DC Pre-Power Checkout for MEC Motion PLC

Purpose

This document describes the power-up procedures and checks to be completed after the termination of a Controls DIN Rail (DRL) and before connecting power. The intention is to ensure the termination and wiring has been done correctly and that it is safe to apply 24V or 48V to the DRL components.

System Information

Sign and date after the procedure has been completed, secondary checker optional.

Name of System: MEC JJ Slits

Definitions

References

Documents & References

1.  EPLAN drawing of the system which also consists of the DC wiring 

       2.  Beckhoff terminal manuals to recheck wiring

       3. DC power wiring drawing 

Equipment Safety State

Before you start the following procedure confirm the following:

• All power connectors on the device side are unplugged (e.g. MKS275, MKS500 etc.).
•  Device controllers (e.g. MKS937B) should be powered off AND disconnected from the AC mains.
• All DC inputs to the DRL are disconnected 
• All personnel involved have the PPE required to do the task

Mandatory PPE Requirements

All PPE must be worn at all times when servicing the DC power system.

• Protective eye-wear (Safety glasses or safety goggles)
• Work gloves
• Safety boots 

Tools and Documents required for Pre-check

Prior to starting the check procedure please READ carefully through the entire procedure and ensure that you have the following documents/tools ready:

• The EPLAN drawing which has information on the DRL termination which has completed ECS-QA and released 

• Multimeter with the following probes:

  • Pomona Electronics 6262-02 probes (These can be found in the PCDS crash carts)

    Do not use these to probe Phoenix Contact terminals/connectors when they are powered on.

    

  • DC Power Cable Probe (Receptacle) (CA-376-423-41-C00)
    

• A roll of “QC Passed” stickers found in the PCDS test carts.
   

Pre power-up check

NOTE: make sure to do these checks for all DIN rail panels as well as bulkhead connectors as on Mirror Control Boxes.

Procedure:

• Visually check to ensure all components are installed and labeled as per the Interconnect Drawing (IC) or the Wiring Drawing (WD). 

  NOTE: make sure to also check panels mounted inside enclosures, e.g. for Mirror systems.
  
  

• Check and verify all DC wires have CAPTARS and are labeled and terminated as per the IC/WD drawing
• Check the correct phoenix contacts keys are installed on the power terminals (Only the grey 24V terminals mounted on the DRL)
  
  

• Using a voltmeter with the needle probes (please refer to the Preparation Section) check that there is no continuity (short circuit) between the following pins:

  • Grey 24V Supply and blue Return pins (Phoenix Contact terminals on DRL)
  • Red 48V Supply and blue Return pins (Phoenix Contact terminals on DRL)
  • Grey 24V and red 48V is Supply pins (Phoenix Contact terminals on DRL)
  • Any of the 24V /48V supply pins and the ground

• Using a voltmeter with the needle probes (refer to the Preparation Section) check that there is a connection (continuity) between the following:

  • Grouped grey 24V (3209510, 3209633) phoenix contact terminals.
  • Grouped red 48V (3209512, 3209634) phoenix contact terminals.

•  Every blue 0V phoenix contact terminal (3209523, 3209646).
  

• Whenever multiple 24V input (3209646, 3209633) or 48V input (3209646, 3209634) contacts are used, ensure a spacer is added between each pair to avoid connection polarity mismatch.
  

• Check the circuit breaker ground and outputs are connected properly as per EPLAN wiring drawing 

  NOTE: Axilon Mirror systems use fuses instead of circuit breakers.

• Check for continuity between DRL and grounding terminal

  •  Verify the connection from the DIN rail to the ground bus bar, or common ground on the stand.

  • This must be a dedicated connection through a grounding cable as shown in the image below.
  • Check for continuity between DRL and PE grounding terminal

    
    

    If you don’t see a cable but still see continuity between DIN rail and ground bus bar, this is not adequate. Continuity can be seen because the panel is making contact with the ground bus bar through the rack screws.

• Check the circuit breaker ground and outputs are connected properly. 
  

  Axilon Mirror systems use fuses instead of circuit breakers.

  
  

  

• Visually confirm that the grounding cables lead back to the 1/0 common ground cable that typically runs along facility walls.

• Confirm with a voltmeter continuity test that the grounding cables connect to the 1/0 common ground cable

For DRL's with Motion terminals

EL7047 Terminals 

For EL7047 motor terminals check the following 

• Verify input 48V (+VE) is on pin 3' or 4'
• Verify return connection for 48V (-VE) is on 7' OR 8'

EL7041 Terminals

•  For EL7041-1000 terminals - verify that pins 7' and 8’ have continuity.
• For EL7041-1000 terminals - verify that pins 3’ and 4' have continuity
  
• Verify positive supply cable for the motor is either on pin 4' or 3'
• Verify return cable is connected to the terminal 7' or 8' 

Power cable checks

Considerations:

1. At this point the power cable is considered live because it was verified by the DC system engineer per the referenced document L2SI-PP-0222-R0. 
2. Each branch circuit supports multiple components, your cables are likely sharing a circuit with another device that may already be powered up and operating.
   • It is critical that all checks have been met up to this point
   • Incorrect wiring in one DRL causing a short can trigger hardware faults in other sections of the branch circuit.

Procedure

Use a multimeter with DC Power Cable Receptacle (please refer to the Preparation Section) CA-376-423-41-C00 to do the following tests:

1. When the power cable does not have power

• Set your multimeter to Continuity test mode
• Plug in your power cable
• Verify there is no continuity. If there is continuity do not proceed.
• Unplug your cable.

  2. When the ICT breaker is ON, and the cable has power  

• Set your multimeter to DC Voltage measurement
• Plug in your power cable.
• Verify it is reading +24V or +48V (± 10% variance is expected) depending on your cable but polarity must be positive

• Check and verify that the red 48V+ and associated Return plugs have their teeth intact.

• Check and verify that the grey 24V+ plugs have their teeth broken, the associated Return plugs should have their teeth intact.

• Plug in your 24V and 48V power cables.

Post power-up checks

Considerations:

This section assumes:

1. Your DIN rail has met all the checks in section Pre power-up checks
2. You have checked your 24V and 48V power cables per the section Power cable checks
3. You have now connected 24V and 48V (if needed) to your DIN Rail, the component is now live.
   

Setup of CB's on the DRL

• Long press on the PTCB E1 circuit breaker to activate programming mode. The LED should start flashing showing the nominal current set by yellow flashing value n times, factory default is 4A. 
  • If 4A is not desired, reprogram by short pressing the button the correct number of times.
  • To exit programming mode, long press the button again. Programming mode will exit automatically if you wait too long without pressing the button.
    
• Repeat for all installed circuit breakers.

• Switch the circuit breaker(s) on one at a time. Ensure that the status LED is green. To switch the circuit breaker on or off press it briefly once.

  NOTE: EL5042 terminals may come up in an error state if the E Bus power turns on before the rail peripheral power.

• After switching on and checking all the circuit breakers, verify that the power and E Bus status LEDs on the EK1100 are as shown in the following picture:
  

• If you do not have a 48V section on your DRL:

• Apply a “QC passed” sticker in a clearly visible location on your DIN rail.
  

Procedure for 48V connections:

For DRL's containing 48V connections, please follow the below procedure

• Verify that the power and E Bus status LEDs on the EL/ES7041 are as shown in the following picture (top most right LED):
  

• Apply a “QC passed” sticker in a clearly visible location on your DIN rail.
  
  

Discrepancy Log 

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