3Com Switch 7750 PoE Power Rack User Manual

www.3com.com Part No. DUA1688-3AAA01 Published: June 2005

Table of Contents
Introduction............................................................................................................................................... 2-1 Switch 7750 PoE Power Rack ............................................................................................................ 2-1 Architecture and Configurations.......................................................................................................... 2-1 Features .............................................................................................................................................. 2-2 Chapter 2 System Description ................................................................................................................ 2-1 Overview ............................................................................................................................................. 2-1 2..1 Power Supply Modules......................................................................................................... 2-1 2..2 PoE Power Rack .................................................................................................................. 2-1 2..3 Power Supply Module Visual indicators ............................................................................... 2-1 System Controller................................................................................................................................ 2-2 AC Distribution Panel .......................................................................................................................... 2-4 DC Distribution Panel.......................................................................................................................... 2-4 Chapter 3 Safety ....................................................................................................................................... 3-1 Safety Statements............................................................................................................................... 3-1 Warning Statements and Safety Symbols .......................................................................................... 3-1 Precautions ......................................................................................................................................... 3-1 Chapter 4 Installation and Debugging.................................................................................................... 4-1 Introduction ......................................................................................................................................... 4-1 4..1 Guidelines............................................................................................................................. 4-1 4..2 EMI Considerations .............................................................................................................. 4-1 4..3 Installation Tools and Hardware........................................................................................... 4-1 4..4 Safety ................................................................................................................................... 4-1 4..5 Installation Sequence ........................................................................................................... 4-1 Physical Mounting ............................................................................................................................... 4-2 Installing Power Supply Modules ........................................................................................................ 4-3 PoE Power Rack Grounding ............................................................................................................... 4-3 DC Connection.................................................................................................................................... 4-4 Connecting to AC utility/ AC grounding............................................................................................... 4-5 Initial Start-up ...................................................................................................................................... 4-5 Powering on the PoE Power Rack...................................................................................................... 4-5 Chapter 5 Engineering, Maintenance and Troubleshooting ................................................................ 5-1 Maintenance and Troubleshooting...................................................................................................... 5-1 LED Indication..................................................................................................................................... 5-1

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PoE Power Rack Installation Guide

Introduction

Introduction
Switch 7750 PoE Power Rack
The 3Com Switch 7750 PoE power rack is a modular stand-alone Power over Ethernet power source. The PoE Power Rack provides a total of 2500Watts of DC power with N+1 power redundancy for PoE powered devices connected to the Switch 7750 Chassis.

Architecture and Configurations

The PoE Power Rack architecture integrates DC power supply modules (maximum 3), a system controller, and power distribution module in a 4-RU high chassis. The system controller provides local monitoring and control of the device. The general configuration is as follows: Table 1-1 PoE Power Rack standard configuration Description 4U high chassis System controller SWITCH 7750 PoE Power Supply Module AC distribution components Standard Configuration D x W x H- 380 x 486 x 177 mm(14.96 x 19.13 6.97 in) One One installed (3 total for power redundancy) 1) Three independent AC power input sockets Three AC Power switches 2) 3-phase AC voltage sensor

Figure 1-1 Switch 7750 PoE Power Rack

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Introduction

The PoE Power Rack is configured with one power supply module as standard. The power rack may be configured with up to 3 power supplies based on the power and power redundancy requirements.

Features
The PoE Power Rack is compatible with a wide range of input voltages from 90 to 290 VAC and uses 20 A/250 VAC EN60320 C20/C19 appliance coupler connectors and connector plugs. Power factor is above 0.99 and efficiency is over 88%

Maximum device output is (N + 1) 93A @ 54VDC Power supply modules are hot-swappable for uninterrupted operation The PoE Power Rack power status may be monitored via RS232 or RS485 interface Advanced EMC design High Safety and reliability

(1)

(1): PoE Power Rack

Figure 1-2 PoE Power Rack configured with two power supply modules (I)

(1) (2) (3)

(4)

(1): AC Input Socket (3): RS232 and RS485

(2): DC Output (4): Chassis Ground

Figure 1-3 PoE Power rear view (II)

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Chapter 2 System Description

Chapter 2 System Description

Overview
Figure 2-1 shows the schematic diagram of the PoE Power Rack power system, showing the interconnections and signal flow through the power supply modules and internal components.

Figure 2-1 Schematic diagram of the PoE Power Rack

2..1 Power Supply Modules

DC power is supplied to the power bus by the power supply modules. (Note: The PoE Power Supply Module (3C16884) is interchangeable between the Switch 7750 PoE Power Rack and the Switch 8800 PoE Power Rack. NO other components are interchangeable).

2..2 PoE Power Rack

Up to three power supply modules can be mounted in each PoE Power Rack. Each power supply module in the PoE Power Rack receives AC power from the AC distribution panel.

2..3 Power Supply Module Visual indicators

The front panel of the power supply module has three LEDs. Their descriptions, colors and functions are as follows. Table 2-1 LEDs state description Condition All OK Thermal alarm (Ambient) Thermal alarm (fan fail) Blown AC fuse in unit Low or no AC > 15mS (single unit) 1 1 1 1 0
2-1

AC OK (green) 1 0 0 0 0

DC OK (green) 0 0 1 1 0

Fault (Red)

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Chapter 2 System Description

Condition AC not present in any power supply module Boost stage Failure Over Voltage Latched shutdown Over current Any internal failure 0 1 1 1 1

AC OK (green) 0 0 0 0 0

DC OK (green) 0 1 1 0 1

Fault (Red)

The Front panel of the power supply module is as follows.

Figure 2-2 (3C16884) Power Supply Module front panel

System Controller
The PoE Power Rack has a system controller at the rear of the chassis. See figure 2-3.

Figure 2-3 Front panel of the controller A green LED (RUN) and red LED (ALM) to indicate operational and alarm status are located on the front panel of the PoE Power Rack controller. When the system has an alarm, such as input failure, input over-voltage or under-voltage, output over-voltage or under-voltage, power supply failure, power supply self-protection, the red (ALM) LED will light. Once the alarm status is cleared, the LED go off. The controller of the Poe Power Rack has two major functions:

Monitoring the system operation status Inside PoE Power Rack there is an AC sensor card which samples the AC input voltage. The sampled signal is sent to the controller for processing. If the AC input voltage is lower than the pre-set alarm level, the controller reports an AC input under-voltage alarm.
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Chapter 2 System Description

Likewise, if the input voltage is higher than the pre-set alarm level, the controller reports an AC input over-voltage alarm. The DC output voltage is also sampled and sent to the controller. If the output voltage is lower than the pre-set alarm level, the controller will report a DC Low alarm. Likewise, if the DC output voltage is higher than the pre-set alarm, the controller reports a DC output High alarm. The power supply module status is communicated to the controller via an internal RS485 bus. If the power supply modules issues an alarm, the alarm is passed to the controller. Power supply module failure alarms include: AC input failure, DC output failure, fan failure, high output voltage, current limit, over temperature, and module shut-down.

Communicate with deamon systems The controller supports interface to the Switch 7750 chassis through RS232 or RS485 cable connection. A cable is provided with the PoE Power Rack for attachment to the Switch 7750 (connect the RS232 connector end to the PoE Power Rack and connect the RJ45 cable end to the port labeled "Com" next to the PoE DC terminal block on the back of the Switch 7750). Using CLI commands, the User can receive and read system information or command the operation of the PoE Power Rack.

There is one RS485 port and one RS232 interface on the rear panel of the PoE Power Rack (the cable provided with the PoE Power Rack is a RS232 cable type). The RS485 and RS232 signals are as follows: Table 2-2 RS485: Pin 1 2 3 4 5 6 7 8 Definition Receive, + Receive, Transmit, + Ground Not used Transmit, Ground Not used

Table2-3 RS232: Pin 1 2 3 4 5 6

2-3

Definition Not used Receive Transmit Not used Ground Not used

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Chapter 2 System Description

Pin 7 8 9

Definition Not used Not used Not used

AC Distribution Panel
There are three EN60320 C20 AC input sockets on the rear panel of the device rated at 20A @ 250VAC. Each socket supplies one power supply module. There is an AC power ON/OFF switch beside each AC input socket.

DC Distribution Panel
The DC distribution panel has two 10 mm2 Copper bus bars and two cables to connect the power rack the Switch 7750 chassis.

Figure 2-4 Distribution panel

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Chapter 3 Safety

Chapter 3 Safety
Safety Statements
Please read and follow all safety instructions and warnings before servicing the PoE Power Rack. Reference the power supply module product manuals for additional safety statements specific to the power supply modules.

The device must be in a restricted access area (dedicated equipment rooms or equipment closets are examples of these areas). The equipment must be in a controlled environment (an area where the humidity is maintained at levels that cannot cause condensation on the equipment, the contaminating dust is controlled, and the steady-state ambient temperature is within the range specified).

Do not install this equipment at a combustible place. This equipment has been evaluated for use in a continuous ambient temperature of up to 50C. Torque electrical connections to the values specified on labels or in the product documentation Refer to the product documentation for the proper hardware. Use only the parts specified in the equipment documentation Improper fuses/circuit breakers may cause serious injury or equipment damage. External circuit breakers must be sized as required by the applicable local codes. Refer to the equipment ratings to assure rating of equipment no to exceed 80% of the value of the breaker chosen.

Warning Statements and Safety Symbols

The symbols may sometimes be accompanied by some types of statement, for example Hazardous voltage/energy inside, Risk of injury. This device must be accessed only by qualified personnel. This symbol identifies the need to refer to the equipment instructions for important information.

This symbol is used to identify the protective safety ground for the equipment.

Note: These symbols are used to identify the presence of hazardous AC/DC main voltage and also can be used to alarm the level of danger.

Precautions
When working on this type of equipment, the following precautions must be noted:

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Chapter 3 Safety

This unit must be installed, serviced, and operated only by skilled and qualified personnel who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this equipment.

The PoE Power Rack can be powered by multiple AC inputs, ensure that the appropriate circuit protection device for each AC input being serviced is disconnected before changing or servicing a Power Supply Module. If servicing the PoE Power Rack, all the AC power cords must be removed from the equipment.

High leakage currents may be possible on this type of equipment. Make sure the equipment is properly grounded before connecting AC input power. Use only properly grounded AC power cords. Hazardous energy and voltages are present in the device and on the DC output cables that can shock or cause serious injury. Follow all safety warnings and practices when servicing this equipment. Insure that the PoE Power Rack AC power cords are unplugged from the PoE Power Rack before connecting the DC output cables to the PoE Power Rack and the Switch 7750.

Exercise care when servicing this area.

In addition to adhering to the safety procedures, the following are some basic precautions that should always be used:

Use only properly insulated tools. Remove all metallic objects (key chains, glasses, rings, watches, or jewelry. Wear safety glasses. Test circuits before touching. Lock out and tag any circuit breakers/fuses when possible to prevent accidental turn on. Be aware of potential hazards before servicing equipment. Identify exposed hazardous electrical potentials on connectors or, wiring. (Note the condition of these circuits, especially any wiring). Be careful when removing or replacing any covers avoid contacting with any circuits.

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Chapter 4 Installation and Debugging

Chapter 4 Installation and Debugging

Introduction
This section outlines the sequence for installing the PoE Power Rack, including plug-in modules, as well as test procedures for verifying the integrity of the installation.

4..1 Guidelines
The device must be installed to allow sufficient front and rear access. All cables must be routed through insulated conduit openings, All service operation can be completed on the front of the power rack.

4..2 EMI Considerations

When running the DC output cables, ensure that the positive and negative cables are routed so as no loops are created.

4..3 Installation Tools and Hardware

The following tools and hardware are required to install and test the PoE Power Rack:

#2 Philips screwdriver Nut driver set or socket set with 10 mm and 13 mm sockets Adjustable wrench Digital meter with an accuracy of 0.02% Small and medium flat screw driver ESD wrist strap

4..4 Safety

Warning

Only qualified personnel can install and service the PoE Power Rack. Hazardous energy is present in the device and on the interface cables, which can cause electric shock or cause serious injury or death if safety precautions are ignored. Follow all safety warnings and practices when servicing this equipment.

4..5 Installation Sequence

Review all safety warnings in Section 3 before beginning the installation process. Observe all warnings and labels on the equipment. The PoE Power Rack consists of a chassis which includes AC and DC distribution modules, one system controller, and power supply module bays. Refer to Figures 2-6 and figure 2-7 for relationship of components.

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Chapter 4 Installation and Debugging

Note that the PoE Power Rack is shipped mostly pre-assembled so as to minimize the overall installation process. The following installation sequence is recommended

Physical mounting Installing power supply modules Frame grounding Connecting to Switch 7750 Chassis Connecting to AC utility/AC grounding Initializing the system

Physical Mounting
All items required for installation are contained within the packaging. Additional power supply modules are shipped separately. Please check the packing list. Rack or frame mounting screws are not included. 1) 2) 3) Place the unit box in a vertical position near the installation site (equipment cabinet or rack). Carefully remove the crate top and sides and the packing material. If possible, recycle the packing crate and the packing material. If not, dispose of properly according to local codes and regulations. The following items are included in the unit packaging: PoE Power Rack, power supply module, RS232 and DC connection cables. Remove all this material and place aside. (Note: Mounting screws are NOT supplied with the PoE Power Rack. Mounting screws may be obtained from the equipment rack/cabinet supplier). 4) Install the chassis into the 19-inch equipment rack or cabinet by using eight screws. (Note: Eight screws must be used to ensure the PoE Power Rack is securely mounted in the equipment rack or cabinet, failure to use eight screw may cause damage to the PoE Power Rack) (Note: When using an electric screwdriver the correct torque setting recommended is 6.2 to 6.5 N.m). Do not over tighten the mounting screws. See figure 4-1.

Figure 4-1 Physical installation

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Chapter 4 Installation and Debugging

Installing Power Supply Modules

Power supply modules are installed by sliding the module into the power rack, pushing until the power supply module is fully inserted, and close the handle on the power supply module. 1) 2) 3) Verify that the AC power switches on the AC distribution panel are in the OFF position and the AC power cords are removed from the EN60320 C20 AC connectors on the PoE Power Rack. Insert the power supply module into the PoE Power Rack and slide it toward the backplane until it contacts the backplane connectors Close the handle on the front of the power supply module and verify that the module is firmly seated.

See Figure4-2 for the power supply module installation.

Figure 4-2 Installing power supply modules

PoE Power Rack Grounding

The PoE Power Rack must be electrically grounded before making any further electrical connections. (Refer to the installation instructions for grounding the PoE Power Rack). 1) It is recommended that the supplied green/yellow 16 mm2 cable with a M6 single hole terminal lug is securely connected to the PE grounding terminal on the rear panel of the chassis, as shown in Figure 4-3. 2) Terminate the other end of the conductor to a grounding plate or other acceptable ground point. (Follow local rules and codes regarding grounding requirements).

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Chapter 4 Installation and Debugging

Frame Ground

Figure 4-3 Frame grounding

DC Connection
The DC cable connections are connected to the PoE Power Rack and the Switch 7750 by heavy-duty type terminal blocks.. The 0Volt (Return) DC cable must be connected to RTN (+) terminal and the -54Volt (negative ) DC cable must be connected to the "NEG (-)" negative terminal. To connect the DC output cables to the PoE Power Rack: 1.) Insure AC power is removed from the PoE Power Rack before connecting the DC output cables. 2.) Using a #2 Philips screwdriver, remove the four Philips head screws that attach the DC terminal protector plate from the PoE Power Rack. 3.) Insert the blue DC cable through the "NEG (-)" grommet hole on the DC terminal protector plate. 4.) Insert the black DC cable through the "RTN (+)" grommet hole on the DC terminal protector plate. 5.) Remove one 13 mm nut and washer from the "NEG (-)" DC terminal stud and attach the blue DC cable to the "NEG (-)" terminal stud. Replace the washer on the terminal stud and securely fasten the 13 mm nut on the DC terminal stud. 6.) Remove one 13 mm nut and washer from the "RTN (+)" DC terminal stud and attach the black DC cable to the "RTN (+)" terminal stud. Replace the washer on the terminal stud and securely fasten the 13 mm nut on the DC terminal stud. 7.) Replace the DC terminal protector plate and tighten the four Philips screws with the #2 Philips Screwdriver.

To connect the DC output cables to the Switch 7750: 1.) Insure AC power is removed from the PoE Power Rack before connecting the DC output cables. 2.) The DC terminal block for PoE input power is located on the back of the SWITCH 7750 chassis. 3.) Using a #2 Philips screwdriver, remove the two Philips head screws that attach the clear DC terminal block cover from the SWITCH 7750. 4.) Remove one 10 mm nut and washer from the "NEG (-)" DC terminal stud and attach the blue DC cable to
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Chapter 4 Installation and Debugging

the "NEG (-)" terminal stud. Replace the washer on the terminal stud and securely fasten the 13 mm nut on the DC terminal stud. 5) Remove one 10 mm nut and washer from the "RTN (+)" DC terminal stud and attach the black DC cable to the "RTN (+)" terminal stud. Replace the washer on the terminal stud and securely fasten the 13 mm nut on the DC terminal stud. 6.) Replace the clear DC terminal block cover and tighten the two Philips screws with the #2 Philips Screwdriver.

Figure 4-4 DC connections

Connecting to AC utility/ AC grounding

AC power input is accessed from the rear of the unit. AC power cord connection is made using power cords with IEC 60320 C-19 connector plugs. AC power cords are provided with the PoE Power Rack. The AC mains connection must follow this procedure: 2) 3) Ensure that the AC input switches are in the OFF position. Plug the AC input power cord into the AC socket that corresponds to the power supply module slot location. For example, the C20 coupler labeled "AC Input1" corresponds to the power supply module in the furthest left power supply module slot, when viewing the PoE Power Rack from the front. Refer to Figure 4-4 for the relationship between the Power supply modules and the AC input sockets.

Initial Start-up
First, verify that all AC branch circuit breakers and AC power switches are in the OFF position.

Powering on the PoE Power Rack

1) 2) 3) Ensure that all power supply modules are seated and locked into position in the PoE Power Rack. Turn the AC mains circuit breakers to the ON position. Turn the PoE Power Rack AC power switches ON position (corresponding to the power supply modules installed). 4.) Verify that the AC OK, DC OK, and green LED are on and the fan is operating

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Chapter 4 Installation and Debugging

on each power supply module.Wait approximately 10-30 seconds to allow the system to go through its start-up procedure. Verify that the green LED on the controller panel is on. 1) 2) 3) Use a digital voltmeter to verify that the DC output voltage is approximately -54VDC For systems with more than one power supply module installed, turn one of the AC power input switches to OFF to verify that the red alarm LED lights on the PoE Power Rack controller. For systems with more than one power supply module installed, turn the second AC input switch off to verify that the FAULT LED lights on the controller. Clear the alarms by turning the AC input switch on.

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Chapter 4 Installation and Debugging

Chapter 5 Engineering, Maintenance and Troubleshooting

Maintenance and Troubleshooting
This section provides field maintenance information and troubleshooting procedures for the PoE Power Rack and power supply modules. Review the safety information in section 3 of this manual before performing maintenance procedures

Warning: All procedures described in this section must be performed by qualified maintenance personnel only.

The power supply modules are not field serviceable and must be replaced in the event of a failure.

LED Indication
Use the following table to determine if there is a fault with PoE Power Rack. When visual indicators do not identify a defective part, notify your authorized service representative. Table 5-1 Troubleshooting guide Controller alarm status RUN ALM Power supply module display NONE Possible problems The AC power input circuit breakers has operated. AC input voltage is too low or power lost RUN ALM RUN ALM RUN ALM AC OK FAULT AC OK DC OK FAULT AC OK Power supply module failure Output beyond normal range Communication error between the power supply module and the controller Power supply module has no output and it is in standby mode Over load Ambient temperature is too high Power supply module failure ALM or None -Controller failure Replace the power supply module Possible solution 1. Verify that AC power input circuit breaker is closed; close circuit breaker if it is open. 2.Verify the AC power is present and in normal range Replace the power supply module

Command the power supply module to work or reset the controller Check if the load is over the rating. Check the ambient temperature. Replace the power supply module Replace the controller

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