GE Data Sheet CAR2548DC series dc-dc converter Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Features Applications 48Vdc distributed power architectures Cellular Base Stations Satellite Hubs Network Equipment Network Attached Storage Telecom Access Nodes Routers/Switches/ATE Equipment 3 front panel LEDs: 1-input;2-output; 3 - fault Output programmable from 43.2 – 56Vdc Remote ON/OFF control of the 48Vdc output Remote sense (up to 0.25V) on the 48Vdc output No minimum load requirements Redundant parallel operation Active load sharing (single wire) Efficiency: typically 91% Standby orderable either as 3.3Vdc or 5Vdc Auto recoverable OC & OT protection Operating temperature: -10 - 70C (de-rated above 50C) Digital status & control: I2C and PMBus serial bus EN/IEC/UL60950-1 2nd edition; UL, CSA and VDE EMI: class B FCC docket 20780 part 15, EN55022 Meets EN6100 immunity and transient standards Shock & vibration: NEBS GR-63-CORE, level 3 Description The CAR2548DC series of DC-DC Converters provide highly efficient isolated power from DC input mains in a compact 1U industry standard form factor in an unprecedented power density of 27W/in3. These converters complement the CAR2548FP rectifier providing comprehensive solutions for systems connected either to commercial ac mains, 48/60Vdc power plants or telecom central offices. This plug and play approach offers significant advantages since systems can be reconfigured and repositioned readily by simply replacing the power supply. 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 SMBusAlert signal pin alerts customers automatically of any state change within the power supply. * † ‡ § ** + UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. Intended for integration into end-user equipment. All the required procedures for CE marking of end-user equipment should be followed. (The CE mark is placed on selected products.) ISO is a registered trademark of the International Organization of Standards. PMBus name and logo are registered trademarks of the System Management Interface Forum (SMIF) December 6, 2013 ©2013 General Electric Company. All rights reserved. GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 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. Parameter Symbol Min Max Unit Input Voltage: Continuous VIN 0 75 Vac Operating Ambient Temperature TA -10 701 °C Storage Temperature Tstg -40 I/O Isolation voltage (100% factory Hi-Pot tested) 85 °C 1500 VDC Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, load, and temperature conditions. INPUT Parameter Symbol Operational Range 48Vdc output turned ON 48Vdc output OFF Max -48/60 -75 -42 -45 -48 -36 35 W 48Vdc output ON Maximum Input Current Typ -36 VIN 48Vdc output turned OFF Idling Power, Min (VIN= 37.5Vdc, VO= VO, set, IO=IO, max) 45 Unit VDC W IIN 75 ADC Cold Start Inrush Current (Excluding x-caps, 25C, <10ms, per ETSI 300-132) IIN 75 APEAK Efficiency (Tamb=25C, Vin= -48Vdc, Vout= 48Vdc); 100% load 30 – 50% load 20% load Holdup time2 (Vin= -48Vdc, Vout= 48Vdc, Tamb 25C, IO=IO, max) Loss of Output Early Warning Signal Isolation; Input/Output T T Input/Frame 90 91 87 % 4 1 1500 ms ms VDC VDC 1500 Output/Frame Input capacitance 25 VDC µf Typ Max Unit 48.00 2500 48.5 +2 W VDC % VDC VDC mVp-p 1000 F 48VDC MAIN OUTPUT Parameter Output power Set point, @ 50% load Overall regulation (load, temperature, aging) Linear droop, NL to FL Remote sense (sum of hot & return) Ripple and noise3 Symbol Min POUT 0 47.5 -2 0.1 VOUT 0.25 500 Derated above 50C at 2.5%/C Full load w/5,000µf external output capacitance, Output may droop down to 44Vdc. 3 Measured across a 10µf tantalum and a 0.1µf ceramic capacitors in parallel. 20MHz bandwidth 1 2 December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 2 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A 48VDC MAIN OUTPUT (continued) Parameter Symbol Min Typ Max Unit 3 2 40 50 % sec ms ms -2 +2 VDC 43.2 56 VDC 60 VDC 52 130 +5 5,0005 ADC W % of FL % of FL µf Max Unit VOUT Turn-ON overshoot Turn-ON delay Remote ON/OFF delay time Turn-ON rise time (10 – 90% of VOUT) Transient response 50% step [10%-60%, 50% - 100%] (dI/dt – 1A/µs, recovery 300µs) Programmable range (hardware & software) Overvoltage protection, latched4 (recover by cycling OFF/ON via hardware or software) Output current, Vout= 48Vdc Power limit, Vout = 48 to 56Vdc Current limit, Hiccup (programmable level) Active current share External capacitance T VOUT 58 IOUT POUT IOUT 59 0 2500 105 -5 0 STANDBY OUTPUT Parameter Symbol Set point Vout Overall regulation (load, temperature, aging) Vout Ripple and noise Output current Iout Min Typ 3.3 / 5.0 Vdc -5 +5 % 0 50 1 mVp-p Adc General Specifications Parameter Min Reliability, at 25C 50C Service Life Typ Max Units Notes 250,000 100,000 Hrs Full load, ; MTBF per SR232 Reliability protection for electronic equipment, method I, case III, 10 Yrs Full load, excluding fans Weight Kgs/ (Lbs) Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Symbol Min Typ Max Unit 20 µA VIH 0.7VDD 12 VDC IIL VIL 0 1 0.8 mA VDC Remote ON/OFF (Needs to be pulled HI via an external resistor) Logic High (Module ON) Logic Low (Module OFF) 4 5 IIH The power supply will attempt three restarts prior to latching the shutdown level. 4,000µf electrolytic and 1,000µf tantalum capacitors December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 3 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Feature Specifications (continued) Parameter Symbol Min Typ Max Unit Vprog range Programmed output voltage range Voltage adjustment resolution (8-bit A/D) Vprog Vo Vo 0 10.8 10 2.5 13.2 VDC VDC mVDC Output configured to 13.2Vdc Vprog 2.5 Output configured to the 12Vdc set-point Vprog 3.0 12V output OFF VI 0.7VDD 12V output ON VI 0 VI VI 0.7VDD 0 Output Voltage programming (Vprog) Equation: Vout = 10.8 + (Vprog * 0.96) 3.0 VDC VDC 12 VDC 0.4 VDC 12 0.8 VDC VDC 20 µA Enable [short pin controlling presence of the 12VDC output] Write protect (Wp) Write protect enabled Write protect disabled INPUT-OK (Needs to be pulled HI via an external resistor) Logic High (Input within normal range) IOH Logic Low (Input out of range) VOH 0.7VDD 12 VDC IOL VOL 0 20 0.4 mA VDC 20 µA VOH 0.7VDD 12 VDC IOL 20 mA VOL 0 0.4 VDC 20 µA VOH 0.7VDD 12 VDC mA DC-OK ( Internally connected to 3.3V via a 10kΩ resistor) Logic High (Output voltage is present) IOH Logic Low (Output voltage is not present) Over Temperature Warning (Needs to be pulled HI via an external i t ) Logic High (temperature within normal range) Logic Low (temperature is too high) Delayed shutdown after Logic Low transition IOH IOL 20 VOL 0 0.4 Tdelay 10 VDC sec Fault (Needs to be pulled HI via an external resistor) Logic High (No fault is present) 20 µA VOH 0.7VDD 12 VDC IOL VOL 0 20 0.4 mA VDC IIL VIL 0 4 0.1 mA VDC IOH Logic Low (Fault is present) PS Present (Needs to be pulled HI via an external resistor) Logic High (Power supply is not plugged in) Logic Low (Power supply is present) December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 4 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Feature Specifications (continued) Parameter SMBAlert# (Interrupt) (Needs to be pulled HI via an external i t ) Logic High (No Alert - normal) Symbol Typ 20 µA 0.7VDD 12 20 0.4 VDC mA VDC 5 % of FL ADC IOH VOH IOL VOL Logic Low (Alert is set) Min 0 Max Unit Output current monitor (Imon) Resolution 100 Accuracy -5 mV/A Measurement range Io 0 52 Analog output range Vmon 0 5.2 VDC 5 mADC Sourced output current Digital Interface Specifications Parameter Conditions Symbol Min Input Logic High Voltage (CLK, DATA) Input Logic Low Voltage (CLK, DATA) VIH VIL Input high sourced current (CLK, DATA) IIH Typ Max Unit 2.1 0 3.6 0.8 VDC VDC 0 10 μA PMBus Signal Interface Characteristics Output Low sink Voltage (CLK, DATA, SMBALERT#) Output Low sink current (CLK, DATA, SMBALERT#) Output High open drain leakage current (CLK,DATA, SMBALERT#) PMBus Operating frequency range IOUT=3.5mA VOL 0.4 VDC IOL 3.5 mA VOUT=3.6V IOH 0 10 μA Slave Mode FPMB 10 400 kHz Measurement System Characteristics Clock stretching IOUT measurement range tSTRETCH Linear IOUT measurement accuracy 25°C VOUT measurement range VOUT measurement accuracy Linear Temp measurement range Temp measurement accuracy6 Linear IIN measurement range IIN measurement accuracy Linear VIN measurement range VIN measurement accuracy Linear PIN measurement range PIN measurement accuracy Linear Fan Speed measurement range Linear Fan Speed measurement accuracy Fan speed control range 6 -direct- 25 ms IRNG 0 52 ADC IACC -3 +3 % of FL VDC VOUT(rng) 0 60 VOUT(acc) -3 +3 % Temp(rng) 0 120 C Temp(acc) -5 +5 C IIN(rng) 0 80 ADC IIN(acc) -5 +5 % VDC VIN(rng) 0 80 VIN(acc) -3 +3 % PN(rng) 0 3000 W PIN(acc) -5 +5 % RPM 0 30k -5 5 % 0 100 % Temperature accuracy reduces non-linearly with decreasing temperature December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 5 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Environmental Specifications Parameter Min Typ Max Units Ambient Temperature -107 70 °C Storage Temperature -40 85 °C 2250/7382 m/ft Operating Altitude Non-operating Altitude Notes Derated above 50C 8200/30k m / ft Power Derating with Temperature 2.5 %/°C Power Derating with Altitude 2.0 C/301 m C/1000 ft Acoustic noise 55 dbA Over Temperature Protection Humidity Operating Storage 110/95 30 10 Shock and Vibration acceleration 50C to 70C Above 2250 m/7382 ft 25C, half load °C Shutdown / restart 95 95 % Relative humidity, non-condensing 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. Earthquake Rating 4 EMC Compliance Parameter Criteria Conducted emissions Enclosure immunity Level Test A8 0.15 – 30MHz A B B B A A 30 – 10000MHz -30%, 10ms -60%, 100ms -100%, 5sec 4kV, 1.2/50µs, common mode 2kV, 1.2/50µs, differential mode 5/50ns, 2kV (common mode) Radiated emissions9 Voltage dips Voltage surge EN61000-4-5, level 4 Fast transients EN61000-4-4, level 3 B Conducted RF fields EN61000-4-6, level 3 A 130dBµV, 0.15-80MHz, 80% AM Radiated RF fields EN61000-4-3, level 3 A 10V/m, 80-1000MHz, 80% AM ENV50140 A EN61000-4-2, level 3 B DC input DC INPUT immunity Standard EN55022, FCC Docket 20780 part 15, subpart J EN55022 EN61000-4-11 ESD 6kV contact, 8kV air 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. Class B EMI conducted and radiated levels met with an external filter. Please contact sales for a recommended filter. 9 Radiated emissions compliance is contingent upon the final system configuration. 7 8 December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 6 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Control and Status Control hierarchy: Some features, such as output voltage, can be controlled both through hardware and firmware. For example, the output voltage is controlled both by the signal pin (Vprog) and the PMBus command, (Vout_command) . Using output voltage as an example; the Vprog signal pin has ultimate control of the output voltage until the Vprog is either > 3Vdc or a no connect. When the programming signal via Vprog is either a no connect or > 3Vdc, it is ignored, the output voltage is set at its nominal 12Vdc and the unit output voltage can be controlled via the PMBus command, (Vout_command). Analog controls: Details of analog controls are provided in this data sheet under Signal Definitions. Common ground: All signals and outputs are referenced to Output return. These include ‘Vstb return’ and ‘Signal return’. Control Signals Voltage programming (Vprog): An analog voltage on this signal can vary the output voltage from 43.2Vdc to 56Vdc. The equation of this signal is: Vout = 42.67 + (Vprog * 5.33) where Vprog = 0.1 to 2.5V For Vprog > 2.5V the output reverts back to 48Vdc. Input_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. DC_OK: A TTL compatible status signal representing whether the output voltage is present. This signal needs to be pulled HI externally through a resistor. 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. If an over temperature should occur, this signal would pull LO 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. This signal activates for OTP, OVP, OCP, INPUT 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. 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. 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. Able to current share with CAR2548FP rectifiers. 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. Remote_ON/OFF: Controls presence of the 48Vdc output voltage. This is an open collector, TTL level control signal that needs to be pulled HI externally through a resistor. A turn OFF command either through this signal (Remote ON/OFF) or firmware commanded would turn OFF the 48V output. Enable: This is a short signal pin that controls the presence of the 48Vdc 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. Status signals Output current monitor (Imon): A voltage level proportional to the delivered output current is present on this pin. The signal level is 0.1V per amp ± 0.25V. December 6, 2013 Serial Bus Communications All signals are referenced to ‘Signal Return’. Device addressing: The microcontroller (MCU) and the EEPROM have the following addresses: Device MCU Broadcast EEPROM Address 0xBx 0x00 0xAx 1 0 1 Address Bit Assignments (Most to Least Significant) 0 1 1 A2 A1 A0 R/W 0 0 0 0 0 0 0 0 1 0 A2 A1 A0 R/W The Global Broadcast instruction executes a simultaneous write instruction to all power supplies. A read instruction cannot be accessed globally. The three programmable address bits are the same for all I2C accessible devices within the power supply. 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 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 ©2013 General Electric Company. All rights reserved. Page 7 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A 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 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. Digital Feature Descriptions PMBus™ compliance: The power supply is fully compliant to the Power Management Bus (PMBus™) rev1.2 requirements. Manufacturer specific commands located between addresses 0xD0 to 0xEF provide instructions that either do not exist in the general PMBus specification or make the communication interface simpler and more efficient. Master/Slave: The ‘host controller’ is always the MASTER. Power supplies are always SLAVES. SLAVES cannot initiate communications or toggle the Clock. SLAVES also must respond expeditiously at the command of the MASTER as required by the clock pulses generated by the MASTER. Clock stretching: The ‘slave’ µController inside the power supply may initiate clock stretching if it is busy and it desires to delay the initiation of any further communications. During the clock stretch the ‘slave’ may keep the clock LO until it is ready to receive further instructions from the host controller. The maximum clock stretch interval is 25ms. The host controller needs to recognize this clock stretching, and refrain from issuing the next clock signal, until the clock line is released, or it needs to delay the next clock pulse beyond the clock stretch interval of the power supply. Note that clock stretching can only be performed after completion of transmission of the 9th ACK bit, the exception being the START command. PEC is a CRC-8 error-checking byte, based on the polynomial C(x) = x8 + x2 + x + 1, in compliance with PMBus™ requirements. The calculation is based in all message bytes, including the originating write address and command bytes preceding read instructions. The PEC is appended to the message by the device that supplied the last byte. SMBAlert#: The µC driven SMBAlert# signal informs the ‘master/host’ controller that either a STATE or ALARM change has occurred. Normally this signal is HI. The signal will change to its LO level if the power supply has changed states and the signal will be latched LO until the power supply either receives a ‘clear’ instruction as outlined below or executes a READ STATUS_WORD. If the alarm state is still present after the STATUS registers were reset, then the signal will revert back into its LO state again and will latch until a subsequent reset signal is received from the host controller. The signal will be triggered for any state change, including the following conditions; The power supply will clear the SMBusAlert# signal (release the signal to its HI state) upon the following events: Clock Stretch Figure 1. Example waveforms showing clock stretching. I²C Bus Lock-Up detection: The device will abort any transaction and drop off the bus if it detects the bus being held low for more than 35ms. Communications speed: Both 100kHz and 400kHz clock rates are supported. The power supplies default to the 100kHz clock rate. The minimum clock speed specified by SMBus is 10 kHz. Packet Error Checking (PEC): Although the power supply will respond to commands with or without the trailing PEC, it is highly recommended that PEC be used in all communications. The integrity of communications is compromised if packet error correction is not employed. There are many functional features, including turning OFF the main output, that should require validation to ensure that the correct command is executed. December 6, 2013 VIN under or over voltage Vout under or over voltage IOUT over current Over Temperature warning or fault Fan Failure Communication error PEC error Invalid command Detected internal faults Receiving a CLEAR_FAULTS command The main output recycled (turned OFF and then ON) via the ENABLE signal pin The main output recycled (turned OFF and then ON) by the OPERATION command Execution of a READ of the STATUS_WORD register Global broadcast: This is a powerful command because it can instruct all power supplies to respond simultaneously in one command. But it does have a serious disadvantage. Only a single power supply needs to pull down the ninth acknowledge bit. To be certain that each power supply responded to the global instruction, a READ instruction should be executed to each power supply to verify that the command properly executed. The GLOBAL BROADCAST command should only be executed for write instructions to slave devices. Read back delay: The power supply issues the SMBAlert # notification as soon as the first state change occurred. During an event a number of different states can be transitioned to before the final event occurs. If a read back is implemented rapidly by the host a successive SMBAlert# could be triggered by the transitioning state of the power supply. In order to avoid successive SMBAlert# s and read back and also to avoid reading a transitioning state, it is prudent to wait more than 2 seconds after the receipt of an SMBAlert# before executing a read back. This delay will ensure that only the final state of the power supply is captured. Successive read backs: Successive read backs to the power supply should not be attempted at intervals faster than every one second. This time interval is sufficient for the internal ©2013 General Electric Company. All rights reserved. Page 8 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A processors to update their data base so that successive reads provide fresh data. PMBusTM Commands Standard instruction: Up to two bytes of data may follow an instruction depending on the required data content. Analog data is always transmitted as LSB followed by MSB. PEC is optional and includes the address and data fields. 1 S 8 Slave address 8 Low data byte 1 A Wr 1 A 8 Command Code 8 High data byte 1 A Block read format: 1 S 7 Slave address 1 Sr 8 ………. 1 A Standard READ: Up to two bytes of data may follow a READ request depending on the required data content. Analog data is always transmitted as LSB followed by MSB. PEC is mandatory and includes the address and data fields. PEC is optional and includes the address and data fields. 1 Sr 1 Wr 7 Slave Address 8 MSB 1 Rd 1 A 1 A 8 Command Code 1 A 8 LSB 8 PEC 1 A 1 A 8 Byte count = N 8 ………. 1 Wr 1 A 1 A 8 Data 1 8 Data 48 1 A 1 No-ack 1 P 8 Command Code 1 A 8 Data 2 1 A 8 PEC 8 Data 1 8 Data 48 1 A 1 A 8 Data 2 1 A 8 PEC 1 NoAck 1 P The Linear Data Format is a two byte value with an 11-bit, two’s complement mantissa and a 5-bit, two’s complement exponent or scaling factor, its format is shown below. Data Byte High 6 5 4 3 2 Exponent (E) 1 0 7 Data Byte Low 6 5 4 3 2 Mantissa (M) 1 0 Where: V is the value, M is the 11-bit, two’s omplement mantissa, E is the 5-bit, two’s complement exponent 1 A 1 A 1 A 1 P PMBusTM Command set: Command Operation ON_OFF_config Clear_faults Write_protect Store_default_all Restore_default_all Capability Vout_mode Vout_command Vout_OV_fault_limit Vout_OV_fault_response Vout_OV_warn_limit Vout_UV_warn_limit Vout_UV_fault_limit Vout_UV_fault_response Iout_OC_fault_limit Iout_OC_fault_response Iout_OC_warn_limit OT_fault_limit OT_fault_response OT_warn_limit UT_warn_limit UT_fault_limit UT_fault_response December 6, 2013 1 A V M 2E Block write format: 7 Slave address 1 A The relationship between the Mantissa, Exponent, and Actual Value (V) is given by the following equation: Block communications: When writing or reading more than two bytes of data at a time BLOCK instructions for WRITE and READ commands must be used instead of the Standard Instructions Error! Reference source not found. write any number of bytes greater than two. 1 S 8 Command Code Linear Data Format The definition is identical to Part II of the PMBus Specification. All standard PMBus values, with the exception of output voltage related functions, are represented by the linear format described below. Output voltage functions are represented by a 16 bit mantissa. Output voltage has a E=9 constant exponent. Bit 7 7 Slave address 1 Rd 1 A 1 A 1 A 1 P Master to Slave Slave to Master SMBUS annotations; S – Start , Wr – Write, Sr – re-Start, Rd – Read, A – Acknowledge, NA – not-acknowledged, P – Stop 1 S 7 Slave Address 8 Byte count = N 1 A 8 PEC 1 Wr ©2013 General Electric Company. All rights reserved. Hex Code 01 02 03 10 11 12 19 20 21 40 41 42 43 44 45 46 47 4A 4F 50 51 52 53 54 Data Byte 1 1 0 1 0 0 1 1 2 2 1 2 2 2 1 2 1 2 2 1 2 2 2 1 Function Output ON/OFF 09, output ON default Clear Status Write control Store permanently Reset defaults 30h, 400kHz, SMBAlert Vout constants Set Vout Set OV fault limit Set OV warn limit Set UV warn limit Latch or hiccup Set OC warn limit Latch or hiccup Set OT warn limit Page 9 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Hex Code 55 57 58 59 78 79 7A 7B 7C 7D 7E 7F 80 81 8B 8C 8D 96 98 99 9A 9B 9C 9D 9E A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 B0 B1 D0 D3 D4 D6 D7 D8 E0 E1 E2 Data Field 2 2 2 2 1 2 1 1 1 1 1 1 1 1 2 2 2 2 1 5 15 4 4 6 15 2 2 2 2 2 2 2 2 2 2 48 48 1 2 2 1 1 2 2 2 2 CMD_OFF_ I2C OTF_limit_ I2C E3 E4 2 2 OTF_recovery_ I2C E5 2 DCOKHI_ I2C DCOKLO_ I2C E6 E7 2 2 Command Vin_OV_fault_limit Vin_OV_warn_limit Vin_UV_warn_limit Vin_UV_fault_limit Status_byte Status_word Status_Vout Status_Iout Status_input Status_temperature Status_CML Status_other Status_mfr_specific Status_fan_1_2 Read_Vout Read_Iout Read_temperature Read_Pout PMBus revision Mfr_ID Mfr_model Mfr_revision Mfr_location Mfr_date Mfr_serial Mfr_Vin_min Mfr_Vin_max Mfr_Iin_max Mfr_Pin_max Mfr_Vout_min Mfr_Vout_max Mfr_Iout_max Mfr_Pout_max Mfr_Tambient_max Mfr_Tambient_min User_data_00 User_data_01 FRW_revision Ilimit_control_I2C Vout_control_ I2C Fan_duty_cycle Fan_speed Vprog_ext Read_Vout_ I2C Read_Iout_ I2C Read_TS_ I2C December 6, 2013 Function Set OV warn limit Set UV warn limit Set UV shutdown Status Register Bit Allocation: Register Code Status_Byte 78 Bit 7 6 5 4 3 2 1 Read output voltage Read output current Read Temperature 0 7 6 5 4 Status_word (includes Status_byte) 79 FRU_ID 36V (linear format) 75V (linear format) 27A (linear format) 950W (linear format) 10V (linear format) 15V (linear format) 71A (linear format) 850W (linear format) 70C (linear format) -10C (linear format) User memory space User memory space Ilimit set (1/100A) Vout set (1/512V) Duty_cycle in % Control in duty cycle Status_Vout 7A Status_Iout 7B Status_input 7C Status_temperature 7D 1/512V 1/100A Heat sink temp C 01-OFF, 00-ON OT fault limit C OT fault recovery C High OV fault (1/512V) Low OV fault (1/512V) ©2013 General Electric Company. All rights reserved. 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 Function Busy DC_ OFF Output OV Fault detected Output OC Fault detected Input UV Fault detected Temperature Fault/warning detected CML (communication fault) detected None of Below OV Fault/Warning detected OC Fault/Warning detected Input Fault/Warning detected Mfr_specific register change detected DC_OFF Fan Fault or Warning detected Other fault Unknown Vout OV Fault Vout OV Warning Vout UV Warning Vout UV Fault N/A N/A N/A N/A IOUT OC Fault N/A IOUT OC Warning N/A N/A N/A N/A N/A Vin OV Fault Vin OV Warning Vin UV Warning Vin UV Fault N/A N/A N/A N/A OT Fault OT Warning N/A N/A N/A N/A N/A N /A Page 10 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Register Code Bit 7 Status_cml Status_mfr_specif ic 7E 80 Function 6 5 4 3 2 1 0 Invalid/Unsupported Command Invalid/Unsupported Data Packet Error Check Failed Memory Fault Detected Processor Fault Detected Reserved Other Communications Fault Other Memory or Logic Fault 7 6 5 4 3 2 1 0 3.3V_fault N/A Interrupt Fault detected PS_remote_OFF DC_fault INPUT_fault N/A Command Descriptions Operation (01) : By default the Power supply is turned ON at power up as long as Power ON/OFF signal pin is active HI. The Operation command is used to turn the Power Supply ON or OFF via the PMBus. The data byte below follows the OPERATION command. FUNCTION Unit ON Unit OFF DATA BYTE 80 00 To RESET the power supply cycle the power supply OFF, wait at least 2 seconds, and then turn back ON. All alarms and shutdowns are cleared during a restart. Clear_faults (03): This command clears all STATUS and FAULT registers and resets the SMBAlert# line. If a fault still persists after the issuance of the clear_faults command the specific registers indicating the fault are reset and the SMBAlert# line is activated again. WRITE_PROTECT register (10): Used to control writing to the PMBus device. The intent of this command is to provide protection against accidental changes. All supported command parameters may have their parameters read, regardless of the write_protect settings. The contents of this register can be stored to non-volatile memory using the Store_default_code command. The default setting of this register is disable_all_writes except write_protect 0x80h. FUNCTION Enable all writes Disable all writes except write_protect Disable all writes except write_protect and OPERATION DATA BYTE 00 80 40 Vout_Command (21) : This command is used to change the output voltage of the power supply. Changing the output voltage should be performed simultaneously to all power supplies operating in parallel using the Global Address (Broadcast) feature. If only a single power supply is instructed to change its output, it may attempt to source all the required power which can cause either a power limit or shutdown condition. December 6, 2013 Software programming of output voltage permanently overrides the set point voltage configured by the Vprog signal pin. The program no longer looks at the ‘Vprog pin’ and will not respond to any hardware voltage settings. If power is removed from the µController it will reset itself into its default configuration looking at the Vprog signal for output voltage control. In many applications, the Vprog pin is used for setting initial conditions, if different that the factory setting. Software programming then takes over once I2C communications are established. To properly hot-plug a power supply into a live backplane, the system generated voltage should get re-configured into either the factory adjusted firmware level or the voltage level reconfigured by the margin pin. Otherwise, the voltage state of the plugged in power supply could be significantly different than the powered system. Vout_OV_warn_limit (42): OV_warning is extremely useful because it gives the system controller a heads up that the output voltage is drifting out of regulation and the power supply is close to shutting down. Pre-amative action may be taken before the power supply would shut down and potentially disable the system. OC and OT_fault_ response (47, 50): The default response for both OC and OT is auto_restart (hiccup). Each register, individually, can be reconfigured into a latched state. Latched and hiccup are the only supported states. Restart after a latch off: Either of four restart possibilities are available. The hardware pin Remote ON/OFF may be turned OFF and then ON. The unit may be commanded to restart via i2c through the Operation command by first turning OFF then turning ON . The third way to restart is to remove and reinsert the unit. The fourth way is to turn OFF and then turn ON ac power to the unit. The fifth way is by changing firmware from latch off to restart. Each of these commands must keep the power supply in the OFF state for at least 2 seconds, with the exception of changing to restart. A power system that is comprised of a number of power supplies could have difficulty restarting after a shutdown event because of the non-synchronized behavior of the individual power supplies. Implementing the latch-off mechanism permits a synchronized restart that guarantees the simultaneous restart of the entire system. A synchronous restart can be implemented by; 1. Issuing a GLOBAL OFF and then ON command to all power supplies, 2. Toggling Off and then ON the Remote ON/OFF signal 3. Removing and reapplying input commercial power to the entire system. The power supplies should be turned OFF for at least 20 – 30 seconds in order to discharge all internal bias supplies and reset the soft start circuitry of the individual power supplies. Auto_restart: Auto-restart is the default configuration for recovering from over-current and over-temperature shutdowns. An overvoltage shutdown is followed by three attempted restarts, each restart delayed 1 second, within a 1 minute window. If within the 1 minute window three attempted restarts failed, the unit will latch OFF. If less than 3 shutdowns occur within the 1 minute window then the count for latch OFF resets and the 1 minute window starts all over again. ©2013 General Electric Company. All rights reserved. Page 11 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Vin_UV_warn_limit (58): This is another warning flag indicating that the input voltage is decreasing dangerously close to the low input voltage shutdown level. Status_word (79): returns two bytes of information. The upper byte bit functionality is tabulated in the Status_word section. The lower byte bit functionality is identical to Status_byte. Fan_speed (D7): This register can be used to ‘read’ the fan speed in adjustment percent (0 – 100%) or set the fan speed in adjustment percent (0 – 100%). The speed of the fan cannot be reduced below what the power supply requires for its operation. The register value is the percent number, it is not in linear format. Invalid commands or data: The power supply notifies the MASTER if a non-supported command has been sent or invalid data has been received. Notification is implemented by setting the appropriate STATUS and ALARM registers and setting the SMBAlert# flag. If a non-supported read is requested the power supply will return all 0x00h. Restart after a lachoff: To restart after a latch_off either of four restart mechanisms are available. The hardware pin Remote ON/OFF may be turned OFF and then ON. The unit may be commanded to restart via i2c through the Operation command by first turning OFF then turning ON . The third way to restart is to remove and reinsert the unit. The fourth way is to turn OFF and then turn ON ac power to the unit. The fifth way is by changing firmware from latch off to restart. Each of these commands must keep the power supply in the OFF state for at least 2 seconds, with the exception of changing to restart. A successful restart shall clear all alarm registers. A power system that is comprised of a number of power supplies could have difficulty restarting after a shutdown event because of the non-synchronized behavior of the individual power supplies. Implementing the latch-off mechanism permits a synchronized restart that guarantees the simultaneous restart of the entire system. A synchronous restart can be implemented by; 1. Issuing a GLOBAL OFF and then ON command to all power supplies, 2. Toggling Off and then ON the Remote ON/OFF signal 3. Removing and reapplying input commercial power to the entire system. Control and Read accuracy: The estimates below are believed to be reasonable under most operating conditions. However, these are typical numbers and not hard bound values that cannot be exceeded. In most nominal operating conditions the returned values are significantly better than these estimates. FUNCTION Vout_command Vout_OV_fault_limit Iout_OC_warn_limit OT_warn_limit Vin_UV_warn_limit Vin_UV_fault_limit Read_Vout Read_Iout Read_temperature Read_Pout ACCURACY ± 2% ± 3% ± 4% of FL ± 5C ± 3% ± 3% ± 2% ± 4% of FL ± 5C ±5% EEPROM The microcontroller has 96 bytes of EEPROM memory available for the system host. A separate EEPROM IC, with write protect features, provides another 128 bytes of memory. This EEPROM contains the following FRU_ID information: EEPROM: model number, revision, date code, serial number etc. Offset Length Value 00 7 07 1 20 08 4 0C 1 20 0D 17 1E 1 20 1F 1 20-FF 224 FF Description Serial number ASCII space Date code [YY,WW], ASCII numeric value ASCII space Model#, ASCII alphanumeric value ASCII space Revision, ASCII value LEDs Three LEDs are located on the front faceplate. When the LEDs are ON GREEN then input and output are normal. When the FAULT_LED is RED then a fault condition exists and the power supply may not provide output power. The table below further defines these states: It is good practice to turn OFF the power supplies for about 20 – 30 seconds in order to discharge all internal bias supplies and reset the soft start circuitry of the individual power supplies. December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 12 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Alarm Table LED Indicator Test Condition DC OK FAULT FAULT DC OK INPUT OK TEMP OK Green OFF OFF Red High Low High Low High Low High High OFF Red Low Low High High OFF Green Red Low Low High High Red Low High High Low OFF Red Low Low High Low 3 OVP Green OFF Green 4 Over Current Green 5 Over Temp Alarm Green Green 1 2 6 Normal Operation Low or NO INPUT Over Temp Fault Monitoring Signals INPUT OK Note: Test condition #2 has 2 modules working in parallel. One module is running and the other has no iNPUT. Outline Drawing #10-32 GROUND STUD AIR INLET HANDLE INPUT CONNECTOR GREEN LED (INPUT-OK) GREEN LED (DC-OK) 1.250 RED LED (FAULT) 0.494 Input connector: FCI Berg 51939-311 or TYCO 6450129-3 Output connector: FCI Berg 51939-030 Input mate: FCI Berg 10080594-1E0101LF10 Output mate: FCI Berg 51915-051 0.50 14.250 ±.020 4.000 ±.020 POT ADJ. 0.330 Airflow COVER 1.610 ±.020 CHASSIS 10 This is a cable harness with 10 foot of #10ga stranded wire (2 – black and 2 – red) not-terminated on user end December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 13 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Connector Pin Assignments Input Pin P1 P2 Function - DC input - DC input Pin P3 P4 Function + DC input + DC input Output Pin Function Pin Function Pin Function Pin Function A1 Vstb [3.3V] B1 Fault C1 ISHARE D1 VProg A2 Vstb [3.3V] Return B2 I Monitor (IMON) C2 N/C D2 OVP Test Point A3 Signal Return B3 PS Present C3 Over Temp Warning D3 Remote ON/OFF A4 Write Protect (WP) B4 Enable C4 I2C Address (A0) D4 DC OK A5 Remote Sense (+) B5 SDA (I2C bus) C5 I2C Address (A1) D5 INPUT OK A6 Remote Sense (-) B6 SCL (I2C bus) C6 I2C Address (A2) D6 SMBAlert P1 N/C P2 N/C P3 N/C P4 +Vout P5 +Vout P6 Output Return P7 Output Return December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 14 GE Data Sheet CAR2548DC series dc-dc converters Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. PRODUCT DESCRIPTION PART NUMBER 2500W converter 48Vdc dc-dc converter w/Bezel, 3.3Vaux CAR2548DCXXXZ01A 10KW SHELF Shelf for CAR2548 modules holds 4 units ACE254RUW48XZ01A PART NUMBER DEFINITION GUIDE EXAMPLE CAR 25 48 DC Output Power 25 = 2500W Output voltage 48 = 48Vdc Type FP – AC; Vo-positive TN – AC; Vo_negative DC - DC x x x Options B – bezel R – reverse airflow Vsb = 5 Z 01 A A – Standard model RTM RoHS Blank – non compliant Y – 5 of 6 compliant Z – 6 of 6 compliant Contact Us For more information, call us at 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 December 6, 2013 ©2013 General Electric Company. All rights reserved. Page 15