GE Industrial Solutions CAR2548DC User Manual

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Page 1

CAR2548DC series dc-dc converter

Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A

Applications



48Vdc distributed power architectures

 Cellular Base Stations  Satellite Hubs  Network Equipment  Network Attached Storage  Telecom Access Nodes  Routers/Switches/ATE Equipment

Features

 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 - 70C

(de-rated above 50C)

 Digital status & control: I  EN/IEC/UL60950-1 2  EMI: class B FCC docket 20780 part 15, EN55022  Meets EN6100 immunity and transient standards  Shock & vibration: NEBS GR-63-CORE, level 3

Data Sheet

C and PMBus serial bus

edition; UL, CSA and VDE

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/in 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 I

C 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)

. These converters

Page 2

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 T

I/O Isolation voltage (100% factory Hi-Pot tested) 1500 VDC

Electrical Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, load, and temperature conditions.

INPUT

Parameter Symbol Min Typ Max Unit

Operational Range

48Vdc output turned ON -42 -45 -48 Idling Power, 48Vdc output OFF 48Vdc output ON 45 Maximum Input Current (VIN= 37.5Vdc, VO= V Cold Start Inrush Current (Excluding x-caps, 25C, <10ms,

per ETSI 300-132) Efficiency (T

=25C, Vin= -48Vdc, V

amb

= 48Vdc); 100% load

out

30 – 50% load 20% load

Holdup time2 (Vin= -48Vdc, V

= 48Vdc, T

out

25C, IO=I

amb

Loss of Output Early Warning Signal T 1 ms Isolation; Input/Output Input/Frame 1500 Output/Frame 1000 Input capacitance F 25 µf

48VDC MAIN OUTPUT

Parameter Symbol Min Typ Max Unit

Output power P Set point, @ 50% load Overall regulation (load, temperature, aging) -2 +2 % Linear droop, NL to FL 0.1 VDC Remote sense (sum of hot & return) 0.25 VDC Ripple and noise3 500 mV

O, set

, IO=I

O, max

)

) I

-40 85 °C

stg

-36 -48/60 -75

75 ADC

75 A

VDC 48Vdc output turned OFF -36

PEAK



T 4 ms

1500 V

OUT

0 2500 W

47.5 48.00 48.5 V

OUT

p-p

Derated above 50C at 2.5%/C

Full load w/5,000µf external output capacitance, Output may droop down to 44Vdc.

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

Page 3

Data Sheet

CAR2548DC series dc-dc converters

Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A

48V

MAIN OUTPUT (continued)

Parameter Symbol Min Typ Max Unit

Turn-ON overshoot Turn-ON delay Remote ON/OFF delay time 40 ms Turn-ON rise time (10 – 90% of V

) 50 ms

OUT

Transient response 50% step [10%-60%, 50% - 100%] (dI/dt – 1A/µs, recovery 300µs)

Programmable range (hardware & software) 43.2 56 V Overvoltage protection, latched4

(recover by cycling OFF/ON via hardware or software) Output current, V Power limit, V

= 48Vdc I

out

= 48 to 56V

out

Current limit, Hiccup (programmable level) Active current share -5 +5 % of FL External capacitance 0 5,0005 µf

STANDBY OUTPUT

Parameter Symbol Min Typ Max Unit

Set point V Overall regulation (load, temperature, aging) V

Ripple and noise 50 mVp-p

Output current I

OUT

3 % 2 sec

-2 +2 V

OUT

58 59 60 V

OUT

2500 W

OUT

0 52 A

105 130 % of FL

OUT

3.3 / 5.0 V

out

-5 +5 %

out

0 1 A

General Specifications

Parameter Min Typ Max Units Notes

Reliability, at 25C 50C

250,000 100,000

Hrs

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

Service Life 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

Remote ON/OFF (Needs to be pulled HI via an external resistor) Logic High (Module ON) I

Logic Low (Module OFF) I

The power supply will attempt three restarts prior to latching the shutdown level.

4,000µf electrolytic and 1,000µf tantalum capacitors

0.7V

 



20 µA 12 V

1 mA

0.8 VDC

Page 4



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

Output Voltage programming (Vprog) Equation: Vout = 10.8 + (Vprog * 0.96) Vprog range V Programmed output voltage range Vo

prog

Voltage adjustment resolution (8-bit A/D) Vo Output configured to 13.2Vdc V Output configured to the 12Vdc set-point V

2.5 3.0 VDC

prog

Enable [short pin controlling presence of the 12VDC output] 12V output OFF VI 12V output ON VI Write protect (Wp) Write protect enabled VI

Write protect disabled V

INPUT-OK (Needs to be pulled HI via an external resistor) Logic High (Input within normal range) I

Logic Low (Input out of range) I

DC-OK ( Internally connected to 3.3V via a 10kΩ resistor) Logic High (Output voltage is present) I

V Logic Low (Output voltage is not present) I V

Over Temperature Warning (Needs to be pulled HI via an external

Logic High (temperature within normal range) I

V Logic Low (temperature is too high) I V Delayed shutdown after Logic Low transition T

10 sec

delay

Fault (Needs to be pulled HI via an external resistor) Logic High (No fault is present) I

V Logic Low (Fault is present) I

PS Present (Needs to be pulled HI via an external resistor)

Logic High (Power supply is not plugged in) IIL Logic Low (Power supply is present) VIL 0

10.8 

3.0

0.7V

 

0.7V

 

0.7V

 

0.7V

 



 



 



 



 



2.5 VDC

13.2 VDC 

mVDC

VDC

12 V

0.4 VDC

12 V

0.8 V

20 µA 12 V

20 mA

0.4 VDC

20 µA 12 V

20 mA

0.4 VDC

20 µA 12 V

20 mA

0.4 VDC

20 µA 12 V

20 mA

0.4 VDC

 



4 mA

0.1 VDC

Page 5

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

SMBAlert# (Interrupt) (Needs to be pulled HI via an external

Logic High (No Alert - normal) I

Logic Low (Alert is set) I

V Output current monitor (Imon) Resolution Accuracy Measurement range Io 0 52 ADC Analog output range V Sourced output current

Digital Interface Specifications

0 5.2 VDC

mon

0.7V

 

100 mV/A

-5 5 % of FL

5 mADC

 



20 µA 12 V

20 mA

0.4 VDC

Parameter Conditions Symbol Min Typ Max Unit

PMBus Signal Interface Characteristics

Input Logic High Voltage (CLK, DATA) VIH 2.1 3.6 VDC Input Logic Low Voltage (CLK, DATA) VIL 0 0.8 VDC Input high sourced current (CLK, DATA) IIH 0 10 μA Output Low sink Voltage (CLK, DATA, SMBALERT#) I

=3.5mA VOL 0.4 VDC

OUT

Output Low sink current (CLK, DATA, SMBALERT#) IOL 3.5 mA Output High open drain leakage current

(CLK,DATA, SMBALERT#)

=3.6V I

OUT

0 10 μA

PMBus Operating frequency range Slave Mode FPMB 10 400 kHz

Measurement System Characteristics

Clock stretching I

measurement range

OUT

measurement accuracy 25°C

OUT

measurement range

OUT

measurement accuracy

OUT

Temp measurement range Temp measurement accuracy6

IIN measurement range IIN measurement accuracy

VIN measurement range VIN measurement accuracy

PIN measurement range PIN measurement accuracy

Linear

tSTRETCH 25 ms

RNG

ACC

OUT(rng)

OUT(acc)

Temp

(rng)

Temp

(acc)

0 80 ADC

IN(rng)

IN(acc)

IN(rng)

IN(acc)

0 3000 W

N(rng)

IN(acc)

0 52 A

-3 +3 % of FL

0 60 VDC

-3 +3 %

0 120

-5 +5

C C

-5 +5 %

0 80 VDC

-3 +3 %

-5 +5 %

Fan Speed measurement range Linear 0 30k RPM Fan Speed measurement accuracy -5 5 % Fan speed control range -direct- 0 100 %

Temperature accuracy reduces non-linearly with decreasing temperature

Page 6

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 Notes

Ambient Temperature

Storage Temperature -40 85 °C

Operating Altitude 2250/7382 m/ft

Non-operating Altitude 8200/30k m / ft

Power Derating with Temperature 2.5

Power Derating with Altitude 2.0

Acoustic noise 55

Over Temperature Protection 110/95 °C Shutdown / restart

Humidity Operating

Storage

Shock and Vibration acceleration

Earthquake Rating

-10

70 °C

%/°C

C/301 m

C/1000 ft

dbA

30 10

95 95

6 Grms

% Relative humidity, non-condensing

Zone

Derated above 50C

50C to 70C

Above 2250 m/7382 ft

25C, half load

NEBS GR-63-CORE, Level 3, 20 2000Hz, min 30 minutes

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

EMC Compliance

Parameter Criteria Standard Level Test

Conducted emissions

DC input

Radiated emissions9 EN55022 A 30 – 10000MHz Voltage dips EN61000-4-11 B -30%, 10ms

DC INPUT immunity

Enclosure immunity

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.

Radiated emissions compliance is contingent upon the final system configuration.

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

Fast transients EN61000-4-4, level 3 B 5/50ns, 2kV (common mode)

Conducted RF fields EN61000-4-6, level 3 A

Radiated RF fields EN61000-4-3, level 3 A 10V/m, 80-1000MHz, 80% AM

ESD EN61000-4-2, level 3 B 6kV contact, 8kV air

EN55022, FCC Docket 20780 part 15, subpart J

ENV50140 A

0.15 – 30MHz

B -60%, 100ms B -100%, 5sec

2kV, 1.2/50µs, differential mode

130dBµV, 0.15-80MHz, 80% AM

Page 7

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.

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.

Able to current share with CAR2548FP rectifiers.

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.

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.

Interrupt (SMBAlert): A TTL compatible status signal,

representing the SMBusAlert# feature of the PMBus compatible

C protocol in the power supply. This signal needs to be pulled

i HI externally through a resistor.

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

MCU Broadcast 0x00 0 0 0 0 0 0 0 0 EEPROM 0xAx 1 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 I 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

Address

0xBx 1 0 1 1 A2 A1 A0 R/W

C accessible devices within the

Data Sheet

Address Bit Assignments

(Most to Least Significant)

Page 8

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 9 being the START command.

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.

ACK bit, the exception

Clock

Stretch

PEC is a CRC-8 error-checking byte, based on the polynomial

+ x2 + x + 1, in compliance with PMBus™

C(x) = x 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;

 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

The power supply will clear the SMBusAlert# signal (release the signal to its HI state) upon the following events:

 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

Data Sheet

Page 9

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 8 1 8 1

S Slave address Wr A Command Code A

8 1 8 1 8 1 1

Low data byte A High data byte A PEC A 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

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 optional and includes the address and data fields.

1 7 1 1 8 1 S Slave address Wr A Command Code A

1 7 1 1 8 1

Sr Slave Address Rd A LSB A

8 1 8 1 1

MSB A PEC No-ack P

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.

Block write format:

1 7 1 1 8 1 S Slave address Wr A Command Code A

8 1 8 1 8 1

Byte count = N A Data 1 A Data 2 A

8 1 8 1 8 1 1

………. A Data 48 A PEC A P

. PEC is

Block read format:

1 S Slave address Wr A Command Code A

7 1 1 8 1

1 7 1 1

Sr Slave Address Rd A

8 1 8 1 8 1

Byte count = N A Data 1 A Data 2 A

8 1 8 1 8 1 1

………. A Data 48 A PEC NoAck P

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.

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 Data Byte Low

Bit 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Exponent (E) Mantissa (M)

The relationship between the Mantissa, Exponent, and Actual Value (V) is given by the following equation:

MV 2

Where: V is the value, M is the 11-bit, two’s omplement mantissa, E is the 5-bit, two’s complement exponent

PMBusTM Command set:

Command

Operation 01 1 Output ON/OFF ON_OFF_config 02 1 09, output ON default Clear_faults 03 0 Clear Status Write_protect 10 1 Write control

Store_default_all 11 0 Store permanently Restore_default_all 12 0 Reset defaults Capability 19 1 30h, 400kHz, SMBAlert Vout_mode 20 1 Vout constants

Vout_command 21 2 Set Vout Vout_OV_fault_limit 40 2 Set OV fault limit Vout_OV_fault_response 41 1 Vout_OV_warn_limit 42 2 Set OV warn limit Vout_UV_warn_limit 43 2 Set UV warn limit Vout_UV_fault_limit 44 2 Vout_UV_fault_response 45 1 Iout_OC_fault_limit 46 2 Iout_OC_fault_response

Iout_OC_warn_limit 4A 2 OT_fault_limit 4F 2 OT_fault_response 50 1 OT_warn_limit 51 2 UT_warn_limit 52 2 UT_fault_limit 53 2 UT_fault_response 54 1

Hex

Code

47 1

Data Sheet

Data Byte Function

Latch or hiccup Set OC warn limit

Latch or hiccup Set OT warn limit

Page 10

CAR2548DC series dc-dc converters

Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A

Hex

Command

Vin_OV_fault_limit 55 2 Vin_OV_warn_limit 57 2 Vin_UV_warn_limit 58 2 Set UV warn limit Vin_UV_fault_limit 59 2 Set UV shutdown

Status_byte 78 1 Status_word 79 2 Status_Vout 7A 1 Status_Iout 7B 1 Status_input 7C 1 Status_temperature 7D 1 Status_CML 7E 1 Status_other

Status_mfr_specific 80 1 Status_fan_1_2 Read_Vout 8B 2 Read output voltage

Read_Iout 8C 2 Read output current Read_temperature 8D 2 Read Temperature Read_Pout

PMBus revision 98 1 Mfr_ID 99 5 FRU_ID Mfr_model 9A 15 Mfr_revision 9B 4 Mfr_location 9C 4 Mfr_date 9D 6

Mfr_serial 9E 15

Mfr_Vin_min A0 2 36V (linear format)

Mfr_Vin_max A1 2 75V (linear format)

Mfr_Iin_max A2 2 27A (linear format)

Mfr_Pin_max A3 2 950W (linear format)

Mfr_Vout_min A4 2 10V (linear format)

Mfr_Vout_max A5 2 15V (linear format)

Mfr_Iout_max A6 2 71A (linear format)

Mfr_Pout_max A7 2 850W (linear format)

Mfr_Tambient_max A8 2 70C (linear format)

Mfr_Tambient_min A9 2 -10C (linear format) User_data_00 B0 48

User_data_01 B1 48 FRW_revision D0 1 Ilimit_control_I2C D3 2 Vout_control_ I2C D4 2 Fan_duty_cycle D6 1 Fan_speed D7 1 Vprog_ext D8 2 Read_Vout_ I2C E0 2 1/512V Read_Iout_ I2C E1 2 1/100A Read_TS_ I2C E2 2 CMD_OFF_ I2C E3 2 01-OFF, 00-ON OTF_limit_ I2C E4 2 OTF_recovery_ I2C E5 2 DCOKHI_ I2C E6 2 High OV fault (1/512V) DCOKLO_ I2C E7 2 Low OV fault (1/512V)

Data

Code

Field Function

Set OV warn limit

7F 1

81 1

96 2

User memory space User memory space

Ilimit set (1/100A) Vout set (1/512V) Duty_cycle in % Control in duty cycle

Heat sink temp C

OT fault limit C OT fault recovery C

Status Register Bit Allocation:

Status_Byte 78

Status_word

(includes Status_byte)

Status_Vout 7A

Status_Iout 7B

Status_input 7C

Status_temperature 7D

Code Bit Function

Data Sheet

7 Busy 6 DC_ OFF 5 Output OV Fault detected 4 Output OC Fault detected 3 Input UV Fault detected 2 Temperature Fault/warning

detected

1 CML (communication fault)

detected 0 None of Below 7 OV Fault/Warning detected 6 OC Fault/Warning detected 5 Input Fault/Warning detected 4 Mfr_specific register change

detected 3 DC_OFF 2 Fan Fault or Warning

detected 1 Other fault 0 Unknown 7 Vout OV Fault 6 Vout OV Warning 5 Vout UV Warning 4 Vout UV Fault 3 N/A 2 N/A 1 N/A 0 N/A 7 IOUT OC Fault 6 N/A 5 IOUT OC Warning 4 N/A 3 N/A 2 N/A 1 N/A 0 N/A 7 Vin OV Fault 6 Vin OV Warning 5 Vin UV Warning 4 Vin UV Fault 3 N/A 2 N/A 1 N/A 0 N/A

7 OT Fault 6 OT Warning 5 N/A 4 N/A 3 N/A 2 N/A 1 N/A 0 N /A

Page 11

CAR2548DC series dc-dc converters

Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A

7 Invalid/Unsupported

Command 6 Invalid/Unsupported Data 5 Packet Error Check Failed

Status_cml 7E

Status_mfr_specif

4 Memory Fault Detected 3 Processor Fault Detected 2 Reserved 1 Other Communications Fault 0 Other Memory or Logic Fault

7 3.3V_fault 6 N/A 5 Interrupt 4 Fault detected

3 PS_remote_OFF 2 DC_fault 1 INPUT_fault 0 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 DATA BYTE

Unit ON 80 Unit OFF 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.

Enable all writes 00 Disable all writes except write_protect 80 Disable all writes except write_protect and OPERATION

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.

FUNCTION DATA BYTE

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 I 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.

Data Sheet

C communications are

Page 12

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.

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.

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 ± 2% Vout_OV_fault_limit ± 3% Iout_OC_warn_limit

OT_warn_limit Vin_UV_warn_limit Vin_UV_fault_limit Read_Vout Read_Iout Read_temperature Read_Pout

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 Serial number 07 1 20 ASCII space

08 4 Date code [YY,WW], ASCII numeric value 0C 1 20 ASCII space 0D 17 Model#, ASCII alphanumeric value

1E 1 20 ASCII space

1F 1 Revision, ASCII value

20-FF 224 FF

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:

Data Sheet

ACCURACY

± 4% of FL

± 5C ± 3% ± 3% ± 2%

± 4% of FL

± 5C

±5%

Description

Page 13

CAR2548DC series dc-dc converters

Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A

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

Note: Test condition #2 has 2 modules working in parallel. One module is running and the other has no iNPUT.

Outline Drawing

1.250

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

Green Green

OFF OFF

Green Green Green

#10-32 GROUND STUD

AIR INLET

HANDLE

INPUT CONNECTOR

GREEN LED (INPUT-OK)

GREEN LED (DC-OK)

RED LED (FAULT)

OFF

OFF High High High High

Red

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

Data Sheet

0.494

Input connector: FCI Berg 51939-311 or TYCO 6450129-3

Input mate: FCI Berg 10080594-1E0101LF

0.50

14.250 ±.020

Output connector: FCI Berg 51939-030 Output mate: FCI Berg 51915-051

POT ADJ.

4.000 ±.020

Airflow

COVER

CHASSIS

0.330

This is a cable harness with 10 foot of #10ga stranded wire (2 – black and 2 – red) not-terminated on user end

Page 14

Data Sheet

CAR2548DC series dc-dc converters

Input: -36Vdc to -75Vdc; Output: 48Vdc @ 2500W; 3.3Vdc or 5 Vdc @ 1A

Connector Pin Assignments

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

P1 - DC input P3 + DC input P2 - DC input P4 + DC input

Function Pin Function

Page 15

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

CAR2548DCxxxZ 01A

A – Standard

Output Power 25 = 2500W

Output voltage 48 = 48Vdc

Type FP – AC; V TN – AC; V DC - DC

positive

_negative

Options B – bezel R – reverse airflow Vsb = 5

model

RTM

RoHS Blank – non compliant Y – 5 of 6 compliant Z – 6 of 6 compliant

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

GE Industrial Solutions CAR2548DC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual