Chassis Power Supplies
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1 PDC24 / PAC Chassis Power Supplies (PDC24 / PAC) Issue 3 October 2005 INTRODUCTION PURPOSE Two Power Supply Units (PSUs) provide a dual-redundant source of 5.4Vand 12Vdc onto the backplane for the modules mounted in a SC300E chassis. The PSUs are mounted one above the other in the left hand side of the chassis as shown. Each PSU has a fault warning system and a power sharing system. The power sharing system operates when both PSUs are working. Either PSU has the capacity to power the system if the other one fails. The PSUs operate from the following supplies detailed in Table 1-1: This document is intended to provide a general understanding of the function of the PAC and PDC24, sufficient to enable basic maintenance operations to be effected in the field. Figure 1-1. PDC24 / PAC General view
2 ASSOCIATED DOCUMENTATION Reference Title Chassis User Manual Specification Model PDC24 PAC Nominal input voltage 24Vdc 110/230Vac Auto ranging Input voltage range 20 to 36Vdc 92 to 132Vac or 184 to 264Vac Input frequency range Not applicable 45 to 65Hz Input power 200W 235W Output power 145W 175W Outputs 18A 4A 23A 4A Output hold up time 20 ms 20mS Inrush current 170A, 1.5ms time constant 30A, 4ms time constant Isolation 2.5kVdc 3kVac Indicators Green Normal Yellow Power Share Red Fault Green Normal Yellow Power Share Red - Fault Alarm contact ratings 175V, 0.25A 175V, 0.25A Overall size (mm) Overall size (inches) 420H x 200L x 68W 16.5H x 7.87L x 2.67W 420H x 200L x 68W 16.5H x 7.87L x 2.67W Weight 2.3kg 2.3kg Table 1-1. PDC24/PDC data 2 PDC24 / PAC October 2005 Issue 3
3 PDC24 / PAC Chassis Power Supplies ENVIRONMENTAL SPECIFICATIONS The maximum ambient temperature measured at the hottest point within the Triguard system shall not be greater than 60 degrees centigrade. Temperature operating: +5 C to +60 C Temperature storage: -25 C to +70 C Humidity: 5% to 95% non-condensing at ambient < 40 C EMC/RFI Immunity: Tested and certified to IEC 1131-Part Vibration/Shock: Tested and certified to IEC 1131-Part Certification: General Certification: Ref. SC300E TMR Product Guide (ref ). TRANSPORT AND HANDLING The PSU must be transported and stored in its original packing material which should be retained for this purpose. PDC24 / PAC October 2005 Issue 3 3
4 TECHNICAL DESCRIPTION PHYSICAL The PSU comprises a front plate mounted at right angles to a chassis plate. All the user controls and indicators are mounted on the front plate as shown in Figure 1-1. The chassis plate supports three main items: Power supply unit: A self-contained switch-mode power supply unit (SMPS). Front panel PCB: Contains printed wiring and physical support for the controls and indicators that are viewed and accessed from the front panel. PSU interface PCB: Contains the power share and fault alarm circuits. Interfaces these circuits and the SMPS to the SC300E chassis backplane via connector PL3. A ribbon cable connects the front panel PCB to the SMPS. A mechanical stop fitted to the AC system chassis power supply slots (marked AC STUD) prevents the insertion of a PDC24 into a PAC slot. 4 PDC24 / PAC October 2005 Issue 3
5 PDC24 / PAC Chassis Power Supplies Figure 2-1 PSU Layout and dimensions PDC24 / PAC October 2005 Issue 3 5
6 EXTERNAL CONNECTIONS Chassis backplane connector PL3 The chassis backplane connector details are given in Table 2-1. DIN41612 type H15 male connector. SK1 acts as a guide to prealign connector PL3 with its mating socket when the PSU is inserted into its slot. Table 2-1. Backplane connector pinouts Pin Signal 4 5V return 6 5V return 8 +5V output 10 +5V output 12 5V reutrn sense 14 5V +ve sense 16 12V return V output 20 Power fail output 22 Power share 24 Alarm contact COM 26 Alarm contacts NO 28 Ac(N) or dc ve input 30 AC(I) or dc +ve input 32 Earth (mates first) 6 PDC24 / PAC October 2005 Issue 3
7 PDC24 / PAC Chassis Power Supplies Test connector The 8-way 270º DIN socket located on the front panel. The connector pinout details are given in Table 2-2. Table 2-2. Test connector pinouts PIN Signal 1 5V return at SMPS 2 12V +ve output at SMPS 3 5V +ve output at SMPS 4 +5V return at backplane 5 Power share line 6 5V supply ve sense 7 5V supply +ve sense 8 Power fail interrupt Figure 2-2 Test connector pin number location PDC24 / PAC October 2005 Issue 3 7
8 THEORY OF OPERATION Main power flow The 5.4V output allows for a drop of about 0.4V across the auctioneering diodes in each module supplied. The output voltage is fed back to the SMPS control circuits via the +ve and -ve sense lines. The SMPS then compensates for any voltage drop along the power supply lines by increasing its output voltage. The rated output voltage is thus present at the load rather than at the PSU output terminals. The -ve sense input to the SMPS is modified by the power share system. The 5V supply current sensor is a ohm resistance formed by two resistors in parallel. The voltage developed across the resistors is used as a measure of output current by the power share and fault alarm circuits. Various system voltages are connected by current limiting resistors to individual pins of the test socket on the front panel. The current limiters protect the system against accidental short circuits on any of the test socket pins. WARNING Plant shutdown - Adjusting the power supplies in a running system could result in a plant shutdown. Power share system The power share control circuit accepts inputs from the 5V supply current sensor, the +ve and - ve sense lines, the output adjustment trimmer (O/P ADJ) on the front panel, and the power share line. It drives the power share line, the power share LED on the front panel, and the voltage on the -ve sense line input to the SMPS. Normally the voltage at the -ve sense input to the SMPS is close to that on the -ve sense line from the backplane. When the power share control circuit detects that an increase in output current is required to maintain power balance, the -ve sense SMPS voltage drops, so that the voltage between the +ve and -ve sense lines is now greater. The SMPS then increases its output voltage. Fault alarm system The power fail output from the SMPS switches from logic high to low just before the SMPS output fails (i.e. to give advance warning following a failure of the ac/dc input supply). The fault alarm circuits de-energise the fault relay in response to: The power fail signal An input from a 70ºC thermal cut-out on the SMPS An undervoltage output condition detected on the +ve and -ve sense lines A set of changeover contacts controls the Fault and Normal LEDs on the front panel. Another pair of relay contacts is available to operate an external alarm. These contacts open under fault conditions. 8 PDC24 / PAC October 2005 Issue 3
9 PDC24 / PAC Chassis Power Supplies SWITCHES AND INDICATORS All user interface is via the front panel (Figure 2-3 ). The following facilities are provided: Table 2-3. Front panel facilities LED Indicator Normal LED (green) Power Share LED (yellow) Fault LED (red) TEST ON/OFF O/P Adi Indication Illuminates to indicate normal operation Illuminates to indicate that power sharing is in balance. It can extinguish if the other PSU supplies about 1.3A more current. Balance can be adjusted (see Section 3.3 Field functionality tests). NOTE: If one PSU is removed, the Power share LED on the remaining PSU illuminates. Illuminates to indicate an over temperature or undervoltage fault condition 8-way 270º DIN socket. Use as described in XRefColorection functionality tests, Default Font. A mating connector is available free of charge. 3A (PAC)/10A (PDC24) circuit breaker and ON/OFF push switch for supply voltage. Screwdriver adjustment of current sharing/output voltage. PDC24 / PAC October 2005 Issue 3 9
10 Figure 2-3 PDC24/PAC Front panel 10 PDC24 / PAC October 2005 Issue 3
11 PDC24 / PAC Chassis Power Supplies SERVICING SCOPE The PSUs have no field replaceable parts. Faulty units should be returned for repair. CONFIGURATION No configurable links. FIELD FUNCTIONALITY TESTS The 12V supply is not calibrated. Set up the 5V supply as follows. For each test use a digital voltmeter across the relevant pair of pins on the 8-way DIN socket. Output voltage (5V) Measure across pins 6 and 7. The voltage should be 5.4V ±0.01V. Output voltage (12V) Measure across pins 1 and 2. The voltage should be within the range 11.5V to 12.5V. Output current (5V) Measure the voltage between pins 1 and 4. This should be proportional to the current supplied by the PSU at Volts per Amp. The current supplied will depend on the configuration of modules within the system. SMPS Output voltage (5V) Measure the voltage between pins 3 and 6. This should not exceed 5.8V. A higher value (nominally 6.3V) may initiate an overvoltage trip. Power share line Measure the voltage between pins 1 and 5. The voltage will depend on the currents being provided by both power supplies. It should not exceed 4.0V at maximum current. Power fail interrupt This can be monitored on pin 8. It is a logic output that is normally pulled up resistively to +5V, but is pulled low if the ac/dc input supply fails. PDC24 / PAC October 2005 Issue 3 11
12 Front panel LEDs Check that the green LED (Normal) is on and the red LED (Fault) is off. A fault condition can be due to: A failure of the ac/dc input supply An output below 5.1V An SMPS over temperature condition. Check that the yellow LED (Power Share) is on. It extinguishes when the other PSU is supplying the greater current. If the Power Share LED is extinguished and no fault is indicated on either PSU, there could be an imbalance in output between the two PSUs. CALIBRATION Calibration is not required in normal operation. Calibration of PSUs must not be performed on a running system. Use the front panel trimmers to adjust the balance until both Power Share LEDs are illuminated. The voltage between pins 6 and 7 of both test sockets will be the same if the PSUs are power sharing to any extent. If this voltage is being measured while adjusting a trimmer, the other PSU will need to be switched off (or short circuit pins 1 and 5 of one test socket to disable current sharing) to see any effect on the meter. Adjust both PSUs until the voltage is the same (normally 5.4V ± 0.01V). 12 PDC24 / PAC October 2005 Issue 3
13 PDC24 / PAC Chassis Power Supplies SERVICE SUPPORT SPARE PARTS Spare parts and technical advice can be obtained from your local area office. PDC24 / PAC October 2005 Issue 3 13
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