TDI UltraFLEX HD User manual

TRANSISTOR DEVICES, INC
UltraFLEX 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 [phone] • Fax [phone]
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ULTRAFLEX HD PDU USER MANUAL
Table of Contents
List of Figures......................................................................................................................................... 5
List of Tables........................................................................................................................................... 6
List of Graphs ......................................................................................................................................... 6
1.0 System Overview .......................................................................................................................... 7
1.1 AC Input Warnings....................................................................................................................... 8
1.2 AC Input Ratings.......................................................................................................................... 8
1.3 Mounting Equipment.................................................................................................................... 9
1.3.1 Introduction............................................................................................................................. 9
1.3.2 Weight..................................................................................................................................... 9
1.4 AC Input ....................................................................................................................................... 9
1.5 AC Outputs................................................................................................................................... 9
1.6 DC Connections ......................................................................................................................... 11
1.6.1 Fans....................................................................................................................................... 11
1.7 EMO Loop.................................................................................................................................. 12
1.8 SMC Connection J72.................................................................................................................. 12
1.9 External Indicators Connection J71 .......................................................................................... 13
2.0 System Start-up........................................................................................................................... 14
2.1 System turn-on............................................................................................................................ 14
2.1.1 EMO breaker CB2 ................................................................................................................ 14
2.1.2 Energize AC input................................................................................................................. 14
2.1.3 Input breaker CB1................................................................................................................. 15
2.1.4 AC Loads............................................................................................................................... 15
2.1.5 Fan breaker CB10................................................................................................................. 16
2.1.6 48V Power Supply AC input breaker CB9............................................................................ 16
2.1.7 48V DC bus turn-on.............................................................................................................. 17
2.2 System Functionality.................................................................................................................. 17
3.0 User Manual............................................................................................................................... 18
3.1 System Overview ........................................................................................................................ 18
3.2 AC Input ..................................................................................................................................... 19
3.2.1 Voltage.................................................................................................................................. 19
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ULTRAFLEX HD PDU USER MANUAL
3.2.2 Frequency ............................................................................................................................. 19
3.3 EMO supply................................................................................................................................19
3.4 AC Input breaker........................................................................................................................ 19
3.4.1 Lock Out Feature.................................................................................................................. 19
3.5 AC Distribution.......................................................................................................................... 20
3.5.1 AC connectors....................................................................................................................... 20
3.5.2 AC outlet J52/J53.................................................................................................................. 21
3.5.3 J59 Pinout............................................................................................................................. 21
3.5.4 Internal AC wiring................................................................................................................ 21
3.6 Grounding .................................................................................................................................. 22
3.6.1 PDU Facility Ground Connection........................................................................................ 22
3.6.2 PDU Frame ground.............................................................................................................. 22
3.6.3 DC Grounding ...................................................................................................................... 22
3.7 DC Distribution.......................................................................................................................... 22
3.7.1 DC Ratings............................................................................................................................ 22
3.7.2 48V DC Output ..................................................................................................................... 23
3.7.3 Fan Power............................................................................................................................. 23
3.7.3.1 Testhead Fan connector J46............................................................................................ 24
3.7.3.2 Cabinet Fan connectors J47/J48..................................................................................... 24
3.7.3.3 Expansion Cabinet power connector J49........................................................................ 25
3.7.4 48V DC Output Voltage........................................................................................................ 26
3.8 EMO loop................................................................................................................................... 26
3.9 Monitor & Control..................................................................................................................... 27
3.9.1 SMC Interface J72 ................................................................................................................ 28
3.9.1.1 48V DC Enable................................................................................................................ 28
3.9.1.2 48V DC Power Fault....................................................................................................... 29
3.9.1.3 DC current monitor......................................................................................................... 29
3.9.2 LED Indicators & Alarm outputs.......................................................................................... 30
3.9.2.1 Alarm output connector J71............................................................................................ 30
3.9.2.2 AC Available.................................................................................................................... 31
3.9.2.3 Main Power On ............................................................................................................... 31
3.9.2.4 48V DC on....................................................................................................................... 31
3.9.2.5 Power Supply LED’s ....................................................................................................... 31
3.9.3 Test Points............................................................................................................................. 31
3.9.4 Thermostat ............................................................................................................................ 31
4.0 System Ratings Summary ........................................................................................................... 33
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ULTRAFLEX HD PDU USER MANUAL
4.1 AC Input ..................................................................................................................................... 33
4.2 AC Distribution.......................................................................................................................... 33
4.3 DC Distribution.......................................................................................................................... 33
4.4 Mechanical Ratings.................................................................................................................... 34
4.5 Environmental Ratings............................................................................................................... 34
5.1 System Interconnect for revision A or higher units.................................................................... 35
5.2 System Interconnect for revisions prior to revision A................................................................ 36
6Vendor Support and Service ......................................................................................................... 37
6.1 Sales Support.......................................................................................................................... 37
6.2 Service for GFS and Customers ........................................................................................ 37
6.3 Service Support for GCS...................................................................................................... 37
7Revision History............................................................................................................................ 38
7.1 Document updates...................................................................................................................... 38
List of Figures
Figure 1– Front view of PDU................................................................................................................................................................................................ 7
Figure 2 – Rear view of PDU................................................................................................................................................................................................. 8
Figure 3 – AC distribution on PDU....................................................................................................................................................................................10
Figure 4 – DC fan connector detail.....................................................................................................................................................................................11
Figure 5 – EMO loop connector detail ..............................................................................................................................................................................12
Figure 6 – SMC connector detail.........................................................................................................................................................................................12
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 ..........................................................................................................................................................15
Figure 10 – Detail of Fan breaker CB10 ............................................................................................................................................................................16
Figure 11 – Detail of Power supply AC input breaker CB9 ...........................................................................................................................................16
Figure 12 – Overall front view of PDU .............................................................................................................................................................................18
Figure 13 – AC breaker lockout...........................................................................................................................................................................................19
Figure 14 – Detail view of AC distribution........................................................................................................................................................................20
Figure 15 – Detail view of J59 ............................................................................................................................................................................................. 21
Figure 16 – 48V DC output bus bars..................................................................................................................................................................................23
Figure 17 – Fan power connectors......................................................................................................................................................................................23
Figure 18 – Testhead fan connector J46 ............................................................................................................................................................................24
Figure 19 – Cabinet fan connectors J47/J48.....................................................................................................................................................................25
Figure 20 – Expansion cabinet power connector J49......................................................................................................................................................25
Figure 21 – EMO loop connectors .....................................................................................................................................................................................27
Figure 22 – Interface PCB connections ............................................................................................................................................................................. 27
Figure 23 – Alarm output (typical for all alarms)..............................................................................................................................................................30
Figure 24 – Thermostat location on interface PCB..........................................................................................................................................................32
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ULTRAFLEX HD PDU USER MANUAL
List of Tables
Table 1 – AC Output table ..................................................................................................................................................................................................... 9
Table 2 – DC Fan connection table ....................................................................................................................................................................................11
Table 3 – SMC connector Pinout (J72) ..............................................................................................................................................................................13
Table 4 – J72 Pinout ..............................................................................................................................................................................................................13
Table 5 – AC Distribution details........................................................................................................................................................................................20
Table 6 – J59 Pinout ..............................................................................................................................................................................................................21
Table 7 – Internal AC Distribution.....................................................................................................................................................................................21
Table 8 – DC Output Ratings ..............................................................................................................................................................................................22
Table 9 – J46 Pinout ..............................................................................................................................................................................................................24
Table 10 – J47/J48 Pinout....................................................................................................................................................................................................25
Table 11 – J49 Pinout............................................................................................................................................................................................................25
Table 12 – EMO connectors................................................................................................................................................................................................27
Table 13 – J72 Pinout............................................................................................................................................................................................................28
Table 14 – J71 Pinout............................................................................................................................................................................................................30
List of Graphs
Graph 1 – Output V vs. load graph ....................................................................................................................................................................................26
Graph 2 – Current monitor signal vs. load graph.............................................................................................................................................................29
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ULTRAFLEX HD PDU USER MANUAL
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.
Figure 1– Front view of PDU
Chapter
1
Power Status
LED’s: Figure 7
AC outlets on lower
half of front panel:
Figure 3
AC input
breaker CB1:
. Figure 8
AC input
breaker
cover:
Figure 8
AC output breakers
on top half of front
panel: Figure 3
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ULTRAFLEX HD PDU USER MANUAL
Figure 2 – Rear view of PDU
Test points:
Figure 22
Alarm & Power
Status LED’s:
Fi
g
ure 22
DC bus protective
cover: Figure 4
EMO connectors:
Figure 5
Fan connector J46: Figure 18
Fan Breaker CB10: Figure 10
Power supply access
panel.:
SMC connector:
Figure 6
Fan connectors J47/J48: Figure
19
External indicator
connector J71:
Figure 6
1.1 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: 200-208VAC, 50-60Hz, 125A Max
Output:48Vdc, 320A Max, 15,200W Max. (4 rectifiers)
Output:208-230VAC, 50-60Hz, 19,000W Max
Output 115VAC, 50-60Hz, 575W Max
AMBIENT: 30°C Max.
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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 with 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
Spare J57
CB6 15
External IEC Spare J54
External IEC Spare J55 CB7 15
External IEC (CPU & Monitor) J52
External IEC (DSP) J53 CB8 5
Table 1 – AC Output table
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ULTRAFLEX HD PDU USER MANUAL
Figure 3 – AC distribution on PDU
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ULTRAFLEX HD PDU USER MANUAL
708401 Rev B Page 11 of 38
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 J46
System Cabinet Fan J47
Expansion Cabinet Fan J48
Expansion cabinet power control J49
CB10 15
Table 2 – DC Fan connection table
Figure 4 – DC fan connector detail
Fan connectors
Fan circuit breaker
DC bus protective
cover

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 in J70. 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.
Figure 5 – EMO loop connector detail
1.8 SMC Connection J72
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.
Figure 6 – SMC connector detail
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ULTRAFLEX HD PDU USER MANUAL
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 3 – SMC connector Pinout (J72)
1.9 External Indicators Connection J71
The external indicator connector is located on the rear of the PDU next to the SMC connector; refer to Figure
2for location of external indicator connector and Figure 6for a detailed view. The pinout of the external
indicator connector is detailed in Table 4.
Pin Number Signal
1 AC Available
2 Not-Used
3 Main Power On
4 48V DC On
5 Not-Used
6 AC Available return
7 Not-Used
8 Main Power On return
9 48V DC On return
Table 4 – J72 Pinout
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ULTRAFLEX HD PDU USER MANUAL
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 functions 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.
Figure 7 – Detail of EMO breaker CB2 (shown in OFF position)
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 Rev B Page 14 of 38
Chapter
2
AC available,
AC ON and
48V DC
LED’s
EMO breaker
CB2

ULTRAFLEX 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 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.
Figure 9 – Detail of AC load breakers CB3 – CB8
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Input breaker
CB1

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.
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.
Figure 11 – Detail of Power supply AC input breaker CB9
708401 Rev B Page 16 of 38
Fan breaker
CB10
Power supply AC
input breaker
CB9

ULTRAFLEX HD PDU USER 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.
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ULTRAFLEX HD PDU USER MANUAL Chapter
3
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
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ULTRAFLEX HD PDU USER MANUAL
3.2 AC 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.
Figure 13 – AC breaker lockout
708401 Rev B Page 19 of 38
Lockout bracke
t
Breaker handle

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.
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
Number
Circuit
Breaker
Breaker
Rating (A) # phases Used Phases
Voltage
(VAC) Connector type
External IEC J52 5-15R
External IEC (DSP) J53 CB8 5 2 B & C 115 5-15R
External IEC Spare J54 6-15R
External IEC Spare J55 CB7 15 2 B & C 208-230 6-15R
SMC J50 60320-C20
Spare J51 60320-C20
Manipulator J56 6-15R
Spare J57
CB6 15 2 A & B 208-230
6-15R
Expansion Cabinet Vault J58 CB4 20 3 A, B & C 208-230 L15-20R
CDU J59 CB5 25 3 A, B & C 208-230 Amp mate-n-lok
DC-PM J66 CB3 30 3 A, B & C 208-230 L15-30R
Table 5 – AC Distribution details
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