE SURGE GND STUD
GND
SUPPRESSOR SUPPRESSOR
+5V LIN E 2 O U T P U T LIN E 2 IN P U T
2 1
L L1 +
N L2 –
MCOM
CB2
+15V
– 15V
YEL
PFI
S TAT U S PEP
B LK
I/O C O M
W HT 24 IN C H W IR E A N D LU G (G R AY ) F O R S TAT U S
+24V C O N N E C T IO N P R OV ID E D W IT H FA N A S S E M B LY
S TAT U S
RED T E M P E R AT U R E O UTPUT D O O R FA N
+5V
WHT S E LE C T M O N ITO R D O O R FA N
MCOM
ORN POW ER
+15V FA N A S S E M B LY GRN
B LK
– 15V TO D O O R FA N
+5V +5V
MCOM MCOM
+15V +15V
– 15V – 15V
PFI PFI
S TAT U S S TAT U S
NO
I/O C O M I/O C O M
C O N N E C T IO N
+24V +24V
ORN
PFI M BUS
YEL
S TAT U S M BUS
WHT
I/O C O M MCOM
+24V
TO N E X T M M U
1 m m 2 (18 AW G )
(3-W IR E T W IS T E D )
W H T/O R N 4.5 m m 2 (1 2 AW G )
W H T/O R N
+24V W H T/O R N TO I/O T E R M IN AT IO N S
W H T/O R N
2
G R AY 6 m m (10 AW G )
G R AY
I/O C O M G R AY
G R AY
MCOM
DC BUS BAR
I/O C O M M O N B U S
T 04466 B
Figure PR9-2. Single Chassis Wiring and Cabling Diagram - Rear of Cabinet

Procedure
M A IN
POW ER
IN P U T
L L1 +
BRN BRN
N L2 – CB1
B LU B LU
AU X ILIA RY
POW ER
IN P U T
L L1 +
BRN BRN
N L2 – CB2
W R IS T S T R A P B LU B LU
PEP
T 044 67 A
Figure PR9-3. Dual Chassis Wiring and Cabling Diagram - Front of Cabinet

Procedure
C H A S S IS
GROUND
6 mm2 STUD
(1 0 AW G ) G R N /Y E L
S e e C a u tio n N o te C 2 in W irin g
a n d C a b lin g G u id e lin e s b e fo re N O D E S TAT U S T O
IN F I-N E T
m a k in g th is c o n n e c tio n T E R M IN AT IO N
1 m m 2 (1 8 AW G )
G R AY
2 5 .5 V D C
I/O P O W E R C H A S S IS
2 5 .5 V R T N
15V RTN
48/125V RTN
STATUS OUT
+15V
–15V
48V
125V
5V RTN
5VDC
W H T /V IO 6 m m 2 (1 0 AW G )
V IO 6 m m 2 (1 0 AW G )
I/O 2 5 .5 V D C
M O D U L E A N D I/O P O W E R C H A S S IS
C O M + 2 4V D C B U S M O N IT O R IN G
2 5 .5 V R T N A S S E M B LY
15V RTN
48/125V RTN
STATUS OUT
+15V
–15V
48V
125V
J1
5V RTN J2
5VDC
6 m m 2 (10 AW G ) G R N /Y E L
S U P P L IE D W IT H P E P
L IN E 1 O U T P U T CB1 L IN E 1 IN P U T
L L1 +
N L2 –
L IN E F ILT E R LIN E F ILT E R
SURG E SURGE GND STUD
GND
SUPPRESSOR SUPPRESSOR
+5V L IN E 2 O U T P U T 2 1 L IN E 2 IN P U T
L L1 +
N L2 –
M COM
CB2
+ 1 5V
– 15V
YEL
PFI
S TAT U S PEP
BLK
I/O C O M 24 IN C H W IR E A N D LU G (G R AY ) F O R S TAT U S
WHT
+ 2 4V C O N N E C T IO N P R O V ID E D W IT H FA N A S S E M B LY
S TAT U S
RED T E M P E R AT U R E OUTPUT D O O R FA N
+5V
W HT S E LE C T M O N IT O R D O O R FA N
M COM PO W ER
ORN FA N A S S E M B LY
+15V GRN
BLK
– 15V T O D O O R FA N
+5V + 5V
M COM MCOM
+ 1 5V + 15 V
– 15V –15V
PFI PFI
M O D U L E M O U N T IN G U N IT
S TAT U S S TAT U S
NO
I/O C O M I/O C O M
C O N N E C T IO N
+ 2 4V + 24 V
ORN
PFI MBUS
YEL
S TAT U S MBUS
WHT
I/O C O M MCOM
+24V
TO N E X T M M U
1 m m 2 (18 AW G )
(3 -W IR E T W IS T E D )
W H T /O R N 4 .5 m m 2 (1 2 AW G )
W H T /O R N
+ 2 4V W H T /O R N T O I/O
W H T /O R N
G R AY 6 m m 2 (1 0 AW G )
G R AY
I/O C O M G R AY
G R AY
M COM
DC BUS BAR
I/O C O M M O N B U S
T 0 4 4 68 B
Figure PR9-4. Dual Chassis Wiring and Cabling Diagram - Rear of Cabinet

Procedure
Wiring and Cabling Guidelines

1. Mixing different input voltages is permitted; however, when
using one AC feed and one DC feed, the AC feed must be the
LINE 1 input.
2. When Overvoltage Category III rating is required, use a PEP

with the optional transient surge suppressor/line filters. When
not using suppressors the circuit breakers on the PEP wire
directly to the output terminals. When Overvoltage Category III
is required, take care to keep input wiring separated from the
cables to the power supply trays.
3. No loads other than system components shown in the fig-

ures are to be connected to the input source. Supplemental
loads (lights, convenience outlets, I/O, etc.) must be powered
from a separate power source.
4. Due to the limitations of the faston connectors on the DC

bus bar, allow no more than 15 Amperes per 24 VDC wire con-
nection. Add terminal blocks or IEPDP01 for more connec-
tions.
5. All modules within a cabinet must source their 5 VDC

C1 power from only one power chassis. Only one power chassis
may supply 24 VDC power to the DC bus bar. If using more
than one power chassis to supply 24 VDC power, care must be
taken not to connect the 24 VDC power provided from different
power chassis or damage to the power system may result.
6. Status connections may be daisy chained with the last

power chassis connected to the INFI-NET ® termination.

Procedure
The power supply chassis used in the MPSIII system contains

two exhaust fans located in the top, rear of the unit used for the
purpose of cooling the power supply trays. These exhaust fans
are powered by 24VDC from the trays themselves. Without the
24VDC, the exhaust fans will not operate. Certain models of the
power supply trays do not supply the needed 24VDC to power
the fans.
In this case, a second power supply system is required to be

C2
installed in the cabinet to supply this voltage. The 25.5 VDC
and 25.5 VDC return bars on the back of the power supply
chassis will need to be connected to their mates as shown in
figure PR9-4.
DO NOT MAKE THIS CONNECTION TO A POWER SUPPLY

TRAY CONTAINING POWER SUPPLIES THAT SUPPLY 24VDC!

Procedure

Power Supply Tray Removal PR10
Purpose/Scope
2 min.
This procedure explains how to remove the power supply trays
from the power chassis.
Parts None.
Tools None.

damage.
1. Turn off the circuit breaker on the power entry panel (PEP)
corresponding to the line (LINE 1 or LINE 2) that powers the
CAUTION power supply tray to be removed or installed. Process upset
may occur if a power supply tray is removed or installed with
power applied.
Procedure
There are two scenarios in which a power supply tray would be
removed from the MPSIII system. One is if power supply tray
removal is part of power chassis replacement. In this case, all
power supply trays are removed from the power chassis to be
replaced with power disconnected at the source (refer to Power
Disconnected at Source). The other scenario is if removal is
necessary to replace the power supply tray itself. In this case,
power is only removed from the power supply tray to be
replaced (refer to Power Disconnected from Single Power
Supply Tray).
Procedure
Power Disconnected at Source

All power supply trays can be removed from a power chassis
as long as power is disconnected at the source. Perform this
procedure as part of power chassis replacement.

W1 procedure.
h 3. Remove the power cord from the front of each power sup-
ply tray to be removed.
h 4. Turn the two thumbscrews (Figure PR10-1) on each power

supply tray counterclockwise to release the power supply trays
from the power chassis.
h 5. Slide the power supply trays out of the power chassis.
T H U M B S C R E W S (4)
T R AY S
F R O N T D O O R R E M OV E D T 0 447 2A
Figure PR10-1. Power Supply Tray Removal
Procedure
Power Disconnected from Single Power Supply Tray

The power supply trays can be removed from an operational
control system. This procedure assumes that the remaining
installed power supply tray is operational and that its status
light is on.
h 1. Open the front door to the cabinet.
h 2. Turn off the circuit breaker on the PEP to the line (LINE 1
C2 or LINE 2) that powers the power supply tray to be removed.
h 3. Remove the power cord from the front of the power supply
tray.
h 4. Turn the two thumbscrews (Figure PR10-1) counterclock-

wise to release the power supply tray from the power chassis.
h 5. Slide the power supply tray out of the power chassis.
DC Bus Monitoring Assembly PR11
Removal
Purpose/Scope
5 min.
This procedure explains how to remove the DC bus monitoring
assembly from the rear of the power chassis.
Parts None.

damage.
Procedure
W1 procedure.
h 3. Disconnect and label the cable from J1 (Fig. PR11-1) on

the DC bus monitoring assembly.
NOTE: Do not disconnect or connect the cable from the DC bus monitoring
assembly to the DC bus bar while the system is operating. Doing so could
cause a PFI to occur.
h 4. Refer to Figure PR11-1 and use the bladed screwdriver to

disengage the locking device on the DC bus monitoring
assembly.
h 5. Remove the DC bus monitoring assembly from the DIN

rail.

Procedure
2 5.5V
2 5.5V R E T
S TAT U S O U T
+15V
– 15V
48V
125V
15V RT N
48V /125V RT N
J1
J2
5V RET
5V
RED
+5 VDC
ORN
R E A R V IE W
+ 15 V D C
B LK
– 15 V D C
WHT
M C O M (+ 5 V D C R T N )
YEL
PFI
T04 48 1B
Figure PR11-1. DC Bus Monitoring Assembly Removal
Power Chassis Removal PR12
Purpose/Scope
10 min.
This procedure explains how to remove the power chassis from
the cabinet.
Parts None.

damage.
Procedure
W1 procedure.
h 3. Disconnect and label all wires connected to the power

chassis.
h 4. Use the Phillips screwdriver to remove the pan head Phil-

lips screws, M4 lockwashers, and M4 flat washers that secure
the power chassis to the rear mounting brackets (Fig. PR12-1).
h 5. While supporting the front of the power chassis, use the

bladed screwdriver to remove the pan head slotted screws and
M8 lockwashers that secure the power chassis to the front
mounting brackets (Fig. PR12-1).
h 6. Remove the power chassis from the cabinet.

Procedure
Figure PR12-1. Power Chassis Removal

PEP Removal PR13
Purpose/Scope
10 min.
This procedure explains how to remove the PEP from the
cabinet.
Parts None.

damage.
Procedure
W1 procedure.
h 3. Label and remove all wires connected to the PEP.
h 4. Use the bladed screwdriver to remove the four screws and

lockwashers that secure the PEP to the front mounting
brackets.
h 5. Remove the PEP from the cabinet.

Procedure
B R AC K E T
C AG E N U T,
LO CKWASHER,
S C R E W (4 )
PEP
F R O N T D O O R R E M OV E D T04473A
Figure PR13-1. PEP Removal

Fan Assembly Removal PR14
Purpose/Scope
5 min.
This procedure explains how to remove the fan assembly from
the cabinet.
Parts None.

damage.
Procedure
W1 procedure.
h 3. Label and remove all cables from the fan assembly.
h 4. Use the bladed screwdriver to remove the four screws and

lockwashers that secure the fan assembly to the vertical
mounting rail. (Fig. PR14-1).
h 5. Slide the fan assembly out of the cabinet from the rear.

Procedure
2 8T H S Q UA R E
C AG E N U T,
LOCKWASHER,
FA N A S S E M B LY S C R E W (4)
R E A R D O O R R E M OV E D T 0 447 4A
Figure PR14-1. Fan Assembly Removal

Cabinet Air Filter Cleaning PR15
Purpose/Scope
10 min.
This procedure explains how to clean the cabinet air filter.
Parts None.
• Clean, dry, filtered compressed air.
• Distilled water.
• Mild detergent (i.e., dishwashing soap).
Procedure
The cabinet air filter mounts over the lower air vent, inside the
cabinet front door.
NOTE: This procedure addresses air filter cleaning. If the air filter does not
come clean or is in any way damaged, refer to the Symphony Enclosures
instruction and replace it with a new one.
h 1. Use the bladed screwdriver to remove one screw securing

the mounting plate at the top of the air filter mounting
bracket.
h 2. Pull the mounting bracket and air filter off the cabinet
door.
h 3. Remove the air filter from its mounting bracket.
h 4. If the air filter is dry and relatively clean, use compressed

air to blow dust and dirt free from the filter.
h 5. Clean a dirty filter in distilled water and mild detergent.

Agitate the filter or squeeze the soapy water through the filter
to remove built-up dirt.
h 6. When the filter is clean, rinse the filter thoroughly with dis-
tilled water.
h 7. Air dry the filter before replacing it.
h 8. Wipe any dust or dirt from the mounting bracket.
Procedure
h 9. Return the dry filter to its mounting bracket.
h 10. Place the mounting bracket into position on the cabinet

door and tighten the screw that holds the mounting plate over
the air filter mounting bracket.

Checking Connections PR16
Purpose/Scope
1 hr
This procedure explains how to check connections.
Parts None.
Tools Individual tools cannot be listed due to the numerous connec-
tions involved.

damage.
Procedure
Check all signal wiring, power, and ground connections within
the cabinet to verify their integrity. When checking connec-
tions, 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 to loosen
the connection.

W1 procedure.
h 2. Check and verify that all line, neutral, and grounding con-
ductor connections on the PEP are secure and within the
torque values listed in Table PR16-1.
h 3. Check and verify that all other power connections within

the cabinet, including connections to the power chassis are
secure and within the torque values listed in Table PR16-1.
h 4. Check and verify that all field wiring connections to the

modules are secure.
Procedure
Table PR16-1. Torque Values
Torque Value
Connection
Nm in.-lbs
PEP terminal blocks 1.58, ±0.11 14, ±1
5 VDC and 24 VDC connections on 6.77, ±0.23 60, ±2
DC bus bar and power chassis
Terminal block on power chassis 1.36, ±0.11 12, ±1

Index
A I
Air filter cleaning ................................ PR15-1 Inspection..................................................3-2
Applications .............................................. 1-2 Installation
DC bus monitoring assembly ............PR8-1
C Fan assembly ....................................PR7-1
Filler panel.........................................PR3-1
Component arrangement..................... PR1-1 Mounting bracket...............................PR2-1
PEP ...................................................PR6-1
D Power chassis ...................................PR4-1
Power entry panel .............................PR6-1
DC bus monitoring assembly Power supply tray..............................PR5-1
Description and operation...................... 2-7 Sequence ...............................................3-4
Installation......................................... PR8-1 Wiring and cabling......................3-3, PR9-1
Removal.......................................... PR11-1 Intended user ............................................1-1
Description and operation......................... 2-1
DC bus monitoring assembly................. 2-7
Fan assembly ........................................ 2-7
M
PEP........................................................ 2-6 Maintenance..............................................5-1
Power chassis........................................ 2-1 Air filter cleaning..............................PR15-1
Power entry panel.................................. 2-6 Checking connections .....................PR16-1
Power supply tray .................................. 2-5 Schedule ................................................5-2
Document conventions ............................. 1-3 Mounting bracket..................................PR2-1
F N
Fan assembly Nomenclature............................................1-4
Description and operation...................... 2-7
Installation......................................... PR7-1 P
Removal.......................................... PR14-1
Troubleshooting ..................................... 4-1 PEP
Features ................................................... 1-2 Description and operation ......................2-6
Filler panel ........................................... PR3-1 Installation .........................................PR6-1
Removal ..........................................PR13-1
G Power chassis
Description and operation ......................2-1
Glossary ................................................... 1-4 Installation .........................................PR4-1
Removal ..........................................PR12-1
H Power entry panel
Description and operation ......................2-6
How to use this instruction........................ 1-3 Installation .........................................PR6-1
Removal ..........................................PR13-1
Power supply tray
WBPEEUI210509A4 August 2011 Index - 1

Index (continued)
Description and operation...................... 2-5 S

Installation......................................... PR5-1
LEDs ...................................................... 4-1 Safety considerations................................3-3
Removal.......................................... PR10-1 Spare parts................................................7-1
Troubleshooting ..................................... 4-1 Special handling........................................3-1
Specifications ............................................1-6
R
T
Reference documents .............................. 1-4
Removal Troubleshooting
DC bus monitoring assembly.......... PR11-1 Fan assembly .........................................4-1
Fan assembly ................................. PR14-1 Power supply tray...................................4-1
PEP................................................. PR13-1
Power chassis................................. PR12-1 U
Power entry panel........................... PR13-1
Unpacking .................................................3-2
Power supply tray ........................... PR10-1
Replacement ............................................ 6-1
W
Wiring and cabling.........................3-3, PR9-1
WBPEEUI210509A4 August 2011 Index - 2

WBPEEUI210509A4 Litho in U.S.A. August 2011
Copyright © 2009 by ABB. All Rights Reserved
® Registered Trademark of ABB.
™ Trademark of ABB.
http://www.abb.com/control
Automation Technology Products Automation Technology Products Automation Technology Products

Wickliffe, Ohio, USA Västerås, Sweden Mannheim, Germany
www.abb.com/processautomation www.abb.com/processautomation www.abb.de/processautomation
email: industrialitsolutions@us.abb.com email: processautomation@se.abb.com email: marketing.control-products@de.abb.com

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WBPEEUI210509A4 en Harmony Modular Power System III User Manual

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ControlIT

Modular Power System III

The Modular Power System III (MPSIII) supplies 5 VDC,

This instruction provides specific hardware installation, trou-

This instruction can be used as a guide by system engineers. It

Some sections of this instruction have been prepared in proce-

The procedures have check boxes in the margin by each step.

Do not perform any procedures related to installation, mainte-

WBPEEUI210509A4 August 2011

Total number of pages in this instruction is 104, consisting of the following:

Page No. Change Date Page No. Change Date

August 2011 WBPEEUI210509A4

Section 1 Introduction ..................................................................................................1-1

Section 2 Description and Operation .........................................................................2-1

Section 3 Installation ....................................................................................................3-1

Section 4 Troubleshooting ..........................................................................................4-1

Section 5 Maintenance .................................................................................................5-1

WBPEEUI210509A4 August 2011 iii

Section 6 Replacement Procedures ...........................................................................6-1

Section 7 Spare Parts ...................................................................................................7-1

iv August 2011 WBPEEUI210509A4

PR1 Component Arrangement

WBPEEUI210509A4 August 2011 v

2-1. MPSIII System Architecture .......................................................................2-2

vi August 2011 WBPEEUI210509A4

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

WBPEEUI210509A4 August 2011 vii

viii August 2011 WBPEEUI210509A4

Electrostatic Sensitive Device

GENERAL Equipment Environment

Electrical Shock Hazard During Maintenance

SPECIFIC Disconnect power before attempting these procedures. Failure to do

ix August 2011 WBPEEUI210509A4

x August 2011 WBPEEUI210509A4

ABB will provide assistance in the operation and repair of its

When ordering parts, use nomenclature or part numbers and

ABB has modern training facilities available for training your

Additional copies of this instruction, or other instructions, can

WBPEEUI210509A4 August 2011 xi

xii August 2011 WBPEEUI210509A4

Registrations and trademarks used in this document include:

xiii August 2011 WBPEEUI210509A4

xiv August 2011 WBPEEUI210509A4

The MPSIII system is designed to operate with 2N power

Personnel working with the power system should:

• Have experience working with AC and DC power.

• Know what safety precautions to take when working with

• Have experience and knowledge of working with basic elec-

• Have training in and experience working with electrical

WBPEEUI210509A4 August 2011 1-1

It is a direct replacement for MPSII systems, used in Harmony

• Power Factor Correction. AC inputs have active power

• Online Replaceable Components. Power supply trays

• Monitoring Functions. Monitors supplies, fans, and cabi-

• Directly Accepts 120 VAC, 240 VAC, or 125 VDC Inputs.

1-2 August 2011 WBPEEUI210509A4

sequence flowcharts that direct installation personnel to the

How to use this Instruction

Some sections of this instruction have been prepared in proce-

Each procedure lists the recommended tools to perform that

WBPEEUI210509A4 August 2011 1-3

Part number: 1234567?0

Glossary of Terms and Abbreviations