UltraFLEX HD User Manual
Contents
1. 708401 Rev B Figure 3 AC distribution on PDU TS A JU Ned Page 10 of 38 TIFIE SHELF gt aw Z BEVERY 2 2 Hos Hill ULTRAFLEX HD PDU USER MANUAL 1 6 DC Connections All DC connections are located on the rear of the PDU The DC connections include the 48V DC output and fan power 1 6 1 Fans All fan connectors are located on the rear of the PDU as shown in Figure 4 In addition refer to Table 2 below for descriptions of the connectors Use Outlet Number Circuit Breaker Breaker Rating A Testhead Fans 46 System Cabinet Fan J47 Expansion Cabinet Fan J48 CB10 15 Expansion cabinet power control J49 Table 2 DC Fan connection table RECT GOOD SYSTEM 7 EX 7 I s amp OPS SS ext INDICATORS SM on Fan connectors OOD 5 O SF AS fa CAUTIUN ELECTRICAL a hai 2 5 N TIO ELECTRICAL Ff as 5 Xr rem SEE MANUAL FOR D C STUD TORQUE SPEC LOKORO MEM Fan citcuit breaker P SAUTION ELECTRICAL ENERGY HAZARI2. 42 1 8 SMC 472 12 19 External Indicators Connection 71 att Tee bn n diis 13 ee busua aa redde 14 2 NIE NE 14 DU ah gt EMO breaker CBZ crac eo 14 2 L2 Energize AC EEKE EE R 14 2o SPARE DIANE Du eser a alat ua ausu at 15 21A AC LOMAS sade css assed salads 15 2 1 93 Fan breaker 16 2 1 6 48V Power Supply AC input breaker 9 16 2 17 OV DC DUS ANON us u 17 2 2 ciao AN lide alo 17 3 0 User ue ir ME 18 Oo ei ede 18 32 AG CERT 19 OE PE 19 708401 Rev B Page 3 of 38 ULTRAFLEX HD PDU USER MANUAL VE ME SIS mu PI A 19 19 S MEN TSEIITI2 6 77002 ga 19 Lock OULD COU FC mE 19 Stn AAC m has
3. Transistor Devices TRANSISTOR DEVICES INC UlraFLEX HD User Manual 708401 Rev B ULTRAFLEX HD PDU USER MANUAL ULTRAFLEX HD PDU User Manual Rev B Transistor Devices Inc 36 Newburgh Road Hackettstown NJ 07840 Phone 908 979 0088 Fax 908 979 0466 708401 RevB Page 2 of 38 ULTRAFLEX HD PDU USER MANUAL Table of Contents List Of FT UU 5 FAD ES fed aset eo 6 6 70 System ae esa TT aera nie Met Oed 8 T AC DUR Gea alti M e QS mah 8 L3 Mounting sawa onan eens gg ina weet 9 L31 LUTON ON ots aa dsc LR 9 Weil A A ARE RE TOT SE OORT TITEL Pe SSS ONT MP 9 TA CACOIMDUS ae DON 9 LS LEC OPIS saat rcm 9 10 DC Connections u tae 11 BORE gaa ya ama a h 11 EJ EMO
4. D C BUS PROTECTIVE COVER DO NOT DISCARD COVER MUST EPLACEI AFTER SERVICE C E DC bus protective E covet Figure 4 DC fan connector detail 708401 Rev B Page 11 of 38 ULTRAFLEX HD PDU USER MANUAL 1 7 EMO Loop The PDU contains 4 EMO loop connectors on the rear of the PDU directly to the left of the test points Supplied with the PDU is an EMO loop connector installed 70 If an external power vault is used remove the jumper installed in J70 and connect the power vault EMO If power vault is used the J70 jumper must remain installed Refer to Figure 2 for where the EMO connectors are located and Figure 5 below for a detailed view of the EMO connectors on the rear of the PDU CHILLERS Figure 5 EMO loop connector detail 1 8 SMC Connection 72 The SMC connector is also located on the rear of the PDU Refer to Figure 2 for the location of the SMC connector and Figure 6 below for a detailed view The pinout of the SMC connector is detailed in Table 3 EXT INDICATORS Figure 6 SMC connector detail 708401 RevB Page 12 of 38 ULTRAFLEX HD PDU USER MANUAL Pin Number Signal Notes 1 Not Used 2
5. bade kusqan ypas Aisa huahua usq aa tains 20 i C COBIEDIORS ER E 20 3 0 2 SAC a Eva m 21 2 2 3 POD Ae T 21 3 3 4 aos sess 21 ET ME CU001707 Reena roe ee AW EE AEE 22 3 0 1 PDU Facility Ground Connection 22 24042 PDU Frame N os 22 22 3 Z DCO Distrib ti n u u ua Dc W 22 IT B18 on a R 22 3 7 2 48V DG OU DU iiia ec nt HR noii dee ta kem asus 25 SOFAS Fan PoWet Meet D C DR MR 23 3 7 3 1 Testhead Fan connector J46 E Pr 24 3 7 3 2 Cabinet Fan connectors 4 7 PIS eo euis wie EH EV pela tuviese ite aes 24 3 Z 3 3 Expansion Cabinet power connector J4O ss aet LE Da Dd icd epe T oo 25 qud ACV DC Volta ede Guss e ee ie od ee o hono aitov ed 26 2 6 EMO 00 26 2 97 MOr amp Control ee eee ee ee 27 2 9 OMO TCC a bose le dag a k ee Du E Tas 28 3911 DC NGC u L a 28 3 9 1 2 ABV DC Power Fault ei idu rt et aes ale a a ie bages
6. No contact 9 No contact Table 9 J46 Pinout 3 7 3 2 Cabinet Fan connectors J 47 48 Refer to Figure 19 and Table 10 below for details on the cabinet fan connectors J47 and J48 The pinout for both connectors is identical Connector used is Amp Mate N Lok series part number 770025 1 with sockets 194213 1 Recommended mating part numbers are housing 770018 1 with pins 194212 1 708401 Rev B Page 24 of 38 ULTRAFLEX HD PDU USER MANUAL Figure 19 Cabinet fan connectors J47 J48 Pin Number Pin type Description 1 Socket 194213 1 48V DC output 2 Socket 194213 1 48V DC return 3 No contact Table 10 J47 48 Pinout 3 7 33 Expansion Cabinet power connector J 49 Refer to Figure 20 and Table 11 below for details on the expansion cabinet power connector J49 Connector used is Amp Mate N Lok series part number 770025 1 with pins 194212 1 Recommended mating part numbers housing 770018 1 with sockets 194213 1 Figure 20 Expansion cabinet power connector J49 Pin Number Pin type Description 1 No contact 2 Pin 194212 1 48V DC return 3 Pin 194212 1 48V DC output Table 11 J49 Pinout 708401 Rev B Page 25 of 38 ULTRAFLEX HD PDU USER MANUAL 3 7 4 48V DC Output Voltage The output voltage will vary slightly with load The output voltage of the PDU is 48V full load Refer to Graph 1 below for the output voltage a
7. Figure 16 48V DC output bus bars 3 7 3 Fan Power Connectors for the Test Head Fantray system cabinet fan expansion cabinet fan and expansion cabinet power vault are provided on the rear of the PDU Refer to Figure 17 for a view of fan connectors 46 J47 48 and expansion cabinet power vault connector J49 Pinout details for each connector are provided below Power to the fan connectors is protected by a 15A circuit breaker CB10 located below the fan connectors as shown in me LAB FA M E Figure 17 AB 5 S CAB FAN 2 Figure 17 Fan power connectors 708401 RevB Page 23 of 38 ULTRAFLEX HD PDU USER MANUAL 3 7 3 1 Testhead Fan connector 6 Refer to Figure 18 and Table 9 below for details on testhead fan connector J46 Connector used is Amp Mate N Lok series part number 770028 1 with sockets 194213 1 for fan power and sockets 1 770253 0 for the fan speed control wires Recommended mating part numbers are housing 770021 1 with pins 194212 1 for fan power and pins 1 770252 0 for the fan speed control wires TH Pin 1 Figure 18 Testhead fan connector 46 Pin Number Pin type Description 1 Socket 194213 1 48V DC output 2 Socket 194213 1 48V DC return 3 Socket 194213 1 Chassis Ground 4 Socket 1 770253 0 Fan speed control 1 5 Socket 1 770253 0 Fan speed control 1 return 6 No contact 7 No contact 8
8. PDU id Figure 3 AC distribution om PDU ceti UO ERREUR ROI eed 0 Fig re4 DC fanconnector details c ten wens e ane ERN sad nad 1 Figure 5 EMO loop connector detail 12 Figure 6 SMC connector detail sse 512 Figure 7 Detail of EMO breaker CB2 shown in OFF position 14 Figure 8 Detail of input breaker CB1 15 Figure 9 Detail of AC load breakers CB3 CB8 513 Figure 10 D tailof Fan breaker ERE ER DE 6 Figure 11 Detail of Powersupply AG input breaker CBI trn en HU HH SEHR HG RIDES IESU I er 6 Figure 12 Overall front view of PDU 18 Figure 13 AC breaker lockout 219 Figure 14 Detail view of AC distribution 20 Figure 15 Detail view of J59 wel Figure 16 48V DC output bus bars 422 Figure T7 Fattpowet connectors Leip rm cash enge 23 Figure 18 Testhead fam Ors rg ORO RUD Ee Figure 19 Cabinet fan connectors J47 48 2 Figure 20 Expansion cabinet power connector 9 ra saan ERIE R EA u a qaqan REE a aqa 25 Figure 21 EMO loop connectors ione eor EIE a E a N ER o EE IEEE EE tas eb tu OU tbi a aS 27 Figure 22 Interface PCB connections RAN Figure 23 Alarm output typical for all alarms Fig
9. While the power supplies are inhibited you may hear a clicking noise This noise is normal and is a result of the magnetics in the power supply operating in a no load condition 3 7 1 DC Ratings Refer to Table 8 below for the DC output ratings of the PDU Refer to Fan Power section 3 7 3 below for pinout details on the fan power connectors DC Output Output connector Max Current Max Power Main 48V Output Bus bars 300 A 14 400 W 7 5 A running 360 W p 9 5 A locked rotor 456 W 1 75 A running 84W is 1 2 25 A locked rotor 108 W I 1 75 A running 84W Hid 2 25 A locked rotor 108 W Expansion cabinet power 49 15W Table 8 DC Output Ratings 708401 Rev B Page 22 of 38 ULTRAFLEX HD PDU USER MANUAL 3 7 2 48V DC Output The main 48V output bus bars are located on the rear of the PDU under a protective cover Refer to Figure 16 for a view of the DC output bus bars with the cover removed The 48V output bus positive is on the top and the 48V return bus negative is on the bottom as shown in Figure 16 To prevent incorrect connections to the bus bars the center to center spacing is 1 0 on the output bus and 1 375 on the return bus f Ax c T positive 48V Return bus negative
10. fault signals of all the power supplies are tied together so any single fault will generate a 48V DC power fault signal The 48V DC power fault will also be generated when no rectifiers are installed Rectifier good LED s are provided for visual indication of a failed power supply The 48V DC power fault output is the transistor side of an optocoupler Maximum recommended current draw through the optocoupler is 3mA 48V DC power fault will be active when the 48V bus is disabled or when any of the power supplies have failed 3 9 1 3 DC current monitor The interface PCB provides a DC current monitor signal to the SMC controller The current monitor signal is designed to produce 2 7V across a 158 Ohm resistor with a load of 300A Refer to Graph 2 below showing the DC current monitor signal for various load conditions Current Monitor Signal 4 rectifiers installed mon Current Monitor V 0 25 50 75 100 125 150 175 200 225 250 275 300 DC Load A Graph 2 Current monitor signal vs load graph 708401 Rev B Page 29 of 38 ULTRAFLEX HD PDU USER MANUAL 3 9 2 LED Indicators amp Alarm outpu LED indicators are provided on the interface PCB for AC available Main power on 48V DC on and power supply status LED s for AC available Main power and 48V DC on are also provided on the front of the PDU Alarm outputs ate also provided for AC available Main power on and 48V DC on connector J71 Refer
11. 007 0 Refer to Figure 21 and Table 12 below for details on the EMO connectors 708401 RevB Page 26 of 38 ULTRAFLEX HD PDU USER MANUAL Figure 21 EMO loop connectors EMO location Connector number Supplied with PDU Test head 167 Support Cabinet 168 Chiller 169 External Power Vault J70 Yes Table 12 EMO connectors 3 9 Monitor amp Control Monitoring and control of the PDU is accomplished via the interface PCB mounted at the rear of the PDU The interface PCB contains test points alarm LED s and connections for external alarms and the SMC The interface PCB also contains a filter for the 48V DC fan output and connections for the EMO loop See below for details on the interface PCB Refer to Figure 22 for a detailed view of the interface PCB connections on the reat of the PDU ECT D SYSTEM _ f f ERN FA FA FAN FN Z N N N N XS Y 2 F N M X K gt lt gt A x x A N y N 4 lt lt lt lt EE amp lt QM x lt gt gt Figure 22 Interface connections 708401 RevB Page 27 of 38 ULTRAFLEX HD PDU USER MANUAL 3 9 1 SMC Interface J 72 The SMC interface connector is 72 on the PDU and is a 25 pin D sub connector The pinout is detailed in Table 13 below Details pro
12. 0320 C20 CB6 15 2 A amp B 0 Manipulator J56 6 15R Spare J57 6 15R Expansion Cabinet Vault J58 CB4 20 3 amp C 208 230 L15 20R CDU 59 5 25 3 A B amp 208 230 Amp mate n lok DC PM J66 CB3 30 3 amp 208 230 L15 30R Table 5 AC Distribution details 708401 Rev B Page 20 of 38 ULTRAFLEX HD PDU USER 3 5 2 AC outlet J 52 53 As shown in Table 5 above the output of AC outlet J52 J53 is 115VAC This output is provided through a step down transformer within the PDU Refer to install section 1 1 2 in the service manual for proper configuration for this AC output 3 5 3 59 Pinout Refer to Figure 15 and Table 6 below for details on CDU connector J59 Connector used is Amp Mate N Lok series part number 770027 1 with sockets 193797 1 and key plugs 770377 1 Recommended mating part MANUAL numbers are housing 770020 1 with pins 193796 1 Pin 1 Figure 15 Detail view of J59 Pin Number Pin type Description 1 Plug 770377 1 Key plug 2 Plug 770377 1 Key plug 3 Socket 193797 1 Ground 4 Socket 193797 1 Phase A 5 Socket 193797 1 Phase B 6 Socket 193797 1 Phase C 3 5 4 Internal AC wiring Internal AC wiring is required for the AC feed to the EMO supply as well as the pow
13. 29 aun h S habia bh Una 29 3 92 LED Indicators amp Alarm oulputs 30 3 9 2 1 30 3 92 22 0 31 3 9 2 3 Main Power 07 31 ASV DEON us aaa a kap 31 3 923 Power BUDD 0 31 249235 Muro TE H M 31 3 94 EMEN T sc an m aD ah a Q E ER 31 4 0 System Ratings Summary hil oad OE asa 33 708401 Rev B Page 4 of 38 ULTRAFLEX HD PDU USER MANUAL ss oe CD 33 qu SAC Distribution 33 43 33 44 Mechanical RQIIMOS ashaku bs s aset 34 4 3 Environmental ROUNDS ania yobs rto 34 5 1 System Interconnect for revision A or 35 52 System Interconnect for revisions prior to revision 36 6 Vendor Support and Service ee 37 Odi SAPS SUDDON 37 6 2 Service for GFS and Customers 8 37 6 3 Service Su ppori Jor GCS ea oa teed at once Ci edel 37 7 Revision History 38 ZE DoeWmentupdglesi u 38 List of Figures 0 7 Figure 2 Rear view of
14. 56 257 804 RECTIFIER SHELF Figure 9 Detail of AC load breakers CB3 CB8 708401 RevB Page 15 of 38 ULTRAFLEX HD PDU USER MANUAL 2 1 5 Fan breaker CB10 Turn on fan breaker CB10 located on the rear of the PDU refer to Figure 2 Without this breaker turned on the cabinet fans cannot power up Refer to Figure 10 for a view of CB10 Note Breaker CB10 shown below is in the off position 48V OUTPUT BUS Fan breaker CB10 T A P Lj Quoi 48VI RETURD AS Figure 10 Detail of Fan breaker CB10 2 1 6 48V Power Supply AC input breaker CB9 Turn the power supply AC input breaker CB9 located on the front panel of the PDU refer to Figure 1 Once the breaker is turned on the AC input will be fed into the power supplies Although the DC output of the power supplies will be off you may hear a clicking noise This noise is normal and is a result of the magnetics in the supplies operating in a no load condition Refer to Figure 11 for a view of CB9 Note Breaker CB9 shown below is in the off position Power supply AC input breaker CB9 ECTIFIER SHELF Figure 11 Detail of Power supply AC input breaker CB9 708401 RevB Page 16 of 38 ULTRAFLEX HD PDU USE
15. AFLEX HD PDU USER MANUAL 2 1 3 Input breaker CB1 Once the AC is energized the AC input breaker can be turned on Turn on the AC input breaker CB1 located on the front of the PDU by pushing the breaker handle upward If the breaker handle is facing the bottom of the PDU as shown in Figure 8 the breaker is off Once the input breaker is on the Main Power On LED is illuminated green refer to Figure 7 for the location of the Main Power On LED If the Main Power On LED is not illuminated verify all EMO loop connectors are plugged in and no EMO buttons are depressed With an open EMO loop the input breaker cannot be turned on Refer to Figure 8 for a view of input breaker Input breaker CB1 Figure 8 Detail of input breaker CB1 2 1 4 AC Loads Once the AC input breaker is on the AC loads can be connected refer to Figure 1 for the location of the AC load breakers and Figure 9 for a detail view Turn on the AC load breakers CB3 CB4 CB5 CB6 CB7 and CB8 one at a time Note All breakers shown in Figure 9 are in the off position T COO JL 5 JE 3 15 15 1 1
16. Fan Speed Control 1 From J46 pin 4 3 PUMA ID bit Jumper to J72 pin 4 4 Common Jumper to J72 pin 3 5 48V current monitor Output to SMC 6 48V current monitor return Output to SMC 7 Not Used 8 Not Used 9 Not Used 10 Not Used 11 5V from SMC to PDU Input from SMC 12 Not Used 13 48V DC Enable Input from SMC 14 Not Used 15 Not Used 16 Not Used 17 Not Used 18 Not Used 19 48V DC power fault Output to SMC 20 48V DC power fault return Output to SMC 21 Not Used 22 Not Used 23 Not Used 24 Fan Speed Control 1 return From J46 pin 5 25 48V DC Enable return Input from SMC Table 3 SMC connector Pinout J72 1 9 External Indicators Connection J 71 The external indicator connector is located on the rear of the PDU next to the SMC connector refer to Figure 2 for location of external indicator connector and Figure 6 for a detailed view The pinout of the external indicator connector is detailed in Table 4 Pin Number Signal AC Available Not Used Main Power On 48V DC On Not Used AC Available return Not Used Main Power On return 48V DC On return Table 4 72 Pinout CO NI AA BY GO 708401 RevB Page 13 of 38 ULTRAFLEX HD PDU USER MANUAL Chapter 2 0 System Start up Verify all AC and DC circuit breakers are turned off Before applying power it is recommended to fully read the User Manual portion of this document to become familiar with all the components and funct
17. Input The AC input to the PDU can be configured as a 3 Phase Delta with or without one leg grounded or a 3 Phase Wye Neutral not used The AC feed must be capable of supplying a continuous current of 150A Voltage and frequency ratings are specified below 3 2 1 Voltage Power Supply operating voltage range is 187 253 VAC AC input operating range is 200 208 VAC 3 2 2 Frequency Frequency range is 47 63 Hz 3 3 EMO supply The PDU contains a 24V EMO supply that is wired directly to the AC input before AC input breaker CB1 This allows the EMO supply to be on as soon as the AC to the PDU is energized The EMO supply is protected by a 3A breaker CB2 on the front panel of the PDU The EMO supply is used to power the interface PCB as well as the UVR under voltage release on the input circuit breaker CB1 3 4 AC Input breaker The AC input breaker is a three phase 150A thermal magnetic circuit breaker and contains a UVR under voltage release The UVR will not allow the breaker to be turned on unless 24V from the EMO supply is provided to the breaker through the EMO loop Conversely the breaker will trip if the supplied 24V to the breaker drops below 16 volts or the EMO loop is opened 3 4 1 Lock Out Feature The AC breaker can be locked in the off position by installing a padlock through the hole in the lockout bracket This will prevent anyone from turning on the PDU Refer to Figure 13 for a view of a lock installed Locko
18. Newburgh Road Hackettstown NJ 07840 908 979 0088 Please have the following information available when you call Description of component including serial no If available In service date Nature of the failure i The TDI authorized factory representative will determine the method of return replacement based upon the information provided 4 Ship the failed unit back to the designated repair facility per the instructions from the authorized representative transportation charges PREPAID Components which fail after the warranty period has expired or which fail due to misuse or abnormal operating conditions will be repaired at the purchaser s expense In such cases an estimate will be made and submitted prior to repair In cases where it is determined that no fault or malfunction exists in the returned unit there will be a nominal handling and verification charge eN 708401 Rev B Page 37 of 38 ULTRAFLEX HD PDU USER MANUAL Chapter 7 Revision History Revision ECN Description of Change Date Change By Checked By Pi Created Document 08 13 07 FQ Updated per Teradyne mark ups Change to User Manual only P2 Updated interconnect drawing 11 27 07 FQ Updated front views of PDU to show new breaker arrangement P3 Updated per Teradyne review of 12 4 07 FQ P2 P4 Change input breaker and AC input 12 5 07 FQ from 125A to 150A Added AC line configurations Correct typing amp table of conten
19. R MANUAL 2 1 7 48V DC bus turn on After all breakers have been turned on the 48V DC bus can be enabled via the SMC controller Once the 48V DC output is energized the 48V On LED will be illuminated green If the 48V does not turn on verify the power supply AC input breaker CB9 is turned on and power supplies are installed Refer to Service Manual for troubleshooting 2 2 System Functionality Once the PDU is operational it is ready for system testing If any portion of the system is found to be non functional or there are active alarms refer to the Troubleshooting section in the Service Manual for assistance 708401 Rev B Page 17 of 38 ULTRAFLEX HD PDU USER MANUAL Chapter 3 0 User Manual This section provides an overview of the PDU system functionality Also detailed in this section are the system specifications connector designations and connector pinouts 3 1 System Overview The PDU is designed to provide overcurrent protected AC distribution and a 48V DC output The 48V DC output is derived from modular power supplies The only cooling within the PDU are the fans on the individual power supply modules Other features of the PDU include alarm indications EMO shutdown feature test points for troubleshooting and connections for the SMC controller Refer to Figure 12 for an overall view of the PDU Figure 12 Overall front view of PDU 708401 RevB Page 18 of 38 ULTRAFLEX HD PDU USER MANUAL 3 2 AC
20. age 5 95 non condensing Ambiant Noise 62dBa 708401 Rev B Page 34 of 38 ULTRAFLEX HD PDU USER MANUAL Chapter 5 1 System Interconnect for revision A or higher units p DISTRIBUTION IBBON CABLE WHT V ECTIFIER RECTIFIE ECTIFIE ECTIFIER SHELF ECTIFIE EVI LINE FILTER ECTIFIER 3 EME LINE FILTE RECTIFIE EMI LINE FILTER RECTIFIER 1 LINE FILTER ADIUS POWER ADIUS POWER E 708401 Rev B Page 35 of 38 ULTRAFLEX HD PDU USER MANUAL 5 2 System Interconnect for revisions prior to revision 14 PIN IBBUN DISTRIBLTION RECTIFIER RECTIFIER RECTIFIER 1 ECTIFIER RECTIFIER 4 LINE FILTE RECTIFIE EMI LINE FILTER RECTIFIER EMI LINE FILTE RECTIFIER 1 EMI LINE FILTER 1 1 TYCO RFI POWER LINE FILTES ADIUS POWER ADIUS POWE RADIUS POWER 708401 Rev B Page 36 of 38 6 1 6 2 6 3 ULTRAFLEX HD PDU USER MANUAL hapter 6 Vendor Support and Service enaps Sales Support All sales support for purchases proposals spares etc is provided from our Hackettstown New Jersey facility Normal hours of operation are 8 00 a m to 5 00 p m Monday through Friday If you should have an urgent requirement for pro
21. ducts or services after these hours a message may be left with our answering service at 908 979 0088 and one of our representatives will return your call Service for GFS and Customers Contact 1 900 Teradyne as with any other Teradyne part Service Support for GCS TDI provides 24 hour response to your technical service needs utilizing our infrastructure of offices and representatives strategically located throughout the United States Should an emergency arise during normal business hours please call 908 979 0088 and request service or technical assistance If you are calling after our normal business hours please use one of the following technical assistance numbers 1 888 575 8875 Or when calling internationally 1 973 283 7236 Your call will be returned as soon as possible by one of our technical service technicians As stated previously in the General Terms and Conditions all components of the TDI DC power plant are warranted to be free of defects in material and workmanship for a period of two 2 years from date of shipment to the original purchaser In the unlikely event a component of the TDI DC power plant should fail the following procedures should be followed to expedite the repair and or replacement of the failed module 1 Contact the authorized TDI repair facility at the address and phone number shown below to obtain a Return Authorization Number for the failed unit TDI Telecommunication Power Systems Division RMA 36
22. er supplies Refer to Table 6 59 Pinout Table 7 for details on the input AC wiring Use Circuit Breaker phases Used Breaker Rating A Phases EMO supply CB2 3 2 A amp B Power supply 1 2 A amp B Power supply 2 CBO 80 2 B amp C Power supply 3 2 A amp C Power supply 4 2 A amp C 708401 Rev B Table 7 Internal AC Distribution Page 21 of 38 ULTRAFLEX HD PDU USER MANUAL 3 6 Grounding 3 6 1 PDU Facility Ground Connection The main AC input ground is located close to the input circuit breaker CB1 Refer to section 1 1 4 in the setvice manual for details on connections to the AC ground 3 6 2 PDU Frame ground A frame ground connection is provided on the PDU near the main AC input Refer to section 1 1 5 in the setvice manual for details on connecting the frame ground 3 6 3 DC Grounding The 48V DC return is connected to chassis ground within the PDU The connection is made between the power supply output and chassis on the power supply backplane PCB the power supplies plug into 3 7 DC Distribution The PDU provides a main 48V DC output as well as a 48V output for system fans The 48V power supplies in the PDU receive AC as soon as the main AC breaker CB1 and power supply AC input breaker CB9 are turned on The 48V output is inhibited off until commanded to turn on by the SMC controller The 48V output is inhibited off even if SMC is not present or is disconnected
23. h a dedicated ground wire The AC input can be configured as a 3 Phase Delta with or without one leg grounded or a 3 Phase Wye Neutral not used The AC feed must be capable of supplying a continuous current of 150A The frequency range for the input is 47 63 Hz All AC wiring should be performed by a licensed electrician and in accordance with local and regional electrical codes Before starting any cabling verify the AC feed breaker CB1 is turned off and follow the facility LOTO Lock Out Tag Out procedure 1 5 AC Outputs All AC connections are located on the front of the PDU next to the AC input circuit breaker Refer to Table 1 and Figure 3 for descriptions of the connections Use Outlet Number Circuit Breaker Breaker Rating A Expansion Cabinet Vault J58 CB4 20 DC PM J66 CB3 30 CDU J59 CB5 25 SMC J50 Spare J51 Manipulator J56 2 Spare J57 External IEC Spare J54 External IEC Spare J55 idi External IEC CPU amp Monitor J52 CBE 5 External IEC DSP J53 Table 1 AC Output table 708401 RevB Page 9 of 38 ULTRAFLEX HD PDU USER MANUAL a e 7 m
24. ions of the system If any problems are encountered during the start up of the system press one of the systems EMO switches to shut down the system 2 1 System turn on 2 1 1 EMO breaker CB2 Turn on EMO breaker CB2 located on the front panel of the PDU refer to Figure 7 for actual location To turn on CB2 rotate the handle on the breaker up toward the top of the PDU If the handle if down toward the bottom as shown in Figure 7 the breaker is off With CB2 on it will allow the EMO supply to turn on as soon as the AC input is energized Refer to Figure 7 for a view of EMO breaker CB2 AC available OCBEO AC ON and 48V DC LED s EMO breaker S 2 CB2 5 N Figure 7 Detail of EMO breaker CB2 shown in OFF position N 2 1 2 Energize AC input Energize the AC input to the PDU by turning on the facility circuit breaker Once the AC input is energized the AC Available LED should be illuminated green refer to Figure 7 above for the location of the AC available LED If the AC Available LED is not illuminated verify the EMO breaker CB2 is on and that the AC input is within the operating range 187 253 VAC 708401 RevB Page 14 of 38 ULTR
25. l monitors phases B amp C of the AC on the output side of circuit breaker CB1 The Main power on LED will be illuminated green provided that both input breaker CB1 is on and the AC voltage is above 170 VAC 3 9 2 4 48V DC 48V DC on signal monitors the 48V DC output The 48V DC on LED will be illuminated green whenever the 48V DC output voltage is above 44 VDC 3 9 2 5 Power Supply LED s The interface PCB contains LED s to show the status of the power supplies When the 48V DC bus is enabled all installed power supplies should have their corresponding LED illuminated green If a power supply is not installed or failed the corresponding LED will be off All power supply LED s will be off when the 48V bus is inhibited off Refer to Figure 22 for a view of the rectifier good LED s 3 9 3 Test Points Test points are provided on the interface PCB as shown in Figure 22 Thete is one set of test points for the 24V EMO supply output and one set for the 48V DC output The test points are protected against short circuit by re settable fuses For all test points red is positive and black is negative 3 9 4 Thermostat A normally closed thermostat is located on the interface PCB which will shut down the PDU due to extreme temperatures The thermostat is rated 45 C 5 C and is installed in the positive leg of the 24V EMO power to the EMO loop If the temperature reaches the thermostat set point the thermostat will open and tri
26. nectors Figure 5 Test points Figure 22 Fan connectors J47 J48 Figure 19 Alarm amp Power Status LED s Figure 22 vL an connector J46 Figure 18 DC bus protective x an Breaker CB10 Figure 10 cover Figure 4 Figure 2 Rear view of PDU 11 AC Input Warnings WARNING HIGH TOUCH CURRENT EARTH CONNECTION ESSENTIAL BEFORE CONNECTING SUPPLY AVERTISSEMENT HAUTE TENSION DE CONTACT LA MISE A LA TERRE EST ESSENTIELLE AVANT DE BRANCHER L ALIMENTATION 1 2 AC Input Ratings SPS5809 4 System PDU supplied with 4 rectifiers 708355 4 Input 200 208 50 60Hz 125A Max Output 48Vdc 320A 15 200W Max 4 rectifiers Output 208 230V AC 50 60Hz 19 000W Max Output 115VAC 50 60Hz 575W Max AMBIENT 30 C Max 708401 RevB Page 8 of 38 ULTRAFLEX HD PDU USER MANUAL 1 3 Mounting Equipment 1 3 1 Introduction The PDU was specifically designed for installation into the Teradyne cabinet Since there are no mechanical mounting features on the PDU it must be installed in a shelf within the Teradyne cabinet Mounting of the PDU to the shelf to be specified by Teradyne Refer to Teradyne service documentation for installation of PDU into the UltraFLEX HD system 1 3 2 Weight The weight of the PDU is approximately 125 Lbs Do not attempt to lift the PDU without assistance or use of mechanical lift 1 4 AC Input The AC input required is a separately protected 200 208 VAC three phase input wit
27. or 3 phase wye 3 wire plug neutral not used PDU AC Input Range 200 208 VAC AC frequency 47 63 Hz Power Factor gt 95 System efficiency gt 90 Max AC input current 187VAC input full load 110A AC circuit breaker rating 150A 4 2 AC Distribution Outlet Number Circuit Breaker Breaker Rating A AC type Voltage VAC Frequency J52 J53 CB8 5 Single phase 115 47 63 Hz J54 J55 CB7 15 Single phase 208 230 47 63 Hz J50 J51 J56 J57 CB6 15 Single phase 208 230 47 63 Hz J58 CB4 20 Three phase 208 230 47 63 Hz J59 CB5 25 Three phase 208 230 47 63 Hz J66 CB3 30 Three phase 208 230 47 63 Hz 4 3 DC Distribution Output connector Circuit Breaker Breaker Rating A Max Current Bus bars 300 A J46 7 5 A running 9 5 A locked rotor J47 1 75 A running CB10 15A 2 25 A locked rotor J48 1 75 A running 2 25 A locked rotor J49 2 708401 Rev B Page 33 of 38 ULTRAFLEX HD PDU USER MANUAL 4 4 Mechanical Ratings Description Rating PDU Dimensions 19W 35 5 D x 12 1 H PDU Weight including 4 power supplies 125 Lbs Individual power supply weight 6 Lbs 4 5 Environmental Ratings Description Rating Temperature range operating 20C 30C Temperature range storage 40C 85C Humidity operating 30 70 non condensing Humidity stor
28. p input breaker CB1 resulting in the shut down the PDU The thermostat will automatically reset after the temperature has reached about 35 degrees C but the PDU will remain off since the input breaker will need to be turned on The thermostat should re set within 1 minute as long as the temperature is 4 degrees below the trip range trip range is 40C 50C The PDU will not be able to be turned on until the thermostat has reset As shown in Figure 24 the thermostat is located on the interface PCB behind the test points To check if the thermostat is open closed refer to section 2 1 item 7 of the Service Manual 708401 RevB Page 31 of 38 ULTRAFLEX HD PDU USER MANUAL _ ef E E Test Points Figure 24 Thermostat location on interface PCB 708401 RevB Page 32 of 38 ULTRAFLEX HD PDU USER MANUAL hapter 4 0 System Ratings Summary 4 1 AC Input Description Rating 3 phase delta 3 wire plus ground
29. t various loads The output voltage range over entire load range is 48 5V 0 5 External adjustments of the 48V output are not available DC Output Voltage 4 Rectifiers 49 2 49 0 48 8 48 6 48 4 DC Output V 48 2 48 0 47 8 47 6 47 4 DC Output Voltage 0 25 50 75 100 125 150 175 200 225 250 275 300 DC Output V 49 0 49 0 48 9 48 7 48 6 48 5 48 4 48 3 48 2 48 1 48 0 48 0 48 0 DC load Graph 1 Output V vs load graph 3 8 EMO loop The PDU contains an EMO loop which will shut down the PDU if the loop is broken When the EMO loop is broken CB1 is opened The EMO supply still remains powered up The EMO connectors on the PDU are J67 J68 J69 and 70 and are located on the rear of the PDU A jumper is provided 70 on all PDU s since an external power vault is not always used When the EMO loop is broken the 24V EMO voltage to the UVR on the input breaker is lost resulting in the circuit breaker tripping which shuts down the PDU The EMO loop connectors used for J67 J68 and J69 are housing 770024 1 with sockets 1 770008 0 Recommended mating connector for J67 J68 and J69 is housing 770017 1 with pins 1 770007 0 The EMO loop connector used for 70 is housing 770027 1 with sockets 1 770008 0 and1 770006 0 Recommended mating connector for J70 is housing 770020 1 with pins 1 770
30. to Figure 22 for a view of the LED indicators and alarm output connector J71 on the rear of the PDU 3 9 2 1 Alarm output connector J 71 The alarm output connector is J71 and is a 9 pin D sub connector These alarm outputs can be used for external LED s Refer to Table 14 below for the pinout on 71 The alarm outputs are open collectors as shown in Figure 23 Logic level for all alarms is TTL high Normal TTL low Fault The maximum ts recommended current through the transistor is 50mA Pin Number Signal AC Available Not Used Main Power On 48V DC On Not Used AC Available return Not Used Main Power On return NI AA BY GO N 48V DC On return Table 14 J71 Pinout Figure 23 Alarm output typical for all alarms 9 AVAIL NR 708401 RevB Page 30 of 38 ULTRAFLEX HD PDU USER MANUAL 3 9 2 2 AC Available The AC available signal monitors phases B amp C of the AC from the input side of circuit breaker CB1 The AC available LED s will be illuminated green provided that both EMO breaker CB2 is on and the AC voltage is above 170 VAC WARNING IF EMO BREAKER IS OFF THERE WILL BE NO INDICATION AC IS PRESENT WITHIN THE PDU WHENEVER WORKING ON THE PDU ALWAYS FOLLOW LOCK OUT TAG OUT PROCEDURES AND MEASURE FOR VOLTAGES BEFORE PERFORMING ANY WORK 3 9 2 3 Main Power On The Main power on signa
31. ts field P5 Change current monitor signal from 1 22 08 FQ 2 5V to 2 7V 300A Update Graph 2 based on data taken from updated PDU P6 Added internal links added section 5 4 08 AO for Service Support GFS and customers to contact 1 800 Teradyne A 28901 Update EMO loop information is 5 14 08 F Q 3 8 Figures 2 5 amp 21 Update interconnect drawing for new EMO loop Release to rev A Changed AC input range to 200 208 VAC 7 1 Document updates This document is supplied to Teradyne for complete review Teradyne can edit this document as needed to incorporate into their system documentation TDI will maintain the revision of this document and make updates agreed between Teradyne and TDI when questions arise about the content or lack thereof 708401 Rev B Page 38 of 38 Filename Directory Template Title Manual Subject Author Keywords Comments Creation Date Change Number Last Saved On Last Saved By Total Editing Time Last Printed On As of Last Complete Printing Number of Pages Number of Words Number of Characters 708401Rev UItraFLEX HD PDU User Manual doc C Documents and Settings naponem Desktop V Power C WINDOWS Temporary Internet Files Content IE5 WKOERLM2 tp625 1 dot tdi 5 14 2008 11 25 00 AM 12 5 30 2008 1 23 00 naponem 588 Minutes 5 30 2008 1 24 00 PM 38 8 662 approx 39 242 approx
32. ure 24 Thermostat location on interface PCB 708401 Rev B Page 5 of 38 ULTRAFLEX HD PDU USER MANUAL List of Tables Ta Tab Tab Tab Tal Tab Tab Ta Tab Tal Tal Tal D D D Ta e 1 Output table e 2 DC Fan connection table e 3 SMC connector Pinout J72 e4 J 72 Pinout ree e 5 AC Distribution details e 6 J59 Pinout e 7 Internal AC Distribution e 8 DC Output Ratings e 9 46 Pinout e 10 J47 J48 Pinout e 11 J49 Pinout e 12 EMO connectors 13 J72 Pinout e 14 J71 Pinout List of Graphs Graph 1 Output V vs load graph Graph 2 Current monitor signal vs load graph 708401 Rev B Page 6 of 38 ULTRAFLEX HD PDU USER MANUAL Chapter 1 0 System Overview Refer to Figure 1 and Figure 2 below for front and rear views of the PDU respectively The major components of the PDU are shown on the diagrams AC output breakers on top half of front panel Figure 3 AC input breaker CB1 Figure 8 AC input breaker cover Figure 8 AC outlets on lower half of front panel Figure 3 Power Status LED s Figure 7 Figure 1 Front view of PDU 708401 Rev B Page 7 of 38 ULTRAFLEX HD PDU USER MANUAL Power supply access 1 External indicator panel A connector J71 Figure 6 SMC connector Figure 6 EMO con
33. ut bracket Breaker handle 6 Figure 13 AC breaker lockout 708401 RevB Page 19 of 38 ULTRAFLEX HD PDU USER MANUAL 3 5 AC Distribution All the AC distribution is provided on the front panel of the PDU Refer to Figure 14 for a detailed view of the AC distribution The AC loads are distributed as evenly as possible across the three phases The system wiring is optimized for the least current phase imbalance for the system For more detailed information on the AC distribution refer to the System Interconnect drawing A RECTIFIER SHELF Figure 14 Detail view of AC distribution 3 5 1 AC connectors Table 5 below details the specifications on the AC distribution connectors Use Outlet Circuit Breaker Used Voltage Number Breaker Rating A P Phases VAC BP External IEC J52 5 15R CB8 5 2 B amp C 115 External IEC DSP J53 5 15R External IEC Spare J54 6 15R CB7 15 2 B amp C 208 230 External IEC Spare J55 6 15R SMC J50 60320 C20 Spare J51 6
34. vided below for the 48V current monitor 48V DC enable and 48V DC power fault signals Pin Number Signal Notes 1 Not Used 2 Fan Speed Control 1 From J46 pin 4 3 PUMA ID bit Jumper to J72 pin 4 4 Common Jumper to J72 pin 3 5 48V current monitor Output to SMC 6 48V current monitor return Output to SMC 7 Not Used 8 Not Used 9 Not Used 10 Not Used 11 5V from SMC to PDU Input from SMC 12 Not Used 13 48V DC Enable Input from SMC 14 Not Used 15 Not Used 16 Not Used 17 Not Used 18 Not Used 19 48V DC power fault Output to SMC 20 48V DC power fault return Output to SMC 21 Not Used 22 Not Used 23 Not Used 24 Fan Speed Control 1 return From J46 pin 5 25 48V DC Enable return Input from SMC Table 13 J72 Pinout 3 9 1 1 48V DC Enable The 48V DC enable is a signal from the SMC to enable the 48V DC output With no connections to J72 the 48V DC output will be off To enable the 48V DC output a 5V signal must be applied between pin 13 positive and pin 25 negative on J72 The 5V signal drives the diode side of an optocoupler to enable the 48V DC output The 48V DC enable must be capable of providing a minimum current of 12mA to enable the power supplies 708401 RevB Page 28 of 38 ULTRAFLEX HD PDU USER MANUAL 3 9 1 2 48V DC Power Fault The 48V DC power fault is a common fault signal for all the 48V power supplies installed in the system The
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