GE Industrial Solutions CAR2024FP User Manual

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24Vdc @ 83A; 3.3Vdc or 5 Vdc @ 1A

Features

 Universal input with PFC

 Constant power characteristic

 3 front panel LEDs: input, output, fault

 Remote ON/OFF control of the 24Vdc output

 Remote sense on the 24Vdc output

 No minimum load requirements

 Redundant parallel operation

 Active load sharing (single wire)

 Hot Plug-ability

Applications



24Vdc distributed power architectures



Telecom Base Stations



Mid to high-end Servers



Enterprise Networking



Network Attached Storage



Telecom Access Nodes



Routers/Switches



Broadband Switches

 Efficiency: typically 90% @ 50% load

 Standby orderable either as 3.3Vdc or 5Vdc

 Auto recoverable OC & OT protection

 Operating temperature: -10 - 70C (de-rated above

50C)

 Digital status & control: I

 EN/IEC/UL60950-1 2nd edition; UL, CSA and VDE

 EMI: class A FCC docket 20780 part 15, EN55022

 Meets EN6100 immunity and transient standards

 Shock & vibration: NEBS GR-63-CORE, level 3

Data Sheet

2

C and PMBus serial bus



ATE Equipment

Description

The CAR2024FP series of Front-End rectifiers provide highly efficient isolated 2000 watts @ 24Vdc power from
worldwide input mains in a compact 1U industry standard form factor in an unprecedented power density of 21W/in
These rectifiers are ideal for either datacom or telecom applications such as enterprise networking, remote base
stations, 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

2

growth. The industry standard PMBus compliant I

C 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.

March 28, 2013 ©2012 General Electric Company. All rights reserved.

3

.

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24 Vdc @ 83A; 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 Device Symbol Min Max Unit

Input Voltage: Continuous All VIN 0 264 Vac

Operating Ambient Temperature All TA -10 701 °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 Device Symbol Min Typ Max Unit

Operational Range All VIN 90 110/230 264 Vac

F

Frequency Range (ETSI 300-132-1 recommendation) All

Main Output Turn_OFF All

Maximum Input Current VIN= 100Vac

(VO= V

, IO=I

O, set

) VIN= 180Vac

O, max

Cold Start Inrush Current

(Excluding x-caps, 25C, <10ms, per ETSI 300-132)

All I

All I

IN

V

IN

IN

IN

Efficiency 100% load
(T

=25C, Vin = 230Vac, V

amb

= 24Vdc, IO=I

out

) 50% load

O, max

All



20% load
Power Factor (Vin=230Vac, IO=I

O, max

Holdup time2 Vin= 220Vac
(Vout= 24V

, Tamb 25C, IO=I

dc

) Vin= 100Vac

O, max

Early warning prior to loss of DC output below regulation

Ride through

Leakage Current (Vin= 250Vac, Fin = 60Hz)

All

)

PF 0.99

All T

All

All

All

3 ms

T 10 ms

I

IN

Isolation Input/Output

Input/Frame 1500 V

All

Output/Frame 100 V

24Vdc MAIN OUTPUT

Parameter Device Symbol Min Typ Max Unit

Output Power HL / LL [180 – 264 / 90-132 Vac] V

V
Set point All
Overall regulation (load, temperature, aging)
Ripple and noise3
Turn-ON overshoot
Turn-ON delay

≥ 24V

dc

dc

= 21Vdc 0 - 1743/1050 W

dc

All W

All

V

All

out

All
All

T 2 sec

47 50/60 63 Hz

85 V

14.3

12.6

40 A

Aac

peak

ac

90
90

%

84

15
15

ms

3 mArms

3000 V

0 - 2000/1200 W

23.976 24.00 24.024 V

ac

ac

dc

dc

-3 +3 %
240

mV

p-p

+3 %

1

Derated above 50C at 2.5%/C

2

24V output can decay down to 20V

3

Measured across a 10µf electrolytic and a 0.1µf ceramic capacitors in parallel. 20MHz bandwidth

March 28, 2013 ©2012 General Electric Company. All rights reserved. Page 2

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24Vdc @ 83A; 3.3Vdc or 5 Vdc @ 1A

24Vdc MAIN OUTPUT (continued)

Parameter Device Symbol Min Typ Max Unit

Remote ON/OFF delay time
Turn-ON rise time (10 – 90% of V

)

out

Transient response 50% step [10%-60%, 50% - 100%]
(dI/dt – 1A/

µs, recovery 300µs)

out

Programmable range (hardware & software)
Overvoltage protection, latched

All
All
All

All
All

V

out

(recovery by cycling OFF/ON via hardware or software)
Output current Vin = HL

V

= LL

in

Current limit, Hiccup (programmable level)
Active current share

All

All
All

I

out

AUXILIARY OUTPUT

Parameter Device Symbol Min Typ Max Unit

Set point All V

Overall regulation (load, temperature, aging) All V

Ripple and noise All 50 mVp-p

Output current All I
Overload protection -
Overvoltage protection
Isolation Output/Frame All 100

3.3 / 5.0 V

out

-5 +5 %

out

out

Environmental, Reliability

Parameter Min Typ Max Units Notes

Ambient Temperature
Operating
Altitude Operating
Power Derating

Storage
Altitude non-operating

Acoustic noise 55 dbA Full load

Over-temperature Protection 125/110 °C Shutdown / restart

Humidity Operating
Storage

Shock and Vibration acceleration 6 Grms NEBS GR-63-CORE, Level 3, 20 -2000Hz, min 30 minutes

Earthquake Rating 4

Reliability 400,000

Service Life 10 Yrs Full load, excluding fans

4

-10

-40

30

2250/7.4k

8200/30k

95

10

50

2.5

2.0

85

95

°C
m / ft
%/°C

C/1000 ft

°C

Air inlet from sea level to 5,000 feet.

51°C to 70C
Above 5,000 ft

m / ft

%

Zone

Hrs

Relative humidity, non-condensing

NEBS GR-63-CORE, all floors, Seismic Zone 4 Designed
and tested to meet NEBS specifications.

Full load, 25C ; MTBF per SR232 Reliability protection
for electronic equipment, method I, case III,

40 ms
60 ms

-5 +5 %V

21 29

30 31 32

0

83
50

out

V

dc

V

dc

A

dc

110 130 % of FL

-5 +5 % of FL

dc

0 1 A

dc

V

dc

4

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.

March 28, 2013 ©2012 General Electric Company. All rights reserved. Page 3

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24 Vdc @ 83A; 3.3Vdc or 5 Vdc @ 1A

EMC

Parameter Criteria Standard Level Test

AC input Conducted emissions EN55022, FCC Docket 20780 part 15, subpart J

EN61000-3-2

Radiated emissions EN55022 A 30 – 10000MHz

Voltage dips EN61000-4-11 A -30%, 10ms

B -60%, 100ms

B -100%, 5sec

Voltage surge EN61000-4-5 A 4kV, 1.2/50µs, common mode

A 2kV, 1.2/50µs, differential mode

immunity Fast transients EN61000-4-4 B 5/50ns, 2kV (common mode)

Enclosure 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

ESD EN61000-4-2 B 4kV contact, 8kV air

A 0.15 – 30MHz

0 – 2 KHz

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 i

2

C

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 (V

signal can vary the output voltage ± 10% from 21Vdc to
29Vdc. The equation of this signal is:

V

= 21 + (V

out

* 3.2) 0 < V

prog

If 2.5 < Vprog < 3, the output is 29V. If Vprog is > 3V or
left open the programming signal is ignored and the unit
output is set at the setpoint of 24Vdc.

): An analog voltage on this

prog

< 2.5

prog

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

24Vdc 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 24Vdc output, while a Logic
0 (TTL LO level) turns OFF the 24Vdc output.

A turn OFF command either through this signal (Remote
ON/OFF) or firmware commanded would turn OFF the
24V output.

Enable: This is a short signal pin that controls the

presence of the 24Vdc 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.

Output signals

Output current monitor (Imon): A voltage level of

0.1V/Amp proportional to the delivered output current is
present on this pin. Accuracy: ± 500mV for loads > 25%
FL.

March 28, 2013 ©2012 General Electric Company. All rights reserved. Page 4

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24Vdc @ 83A; 3.3Vdc or 5 Vdc @ 1A

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 ≤ 4mA 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 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 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 ≤ 4mA 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 i
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.

2

C protocol in the power supply. This signal

Serial Bus Communications

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:

Device Address Address Bit Assignments

MCU 0xBx 1 0 1 1 A2 A1 A0 R/W
EEPROM 0xAx 1 0 1 0 A2 A1 A0 R/W

(Most to Least Significant)

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 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.

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 following I²C protocol commands are not supported:

FAN1_SPEED_ I²C, FAN2_SPEED_ I²C

VIN_ I²C, IIN_ I²C, PIN_ I²C

The following PMBus protocol commands are not
supported:

FAN_COMMAND_1 0 x 21

STATUS_FAN_1_2 0 x 81

READ_VIN 0 x 88

READ_IIN 0 x 89

READ_FAN_SPEED_1 0 x 90

READ_FAN_SPEED_2 0 x 91

READ_PIN 0 x A3

The STAUS_MFR_SPECIFIC (Register 0 x 80) has a bit
changed;

Bit 5 0 = interrupt, 1 = no interrupt

March 28, 2013 ©2012 General Electric Company. All rights reserved. Page 5

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24 Vdc @ 83A; 3.3Vdc or 5 Vdc @ 1A

LEDs

Three LEDs are located on the front faceplate. The AC
LED provides visual indication of the INPUT signal
function. When the LED is ON GREEN the power supply
input is within normal design limits.

Alarm Table

LED Indicator Monitoring Signals

Test Condition

1 Normal Operation
2 Low or NO INPUT OFF OFF
3 OVP
4 Over Current
5 Over Temp Alarm
6 Over Temp Fault
7 Remote ON/OFF, OFF

Note: Test condition #2 had 2 modules plug in. One module is running and the other one is with no AC.

AC OK DC OK FAULT FAULT DC OK INPUT OK TEMP OK

Green Green

Green
Green
Green Green
Green
Green

OFF
OFF

OFF
OFF

The second LED DC provides visual indication when the
output is ON. When the LED is GREEN then the DC
output is present.

The third LED FLT provides visual indication when a fault
is present. When the LED is RED then a fault condition
exists and the power supply does not provide output
power.

OFF High High High High

Red

Red

Red

OFF High High High Low

Red

Red

Low Low Low High
Low Low High High
Low Low High High

Low Low High Low
Low Low High High

Outline Drawing

March 28, 2013 ©2012 General Electric Company. All rights reserved. Page 6

GE Energy

CAR2024FP series rectifier

Input: 90Vac to 264Vac; Output: 24Vdc @ 83A; 3.3Vdc or 5 Vdc @ 1A

Connector Pin Assignments

Mating Connector: Molex P/N 87663-4002 or equivalent

Mating connector: Molex P/N 87664-2001

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 N/C 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 Return C4 I2C Address (A0) D4 DC OK

A5 Remote Sense (+) B5 SDA (I2C bus) C5 I2C Address (A1) D5 AC OK

A6 Remote Sense (-) B6 SCL (I2C bus) C6 I2C Address (A2) D6 SMBAlert

P1 Line P2 Neutral P3 Frame

P4 – P6 +24Vdc P7 – P9 Return

Ordering Information

Please contact your GE Energy Sales Representative for pricing, availability and optional features.

PRODUCT DESCRIPTION PART NUMBER

2000W Front-End +24Vout Front-End, 3.3Vaux, with face plate and PMBus interface CAR2024FPB-Z01A

Contact Us

For more information, call us at

USA/Canada:

[phone], or [phone]

Asia-Pacific:

+86.021.54279977*808

Europe, Middle-East and Africa:

+49.89.878067-280

India:

+91.80.28411633

March 28, 2013 ©2012 General Electric Company. All rights reserved. Page 7

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