GE Energy Data Sheet CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: 12Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A Features Universal input with PFC Constant power characteristic 2 front panel LEDs: 1-input;2-[output, fault, over temp] Remote ON/OFF control of the 12Vdc output Remote sense on the 12Vdc output No minimum load requirements Active load sharing (single wire) Hot Plug-ability Applications Efficiency: typically 92.5% @ 50% load and 90.0% @ 20% load 12Vdc distributed power architectures Standby orderable either as 3.3Vdc or 5Vdc Datacom and Telecom applications Auto recoverable OC & OT protection Mid to high-end Servers Operating temperature: -10 - 70C (de-rated above 50C) Enterprise Networking Digital status & control: I2C and PMBus serial bus EN/IEC/UL60950-1 2nd edition; UL, CSA and VDE Network Attached Storage EMI: class A FCC docket 20780 part 15, EN55022 Telecom Access Nodes Meets EN6100 immunity and transient standards Routers/Switches Shock & vibration: NEBS GR-63-CORE, level 3 Broadband Switches ATE Equipment Description The CAR2512FP series of Front-End rectifiers provide highly efficient isolated power from worldwide input mains in a compact 1U industry standard form factor in an unprecedented power density of 25W/in3. These rectifiers are ideal for datacom applications such as enterprise networking, mid to high-end servers, and storage equipment, where mid to light load efficiency is of key importance given the nature of the power consumption of the end application. The high-density, front-to-back airflow is designed for minimal space utilization and is highly expandable for future growth. The industry standard PMBus compliant I2C communications buss offers a full range of control and monitoring capabilities. The SMBAlert signal pin alerts customers automatically of any state change within the power supply. July 18, 2012 ©2012 General Electric Company. All rights reserved. GE Energy CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: 12 Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability. Device Symbol Min Max Unit Input Voltage: Continuous Parameter All VIN 0 264 Vac Operating Ambient Temperature All TA -10 1 70 °C Storage Temperature All Tstg -40 85 °C I/O Isolation voltage to Frame (100% factory Hi-Pot tested) All 1500 Vac Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, load, and temperature conditions. INPUT Parameter Min Typ Max Unit VIN 90 110/230 264 Vac FIN 47 50/60 63 Hz VIN 80 Vac All IIN 14.3 16 Aac All IIN 40 Apeak 50% load 20% load Power Factor (Vin=230Vac, IO=IO, max) Holdup time2 Vin= 230Vac (Vout= 12Vdc, Tamb 25C, IO=IO, max) Vin= 100Vac Early warning prior to output falling below regulation All All PF All T Ride through All T All IIN Operational Range Frequency Range (ETSI 300-132-1 recommendation) Main Output Turn_OFF Maximum Input Current VIN= 100Vac (VO= VO, set, IO=IO, max) VIN= 180Vac Cold Start Inrush Current (Excluding x-caps, 25C, <10ms, per ETSI 300-132) Efficiency Device Symbol All All All 100% load (Tamb=25C, Vin = 230V, Vout= 12V, IO, max) Leakage Current (Vin= 250Vac, Fin = 60Hz) Isolation % 0.99 12 15 All ms 2 Input/Output Input/Frame 91.6 92.5 90 All Output/Frame ms 10 ms 3 mArms 3000 Vac 1500 Vac 100 Vdc 12Vdc MAIN OUTPUT Parameter Output Power Device HL / LL [180 – 264 / 90-132 Vac] Vdc ≥ 12Vdc Vdc = 10.8Vdc All Set point Overall regulation (load, temperature, aging) All All Ripple and noise3 All Turn-ON overshoot All Turn-ON delay All Symbol W Vout Min Typ Max Unit 0 - 2500/1200 W 0 11.9 -3 12.00 2246/1078 12.1 +3 W Vdc % 120 mVp-p T +3 % 2 sec Derated above 50C at 2.5%/C 12V output can decay down to 10.8V 3 Measured across a 10µf electrolytic and a 0.1µf ceramic capacitors in parallel. 20MHz bandwidth 1 2 July 18, 2012 ©2012 General Electric Company. All rights reserved. Page 2 GE Energy CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: 12 Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A 12Vdc MAIN OUTPUT (continued) Max Unit Remote ON/OFF delay time Parameter Device All 40 ms Turn-ON rise time (10 – 90% of Vout) All 50 ms Transient response 50% step [10%-60%, 50% - 100%] (dI/dt – 1A/outµs, recovery 300µs) All -5 +5 %Vout Programmable range (hardware & software) All 10.8 13.2 Vdc Overvoltage protection, latched (recovery by cycling OFF/ON via hardware or software) Output current [V All 15.8 Vdc 0 208 100 Adc 110/110 130/140 % of FL -5 +5 % of FL Current limit, Hiccup (programmable level) Vin = HL Vin = LL All HL / LL All Symbol Min Vout 13.8 Iout All Active current share Typ 14.8 AUXILIARY OUTPUT Device Symbol Set point Parameter All Vout Overall regulation (load, temperature, aging) All Vout Ripple and noise All Output current All Min Typ Max 3.3 / 5.0 -5 Iout 0 Unit Vdc +5 % 50 mVp-p 1 Adc Overload protection Overvoltage protection Isolation Output/Frame All Vdc 100 Environmental, Reliability Parameter Min Typ Max Units 50 1524/5k 2.5 2.0 °C m / ft %/°C C/1000 ft 85 8200/30k °C m / ft 55 dbA Notes Ambient Temperature Operating Altitude Operating Power Derating -104 Storage Altitude non-operating -40 Acoustic noise Over Temperature Protection Humidity Operating Storage 125/110 30 10 Reliability Service Life 4 51°C to 70C Above 5,000 ft Full load Shutdown / restart 95 95 % 6 Grms NEBS GR-63-CORE, Level 3, 20 -2000Hz, min 30 minutes Zone NEBS GR-63-CORE, all floors, Seismic Zone 4 Designed and tested to meet NEBS specifications. 250,000 Hrs Full load, 25C ; MTBF per SR232 Reliability protection for electronic equipment, method I, case III, 10 Yrs Full load, excluding fans Shock and Vibration acceleration Earthquake Rating °C Air inlet from sea level to 5,000 feet. 4 Relative humidity, non-condensing Designed to start at an ambient down to -40°C; meet spec after 30 min warm up period, may not meet operational limits below -10°C. July 18, 2012 ©2012 General Electric Company. All rights reserved. Page 3 GE Energy CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: 12 Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A EMC Parameter AC input Criteria Level Test Conducted emissions EN55022, FCC Docket 20780 part 15, subpart J EN61000-3-2 A* 0.15 – 30MHz 0 – 2 KHz Radiated emissions EN55022 A* 30 – 10000MHz Voltage dips EN61000-4-11 A -30%, 10ms B -60%, 100ms B -100%, 5sec A 4kV, 1.2/50µs, common mode A 2kV, 1.2/50µs, differential mode Voltage surge Enclosure Standard EN61000-4-5 immunity Fast transients EN61000-4-4 B 5/50ns, 2kV (common mode) immunity Conducted RF fields EN61000-4-6 A 130dBµV, 0.15-80MHz, 80% AM Radiated RF fields EN61000-4-3 A 10V/m, 80-1000MHz, 80% AM ENV 50140 A EN61000-4-2 B ESD 4kV contact, 8kV air * Note: Contact the factory for a recommended external EMI filter to meet Class B emissions Status and Control Some functions have two means of monitor/control; A signal level that represents the analog value being measured or controlled, or, reading/writing via the i2C port the measured value or the control command. Unless otherwise noted, control via the signals pins is ‘active’ so long that a firmware based command is not initiated. Once firmware initiates a command that is also represented on a signal pin, the firmware takes over and replaces the hardware based control signal. Firmware control is maintained until bias power to the processor is interrupted. Once bias power is removed the processor resets and the analog signal pin control is ‘active’ until firmware takes over control. Details of analog controls are provided in this data sheet under Signal Definitions. GE Energy will provide separate application notes on the I2C protocol. Contact your local GE Energy representative for details. Signal Definitions All signals and outputs are referenced to Output return. These include ‘Vstb return’ and ‘Signal return’. Input Signals Voltage programming (Vprog): An analog voltage on this signal can vary the output voltage ± 10% from 10.8Vdc to 13.2Vdc. The equation of this signal is: Vout = 10.8 + (Vprog * 0.96) 0 < Vprog < 2.5 July 18, 2012 If 2.5 < Vprog < 3, the output is 13.2V. If Vprog is > 3V or left open the programming signal is ignored and the unit output is set at the setpoint of 12Vdc. Load share (Ishare): This is a single wire analog signal that is generated and acted upon automatically by power supplies connected in parallel. The Ishare pins should be tied together for power supplies if active current share among the power supplies is desired. No resistors or capacitors should get connected to this pin. Remote ON/OFF: Controls the presence of the main 12Vdc output voltage. This is an open collector, TTL level control signal. This signal needs to be pulled HI externally through a resistor. Maximum collector voltage is 12Vdc and the maximum sink current is 1mA. A Logic 1 (TTL HI level) turns ON the 12Vdc output, while a Logic 0 (TTL LO level) turns OFF the 12Vdc output. A turn OFF command either through this signal (Remote ON/OFF) or firmware commanded would turn OFF the 12V output. Enable: This is a short signal pin that controls the presence of the 12Vdc main output. This pin should be connected to ‘output return’ on the system side of the output connector. The purpose of this pin is to ensure that the output turns ON after engagement of the power blades and turns OFF prior to disengagement of the power blades. Write protect (WP): This signal protects the contents of the EEPROM from accidental over writing. When left open the EEPROM is write protected. A LO (TTL compatible) permits writing to the EEPROM. This signal is pulled HI internally by the power supply. ©2012 General Electric Company. All rights reserved. Page 4 GE Energy CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: 12 Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A Output signals Device Address Output current monitor (Imon): A voltage level of 3V = 200A proportional to the delivered output current is present on this pin. MCU EEPROM 0xBx 0xAx AC OK: A TTL compatible status signal representing whether the input voltage is within the anticipated range. This signal needs to be pulled HI externally through a resistor. Maximum sink current ≤ 20mA and the max voltage is 12Vdc. Open collector (HI) on this signal indicates that the input voltage is applied within the specified input range. DC OK: A TTL compatible status signal representing whether the output voltage is present. This signal is internally pulled HI to 3.3V via a 10kΩ resistor. Maximum sink current ≤ 4mA and the max voltage is 12Vdc. Open collector (HI) on this signal indicates that the output voltage is present. Over temp warning: A TTL compatible status signal representing whether an over temperature exists. This signal needs to be pulled HI externally through a resistor. Maximum sink current ≤ 20mA and the max voltage is 12Vdc. Open collector (HI) on this signal indicates that temperatures are normal. If an over temperature should occur, this signal would pull LO for approximately 10 seconds prior to shutting down the power supply. The unit would restart if internal temperatures recover within normal operational levels. At that time the signal reverts back to its open collector (HI) state. Fault: A TTL compatible status signal representing whether a Fault occurred. This signal needs to be pulled HI externally through a resistor. Maximum sink current ≤ 4mA and the max voltage is 12Vdc. Open collector (HI) on this signal indicates that no Fault is present. This signal activates for OTP, OVP, OCP, AC fault or No output. PS Present: This pin is connected to ‘output return’ within the power supply. Its intent is to indicate to the system that a power supply is present. This signal may need to be pulled HI externally through a resistor. Interrupt (SMBAlert): A TTL compatible status signal, representing the SMBusAlert# feature of the PMBus compatible i2C protocol in the power supply. This signal needs to be pulled HI externally through a resistor. Maximum sink current ≤ 4mA and the pull up resistor should be tied to 3.3Vdc. Open collector (HI) on this signal indicates that no Interrupt has been triggered. Serial Bus Communications 1 1 Address Bit Assignments (Most to Least Significant) 0 1 1 A2 A1 A0 0 1 0 A2 A1 A0 R/W R/W Address lines (A2, A1, A0): These signal pins allow up to eight (8) modules to be addressed on a single I²C bus. The pins are pulled HI internal to the power supply. For a logic LO these pins should be connected to ‘Output Return’ Serial Clock (SCL): The clock pulses on this line are generated by the host that initiates communications across the I²C Serial bus. This signal is pulled up internally to 3.3V [ 5V5 ] by a 10kΩ resistor. The end user should add additional pull up resistance as necessary to ensure that rise and fall time timing and the maximum sink current is in compliance to the I²C specifications. Serial Data (SDA): This line is a bi-directional data line. . This signal is pulled up internally to 3.3V [ 5V ] by a 10kΩ resistor. The end user should add additional pull up resistance as necessary to ensure that rise and fall time timing and the maximum sink current is in compliance to the I²C specifications. EEPROM The microcontroller has 96 bytes of EEPROM memory available for the system host. Another separate EEPROM IC will provide another 128 bytes of memory with write protect feature. Minimum information to be included in this separate EEPROM: model number, revision, date code, serial number etc. See the communications protocol for further information. Communications Protocol The I²C protocol is described in detail by the I2C and PMBus Serial Communications Protocol for the CAR Family of Power Supplies application note. The Y01A suffix module supports only the I2C command set. LEDs Two LEDs are located on the front faceplate. The AC_OK LED provides visual indication of the INPUT signal function. When the LED is ON GREEN the power supply input is within normal design limits. The second LED DC/FLT is a tri-state LED. When GREEN there are no faults and DC output is present. When AMBER a fault condition exists but the power supply still provides output power. When RED then a fault condition exists and the power supply does not provide output power. The I²C interface facilitates the monitoring and control of various operating parameters within the unit and transmits these on demand over an industry standard I²C Serial bus. All signals are referenced to ‘Signal Return’. Device addressing: The microcontroller (MCU) and the EEPROM have the following addresses: 5 July 18, 2012 Module configured with 5V standby output ©2012 General Electric Company. All rights reserved. Page 5 GE Energy Preliminary Data Sheet CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: +12 Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A Alarm Table LED Indicator Monitoring Signals Test Condition LED1 AC Tri-Color LED2 DC / FLT FAULT DC OK INPUT OK TEMP OK 1 Normal Operation Green Green High High High High 2 Low or NO INPUT Off Red Low Low Low High 3 OVP Green Red Low Low High High 4 Over Current Green Red Low Low High High 5 Temp Alarm Warning Green Orange High High High Low 6 Fault Over Temp Green Red Low Low High Low 7 Remote ON/OFF Green Red Low Low High High Notes: Test condition #2 had 2 modules plug in. One module is running and the other one is with no AC. Outline Drawing airflow 12 April 2012 ©2012 General Electric Company. All rights reserved. Page 6 GE Energy CAR2512FP series rectifier Input: 90Vac to 264Vac; Output: 12 Vdc @ 208A; 3.3Vdc or 5 Vdc @ 1A Connector Pin Assignments Input Mating Connector: IEC320, C19 type Output Connector: Tyco P/N 6600122-7 or equivalent Mating connector: Primary Source: FCI berg P/N 51915-176LF Secondary Source: Tyco P/N 6450171-5 Pin Function Pin Function Pin Function Pin Function A1 Vstb [3.3V] B1 Fault C1 IShare D1 VProg A2 PS Present B2 I Monitor (IMON) C2 No connect D2 OVP Test Point A3 Signal Return B3 Enable: “0” –ON “1” -OFF C3 Over Temp Warning D3 Remote ON/OFF A4 Write Protect (WP) B4 Vstb [3.3V] Return C4 I2C Address (A0) D4 DC OK A5 Remote Sense (+) B5 2 SDA (I C bus) C5 I C Address (A1) D5 AC OK A6 Remote Sense (-) B6 SCL (I2C bus) C6 I2C Address (A2) D6 SMBAlert P1 – P6 Output Return P7– P12 +12Vout 2 Ordering Information Please contact your GE Energy Sales Representative for pricing, availability and optional features. PRODUCT DESCRIPTION PART NUMBER 2500W Front-End +12Vout Front-End, 3.3Vaux, with face plate and PMBus interface, RoHS 6 of 6 CAR2512FPBXXZ01A 2500W Front-End +12Vout Front-End, 5Vaux, with face plate and PMBus interface, RoHS 6 of 6 CAR2512FPBC5Z01A Part number definition guide CAR 25 12 F P x x x x -01A Contact Us For more information, call us at Series Revision 25 = 2500W Y = 5 of 6, Z = 6 of 6 12 = 12Vdc Blank = 3.3V, 5 = 5V Blank = PMBus, C = I2C F = front end Blank = none, B = bezel option P = positive, N = negative USA/Canada: +1 888 546 3243, or +1 972 244 9288 Asia-Pacific: +86.021.54279977*808 Europe, Middle-East and Africa: +49.89.878067-280 India: +91.80.28411633 www.ge.com/powerelectronics July 18, 2012 ©2012 General Electric Company. All rights reserved. Page 7