Close
0%
0%

Network PDU-S

Network Power Distribution Unit with Sequencing

Similar projects worth following
The Network PDU-S is a product combines a number of features to satisfy power distribution needs for Data Centers, Professional A/V applications, home/business automation, and of course the seasonal Christmas light display.

High Level Design Requirements
1. Its simplest function is power distribution. the Network PDU-S will provide a 6rear + 2front outlet power strip.

2. This device includes a programmable sequencer that allows you to power equipment on/off in a specific order.

3. This device includes network control. From a webpage you will be able to configure the sequencer settings as well as toggle individual outlets on and off. The device will also be able to send commands to other sequencers allowing you to control the power-up sequence of equipment at remote locations via the internet.

The Network PDU-S is a product combines a number of features to satisfy power distribution needs for Data Centers, Professional A/V applications, home/business automation, and of course the seasonal Christmas light display.

Features

1. Six rear switchable power outlets.

2. Two front unswitched power outlets.

3. Programmable Power Sequencer.

4. Network Controlled outlets.

5. 19inch rack mount case.

6. Surge Suppression (Coming in RevB).

7 Circuit Breaker (Coming in RevB).

8. Power Meter per outlet (Coming in RevB).

Typical Use Cases

1. With the features of a standard surge protector / power strip, the Network PDU-S is perfect (err overkill) for everyday power distribution options.

2. Professional Audio/Visual systems often require equipment to be switched on in a specific sequence:

a. By turning on the Amplifier after the Sound Board you avoid dangerous "Pops" that can blow out a speaker.

b. By staggering equipment power on inrush current can be reduced.  This helps avoid tripping breakers, GFCIs, or causing mini brownouts that can cause digital equipment to malfunction.

3. Data Centers can take advantage of the switchable outlets that can be controlled over the internet as well as the power sequencing capabilities to ensure servers are powered up in the correct order.

Advanced Use cases

The network interface allows the Network PDU-S to be controlled from a web page as well as with direct HTTP POST commands.  These commands could originate from a script running on a server, or from another device.   Here are a few use cases I've already experimented with:

a. Multiple Network PDU-S devices can be "daisy chained" over the internet.  For example, I may have one Network PDU-S unit at the Sound board and another in a remote equipment closet.  When I push the "Start" button on the Network PDU-S at the  Sound Board I can have it issue a sequence of local and remote start-up commands to ensure the entire facility powers up in the correct order.

b. Using a script I can poll each outlet for power consumption to and generate statistics.

c. Using a script I can conditionally activate different outlets.  Perhaps some equipment needs to be switched on at a certain time of day or switched off after some duration.

d. Using a script I may be able to monitor the functionality of devices attached to the Network PDU-S.  If the current measured is outside some tolerance it may indicate a failure in the connected device.

  • 1 × Protocase Enclosure
  • 1 × Custom PCB
  • 1 × Power Supply
  • 8 × NEMA 5-15 Outlets
  • 1 × IDC Power Inlet

View all 10 components

  • Network PDU-S: Enclosure Design

    peter.j.ogden08/20/2014 at 22:30 0 comments

    Protocase

    Protocase Logo

    When I first found out about Protocase from a Midi Workstation project listed on Hack A Day I couldn't wait to design something to take advantage of their service.

    The Protocase website has a template generator that will create a complete assembly for use in your CAD program so you can get started right away. I chose Solidworks since that's the software I've been using.

    Engineers at Protocase were very helpful and were able to use the 3d Solids directly which was great.

    Solidworks
    Original assembly from Protocase

    With the Protocase assembly generator I was able to start with a model that was 90% complete.

    I attempted to import my VRML 3d PCB model directly from Kicad. Unfortunately, I never quite got that working so I ended up making a simple model of the board outline and mounting holes in Solidworks.

    From the various manufacturer's websites I was able to find 3d models for the PSU, IDC Connector, and the RJ45 pass-through jack. This not only saved time but also gave me confidence in the design. I couldn't find any model for the NEMA 5-15 outlets so I made one using the suggested panel cutout drawing.

    Completed Assembly Isometric

    When I designed the board I included 8 relays, however when it came to designing the case it became obvious that 8 switchable outlets can't fit on the back. I thought about making the front outlets switchable, but it didn't really fit any of my use cases.

    In the future I will need to spend more time on a top-down design of the project before jumping into the sub-assemblies like the electronics.

    Front
    Back
    Exploded View

  • Debug Environment

    peter.j.ogden08/15/2014 at 20:13 0 comments

    This is what real work looks like

    In order to debug I used the following:

    • ICSP Programmer. I use the UsbTinyISP programmer from Adafruit.
    • Network Serial Port. I use a BrainBox ES246 network serial adapter so I can access the serial console while on Wifi since I like to debug while lying in bed.
    • Current Limiting Bench Power supply
    • Fluke 87v DMM
    • Rigol Oscilloscope

    Arduino Environment

    Before I could even get started debugging, I needed to create a custom boards.txt and pins_arduino.h files so the Arduino programming environment would know how to map things like the friendly "LED_BUILTIN" to the actual I/O register.

    To keep thing simple, I started with the timeless "Led Blink" sketch.

    Wiznet W5100 Debug
    Programmer, Serial Port, and Ethernet Hooked Up

    I discovered a short on the 1.8V LDO output of the W5100. After some rework with the hot air and some solder wick I managed to repair the short. It looks like I made the pads extend under the device a little too far making it very difficult to clear a solder bridge under the IC.

    After that, it was smooth sailing...well not exactly. The 3.3v and 1.8Vdd and 18.Vda rails all were outputting the correct voltage, and much to my surprise the Link and Activity lights on the RJ45 mag jack were lit, so at least the chip was alive.

    Oscilloscope and Hot Air Rework Station

    I probed around the SPI bus a bit, I discovered the SlaveSlect signal was not toggling. It turned out that the SlaveSlect pin was hard coded in the Arduino Ethernet library. Having it configured with a header or constructor would have been much better. Nevertheless, another quick hack and the Arduino Ethernet tutorial I was using was fully operational. Hello World!

  • Network PDU-S: Layout

    peter.j.ogden08/14/2014 at 15:11 0 comments

    Layout Today I finished the layout for the Network PDU-S. I used Kicad for the entire PCB process.

    The board is much bigger than I would have liked. Next time I will probably put the relays on a separate board from the logic.

    Network PDU-S RevA layout

  • Network PDU-S: Schematic

    peter.j.ogden08/08/2014 at 03:59 0 comments

    Circuit Design

    The Network PDU-S will be based on the Arduino Ethernet board, however instead of the ATMega328 I'm going to use an ATMega2560. This is the same chip that is used in the Arduino Mega, and I've used it in several designs before so I've already got most of what I need to create the schematic.

    For the Ethernet controller, I've chosen to use the same Wiznet W5100 chip as the Arduino Ethernet so I can take advantage of the existing code libraries.

    I'm including a Max232 RS232 to TTL level converter in the design. This will be used for debugging, and possibly included in the final product to send/receive commands to RS232 compatible devices.

    Schematic

    Here's the top level schematic designed in Kicad:

  • Network PDU-S: High Level Design

    peter.j.ogden08/06/2014 at 04:02 0 comments

    (cross post from blog)

    Design Requirements

    1. Its simplest function is power distribution. the Network PDU-S will provide a 6rear + 2front outlet power strip.

    2. This device includes a programmable sequencer that allows you to power equipment on/off in a specific order.

    3. This device includes network control. From a webpage you will be able to configure the sequencer settings as well as toggle individual outlets on and off. The device will also be able to send commands to other sequencers allowing you to control the power-up sequence of equipment at remote locations via the internet.

    Motivation for this project

    1. I travel a lot for work, and sometimes I need to remotely power cycle the servers in my home data center.

    2. For my A/V work I need a power sequencer to turn on the sound board and amplifiers in a specific order to avoid equipment damage.

    3. In some A/V venues I need to sequence equipment in the sound booth, on stage, and also back in electrical rooms.

    4. I would like to get per-outlet power metering so I can closely monitor peak/average power consumption of all of my equipment.

    High Level Design Document
    High Level Block Diagram


    I created this diagram with DIA diagram tool..

  • check out the web log for now

    peter.j.ogden07/24/2014 at 07:16 0 comments

    check out the web log for now

View all 6 project logs

Enjoy this project?

Share

Discussions

midnightcow wrote 05/13/2015 at 05:16 point

Dear Peter.

It's so good project. I'm interested in your project. I'm a WIZnet engineer.

Will I introduce your project on my blog & wiznet museum site(http://mdnightcow.tistory.com, www.wiznetmuseum.com).

Thank you in advanc.

If you intrested in other WIZnet product such like as W5500, WizFi250 and WIZwiki-W7500, I will send them free to you.

Feel free send to me a private message.

Thank you.

  Are you sure? yes | no

J Groff wrote 07/24/2014 at 16:49 point
ooh, ooh, how about a couple programmable DC buck/boost converter drops and some USB charge jacks?

  Are you sure? yes | no

peter.j.ogden wrote 07/24/2014 at 16:59 point
Thanks for the suggestion, I'll definitely consider it for RevB.

The SMPS circuit on the PCB is the same as I have used for iPAD charging in the past. it can do 10W fast charging, so all that would be needed is a panel mount USB header and some termination resistors.

Plus then I can label it as an Apple accessory.

  Are you sure? yes | no

Similar Projects

Does this project spark your interest?

Become a member to follow this project and never miss any updates