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2024年10月29日发(作者：壤驷良吉)

Lifecycle Solutions & Services

Preventive Maintenance Tips: Power Systems 1

It Doesn’t Run Without Power—Proper Maintenance

of Power Systems

Maintaining the power system is critical for any of your systems

and that is definitely true when dealing with the PM/APM/HPM

(xPM) family. Depending on your configuration and process, the

failure of proper maintenance practices and ignoring alarms from

the power system could lead to failures that have the potential to

bring a process or plant to a standstill. This includes loss of view,

loss of control, or even loss of the process.

How Proper Power System Maintenance Can Help You

• Reassurance that your power system and battery

back-ups are running properly

• Reduced risk of downtime due to power system issues

• Allows you to be proactive in your maintenance approach

• Simplified ordering for maintenance items available in

a kit versus individual components

• Lower cost of replacement to mitigate costly unplanned

system downtime

•

Current version of Power Supply has multiple improved

characteristics

Proper maintenance of the power system includes addressing

the power supplies, battery backup and the CMOS memory backup

batteries. The expected lifespan of each of these components is

different and the lifespan of each is also affected by the environment

in which they are used. Benchmarks for changing out each component

are every 10 years for the power supply, every five years for the

battery backup (and possibly every three), and every two years

for the CMOS batteries. Honeywell now offers an upgrade kit,

MC-ZPSUG2, which provides all of these components packaged

together. The power supply provided is the current version with

improved characteristics.

Any failures of these power system components should be

changed immediately.

Description

Life

Expectancy

Replacement

Part #

Power Supply

10 years 51198651-100

48V Battery Backup

3 to 5 years 51303948-100

Size “AA” Ni-Cad 2 years 51190422-100

CMOS Battery

Size “C” Ni-Cad 2 years 51192060-100

CMOS Battery

CMOS Memory Battery Backup

The xPM power systems are designed to provide battery backup

to all the CMOS memory. The CMOS battery backup prevents the

loss of the data base during a power outage after the battery backup

has been depleted or if no battery backup module is present.

There are two different power system chassis out in the field with

CMOS batteries. The older style power system introduced with

PM/APM requires three specific “AA” size Ni-Cad batteries. For the

current back panel introduced for HPM the CMOS memory requires

three specific “C” size Ni-Cad batteries. The size “C” batteries are

required if the full 50 hours of CMOS memory backup is desired for

HPM due to the larger memory available in HPM. In either scenario,

the incorrect usage of other batteries than what have been tested

and qualified by Honeywell may result in the battery overheating

and could possibly cause the battery to rupture.

The batteries in the standard power system are periodically tested

by the charging circuit. If the voltage falls below the allowed limit,

a battery failure alarm will be generated and the batteries should

be replaced. Regardless of alarms, Honeywell recommends that

new batteries be installed every two years. All three batteries should

be replaced at one time.

Description Replacement Part #

Size “AA” Ni-Cad CMOS 51190422-100

Battery

Size “C” Ni-Cad CMOS 51192060-100

Battery

Preventive Maintenance Tips

Preventive Maintenance Tips: Power Systems 2

48 Volt Battery Backup

The battery backup is designed to maintain a fully loaded xPM for

a minimum of 20 minutes. It will shutdown when the voltage reaches

38 volts to prevent the power supply from going out of regulation and

an alarm will be generated. Rechargeable batteries will lose their

full charging capabilities over time and will need to be tested and

replaced when they fall below 60 percent of their original capacity.

The battery backup has been designed to operate in standby (float)

service for approximately five years. The five years is based on the

battery being kept at 20C (68F) and the float charge voltage being

maintained between 2.25 and 2.30 volts per cell. This includes the

battery being fully discharged once every three months. No battery

should be left in service over five years, and if no maintenance is

done it should be replaced every three years.

The service life is directly affected by the number of discharges,

the depth of discharge, ambient temperature, and the charging

voltage. The expected service life can be shorted by 20% for each

10C that the ambient is above 20C.

The batteries should never be left in a discharged state. This allows

sulfating to occur which will increase the internal resistance of the

battery and lower its capacity. The self-discharge rate is about 3% per

month at an ambient of 20C. The self discharge rate doubles for each

10C in ambient above 20C. The discharged voltage of the battery

should never go below 1.30 volts to maintain the best battery life.

With this in mind it is recommended to periodically load test the

batteries to ensure they have sufficient capacity to maintain the

system during a power outage. Tests should be done on an annual

basis and more frequently as they become older and begin to

lose capacity. The load test is recommended off-process if possible

as there will be no battery backup available while performing the

test and recharging of the battery pack can take up to 16 hours.

Having a spare available to swap, especially if doing on process,

is a wise option leading to minimal time without battery backup

and allowing the tested battery to be recharged on a bench outside

the system for future swap with the next test.

If regular maintenance is not performed the recommendation is to

change at least every three years rather than every five.

Power Supplies

The power supply is the heart of the xPM power system and the

recommendation is for a redundant power supply configuration

having each power supply fed by its own dedicated power source.

Honeywell has introduced the next generation power supply for

this family which increases the robustness of the power system.

Even with redundant power supplies, one must be careful when

changing out a failed power supply. This is to minimize disturbance

of the environment and to reduce the introduction of particles into

the area around and near the power supplies. Those particles can

be pulled through the airflow of the working power supply and

result in the second power supply failing.

For this reason, Honeywell does not recommend replacing a

working power supply on-process (other than the black-colored

version). However, power supplies do not last forever and you

should consider upgrading older power supplies, or prepare to

do so, when the opportunities arise.

The recommendation for changing out the power supplies is every

ten years and this replacement should be included during a scheduled

down time if possible. The power supply replacement procedure

listed in the Honeywell xPM Service manual should be followed

at all times.

Recommend Change of Original Black Power Supplies

In October of 1996 Honeywell issued a customer priority notification

(PN #1986) about a possible over-voltage issue with the black-

colored (51109456-200) power supplies that were sold from 1988

through 1994. The Honeywell recommendation was to change

out those black power supplies with the new silver version.

Honeywell still recommends and strongly suggest that these

black power supplies be replaced with the current power supply

under part number 51198651-100 regardless of when they were

put into service.

Silver Power Supplies

There have been three part number versions of the silver power

supplies. The first (51109684-100/300) was sold from 1993

through 1997. The second (51198947-100) sold from 1997 through

today. The next generation power supply was released in early

2009 and was introduced initially through the power system

maintenance upgrade kit. If a site is running the original silver

version they have now been in service for over 10 years and

sites should consider the need to replace before they are forced

to do so by failure of the power supply. Note that there is always

risk involved when powering down equipment and possible issues

when the equipment is powered back up. As stated previously,

it is recommended to change these out off-process if possible.

Replacements on- process should be done only when a power

supply fails and replacement is then required immediately.

Description Replacement Part #

48V Battery Backup

51303948-100

Preventive Maintenance Tips

Preventive Maintenance Tips: Power Systems 3

Power Supply Issues

The xPM power supplies have proven to be a reliable and robust

power source. However, as with any electrical component they

do not last forever and there is the potential for failure modes.

Issues such as foreign particles introduced have already been

discussed. In addition, even clean environments are susceptible

to whiskers which have the potential to short out active circuits.

Whiskers are a real issue and further details may be found in the

Customer Resource Manual (CRM) in the Process Manager

section PD22_G97(G).

The new power supply available through the power system

maintenance kit includes design improvements specifically done

to address some of these possible failure modes to make a robust

power supply even better.

Remember that the power supply is a critical component to your

system and regular maintenance as well as having spares available

is highly recommended to keep your site running without problems.

Monitor the power system alarms and take action when they do occur.

Description Replacement Part #

Power Supply 51198651-100

Preventive Maintenance Tips: Power Systems 4

Importance of Power System Alarms

Always ensure that all power supply alarm contacts are properly

implemented, working, and are being monitored. Failure to monitor

these alarms and take appropriate action in a timely manner can

lead to failures of the power system that could have otherwise been

prevented. There are DC Out, Battery, Fan/Temp, AC In, and Charging

LED indicators for each Power Supply module. If the Power system

is fully functional, all five of the indicators are illuminated. In addition,

each of these conditions, plus a CMOS/Memory is available as a

digital input for each supply.

DC Out Indicator

If a DC Out LED is off, AC line power has been lost (check the

AC In LED) or the Power Supply Module has failed. If the Power

System is non-redundant, or if both DC Out LEDs are off, the HPM

has lost 24 VDC. The CMOS backup system maintains power to the

CMOS memory, so subsystem programs are not lost. See the Battery

LED description below. The annunciator contact illustrated in

the following figure will open when these conditions occur.

Battery Indicator

If the Battery LED is off and the Charging LED is on, the 48 Volt

Battery switch is in the off position or the 48 V Battery Backup system

has failed. The annunciator contact illustrated in the following

Figure will open when these conditions occur. If the Power System

does not have the battery pack option, the Battery LED will

normally be on, and the Charging LED will normally be on.

Fan/Temp Indicator

If the Fan/Temp LED is off, the fan in the Power Supply Module

has failed or the temperature of the supply has exceeded a safe

value. The annunciator contact, discussed below, is activated.

AC In Indicator

If the AC In LED is off, AC power to the HPM has been lost or

the switch on the Power Supply Module is off. Backup systems, if

operating, are maintaining the unit. Check the DC Out and Battery

indicators to determine the state of the system. Many installations

may have the Power Supply Modules connected to separate

AC power sources to minimize outage caused by a power loss.

The Annunciator contact signifying power loss from either supply,

are opened independently.

Charging Indicator

When the Charging LED is off, the charging circuit that maintains

the optional 48 V Battery Backup system has failed. Check the

batteries, their corresponding connections, and the charging circuits

in the Power Supply Module(s). The annunciator contact output is

opened by this condition.

Preventive Maintenance Tips

Alarms

Preventive Maintenance Tips: Power Systems 5

Orderable Power System Components

• CMOS Batteries

• 48V Battery Backup

• Power Supply

• Power System Chassis Assembly

The primary Power Supply Module alarm and secondary Power

Supply Module alarm contacts monitor five functions within each

Power Supply Module. The appropriate contact will open when

any of the following occur:

• The DC output voltage is not within normal limits.

• AC input power to the supply has failed.

• The Power Supply Module electronics have overheated or the

Power Supply Module fan has failed.

• The 48 V backup-battery system has failed because the

batteries have discharged or they have been disconnected.

• The battery charger in the Power Supply Module has failed.

Benefits of New Power Supply

• Improved airflow handling

• Conformal coating of all metallic components

• Enhanced mechanical design

• Extended temperature range

• Added thermal shutdown capability

• More reliable power switch design

• More consistent alarm handling

Servicing the Power System

The power system is critical to your process. Loss of the power

system may lead to loss of control, loss of view, or loss of process.

Honeywell strongly recommends regular maintenance to the

power system and service checks with regular component

replacements performed by Honeywell trained service technicians.

• Options for Power System Upgrade/Maintenance

• Order the power system upgrade kit

• Order replacement parts for immediate installation.

• Order spares to have in stock as needed.

• Add power system components to a parts contract.

Additional Power System Information

Additional details on proper maintenance procedures such as load

testing and specifics on the power supplies and batteries may be

found in the Honeywell Customer Resource Manual. This is located

in the Process Manager section of the CRM under TAB 22. As always,

you may also contact your local Honeywell account manager or

service technician for further details.

For More Information

Learn more about how Honeywell’s Preventive

Maintenance Tips can limit downtime and assure

system power supplies and battery backups are

working properly visit our website

or contact

your Honeywell account manager.

Honeywell Process Solutions

Honeywell

1250 West Sam Houston Parkway South

Houston, TX 77042

Honeywell House, Arlington Business Park

Bracknell, Berkshire, England RG12 1EB

Shanghai City Centre, 100 Junyi Road

Shanghai, China 20051

SV-12-37-ENG

May 2012