Control Van Electrical Power System 2A5A2 Maintenance Manual 2A5A2-ELEC-MM-1-0 DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE. DISTRIBUTION IS UNLIMITED.
Submarine Rescue System – Rescue Capable System Control Van (CV) Electrical Power System (ELEC) 2A5A2 Maintenance Manual GOVERNMENT PURPOSE RIGHTS – TECHNICAL DATA Contract No: N00024-00-C-4010 Contractor Name: OceanWorks Intl. Corp.
Document Release Record Release Description Approved For Release By Date D-0 to internal review and Phoenix Richard Pomerleau October 30, 2007 D-1 to Phoenix request for letter of approval Beverly Dunne November 16, 2007 1-0 to NAVSEA first submission Beverly Dunne November 21, 2007 CV ELECTRICAL POWER SYSTEM MAINTENANCE MANUAL 2A5A2-ELEC-MM-1-0 ii
Table of Contents 1 Introduction 1.1 1.2 1.3 1.4 1.5 1.6 Purpose Scope Drawing References Document References Abbreviations and Acronyms Danger, Warning, Caution, and Note 1 1 1 2 3 3 3 2 System Overview 4 3 Preventive Maintenance 5 3.1 3.2 3.3 3.4 3.5 3.
.6 5.7 5.8 5.9 5.10 Unit Plugged in UPS #1 Doesn't Work Unit Plugged in UPS #2 Doesn't Work Unit Plugged in Power Bus #1 Doesn't Work Unit Plugged in Power Bus #2 Doesn't Work Device Related to Power Tray Doesn't Work 6 General Maintenance Routines 6.1 6.2 6.3 Overview General Notes 6.2.1 Hazmat Requirements 6.2.2 Torque Specifications 6.2.3 Mounting Hardware 6.2.
1 1.1 Introduction Purpose This manual provides specific maintenance procedures for the Control Van (CV) Electrical Power System (ELEC). The information is intended to be used as a general reference and to assist with system understanding for training and maintenance purposes. 1.2 Scope This manual applies only to the CV Electrical Power System and its interface to directly related subsystems.
INTRODUCTION 1.3 Drawing References Table 1 lists drawings referenced in this manual.
INTRODUCTION 1.4 Document References Table 2 lists documents referenced in this manual. Table 2 Document References Document Type Document # COTS Manuals This manual does not reference COTS Manuals.
2 System Overview The CV Electrical System consists of the following components: • • • CV power room: • One (1) power demarcation panel • Two (2) CV service transformers • Two (2) HPU boost transformers • Two (2) PRM hotel boost transformers • One (1) PRM hotel uninterruptible power supply (UPS) unit • One (1) smoke detector • One (1) 2-foot, fluorescent light (white) • One (1) emergency light unit CV control room: • One (1) 480 VAC 3 Ø distribution panel • One (1) power distribution
3 3.1 Preventive Maintenance Preventive Maintenance Schedule and Index Table 3 provides an index and schedule for preventive maintenance required for the CV Electrical Power System. Table 3 Preventive Maintenance Schedule and Index Section # Procedure Monthly 6 Months Yearly 3-year Overhaul 3.2 Replacing a UPS External Battery Pack X 3.3 Replacing a Control Power UPS Internal Battery Pack X 3.4 Replacing the PRM Hotel Power UPS Battery Pack X 3.5 Replacing a Smoke Detector Battery 3.
PREVENTIVE MAINTENANCE 3.2 Replacing a UPS External Battery Pack WARNING! Shock hazard! Verify power to the unit is isolated before performing this maintenance procedure. CAUTION! Avoid touching battery terminals with objects that could create a short circuit.
PREVENTIVE MAINTENANCE 11. Ensure the preceding steps were performed in accordance with local requirements for SOC and tag in/out, as applicable. 0. 3.3 Replacing a Control Power UPS Internal Battery Pack WARNING! Shock hazard! Verify power to the unit is isolated before performing this maintenance procedure. CAUTION! Avoid touching battery terminals with objects that could create a short circuit.
PREVENTIVE MAINTENANCE 9. Return valves and electrical switches to the state that they were in before this procedure was performed. 10. Inspect and determine disposition of any parts removed. If applicable, dispose of removed parts and/or fluids in accordance with local requirements. 11. Ensure the preceding steps were performed in accordance with local requirements for SOC and tag in/out, as applicable. 0. 3.
PREVENTIVE MAINTENANCE 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove the bracket securing the UPS. Open the UPS casing and remove the battery pack. Install the new battery pack. Close the UPS casing and reinstall the bracket securing the UPS. At the 480 V 3Ø DISTRIBUTION PANEL, turn on BUS #1 MAIN DISCONNECT (2A5A2-CBEPO8-1) and BUS #2 MAIN DISCONNECT (2A5A2-CB-EPO8-2) switches. In the Control Van (CV), at the POWER DISTRIBUTION UNIT, set POWER BUS 1 (2A5A2-1B-EP01-1) and POWER BUS 2 (2A5A2-CB-EP01-2) to ON.
PREVENTIVE MAINTENANCE 6. Test the smoke detector by pressing the test button. 7. Inspect and determine disposition of any parts removed. If applicable, dispose of removed parts and/or fluids in accordance with local requirements. 8. Ensure the preceding steps were performed in accordance with local requirements for SOC and tag in/out, as applicable. 0. 3.
4 4.1 Corrective Maintenance Corrective Maintenance Index Table 4 provides an index to procedures for correcting malfunctions of the CV Electrical Power System. See Chapter 5, Troubleshooting, for assistance in selecting an appropriate procedure. Table 4 4.2 Corrective Maintenance Index Section # Procedure 4.2 Replacing a Cable 4.3 Replacing the Ground Fault Monitor 4.4 Measuring High Voltage 4.5 Replacing an HPU Boost Transformer 4.6 Replacing a Hotel Boost Transformer 4.
CORRECTIVE MAINTENANCE Special Tools None Spare Parts 7533422 7533460 SPC11683 Exterior utility power cable assembly GFM power cable assembly Power cable – SPC Technology Preconditions None Procedure 1. Follow instructions in Section 6.2, General Notes, regarding hazmat requirements, torque specifications, inspection of mounting hardware, and use of Nylok® nuts, as applicable. 2. Perform the following steps in accordance with local requirements for SOC and tag in/out, as applicable. 3.
CORRECTIVE MAINTENANCE 4.3 Replacing the Ground Fault Monitor WARNING! Shock hazard! Verify power to the unit is isolated before performing this corrective maintenance procedure.
CORRECTIVE MAINTENANCE 4.4 Measuring High Voltage DANGER! Shock hazard! Verify power to the unit is isolated before performing this corrective maintenance procedure. This procedure exposes conductors that carry high voltage sufficient to cause lethal electric shock. When performing work in the CV power room, be aware of potential exposure to high voltages sufficient to cause lethal electric shock.
CORRECTIVE MAINTENANCE 9. Read the voltage and confirm acceptable reading. Table 5 Acceptable High Voltage Readings Test point Acceptable readings HPU power Bus #1 or #2 Negative Positive ØA ØB 3000 ± 300 VAC ØA ØC 3000 ± 300 VAC ØB ØC 3000 ± 300 VAC Hotel power Bus #1 or #2 Negative Positive ØA ØB 1900 ± 190 VAC 10. In the CV, at the POWER DISTRIBUTION UNIT, set POWER BUS #1 (2A5A2-1B-EP01-1) and POWER BUS #2 (2A5A2-CB-EP01-2) to OFF. 11.
CORRECTIVE MAINTENANCE 4.5 Replacing an HPU Boost Transformer DANGER! Shock hazard! Verify power to the unit is isolated before performing this maintenance procedure. This procedure exposes conductors that carry high voltage sufficient to cause lethal electric shock. When performing work in the CV power room, be aware of potential exposure to high voltages sufficient to cause lethal electric shock.
CORRECTIVE MAINTENANCE 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Remove the transformer. Install the new transformer. Reinstall the transformer sensor panel support straps. Reconnect ground wire. At the input transformer tap, reconnect the input power wires at each of three (3) taps 480. Reconnect two (2) voltage condition wires at ØA at tap 0 and 480. At the output transformer terminal beam, reconnect three (3) PRM HPU power wires at tap 3100. Perform high voltage test (see Section 4.
CORRECTIVE MAINTENANCE Spare Parts 7533342 Hotel boost transformer assembly Preconditions None Procedure 1. Follow instructions in Section 6.2, General Notes, regarding hazmat requirements, torque specifications, inspection of mounting hardware, and use of Nylok® nuts, as applicable. 2. Perform the following steps in accordance with local requirements for SOC and tag in/out, as applicable. 3.
CORRECTIVE MAINTENANCE 4.7 Replacing a Service Transformer DANGER! Shock hazard! Verify power to the unit is isolated before performing this maintenance procedure. This procedure exposes conductors that carry high voltage sufficient to cause lethal electric shock. When performing work in the CV power room, be aware of potential exposure to high voltages sufficient to cause lethal electric shock.
CORRECTIVE MAINTENANCE 14. Return valves and electrical switches to the state that they were in before this procedure was performed. 15. Inspect and determine disposition of any parts removed. If applicable, dispose of removed parts and/or fluids in accordance with local requirements. 16. Ensure the preceding steps were performed in accordance with local requirements for SOC and tag in/out, as applicable. 0. 4.
CORRECTIVE MAINTENANCE 10. Restore power and confirm functionality of the UPS. 11. Return valves and electrical switches to the state that they were in before this procedure was performed. 12. Inspect and determine disposition of any parts removed. If applicable, dispose of removed parts and/or fluids in accordance with local requirements. 13. Ensure the preceding steps were performed in accordance with local requirements for SOC and tag in/out, as applicable. 0. 4.
CORRECTIVE MAINTENANCE 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove the UPS. Install the new UPS. Reconnect two (2) cables at the UPS. At the 480 V 3Ø DISTRIBUTION PANEL, turn on BUS #1 MAIN DISCONNECT (2A5A2-CBEPO8-1) and BUS #2 MAIN DISCONNECT (2A5A2-CB-EPO8-2) switches. In the CV, at the POWER DISTRIBUTION UNIT, set POWER BUS #1 (2A5A2-1B-EP01-1) and POWER BUS #2 (2A5A2-CB-EP01-2) to ON. Confirm functionality of the UPS.
CORRECTIVE MAINTENANCE Procedure 1. Follow instructions in Section 6.2, General Notes, regarding hazmat requirements, torque specifications, inspection of mounting hardware, and use of Nylok® nuts, as applicable. 2. Perform the following steps in accordance with local requirements for SOC and tag in/out, as applicable. 3. At the 480 V 3Ø DISTRIBUTION PANEL, turn off BUS #1 MAIN DISCONNECT (2A5A2-CBEPO8-1) and BUS #2 MAIN DISCONNECT (2A5A2-CB-EPO8-2) switches. 4.
CORRECTIVE MAINTENANCE 4.11 Replacing a Power Tray Power Supply WARNING! Shock hazard! Verify power to the unit is isolated before performing this corrective maintenance procedure. Drawing References 7533009 7533010 7533011 7533014 7533015 7533118 Power system assembly (2A5A2) Power system cable routing CV electrical power system schematic (2A5A2) Power tray assembly Power tray wiring diagram Power tray installation details Special Tools None Spare Parts HAA15-0.8A HAA5-1.5/OVP-A HC12-3.
CORRECTIVE MAINTENANCE 11. At the power tray front panel, turn on BUS 1 POWER and BUS 2 POWER. Confirm functionality of the power supply. 12. Return valves and electrical switches to the state that they were in before this procedure was performed. 13. Inspect and determine disposition of any parts removed. If applicable, dispose of removed parts and/or fluids in accordance with local requirements. 14.
CORRECTIVE MAINTENANCE Procedure 1. Follow instructions in Section 6.2, General Notes, regarding hazmat requirements, torque specifications, inspection of mounting hardware, and use of Nylok® nuts, as applicable. 2. Perform the following steps in accordance with local requirements for SOC and tag in/out, as applicable. 3. At the power tray front panel, turn off BUS 1 POWER and BUS 2 POWER. 4. Remove four (4) bolts securing power tray to the control/power console and gently pull out power tray.
CORRECTIVE MAINTENANCE Preconditions None Procedure 1. Follow instructions in Section 6.2, General Notes, regarding hazmat requirements, torque specifications, inspection of mounting hardware, and use of Nylok® nuts, as applicable. 2. Perform the following steps in accordance with local requirements for SOC and tag in/out, as applicable. 3. At the 208/120 VAC 3 ∅ distribution panel, BUS #2, turn off breaker CB 10, POWER ROOM OUTLET , POWER ROOM LIGHT, and EMERGENCY LIGHTS. 4.
CORRECTIVE MAINTENANCE 4.14 Replacing a Control Room Fluorescent Assembly WARNING! Shock hazard! Verify power to the unit is isolated before performing this maintenance procedure.
CORRECTIVE MAINTENANCE 14. At the 208/120 VAC 3 ∅ distribution panel, BUS #2, turn on breaker CB 4, CV ENTRANCE OUTLET, CONTROL ROOM LIGHT, and EMERGENCY LIGHT. Confirm functionality of the fluorescent light assembly. 15. Return valves and electrical switches to the state that they were in before this procedure was performed. 16. Inspect and determine disposition of any parts removed. If applicable, dispose of removed parts and/or fluids in accordance with local requirements. 17.
CORRECTIVE MAINTENANCE Procedure 1. Follow instructions in Section 6.2, General Notes, regarding hazmat requirements, torque specifications, inspection of mounting hardware, and use of Nylok® nuts, as applicable. 2. Perform the following steps in accordance with local requirements for SOC and tag in/out, as applicable. 3. Turn off the light. 4. For the forward external light, disconnect cable 2A5A2-CBL-EP31, connector J4 at the signal demarcation panel.
CORRECTIVE MAINTENANCE 4.16 Replacing an Emergency Light DANGER! Shock hazard! When performing work in the CV power room, be aware of potential exposure to high voltage sufficient to cause lethal electric shock. Drawing References 7533011 7533125 7533127 CV electrical power system schematic (2A5A2) Lighting system assembly Lighting cable routing Special Tools None Spare Parts M636120CSCSA Emergency light – Lithonia Preconditions None Procedure 1. Follow instructions in Section 6.
CORRECTIVE MAINTENANCE 4.17 Replacing a Rotating Light WARNING! Shock hazard! Verify power to the unit is isolated before performing this maintenance procedure. Drawing References 7533009 7533010 7533011 Power system assembly (2A5A2) Power system cable routing CV electrical power system schematic (2A5A2) Special Tools None Spare Parts AVG 110 Y Rotating light – ISE Inc Preconditions None Procedure 1. Follow instructions in Section 6.
5 5.1 Troubleshooting Overview DANGER! The decision trees provided in this Chapter are a guide, not a step by step procedure. Follow tag in/out and other safety procedures as set out in the corrective and preventive maintenance procedures in this manual. This Chapter provides troubleshooting decision trees for identifying malfunctioning components of the CV Electrical Power System.
TROUBLESHOOTING 5.2 Troubleshooting Subroutine — 10 kVA 480-208/120 VAC 3Ø Transformer #1 or #2 Power Check Procedure 1. Follow the troubleshooting steps in Figure 1. 0.
TROUBLESHOOTING 5.3 PRM Hotel Power #1 Doesn't Work Procedure 1. Follow the troubleshooting steps in Figure 2. 0. At the 208/120 VAC 3ø distribution panel #1, reset breaker hotel power #1 UPS. At the power room, reset hotel power UPS. Problem solved? Yes Done No At PRM hotel power #1 UPS, measure voltage at the input: Negative Probe Positive Probe Acceptable Reading L1 L2 208 ± 21 VAC Voltage OK? No Follow decision tree in Section 5.
TROUBLESHOOTING 5.4 PRM Hotel Power #2 Doesn't Work Procedure 1. Follow the troubleshooting steps in Figure 3. 0. At the 208/120 VAC 3ø distribution panel #2, reset breaker PRM hotel power #2 Problem solved? Yes Done No At hotel #2 boost transformer, measure voltage at the input: Negative Probe Positive Probe Acceptable Reading tap 0 tap 210 208 ± 21 VAC Voltage OK? No Follow decision tree in Section 5.
TROUBLESHOOTING 5.5 HPU Power #1 or #2 Doesn't Work Procedure 1. Follow the troubleshooting steps in Figure 4. 0.
TROUBLESHOOTING 5.6 Unit Plugged in UPS #1 Doesn't Work OTL-EPO2-7 PB-EPO2-2 PB-EPO2-8 PB-EPO2-1 PB-EPO2-7 PB-EPO2-3 – Pilot video projector – Sonar VGA splitter – INS VGA splitter – UWT – Video SW box – INS computer – Sonar computer – APS C/D module – RS232/ RS422 – APS sensor repeater – Touchscreen VGA splitter – Power tray – SCC #1 – Pilot Touchscreen – Sonar LCD Procedure 1. Follow the troubleshooting steps in Figure 5. 0.
TROUBLESHOOTING At the 208/120 VAC 3ø distribution panel #1, reset breaker control UPS #1. Reset UPS #1. Problem solved? Yes No Measure voltage at UPS #1 outlets: Outlets Acceptable Readings 2A5A2-OTL-EP02-1 120 ± 12 VAC 2A5A2-OTL-EP02-2 120 ± 12 VAC 2A5A2-OTL-EP02-4 120 ± 12 VAC 2A5A2-OTL-EP02-7 120 ± 12 VAC Voltage OK? Yes Replace the power bar where the defective unit is plugged (see Section 4.10, Replacing a Power Bar) No Follow decision tree in Section 5.
TROUBLESHOOTING 5.7 Unit Plugged in UPS #2 Doesn't Work PB-EPO2-4 PB-EPO2-12 PB-EPO2-9 PB-EPO2-5 PB-EPO2-6 Hardwired – Ethernet hub – VSC – Overlay computer – Video switcher – TDT generator 1 – TDT generator 2 – Sonar VGA converter – APS VGA converter – INS VGA converter – SWBD translator – Overlay VGA splitter – Intercom – VHF radio – VCR display 2 – VCR 2 – SCC #2 – Power tray – GFM – Pilot LCD – Navigator LCD – Life support LCD – KVM switcher – Fluorescent light (starboard) Procedure 1.
TROUBLESHOOTING At the 208/120 VAC 3ø distribution panel #2, reset breaker control UPS #2. Reset UPS #2. Problem solved? Yes No Measure voltage at UPS #2 outlets: Outlets Acceptable Readings 2A5A2-OTL-EP02-3 120 ± 12 VAC 2A5A2-OTL-EP02-5 120 ± 12 VAC 2A5A2-OTL-EP02-6 120 ± 12 VAC Problem with: Fluorescent Light See Section 4.14, Replacing a Control STBD Room Fluorescent Light Assembly Voltage OK? Yes No Ground Fault Monitor See Section 4.
TROUBLESHOOTING 5.8 Unit Plugged in Power Bus #1 Doesn't Work PB-EPO2-11 PB-EPO2-10 Hardwired OTL-EPO1-1 – VCR display 1 – VCR 1 – Winch control panel – Red lights – Empty Procedure 1. Follow the troubleshooting steps in Figure 7. 0.
TROUBLESHOOTING 5.9 Unit Plugged in Power Bus #2 Doesn't Work OTL-EPO1-9 OTL-EPO1-7 OTL-EPO1-8 Hardwired OTL-EPO1-6 OTL-EPO1-5 – Center video projector – Forward video projector – Emergency light (control room) – Emergency light (power room) – Fluorescent light (port) – Fluorescent light (power room) – Empty – Empty Procedure 1. Follow the troubleshooting steps in Figure 8. 0.
TROUBLESHOOTING At the 208/120 VAC 3ø distribution panel #2, reset breakers: - video projectors - entrance outlet and CV light - power room outlet and lights Problem solved? Yes No Yes Is the problem with the video projector? No Measure voltage at outlets: Outlets Acceptable Readings 2A5A2-OTL-EP01-6 120 ± 12 VAC 2A5A2-OTL-EP01-9 120 ± 12 VAC 2A5A2-OTL-EP01-7 120 ± 12 VAC 2A5A2-OTL-EP02-8 120 ± 12 VAC 2A5A2-OTL-EP02-5 120 ± 12 VAC Voltage OK? Yes Replace defective unit: Section 4.
TROUBLESHOOTING 5.10 Device Related to Power Tray Doesn't Work Procedure 1. Follow the troubleshooting steps in Figure 9. 0. At the power tray measure voltage at terminal: Negative Probe Positive Probe Acceptable Readings Terminal 6 Terminal 3 120 ± 12 VAC Voltage OK? No See Section 5.
6 6.1 General Maintenance Routines Overview This Chapter contains general maintenance routines that apply to several corrective and preventive procedures for the CV Electrical Power System. 6.2 General Notes 6.2.1 Hazmat Requirements When disposing of parts and/or fluids removed from the CV Electrical Power System, follow hazmat procedures in accordance with local requirements. 6.2.2 Torque Specifications Fasteners, through hull penetrators, and tube fittings are torqued to standard values.
APPENDIX 6.3 Electrical Cables Testing CAUTION! If salt water remains on a connector when it is inserted, the salt crystals could potentially ruin the rubber connector seal. Thoroughly clean the contact points with alcohol before connecting. Special Tools 500 VDC insulation resistance meter Calibrated thermometer Procedure Verify Continuity 1. Using a Digital MultiMeter (DMM) and the cable schematic, verify the cable continuity. Verify that the resistance of each conductor is less than 1 ohm.
APPENDIX Minimum Required Insulation Resistance Values for Observed Test Temperatures Range of Test Temperature Observed Required Minimum Insulation Resistance Reading Degrees F Degrees C Megohm 41–50 5–10 40 50–59 10–15 30 59–68 15–20 20 68–77 20–25 15 77–86 25–30 10 86–95 30–35 7.5 95–104 35–40 5 Dielectric Absorption Ratio 8.
Glossary This Glossary contains definitions specific to this manual.
GLOSSARY VGA Video graphics array VHF Very high frequency VSC Video switching computer 3Ø Three phase CV ELECTRICAL POWER SYSTEM MAINTENANCE MANUAL 2A5A2-ELEC-MM-1-0 50
