Tait T809-10 Service Manual Download

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MBZ-00001-01

November 2004

DRAFT 2.5

T809-10 Power Supply

Service Manual

Issue 1

November 2004

MBZ-00001-01

Summary of Contents for T809-10

Page 2: ...m Technical Support contact details are on page 42 Updating Equipment and Manuals In the interests of improving performance reliability or servicing Tait Electronics Ltd reserve the right to update the power supply and or manuals without prior notice Copyright All information contained in this manual is the property of Tait Electronics Ltd All rights are reserved This manual may not in whole or pa...

Page 3: ...lation Guidelines 3 1 Rack Mounting 19 3 1 1 T809 10 0000 Configuration 19 3 1 2 T809 10 00C1 and 00C2 Configuration 19 3 2 Wiring and Protection Devices 20 3 2 1 Protection Device Positioning 20 3 2 2 Wire Gauges 21 3 2 3 Power Supply Cord AC Input 22 3 3 Rear Panel Connectors 23 3 3 1 DC Output Terminal Block 24 3 3 2 Auxiliary Inputs Connector 24 3 4 Rack Frame Earthing 25 3 4 1 Earthing Proced...

Page 4: ... Overall Power Supply Stability 34 5 Troubleshooting 6 Service Information 6 1 Warnings 37 6 1 1 Warning Lethal Voltages 37 6 1 2 Caution Handle With Care 37 6 1 3 Warning Safety Approval 37 6 2 Mechanical 38 6 2 1 Wiring Diagram 38 6 2 2 Screw Heads and Torque Settings 39 6 2 3 Assembly Drawing 40 6 2 4 Parts List 40 ...

Page 5: ... 60mm wide vertical module designed for use in a standard 483mm 19inch T800 subrack The T809 10 00C1 and the T809 10 00C2 are both 2U subracks designed to fit directly into a standard 483mm rack or cabinet The T809 10 00C1 has a single power supply unit fitted horizontally on the 2U front panel while the 00C2 has two power supplies Functions of the power supply include remote ON OFF control remote...

Page 6: ...e free functioning of a switched mode power supply For detailed specifi cations refer to Sections 1 3 1 EMC Conformity and 1 3 2 Safety Approvals Caution To prevent the T809 10 equipment from overheating do not exceed the rated current Note the rated output of the power supply may need to be lowered derated depending on AC input voltage and ambient tempera ture refer to Section 3 9 ...

Page 7: ...wer Indicator LED glows green when DC output is ON Cooling Convection and forced air fan Efficiency 85 full load typical Working Temperature Range 10 C to 60 C ambient air temp1 Note Derating may apply depending on AC input voltage and ambient tempera ture Over temperature Protection Shutdown of output voltage Auto recovery with temperature reduction Temperature sensed on power transistors and dio...

Page 8: ...r 230VAC supply 0 95 full load 115VAC supply 0 98 full load Note Exact power factor depends on the impedance of the mains supply Input Fuse Internal to module 10A 250V fast acting Glass tube 5 x 20mm Tait IPN 265 00010 21 1 2 4 Output Output Voltage 13 8VDC adjustable 13 5 to 18V Load Regulation 0 5 Line Regulation 0 3 full load Current Range 0 to 30A Output Derating Derating may apply depending o...

Page 9: ...th 230VAC sup ply Overload Current Limit 37 to 48A Type Constant current limiting voltage foldback Reset Auto recovery DC Output Connector Phoenix Contact Feed through terminal block refer to Section 3 3 1 1 2 5 Miscellaneous Remote Control Auxiliary inputs RC and RC Power OFF 4 to 10V across RC and RC Power ON 0 to 0 8V across RC and RC Note The remote control circuit is optically isolated from t...

Page 10: ...ced by RF fields EN 61000 4 11 1994 Voltage dips short interruptions and voltage varia tions immunity For a Declaration of Conformity refer to eudocs taitworld com FCC 47 Part 15 2004 for Class B of the FCC rules for the United States Radiated and conducted emissions and electromagnetic susceptibility specifications Operation is subject to the following conditions 1 This device may not cause harmf...

Page 11: ...ass B Radiated and conducted emissions and electro magnetic susceptibility specifications 1 3 2 Safety Approvals This equipment complies with IEC 60950 1 2001 edition 1 Safety of information technology equipment Tested according to national requirements for the following countries All CB members as listed in CB Bulletin 107A May 2004 including Aus tralia New Zealand Israel and the Republic of Kore...

Page 13: ...er Supply Unit PSU module Connectors Ferrite filters ON LED DC power indicator Mains power switch Figure 2 1 T809 10 internal view Refer to Section Section 6 2 4 Parts List for more detail 9 way D range connector Auxiliary inputs Phoenix Contact Feedthrough terminal block DC output Ferrite sleeve DC output Protective earthing Power switch Protective bonding Ferrite sleeve AC input IEC plug mains i...

Page 14: ...on the front panel refer to Figure 2 1 This path is filtered The mains ground line is connected directly to the T809 10 chassis stud terminal and from there to the module s ground terminal The PSU module s output is filtered by a ferrite sleeve and then interfaces to the rack through a Phoenix Contact Feed through terminal block on the T809 10 rear panel For the wiring diagram refer to Section 6 2...

Page 15: ...ont Panel Indicator Status Power switch illuminates when the unit is connected to the mains power supply The power supply has AC power Green ON LED illuminates brightly Voltage output is at normal operational level Green ON LED illuminates faintly PSU module has entered over current mode Green LED is OFF but the power switch is in the ON position Power supply has shut down due to over temperature ...

Page 16: ...t and produces more heat Output derating may apply in this situation refer to Derating Curves in Section 3 9 Power Supply Cooling and Derating 2 3 2 Protection The PSU module has inrush current limiting and over temperature over current and over voltage protection For detailed specifications refer to Section 1 2 2 3 2 1 Inrush Current A thermistor and relay are used within the PSU module for prote...

Page 17: ...n guidelines refer to Section 3 9 Power Supply Cooling and Derating Ignor ing these conditions may cause the module to overheat and consequently shut down 2 3 3 Remote Sense The remote sense function enables the power supply to adjust its output to compensate for voltage drop lost along the cables to the load Connecting the remote sense allows the power supply to maintain a 13 8VDC at the load ter...

Page 18: ...opyright 2004 Tait Electronics Ltd DC voltage at the load the output voltage of the power supply can be increased up to 18V approximately to compensate for the voltage drop lost along the cable For more information refer to Section 3 8 Output Voltage Adjust ...

Page 19: ... a standard 483mm 19inch T800 subrack fitted with the same supporting guide rails as those used for the T808 T807 To mount the T809 10 0000 into a subrack use the two front panel mounting screws 3 1 2 T809 10 00C1 and 00C2 Configuration The T809 10 00C1 and the T809 10 00C2 are both 2U subracks designed to fit into a standard 483mm rack or cabinet The T809 10 00C1 has a single power supply unit fi...

Page 20: ...e located as close as possible to the output of the power supply as shown in the diagram Figure 3 1 Protection device without remote sense 3 2 1 2 When Remote Sense Is Used When installing a protection device with the remote sense connected Connect the sensing wires to the power supply side of any protection device Failure to do this will cause the power supply to shut down if the protection devic...

Page 21: ...g is between the power supply and the protection device 3 2 2 3 or between the protection device and the load 3 2 2 4 3 2 2 3 Between Power Supply and Protection Device The wire length between the power supply output and the protection device is essen tially unprotected and must be rated for the power supply s overload current that is 48A max The minimum allowable wire gauge for this connection al...

Page 22: ...output and the load does not exceed 0 3V when the remote sense feature is connected The minimum recommended wire sizes for a maximum operating temperature of 60 C are as follows Note The recommended wire insulation temperature rating for all output wiring is 105 C 3 2 3 Power Supply Cord AC Input For the AC input connection Use only an IEC type power supply cord Ensure the power supply cord has a ...

Page 23: ...ar Panel Connectors The pinouts of the rear panel connectors are shown below Figure 3 3 T809 10 Rear panel 1 2 3 4 5 6 7 8 9 Mains input Live Earth Neutral Negative Positive Phoenix Contact Feedthrough terminal block 13 8DC output Output voltage adjust Auxiliary inputs Protective bonding terminal ...

Page 24: ...ed minimum Observe maximum wire cross sections as outlined in the table below 3 3 2 Auxiliary Inputs Connector The 9 way D range connector on the T809 10 rear panel auxiliary inputs provides access to the remote control and remote sense functions of the power supply For con nection details refer to Sections 3 5 Remote Sense and 3 6 Remote Control Conductor Type Number of Conductors Maximum Cross s...

Page 25: ... earthing wire between the earthing stud terminal at the rear of the T809 10 and a conveniently located screw on the subrack The connec tion to the power supply s M5 earthing stud can be made using bare wire or a Ring Spade Terminal Ensure that a secure electrical and mechanical connection is achieved by testing continuity 3 4 2 Earthing Procedure Method 2 Warning This method can only be used if a...

Page 26: ...n 0 3VDC Heavy gauge wire must be used to minimise this voltage drop 3 5 1 Connecting the Remote Sense Wires The remote sense feature is located on the auxiliary input connector 9 way D range on the rear panel of the T809 10 refer to Figure 3 3 on page 23 To connect the remote sense feature use the information supplied below The remote sense wires should be connected as close as possible to the lo...

Page 27: ...This happens because the power supply senses 0 volts across the remote sense terminals and the output voltage then increases to compensate for the apparent reduction If this occurs the power supply can be reset by switching OFF the mains supply discon necting the load and disconnecting the remote sense wires Wait 30 seconds before switching the power supply ON again Warning The heavy gauge wire co...

Page 28: ...FF while a low level 0 to 0 8VDC switches the output ON 3 6 1 Using a Control Voltage Above 10VDC If a control voltage greater than 10VDC is used an additional series current limiting resistor is required to keep the input current below 10mA 1mA 1V The additional series resistor is shown as R in the circuit diagrams below Figure 3 5 Function Aux Input Name D range Pin Details Remote Control RC 6 P...

Page 29: ...Note When VCC is 4 to 10VDC the resistor R is not required When VCCis 10VDC the resistor R must be connected The value of R in kΩ is given by 3 7 Parallel Operation for Redundancy Content to come PSU 1K RC RC VCC PSU 1K RC RC VCC R R 10mAmax External power source Standard Switch Transistor Switch Additional resistor Additional resistor R KΩ Vcc 1 1 10 1 ...

Page 30: ...ool do not use a standard flat blade screwdriver to make the adjustment To increase the output voltage turn the trim pot clockwise To decrease the output voltage turn the trim pot anticlockwise Warning If the output voltage is increased on a power supply operating at or close to full load the power supply loading must be reduced accordingly or the module may overheat Always check using the followi...

Page 31: ...he following conditions The ambient temperature immediately around the power supply unit dur ing normal operation The AC supply voltage The following chart can be used to determine the derating factor load x 0 01 for the given operating conditions The derating factor can then be used to calculate the maxi mum output current Use the following information to calculate the maximum output current It i...

Page 32: ...er supply Ensure airflow is not restricted 3 10 Battery Charging The T809 10 is not designed for battery charging In order to use the T809 10 as a battery charger a battery management module will be required Any current T808 T807 installations being replaced with the T809 10 and set up for bat tery charging must be fitted with a battery management module if not already fitted ...

Page 33: ...ure 4 1 above 3 Set the DC output load to maximum resistance minimum current 4 Connect the T809 10 to the mains supply and switch it on The power switch and the ON LED should be illuminated 5 Vary the DC load and check that the output voltage and current are within the specifications refer to Section 1 2 4 4 2 Output Current Overload To confirm the operation of the current overload protection circ...

Page 34: ...or example Fluke 77 across the load terminals and set the meter to its lowest AC volts range 5 Check that the reading is less than 70mVrms AC under all load and line con ditions Note While the procedure outlined above will give a good indication of the out put noise level an accurate reading is very difficult to obtain on a switched mode power supply This is because low noise levels common mode no...

Page 35: ...for servi cing 2 Output voltage below specification ON LED lights up but the intensity is low Mains supply is too low Check and correct mains supply problem Current overload protec tion is active Check for possible causes that is short circuits Defective switching cir cuitry Replace module or return faulty module for servi cing 3 Power supply over heats Mains supply is too low Check and correct ma...

Page 37: ...supply to the whole of the repair and test area is supplied via an earth leakage circuit breaker 6 1 2 Caution Handle With Care Although this is a lightweight unit it contains a number of quite heavy and fragile indi vidual components that are mounted directly onto the module s printed circuit board PCB Severe mechanical shock may damage the PCB for example solder joints and copper tracks and or c...

Page 38: ...ter servicing the wiring inside the power supply must be refitted to duplicate the original layout as shown above and in Figure 2 1 on page 13 Any deviation from the original layout may void safety approvals and or adversely affect airflow through the power supply This in turn may result in overheating 1 2 3 4 5 6 9 7 8 Illuminated power switch IEC mains connector Live Neutral Ground Ferrite sleev...

Page 39: ...ettings The T809 10 uses three types of screw head To avoid damaging the screw heads please ensure when servicing the power supply that you select the appropriate screwdriver tip from the table below Screwdriver Screw Head Screwdriver Tip Torque Setting Hex M4 x 10mm 2 5mm 1 7Nm Torx M3 T10 0 9Nm Posidriv M4 PZ2 1 7 ...

Page 40: ...5 Panel Rocker Switch 250V 8A 230 00010 23 6 Screw M4x6mm Pozi 345 00050 08 7 Screw M3x6 C sunk Torx 345 40460 00 8 LED 3mm Green 14V 008 00010 17 w int Res 9 Rear Panel 316 02024 01 10 Handle internal thread 308 01007 02 11 Terminal Earthing Stud 356 00010 61 12 IEC plug 3pin panel mount 240 00011 16 13 Screw M4x10mm hex head 345 00050 16 14 Feed through Term Block 240 04031 00 HDFKV10 Item No De...

Page 42: ... 10 6518 6290 Fax 86 10 6518 6296 E mail beijing taitworld com Taiwan Tait Mobile Radio Taiwan Ltd 5Fl No 159 Keelung Road Sec 1 Taipei 110 Taiwan Phone 886 2 2768 6600 Fax 886 2 2761 9970 E mail taiwan taitworld com South East Asia Regional Head Office Singapore Tait Electronics Far East Pte Ltd 491B River Valley Road 09 02 Valley Point Office Tower Singapore 248373 Phone 65 471 2688 Fax 65 479 7...

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