Topic ID: id_11038882
Version: 4.0
Date: Mar 29, 2022 8:54:16 AM

PDU Spare Part Replacement Procedures

Prerequisites

Table 4. Safety

warning

Biological Hazard
Bodily fluids, sharps, and medical waste from patients are present. Do not place hands or fingers under the gantry, base of the table, or foot pedal assembly.
Follow all of your organization’s bloodborne pathogen procedures and policies as well as any local policies, laws, and regulations.

danger

Electrocution (Stored Energy) Hazard
Risk of Severe Personal Injury or Death
Wear proper electrical PPE. Perform proper electrical Lockout-Tagout (LOTO). Wait five minutes after applying electrical LOTO before using a meter to measure voltage or service the equipment.

caution

Pinch Hazard
Failure to keep fingers and hands away from pinch points may result in personal injury.
Be careful when moving, removing, or installing heavy components (or components in tight spaces).

caution

Mechanical Edge Hazard
With the covers removed, sheet metal edges are exposed. Avoid forceful contact with abrasive edges.

danger

ELECTROCUTION HAZARD.
HIGH VOLTAGE PRESENT.
USE PROPER LOCKOUT / TAGOUT PROCEDURES BEFORE REPLACING THE COMPONENTS.

caution

Burn injury possible.
Transformers and contactors may be hot to touch.
Use caution to prevent possible burn injury from hot surface contact.

notice

Follow ALL required safety and PPE procedures customary for your organization when working on this product.

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

Refer to the following table for a list of spare part replacements.

1 24 VDC Supply Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new 24 VDC Power Supply in the PDU and secure it with the screws removed earlier.
2. Attach the connectors to the replacement 24 VDC Power Supply.
3. Install the front plastic safety shield.
4. Install the PDU Front Cover and Top Cover.
5. Remove all Lockout/tagout devices installed.
6. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

2 Capacitor Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Slide in the new capacitor.
2. Tighten the clamping screw around the new capacitor to hold it in place.
3. Install the plate over the capacitors using the 8 screws previously removed, attaching all connectors to their original connections.
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. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

3 Circuit Breaker Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new circuit breaker.
2. Install the screws or restraint device holding the circuit breaker in place.
3. Connect the previously removed wires to the circuit breaker.
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. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

4 Contactor Replacement

Procedure

(For Removal)
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 Contactor.
5. Remove the four screws holding the Contactor in place.
6. Remove the Contactor.
(For Re-Install)
1. Install the new Contactor.
2. Install the four screws holding the Contactor in place.
3. Connect the wires to the Contactor.
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. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

5 Diode Bridge Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new Diode Bridge.
2. Install the two screws holding the Diode Bridge in place.
3. Connect the wires to the Diode Bridge.
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. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

6 E-Stop Switch Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new E-Stop Switch.
2. Tighten the housing to hold the E-Stop Switch in place.
3. Connect the wires to the E-Stop Switch.
4. Install the switch mount using the two screws removed earlier.
5. Install the front plastic safety shield. (Also install top plastic cover if it was removed.)
6. Install the PDU Front Cover and Top Cover.
7. Remove all Lockout/tagout devices installed.
8. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

7 Fuse Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new fuse using the two previously removed bolts.
2. Install the front plastic safety shield.
3. Install the PDU Front Cover and Top Cover.
4. Remove all Lockout/tagout devices installed.
5. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

8 Indicator Lamp Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new socket of the affected Indicator Lamp
2. Tighten the housing holding the Indicator Lamp in place.
3. Connect wires to the Indicator Lamp.
4. Install the front plastic safety shield. (Also install top plastic cover if it was removed.)
5. Install the PDU Front Cover and Top Cover.
6. Remove all Lockout/tagout devices installed.
7. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

9 PDU Control Board Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the PDU Control Board in the PDU and secure it with the screws removed earlier.
2. Attach the cable connector to the replacement PDU Control Board.
3. Attach the plugs into the connectors on the replacement PDU Control Board.
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. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

10 Relay Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Insert the new relay into place.
2. Install clip restraint device to hold the relay.
3. Install the front plastic safety shield.
4. Install the PDU Front Cover and Top Cover.
5. Remove all Lockout/tagout devices installed.
6. Restore power to the system. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

11 Soft Start Resistor Replacement

Procedure

(For Removal)
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.
(For Re-Install)
1. Install the new Soft Start Resistor assembly.
2. Install the two screws holding the Soft Start Resistor assembly in place.
3. Connect the wires to the Soft Start Resistor assembly.
4. Install the top 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. Refer to “Equipment Service - Lockout-Tagout-PPE” procedure in Safety folder of publication.

12 Finalization

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