• Topic ID: id_23554156
  • Version: 4.0
  • Date: Nov 27, 2020 2:19:45 AM

NGPDU—61 Spare Part Replacement Procedures

Prerequisites

Overview

This procedure covers the replacement of components within the PDU. If necessary, refer to the PDU Covers Remove/Install procedure.

1 NGPDU-61 Replacement Parts

Refer to Figure 1 for component location numbering. Refer to Table 6 and Links for replacement steps for that component.

1.1 24 VDC Supply Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Remove the connectors from the 24 VDC Power Supply (located in the lower right corner of the PDU).
  5. Remove the two screws holding the 24 VDC Power Supply in place.
  6. Remove the 24 VDC Power Supply from the PDU.
  7. Install the new 24 VDC Power Supply in the PDU and secure it with the screws removed earlier.
  8. Attach the connectors to the replacement 24 VDC Power Supply.
  9. Install the front plastic safety shield.
  10. Install the PDU Front Cover and Top Cover.
  11. Remove all Lockout/tagout devices installed.
  12. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.2 DC Capacitor Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Remove the plate on top of the capacitors by removing the eight screws and connectors.
    note:

    Observe capacitor polarity and connector alignment.

  5. Loosen the clamping screw holding the capacitor in place.
  6. Slide the capacitor out towards the front of the PDU.
  7. Slide in the new capacitor.
  8. Tighten the clamping screw around the new capacitor to hold it in place.
  9. Install the plate over the capacitors using the 8 screws previously removed, attaching all connectors to their original connections.
  10. Install the front plastic safety shield.
  11. Install the PDU Front Cover and Top Cover.
  12. Remove all Lockout/tagout devices installed.
  13. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.3 Circuit Breaker Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Remove the wires connected to the failed circuit breaker.
  5. Remove the screws or restraint device holding the circuit breaker in place.
  6. Remove the circuit breaker.
  7. Install the new circuit breaker.
  8. Install the screws or restraint device holding the circuit breaker in place.
  9. Connect the previously removed wires to the circuit breaker.
  10. Install the front plastic safety shield.
  11. Install the PDU Front Cover and Top Cover.
  12. Remove all Lockout/tagout devices installed.
  13. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.4 Contactor Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service – Electrical Lockout Tagout - A1 Panel” procedure in Safety folder of publication.
  2. Refer to KXG Contactor Replacement Procedure
  3. Restore PDU to original configuration
  4. Install the front plastic safety shield.
  5. Install the PDU Front Cover and Top Cover.
  6. Remove all Lockout/tagout devices installed.
  7. Restore power to the system.

1.5 Diode Bridge Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Remove the wires connected to the failed Diode Bridge.
  5. Remove the two screws holding the Diode Bridge in place.
  6. Remove the Diode Bridge.
  7. Install the new Diode Bridge.
  8. Install the two screws holding the Diode Bridge in place.
  9. Connect the wires to the Diode Bridge.
  10. Install the front plastic safety shield.
  11. Install the PDU Front Cover and Top Cover.
  12. Remove all Lockout/tagout devices installed.
  13. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.6 E-Stop Switch Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield. (Top plastic cover may also be removed if necessary.)
  4. Remove the two screws holding the E-Stop Switch mount to the chassis.
  5. Remove the wires connected to the E-Stop Switch.
  6. Loosen the housing holding the E-Stop Switch in place.
  7. Remove the E-Stop Switch.
  8. Install the new E-Stop Switch.
  9. Tighten the housing to hold the E-Stop Switch in place.
  10. Connect the wires to the E-Stop Switch.
  11. Install the switch mount using the two screws removed earlier.
  12. Install the front plastic safety shield. (Also install top plastic cover if it was removed.)
  13. Install the PDU Front Cover and Top Cover.
  14. Remove all Lockout/tagout devices installed.
  15. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.7 Fuse Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Remove the failed fuse from the fuse holder device by removing the two bolts holding the fuse in place.
  5. Install the new fuse using the two previously removed bolts.
  6. Install the front plastic safety shield.
  7. Install the PDU Front Cover and Top Cover.
  8. Remove all Lockout/tagout devices installed.
  9. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.8 Indicator Lamp Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield. (Top plastic cover may also be removed if necessary.)
  4. Remove the wires connected to the failed Indicator Lamp.
  5. Loosen the housing holding the Indicator Lamp in place.
  6. Remove the socket of the Indicator Lamp.
  7. Install the new socket of the affected Indicator Lamp.
  8. Tighten the housing holding the Indicator Lamp in place.
  9. Connect wires to the Indicator Lamp.
  10. Install the front plastic safety shield. (Also install top plastic cover if it was removed.)
  11. Install the PDU Front Cover and Top Cover.
  12. Remove all Lockout/tagout devices installed.
  13. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.9 PDU Control Board Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Remove the plug connectors from the PDU Control Board (located in the upper right corner of the compartment).
  5. Remove the cable connector at the bottom of the PDU Control Board.
  6. Remove the seven screws holding the PDU Control Board in place.
  7. Remove the PDU Control Board from the PDU.
  8. Install the PDU Control Board in the PDU and secure it with the screws removed earlier.
  9. Attach the cable connector to the replacement PDU Control Board.
  10. Attach the plugs into the connectors on the replacement PDU Control Board.
  11. Install the front plastic safety shield.
  12. Install the PDU Front Cover and Top Cover.
  13. Remove all Lockout/tagout devices installed.
  14. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.10 Relay Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the front plastic safety shield.
  4. Release retaining clips on failed relay.
  5. Remove the relay.
  6. Insert the new relay into place.
  7. Install clip restraint device to hold the relay.
  8. Install the front plastic safety shield.
  9. Install the PDU Front Cover and Top Cover.
  10. Remove all Lockout/tagout devices installed.
  11. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

1.11 Soft Start Resistor Replacement

Procedure

  1. Make sure to follow all Lockout/Tagout requirements while performing this procedure. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.
  2. Remove the Top Cover and Front Cover of the PDU.
  3. Remove the top plastic safety shield.
  4. Remove the wires connected to the failed Soft Start Resistor assembly.
  5. Remove the two screws holding the Soft Start Resistor assembly in place.
  6. Remove the Soft Start Resistor assembly.
  7. Install the new Soft Start Resistor assembly.
  8. Install the two screws holding the Soft Start Resistor assembly in place.
  9. Connect the wires to the Soft Start Resistor assembly.
  10. Install the top plastic safety shield.
  11. Install the PDU Front Cover and Top Cover.
  12. Remove all Lockout/tagout devices installed.
  13. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

2 Finalization

Perform Daily Quality Assurance (DQA) scan or equivalent to verify system operation.