Thursday, July 15, 2010

Redundant 48 Volt Power Supply - Part 1 - Mounting and PSU

I have started construction of two redundant 48 VDC power supplies for use with large scale telecommunication equipment.

They will be powered by a 240VAC UPS with a diesel backup generator.

These two PSUs are for two X-Band Longreach Wireless backhauls (CarrierComm backhauls), which can transmit <300Mbps over 50km.

More about them later... 

First of all, I needed something to mount everything into. Preferably a 2RU rack mounting. Found the rack kits at Jaycar Online. Jaycar is a handy place with loads of equipment and parts, and I wish they paid me for this ad.

Rack Mounting from Jaycar
Rack Mounting from Jaycar

Rack and Rack Mounting Kit
Rack and Rack Mounting Kit

Next I needed to find some power supplies to fit the rack units. I shopped around online and picked up two TDK-Lambda HWS15-150-48A caged PSUs from Digikey.

These units are quiet, cool and slim, while still producing 3.3 amps at 48 volts.

Top view of the HWS15-150
Top View of the hws15-150
Front view of the HWS15-150
Front View of the hws15-150

The kits was easy to build, with easy installable din rails. The front and back panels are simple to remove and replace for case work. Mounting PSUs was also straight forward, with a few small screw holes to mount the fames at the bottom.

Rack with the PSUs mounted
Rack with the PSUs mounted

Close-up of the rack mounted PSU
 Close-up of the rack mounted PSU

Removed the front and back panels to work on in the lab.

I had to cut and drill some mount holes into the panels for the IEC power mounts, LEDs, fuses and switches.

Sparks and aluminium bits flew everywhere. The front 3mm aluminium panel was a challenge to work with.
After preparing the panels, I then gave them a fresh coat of black paint to remove any of the scratches.

24 hours later, the dry panels are ready for components to be mounted.

Then I assembled the main rack case.


Finished Panels
Finished Panels

Look on Burning the Midnight for the next part of this project.

I will be wiring up the rack mount and PSUs and publishing the wiring diagrams, pictures and comments as the unit comes together.

News Flash!
"Part 2 - Wiring up the Rack and PSU" on up and online, so check the next chapter..

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