PKS™ - TDC 3000® TAB PD 22

CUSTOMER PAGE G97 (D)

RESOURCE MANUAL DATE 24 AUG 2015

PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT

Background Three different styles of power supplies (PS) have been furnished with the
PM product line. The first style PS is black and supplied by Cherokee. See
"PD 22 G97 (C)" for details on this PS. The next silver colored PS was
developed by Bikor. Bikor was later acquired by Cherokee so newer silver
PSs will also be labeled Cherokee. In late 1997 a redesign was made to
these silver PSs to use surface mount semiconductors. This resulted in a
change in its part number. Older silver PSs that have been reworked by
Cherokee have been upgraded with the same electronics used in the newer
supplies. These still have the older number, but its tab number is changed.
In 2007 the third PS built by TDI introduced with new part number,also silver.

All power systems prior to the MU/MC-PSxx04 can use any of the listed
power supplies, and they can be mixed in any combination. However, due to
differences in LED indicator light behavior, best not to mix certain different
revision levels of the TDI silver power supplies or with previous types of
power supplies (see Table 1, Note 4 below and Page 3 of this document).

Supply Matrix Table 1 shows all the PM power supplies that have been used.
Table 1
Part Number Supply Voltage Details
51109456-100 120 Vac (100-132) or Black PS, not available PS
51109456-200 240 Vac (187-264) Voltage set by a switch 
51109684-100 120 Vac (100-132) or Silver PS, not available PS
240 Vac (187-264) No voltage selection required
51109684-300 120 Vac (100-132) or Silver PS, not available PS
240 Vac (187-264) No voltage selection required 
51198947-100 120 Vac (100-132) or Silver PS, not available PS
240 Vac (187-264) No voltage selection required 
51198651-100 120 Vac (100-132) or Silver PS, current available PS
240 Vac (187-264) No voltage selection required 

Notes:  This PS cannot be used in the HPM MU/MC-PSxx04 power system

 This is a 51109684-100 PS that has been upgraded to contain the same
functions as the newer 51198947-100 PS.
 This is a redesign of the 51109684-100 using SMT (Surface Mount
Technology) for improved reliability and containing more diagnostic circuits.
 Now released at Revision D and later with LED indicator configuration and
performance adjusted to be in alignment with that of HPM Power Supply
51198947-100. Revision C or earlier have different LED indications and no
longer available. See Page 3 of this document for more information.

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 TAB PD 22 G97 (D) PAGE 2 DATE 24 AUG 2015

PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

Power Supply Figures 1 and 2 show the front of the first two types of PM power supplies.
Operation Only the black case requires the AC voltage be selected. It is strongly
recommended that any black power supplies still in use be replaced with the
newer improved silver supplies. The PS is made up of three components:
AC to DC converter (58 VDC), battery charger, and 24 VDC regulator. The
power switch on the PS removes the AC from the AC to DC converter. If the
backup battery is present, it will keep the 24 VDC regulator operating until
the battery voltage drops below 38 volts.

DC OUTPUT BATTERY FAN/TEMP AC IN CHARGING COMMON

ON

Air Flow Direction

OFF

115
230

BLACK CASE POWER SUPPLY

P1023

Figure 1

DC OUTPUT BATTERY FAN/TEMP AC IN CHARGING

COMMON

ON

SILVER CASE POWER SUPPLY OFF

Figure 2

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PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

Power Supply Figures 3 shows a picture of the front LEDs of the TDI types of HPM power
Operation supplies part number 51198651-100 all revisions (revs.). Users of HPM
Power Supply 51198651-100 at Revision C or earlier should be aware that
the LED indicators configuration and performance is different to that of HPM
Power Supplies 51198651-100 at Revision D and later and to that of HPM
power supply 51198947-100 (at any rev.).

We recommend not to mix 51198651-100 rev. C or earlier power supplies

with rev. D and later or with 51198947-100 (at any rev.). Use another rev. C
or earlier or upgrade both power supplies to rev. D or later. In 2012
Honeywell upgraded all 51198651-100 power supplies in stock at rev. C to
rev. D. The rev. C or earlier PS are no longer sold.

The performance of the LEDs between the 51198651-100 rev. D and later
and 51198947-100 can be explained in Table 2. It should be noted that
there are differences in the LEDs performance across the power supplies,
especially when set up in mixed pairs. If power supplies must be mixed, the
difference can be significantly mitigated by using the 51198651-100 unit in
the RIGHT slot (this will result in the only unexpected LED behaviors if the
51198947-100 unit is off/failed).

Figure 3

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 TAB PD 22 G97 (D) PAGE 4 DATE 24 AUG 2015

PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

Table 2: LEDs Comparisons PS 51198947-100 and 51198651-100 at Rev. D and Later

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PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

Power Supply These are the difference in behaviors in the front LEDs of the TDI types of
Operation HPM power supplies part number 51198651-100 rev. C and earlier to the
Cherokee 51198947-100 (at any rev.):

1) Charge LED operation:

Cherokee operation - when the secondary power supply (right side in
chassis) is powered off, the charge LED blinks once every 7 seconds to
show that the battery charger is still working.
TDI rev. C operation - The Charge LED on the powered power supply
indicates that charging is taking place. The TDI power supply (if placed in the
secondary position and powered off) does not blink the charge LED.

2) LEDs when TDI and Cherokee are in a mixed system:

Cherokee operation – When the Cherokee power switch is OFF and TDI
power supply is ON (supplying system power) all LEDs on the Cherokee
power supply are OFF.
TDI rev. C operation - When the TDI power switch is OFF and Cherokee
power supply is ON (supplying system power) the D C OUTPUT,
FAN/TEMP, and BATTERY LEDs (if BATTERY SWITCH is ON) are ON.

3) LEDs during Normal (both on) Operation (mixed system):

a) the external BATTERY SWITCH is ON – all the LEDs are ON - both
power supplies.
b) the external BATTERY SWITCH is OFF – a) the DC OUTPUT,
FAN/TEMP, and AC IN LEDs are ON – both power supplies; b) the
Battery LED is OFF - both power supplies; c) the CHARGING LED is ON
– the Cherokee power supply; the CHARGING LED is OFF – the TDI
power supply.

Table 3 shows the above behaviors and others (meaning of headings:

Updated/Revised TDI = 51198651-100 rev. D and later,
Existing TDI = 51198651-100 rev. C and earlier,
Cherokee = 51198947-100 (at any rev.),
RHS = Right-Hand Side,
LHS = Left-Hand Side).

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 TAB PD 22 G97 (D) PAGE 6 DATE 24 AUG 2015

PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

Table 3: LEDs Comparisons PS 51198947-100 and 51198651-100

Differences in LED behavior between power supplies (rev. D has less than rev. C).

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 TAB PD 22 G97 (D) PAGE 7 DATE 24 AUG 2015

PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

PS Replacement These are two possible difficulties thought very unlikely of happening, but
Cautions they can occur during the replacement of a power supply.

Caution #1 Shorting the battery to ground when removing the left power supply.

Background: If the left Power Supply is being pulled out of the Power Module and
the front of the supply is tilted down while it is being partially withdrawn, the left
back corner of the power supply chassis can come in contact with the Battery
Switch terminal #3. While the supply is being withdrawn, there is a very narrow
window of travel distance (roughly ¼ inch) that presents the possibility of the supply
shorting against the switch terminal. As the chargers are current limited, this short
will only affect the battery and will not stop the Process Manager from operating.

Action: All power modules built after May 1998 will have terminal #3 on the toggle
switch insulated with heat shrink tubing as shown in Figure 4. As we have had only
one report of this in many years, the probability of this happening is very low. If you
wish to totally eliminate any possibility of this happening with an older power module
the following action can be taken. Since the risk of this occurrence is so low, it is
best to wait for a process shutdown period but it can be done on line. Battery
backup will not be available while this action is being done.
1. Switch the battery backup off.
2. Disconnect the battery cable from the battery. The single red wire connected to
both terminals #3 & #6 on the switch now have no voltage on them. This is the
wire that goes to the +48 volt battery terminal.
3. Unplug the female connector from terminal #3.
4. Slide a 1 to 2 inch piece of heat shrink tubing over the female connector.
5. Re-connect the wire to the switch and slide the heat shrink against the switch.
6. Use a suitable heat source and shrink the tubing in place.
7. Reconnect the battery cable to the battery and place the switch in the ON
position.

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 TAB PD 22 G97 (D) PAGE 8 DATE 24 AUG 2015

PM/APM/HPM POWER SUPPLY MATRIX & REPLACEMENT, Continued

51190589-100
48 VOLT BATTERY BACKUP
TOGGLE SWITCH

1 4
5

2
6
TERMINAL #3
3

3/8" HEAT SHRINK

P1022 TUBING

Figure 4

Caution #2 PM/APM/HPM Power Supply Fails to ‘Power On’

Background: This problem can occur when installing or repowering a PS with the
Battery Backup and Redundant PS present and ON. The failure to Power On does
not affect the already running PS. This failure can occur on any 51109684 or
51198947 Power Supply without an ECO fix (ECO fix added in May 1998). The
failure only occurs when the battery is Fully charged to 53 volts or above, the
battery switch is ON, and the Redundant PS is ON. Even under these conditions
not all the power supplies will fail.

Symptom: The failure occurs when the Redundant PS is ON, the battery backup
switch is ON, and the PS is powered on from an all LED’s off state. The failing
supply will show only two of the LEDs ON, BATTERY and FAN/TEMP. One section
of the power supply that takes the AC input and converts it to a 58 V DC (input
switcher) fails to start running. This leaves the complete power supply outputs
dead. The supply will be missing Battery Charge voltage (54.5 VDC) and DC
Output (25.5 VDC) .

Recovery: The PS is not bad, it was just fooled into thinking the input switcher was
running when the power was turned on by the presence of the full battery voltage.
If the Battery Switch is turned off, the PS recycled on, then the Battery Switch
turned back on, the PS will start up OK. The Battery LED will initially be off, but will
come on after 8-10 seconds. During a AC loss and Battery present and on, there is
no problem. When the AC power interruption occurs, the PS or PS’s will run on the
battery, and when AC power returns, the PS or PS’s will return to AC operation
automatically, with no problem.

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