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OPERATING MANUAL
RACK-MOUNT DC/DC CONVERTERS
TPCMQ48/TPCMQ24 SERIES
www.unipowercorp.com
Manual No. TPCMQ-051209
Manual No. TPCMQ-0904-2
TPCMQ-ManRevD-051209
TPCMQ-ManRevC-07-06-05
NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: 954-346-2442 • Fax: 954-340-7901 • sales@unipower-corp.com
EUROPE • Parkland Business Centre, Chartwell Road, Lancing BN15 8UE, ENGLAND • Tel: +44(0)1903 768200 • Fax: +44(0)1903 764540 • info@unipower-europe.
UNIPOWER Corporation
©2009
© 2005 UNIPOWER Corp.
All Rights Reserved
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CONTENTS
SECTION TOPIC PAGE
1.0 Introduction .............................................................................1
2.0 Features .................................................................................3
3.0 Product Line ...........................................................................3
4.0 Safety Warnings .....................................................................4
5.0 Warranty .................................................................................4
6.0 Unpacking and Inspection ......................................................5
7.0 Front Panel Description ..........................................................5
8.0 DC/DC Converter Module Specifi cations ...............................5
9.0 Description of Features and Options ......................................7
10.0 Mechanical Specifi cations ......................................................8
11.0 Safety and Industry Standards ...............................................8
12.0 Operating Information ...........................................................10
13.0 Parallel Operation ..................................................................11
14.0 Control & Supervisory Signal Connections ..........................14
15.0 Converter Module Connections ............................................15
16.0 Description of Rack/Shelf Control & Supervisory Signals ....17
17.0 Installation ............................................................................19
18.0 Maintenance .........................................................................20
19.0 DC/DC Converter & Rack/Shelf Setup and Testing ..............20
20.0 Troubleshooting Guide .........................................................22
Appendix TPCMQ48 DC/DC Converter Data Sheet ............................A1
Appendix TPCMQ24 DC/DC Converter Data Sheet ............................A2
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ILLUSTRATIONS
FIGURE TITLE PAGE
1 TPCMQ48/TPCMQ24 DC/DC Converter Module and Rack/Shelf ................... 2
2 Front Panel of TPCMQ48/TPCMQ24 DC/DC Converter Module .................... 2
3 TPCMQ48/TPCMQ24 Series Module Mechanical Dimensions ...................... 9
4 Front and Back of TPCMQ Series Rack/Shelves ........................................... 9
5 Rated Output Current vs. Ambient Temperature .............................................. 9
6 Remote Sensing Connection ........................................................................ 12
7 Parallel Connection of TPCMQ Rack/Shelves ............................................... 12
8 Checking the Remote Adjust Input ................................................................ 12
9 TPCMQ48 Converter Module Pin Connections ............................................. 16
10 TPCMQ24 Converter Module Pin Connections ............................................. 16
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TPCMQ48 & TPCMQ24 SERIES DC/DC CONVERTERS
1.0 INTRODUCTION
This operating manual should be read through carefully before installing and
operating the TPCMQ48 and TPCMQ24 DC/DC converter systems.
Unipower’s 1U high DC/DC converter systems convert a 48VDC nominal
input to 12 and 13.6VDC at 1800 and 1950 watts, respectively, or to 24 and
27.2VDC at 2,100 watts; or a 24VDC nominal input to 48 or 54.4VDC at
3,000 watts. The converter system consists of three DC/DC converter modules
in a compatible 19-inch rack/shelf. See Figure 1. The input is a wide
range 40 to 60 or 20 to 30VDC, and the output has a -25 to +10% adjustment
range. In 2+1 redundant operation the output is 1,400 watts for the
TPCMQ48 or 2,000 watts for the TPCMQ24. In this case a converter module
can be hot-swapped without affecting the output. The output voltage can be
controlled by a remote analog input in the range 0 to +5V.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
OPERATING MANUAL
AND RACK/SHELF
Each TPCMQ48 converter module produces 12, 13.6, 24 or 27.2VDC at 700
watts, and each TPCMQ24 module produces 48 or 54.4VDC at 1,000 watts.
The modules, which are connected in parallel in the rack/shelf, have automatic
load sharing and ORing diodes so they can be added or replaced while the
system is operating. The modules are up to 89% effi cient and have up to 12.5
watts per cubic inch power density.
A 25-pin interface subminiature D connector on the back of the rack/shelf provides control and monitoring inputs and outputs. An inhibit input turns the entire
rack/shelf output off or on. Remote sensing connections provide precise regulation at the point of load. Other control signals are input power fail and output
power good logic signals, and analog voltage remote adjust inputs- all for each
individual converter module.
Front-panel green LEDs indicate input power good and output power good for
each converter module. The converter modules and rack/shelf are safety agency certifi ed and CE marked.
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TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
Figure 1. TPCMQ48/TPCMQ24 DC/DC Converter Module and Rack/Shelf.
INPUT POWER
GOOD LED
HANDLE
OUTPUT POWER
GOOD LED
Figure 2. Front Panel of TPCMQ48/TPCMQ24 DC/DC Converter Module.
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2.0 FEATURES
The following is a summary of the important features of the TPCMQ DC/DC converter
modules and rack/shelf:
Constant Output Voltage
Remote -25 to +10% Output Adjustment
Output Overload Protected
Six Different Models
-20
Low Profi le: 1U (1.72 inches or 44mm) High
19-Inch Compatible Rack/Shelf
19- or 23-Inch Rack Mounting
Shelf Capacity Up to 3 Converter Modules
Power Density Up to 12.5 Watts/Cubic Inch
Up to 89% Effi ciency
Wide Range DC Inputs
I2C Serial Data Bus Option
Remote Sensing
Active, Single-Wire Load Sharing
Integral Output ORing Diodes
Hot-Swappable Converter Modules
Redundant or Non-Redundant Operation
LED Operating Indicators
Control and Monitoring Interface Signals
0
C to +700C Operating Temperature
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
3.0 PRODUCT LINE
3.1 DC/DC Converter Modules
MODEL
TPCMQ48-12/54 40-60VDC 12VDC 54.2A 150A
TPCMQ48-13/48 40-60VDC 13.6VDC 47.8A 143.4A
TPCMQ48-24/29 40-60VDC 24VDC 29.2A 87.6A
TPCMQ48-27/26 40-60VDC 27.2VDC 25.7A 77.1A
TPCMQ24-48/20 40-60VDC 48VDC 20.8A 62.4A
TPCMQ24-54/18 40-60VDC 54.4VDC 18.4A 55.2A
INPUT
VOLTAGE
* For 3 Modules in a rackshelf
3.2 System Rack/Shelves
MODEL WIDTH HEIGHT NO. MODULES
TPCMQR1U3-48 19” (483 mm) 1.72” (43.7 mm) 3
TPCMQR1U3-24 19” (483 mm) 1.72” (43.7 mm) 3
NOTE: System shelf and hot-swap modules must be ordered separately.
3
OUTPUT
VOLTAGE
MAX. OUTPUT
CURRENT
MAX. SYSTEM
CURRENT*
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3.3 Options
CODE DESCRIPTION
ZI
NOTE: Add Option Code as suffi x to model no. on both modules and rack/shelf.
Contact factory on availability of Option Z.
4.0 SAFETY WARNINGS
3.1 These converter modules and shelf have hazardous external and
internal voltages. They should be handled, tested and installed only
by qualifi ed technical persons who are trained in the use of power
systems and are well aware of the hazards involved.
4.2 The input terminals are at hazardous voltage potentials. Do not touch this
area when power is applied.
2
C Serial Data Bus
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
4.3 When operating this converter system, the frame ground terminal must be
connected to safety ground to minimize electrical shock hazard.
4.4 The internal voltages are at hazardous potentials. The converter module
covers should not be removed. There are no user-serviceable components
in these units. Removing the covers of the modules will void the warranty.
5.0 WARRANTY
All products of UNIPOWER Telecom, a division of UNIPOWER Corporation, are warranted for two
(2) years from date of shipment against defects in material and workmanship. This warranty does
not extend to products which have been opened, altered or repaired by persons other than persons authorized by the manufacturer or to products which become defective due to acts of God,
negligence or the failure of customer to fully follow instructions with respect to installation, application or maintenance. This warranty is extended directly by the manufacturer to the buyer and
is the sole warranty applicable. EXCEPT FOR THE FOREGOING EXPRESS WARRANTY, THE
MANUFACTURER MAKES NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. As the sole and exclusive remedy under this warranty, the manufacturer, at its option,
may repair or replace the non-conforming product or issue credit, provided the manufacturer’s
inspection establishes the existence of a defect. To exercise this remedy, the buyer must contact
the manufacturer’s Customer Service Department to obtain a Return Material Authorization number and shipping instructions. Products returned without prior authorization will be returned
to buyer. All products returned for repair must be shipped freight prepaid to UNIPOWER. If the
buyer fails to fully comply with the foregoing, the buyer agrees that no other remedy (including,
but not limited to, incidental or consequential damages for lost profi ts, lost sales, injury to person
or property or any other incidental or consequential losses) shall be available to the buyer.
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6.0 UNPACKING AND INSPECTION
6.1 These TPCMQ Series DC/DC Converters were carefully tested, inspected
and packaged for shipment from our factory. Upon receipt of them they
should be carefully unpacked and inspected for any damage in shipment.
6.2 If there is evidence of damage, do not attempt to test the unit. The freight
carrier should be notifi ed immediately and a claim for the cost of the converter system should be fi led with the carrier for direct reimbursement. Be
sure to include the model and serial number of the damaged unit in all
correspondence with the freight carrier. Also save the shipping carton and
packing material as evidence of damage for the freight carrier’s inspection.
6.3 UNIPOWER Corporation will cooperate fully in case of any shipping
damage investigation.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
6.4 Always save the packing materials for later use in shipping the unit. Never
ship the converter system without proper packing.
7.0 FRONT PANEL DESCRIPTION
The front panel of a TPCMQ converter module is shown in Figure 2. At the top
left is the Input Good LED (green) and at the top right is the Output Good LED
(green) Three 40mm fans cool the module.
8.0 DC/DC CONVERTER MODULE SPECIFICATIONS
Specifi cations for a Single Converter Module. Typical at 24 or 48VDC Input, Full Load and 25°C
Unless Otherwise Noted.
INPUT TPCMQ48 TPCMQ24
Voltage Range ...................................... 40-60VDC 20-30VDC
Inrush Current Limiting ............................. 20A Peak 100A Peak
Input Current, Full Load ............................... 16.6A@48VDC 46.8A@24VDC
EMI Filter, Conducted .................................. Standard Standard
Analog Voltage Adjust Input ..................... 0 to +5V 0 to +5V
Input Protection ........................................... Internal Fuse, 30A Internal Fuse, 100A
OUTPUT
Current & Voltage1, ...................................... 54.2A@12VDC 20.8A@48VDC
............................... 47.8A@13.6VDC 18.4A@54.4VDC
................................. 29.2A@24VDC
............................. 25.7A@27.2VDC
Voltage Adjustment Range, Remote ............ -25 to +10% -25 to +10%
Voltage Trim Pot Adjust ............................ ±5% ±4%
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TPCMQ DC/DC CONVERTER SERIES
CORPORATION
OPERATING MANUAL
OUTPUT (Cont’d)
Total Regulation, Max. ....................... ..............................2.0% 2.0%
Overvoltage Protection ............... ..................................... Latched Shutdown Latched Shutdown
Filtering: Wideband Noise, 20MHz BW, P-P .................... 2.0% 2.0%
Voice Band Noise ............................ ................................ <32dBrnC <32dBrnC
Current Limit ................................ .................................... 105% Rated Current 105% Rated Current
Effi ciency .................................... ..................................... 86% 89%
SAFETY STANDARDS .................................. UL60950, CSA22.2 No.60950, EN60950
STATUS INDICATORS
Input Power Good .......................... .................................. Green LED and Logic LO Output
Output Power Good ......................... ................................ Green LED and Logic LO Output
ENVIRONMENTAL
Operating Temp. Range .................... .............................. -20°C to +70°C
Output Current Derating .................... .............................. 2.5%/°C, 50°C to 70°C
Storage Temp. Range .................... .................................. -40°C to + 85°C
Humidity ........................................ ................................... 0% to 95%, Non-Condensing
ESD .............................................. ................................... Bellcore GR-1089-Core and EN61000-4-2
Cooling ...................................... ...................................... DC Ball Bearing Fans
PHYSICAL SPECIFICATIONS
Case Material, Module ........................ ............................. Aluminum
Rack/Shelf ................. .............................. Aluminum
Dimensions, Inches (mm)
Converter Module .................. ............................. 1.60 H x 5.00 W x 10.00 D
(40.6 x 127 x 254)
19” Rack/Shelf .............................. ......................1.72 H x 19.00 W x 11.56 D
(43.7 x 483 x 294)
Weight
Converter Module ......................... ...................... 3.15 lbs (1.43 kg.)
19” Rack/Shelf ............................. ....................... 4.15 lbs (1.88 kg.)
NOTE: 1. Voltage set at factory.
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9.0 DESCRIPTION OF FEATURES & OPTIONS
FEATURE / OPTION DESCRIPTION
Wide Range DC Input The DC input range is from 40 to 60 or 20 to 30VDC.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
EMI Input Filter
Inrush Current Limiting
Output Voltage
Adjustment
Remote Output Adjust
Thermal Protection
Current Sharing
This fi lter suppresses conducted noise from the converter back
onto the DC input line.
When the converter is turned on, the input inrush current is limited by an electronic circuit.
The output voltage adjustment range for all models is approximately -25 to +10% of the nominal output voltage, made at the
input to the remote adjust terminal. There is also a trimming
potentiometer on the top of the case which gives a smaller output
adjustment range of about ±5%.
This input is used to remotely adjust each converter output voltage. An analog voltage from 0 to +5V controls approximately -25
to +10% output range. This input can be controlled externally by
a power control system. The module analog inputs can also be
connected together so that the external control voltage adjusts all
the module outputs simultaneously.
If the converter module overheats internally, it will automatically
shut down. The Output Power Good LED turns off, the Output
Power Good signal goes HI and the Overtemperature Warning
signal goes HI.
The TPCMQ converter modules are automatically connected to
current share with each other when they are inserted into the
rack/shelf. A single-wire connection provides this. The modules
current share with an accuracy of 10% of their full load output
current for total loads of 50% to 100%. The rack/shelf current
share pin can be used to current share with another rack/shelf of
the same output voltage.
ORing Diode
Overvoltage Protection
This diode in series with the module output protects the parallelconnected modules. If the output of one module fails to a short or
to a lower than normal output voltage, the other modules are not
affected. Also when hot-swapping modules, the diode prevents
a glitch in the output voltage while the output is still rising on the
inserted module. The 5V 250mA standby output also has an ORing diode.
The output is protected from overvoltage due to fault conditions
in the module. Overvoltage protection is set at greater than 110%
of the output voltage. The result is a latched shutdown of the
converter module. It is reset by cycling the DC input off and then
back on.
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9.0 DESCRIPTION OF FEATURES & OPTIONS (cont’d)
FEATURE / OPTION DESCRIPTION
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
No Load Operation
Hot Swap Operation
Output Protection
LED Indicators
Control and Monitoring
Signals
The module output can be operated down to zero load while
maintaining output regulation.
Hot swap operation means that the converter modules can be
removed and replaced while the rack/shelf is powering the load.
If the system is operated in an N+1 redundant mode, hot-swap
replacement will not affect the output voltage.
Output current limiting protects the output of each converter
module
from damage due to an overload or short circuit condition. This
protection is continuous, without damage, and recovery is automatic when the overload is removed. Current limiting begins at
about 105% of rated output current.
The Input Power Good indicator is a green LED, showing that
input DC is present. The Output Power Good indicator is a green
LED showing that the output voltage is present and within operating range.
For detailed description of Inhibit, Current Share, Remote Sense,
Remote Adjust, Input Power Good and Output Power Good
signals, see Section 16, Description of Control and Supervisory
Signals.
10.0 MECHANICAL SPECIFICATIONS
The mechanical dimensions of the TPCMQ Series converter modules and the
rack/shelves are shown in Fig. 3.
11.0 SAFETY AND INDUSTRY STANDARDS
11.1 The TPCMQ DC/DC Converters and rack/shelves meet the following
safety
certifi cations:
STANDARD AGENCY
UL60950 UL
CSA22.2 No. 60950 CUL
EN60950 DEMKO
11.2 The TPCMQ DC/DC Converters and rack/shelves are CE marked to
indicate conformance to the European Union’s Low Voltage Directive.
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TPCMQ DC/DC CONVERTER SERIES
CORPORATION
Figure 3. TPCMQ48/TPCMQ24 Series Module Mechanical Dimensions.
OPERATING MANUAL
V. ADJ.
1.72
(43.7)
GRD
17.19
(437)
FRONT
VIEW
1
23
GRD
NO. 10-32 STUDS,
2 PER MODULE
+
BACK
VIEW
-
TPCMQR1U3-48
+V -VJ4
DC OUT
3 2 1
DC IN
NO. 8-32 STUDS, 2
PER MODULE
+
BACK
VIEW
-
TPCMQR1U3-24
J4
+V -V
3 2 1
DC OUT
Figure 4. Front and Back of TPCMQ Series Rack/Shelves
Figure 5. Rated Output Current vs. Ambient Temperature
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12.0 OPERATING INFORMATION
12.1 Input Voltage. The TPCMQ Series converters operate off DC input volt-
ages within the range of 40 to 60 or 20 to 30VDC. There is a separate
input connection for each converter module to bus bars at the rear of the
rack/shelf. For complete details see Section 17.2 and Figure 4.
12.2 Output Connection. The DC output of the rack/shelf is provided at two
copper bus bars. Each bus bar has a no. ¼-20 stud and nut for the output
connections. For complete details see Section 17.3 and Figure 4. Both
positive and negative outputs are fl oating and isolated from the chassis.
12.3 Output Voltage. The output voltage of each converter module is factory
set to its specifi ed voltage. This voltage can be adjusted in two ways. First,
there is a V adjust potentiometer at the top of the module case. See Figure
3. This adjustment has a range of approximately ±5% for the TPCMQ48
and ±4% for the TPCMQ24.
Second, there is a wide-range adjustment of approximately -25% to +10%
by means of the Remote Adjust input to each converter module. This is
found at pin 16 of the TPCMQ48 and pin 29 of the TPCMQ24. On the
rack/shelf the Remote adjust is found at J4 pins 12, 24 & 25 for each
module. A zero to +5V input to these pins adjusts the output from -25% to
+10%. An input voltage of +2.5V, or an open, gives the factory-set voltage
at the output. The output voltage can actually go above +10%, but this
could trip the overvoltage protection (OVP) circuit.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
All three converter modules in a rack/shelf can be controlled from a single
analog control voltage by connecting J4 pins 12, 24 & 25 together.
12.4 Output Power. Maximum output power for the TPCMQ48 modules is 700
watts for the 24 or 27.2V output models and 650 watts for the 12 or 13.6V
models. The maximum output power for the TPCMQ24 modules is 1,000
watts. The maximum output power of a module may be drawn at up to
50oC ambient temperature. Above 50oC the output current must be derated by 2.5%/oC. See Fig. 5. The maximum operating temperature is 70oC,
at which the output current must be derated by 50%.
12.5 Output Overload Protection. Each converter module output is protected
from damage due to overload or short circuit conditions. This protection is
continuous and without damage; recovery is automatic when the load is
removed. Current limiting takes place at approximately 105% of the rated
output current.
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TPCMQ DC/DC CONVERTER SERIES
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OPERATING MANUAL
12.6 Remote Sensing. Remote sensing connections are made to pins 11
(+Sense) and 23 (-Sense) of the converter rack/shelf J4 connector. Remote sensing is used to regulate the output voltage at the point of load by
compensating for the voltage drop in the wires to the load. The +Sense
lead must be connected to the + side of the load and the -Sense to the
- side of the load. The sense leads should be a color-coded, twisted pair of
AWG no. 22 or 24 copper wire. See Fig. 6.
Remote sensing can compensate for a total voltage drop of 0.5V, or 0.25V
per load wire. The sense leads should not exceed 10 feet (3 meters) in
length. If remote sensing is not required, the sense leads may be left open
for local sensing at the output terminals. Be careful not to reverse the
sense lead connections, as this could damage the output.
12.7 Control and Supervisory Signals. All control and supervisory signals are
accessible at J4, a 25-pin subminiature D connector at the back of the
converter rack/shelf. See Section 16 for a complete description of these
input and output signals.
12.8 Alarm Signals. Among the control and supervisory signals are three logic
alarms: Input Power Fail, Output Power Good and Overtemperature Warning.
They are logic signals referenced to -Sense, J4 Pin 23. There are logic
alarms for each converter module. The fi rst alarm is Input Power Fail. A
logic HI indicates that there is no DC input. The second alarm is Output
Power Good. A logic HI indicates a DC output failure. The third alarm is
Overtemperature Warning. A logic HI indicates the internal air temperature
has reached a critical level just prior to the unit shutting down.
13.0 PARALLEL OPERATION
The converter modules in the rack/shelf are all connected in the parallel, current
sharing mode by means of a single-wire current share connection among them.
A rack/shelf can be operated in either an N+1 redundant mode or non-redundant
mode.
13.1 Redundant Operation. From Table 13-1, the 19-inch shelf can be oper-
ated in a 2+1 redundant mode. This means that the full load current must
be carried by two converter modules. While operating normally, the current
is shared approximately equally among the three modules. If one module
fails, however, the output current is then maintained by the two operating
modules. The failed unit can then be replaced without affecting
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TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
No. 22 or 24 AWG TWISTED PAIR
UP TO .0.25V DROP
UP TO .0.25V DROP
Figure 6. Remote Sensing Connection
CONVERTER
RACKS/SHELF
NO. 1
LOAD
CONVERTER
RACKS/SHELF
NO. 2
Figure 7. Parallel Connection of TPCMQ Rack/Shelves.
Figure 8. Checking the Remote Adjust Input
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TPCMQ DC/DC CONVERTER SERIES
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OPERATING MANUAL
the output current to the load. N+1 redundancy with quick replacement of
a failed module results in virtually infi nite MTBF.
Table 13-1 Redundant and Non-Redundant Operation
MODULE
MODEL NO.
TPCMQ48-12/54
TPCMQ48-12/54
TPCMQ48-13/48
TPCMQ48-13/48
TPCMQ48-24/29
TPCMQ48-24/29
TPCMQ48-27/26
TPCMQ48-27/26
TPCMQ24-48/20
TPCMQ24-48/20
TPCMQ24-54/18
TPCMQ24-54/18
OUTPUT
VOLTS
12V
12V
13.6V
13.6V
24V
24V
27.2V
27.2V
48V
48V
54.4V
54.4V
MODE NO. OF
2+1 Redundant
Non-Redundant
2+1 Redundant
Non-Redundant
2+1 Redundant
Non-Redundant
2+1 Redundant
Non-Redundant
2+1 Redundant
Non-Redundant
2+1 Redundant
Non-Redundant
MODULES
3
3
3
3
3
3
3
3
3
3
3
3
MAX. OUTPUT
CURRENT
108.4A
150.0A
95.6A
143.4A
58.4A
87.6A
51.4A
77.1A
41.6A
62.4A
36.8A
55.2A
OUTPUT
WATTS
1300
1800
1300
1950
1400
2100
1400
2100
2000
3000
2000
3000
13.2 Non-Redundant Operation. Higher output current can be achieved by
operating the rack/shelf in a non-redundant mode as also seen in Table
13-1. However, in this case if a converter module fails, the load will lose
power since only part of the required current can be supplied by the remaining modules, and they will go into current limit. The failed converter
module, however, can be quickly replaced to restore the load current.
Note that the rack/shelf output current is limited to 150A, and therefore the
output of three 12V modules is not 162.6A as is their capability.
13.3 Multiple Parallel Shelf Operation. Multiple rack/shelves can also be
operated in parallel by interconnecting their current share terminals (J4 Pin
10). The total power can be expanded by several times. In this case N+1
redundant operation is achieved by reserving one module of the total for
redundancy. For example, if two full 19-inch rack/shelves are employed
with a total of six converter modules, then for 5+1 redundancy the full load
must be able to be carried by the output of fi ve modules. In such applications each set of remote sense wires must be separately connected to
the point of load. See Figure 7 for a simplifi ed illustration of two converter
rack/shelves connected in parallel.
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14.0 CONTROL & SUPERVISORY SIGNAL CONNECTIONS
14.1 Connections for control and supervisory signals are made at the rack/shelf
rear to connector J4, a standard 25-pin subminiature D connector (Positronics No. SD25F0S5OOX with FC752OD pins). The mating connector is
Positronics SD25M00OOZ with MC752OD pins.
14.2 The pin connections to J4 are shown in the table.
J4 SIGNAL CONNECTOR
J4 PIN CONNECTIONS
PIN FUNCTION PIN FUNCTION
1 Inhibit 14 Input Power Fail -1
2 Overtemp. Warning -1 15 Output Power Good -1
3 Current Monitor -1 16 Input Power Fail -2
4 Overtemp. Warning -2 17 Output Power Good -2
5 Current Monitor -2 18 Input Power Fail - 3
6 Overtemp. Warning -3 19 Output Power Good -3
7 Current Monitor - 3 20 Module Present -1
8 +5V Standby 21 Module Present -2
9 SDA 22 Module Present -3
10 Current Share 23 - Sense
11 + Sense 24 Remote Adjust - 1
12 Remote Adjust -2 25 Remote Adjust - 3
13 SCL
NOTES: Standby return is connected to -Sense lead. Current rating of +5V standby is
250mA. All signals are referenced to -Sense lead. Pins 9 & 13 are I2C
functions when that option is fi tted. When I2C is present, pins 2-7 and 14-19
have no function.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
Standard subminiature D
Connector
(Positronic SD25F0S5OOX
with FC7520D pins)
14.3 I2C Serial Data Bus. The I2C serial data bus (Option Z) is available on
both the TPCMQ48 and TPCMQ24 modules and rack/shelves. It must
be ordered on both. Pin 9 of J4 on the rack/shelf is the SDA (serial data)
output and pin 13 is the SCL (serial clock) output. The I2C data output
provides output voltage, output current, internal temperature and manufacturing data on each module (model no., serial no., etc.). When this option is
present, pins 2 to 7 and 14 to 19 do not function. For complete information
on the I2C option, please contact the factory.
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15.0 CONVERTER MODULE CONNECTIONS
If the converter module or modules are used separately from the rack/shelf or in
a user-confi gured rack/shelf, connections should be made to the hot-swap connector on the back of the module with the functions shown in Figure 9 for the
TPCMQ48 and Figure 10 for the TPCMQ24. There is a Mating Interface Board
available for the TPCMQ48 module (but not the TPCMQ24), providing easy connections for testing purposes.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
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TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
CONNECTOR: POSITRONICS PCIB26W11M400A1
NOTES: For unit to operate, pin 7 must be at logic LO or
shorted to pin 9. For proper operation the following pins
must be connected together: All V Out pins (1-3); all V Return pins (4-6). Pins 11, 12, 14, 17 & 19 carry I
when the I2C option is fi tted.
MATE: PCIB26W11F400A
2
C functions
MATING INTERFACE BOARD
Order Kit Number
009-0280-0009
Figure 9. TPCMQ48 Converter Module Pin Connections
PIN CONNECTIONS
PIN FUNCTION PIN FUNCTION
1 +V Out 14 Output Power Good/ADD GA1
2 +V Out 15 Input Power Fail
3 +V Out 16 V Trim
4 V Return 17 Overtemp. Warning/ADD GA0
5 V Return 18 Current Share
6 V Return 19 Current Monitor/ADD GA2
7 Enable 20 +5V Standby
8 + Sense 21 Standby Return
9 - Sense 22 Chassis Ground
10 Inhibit 23 Chassis Ground
11 Spare/SDA 24 -DC Input
12 Spare/SCL 25 -DC Input
13 - Sense 26 +DC Input
CONNECTOR: POSITRONICS PCIM37W16RM400A1
NOTES: For unit to operate, pin 17 must be at logic LO or
shorted to pin 30. For proper operation the following pins
must be connected together: All +V Out pins (35-37); all -V
Out pins (32-34). Pins 24-28 carry I
I2C option is fi tted.
MATE: PCIM37W16RF400A1
2
C functions when the
PIN CONNECTIONS
PIN FUNCTION PIN FUNCTION
1 -DC Input 20 Module Present
2 -DC Input 21 N.C.
3 -DC Input 22 Input Power Fail
4 -DC Input 23 N.C.
5 +DC Input 24 GA2
6 +DC Input 25 GA1
7 +DC Input 26 SCL
8 +DC Input 27 SDA
9 Chassis Ground 28 GAO
10 Chassis Ground 29 V. Adjust
11 N.C. 30 - Sense
12 Standby Return 31 + Sense
13 +5V Standby 32 -V Out
14 Output Power
Good
15 Overtemp. Warning 34 -V Out
16 Inhibit 35 +V Out
17 Enable 36 +V Out
18 Current Share 37 +V Out
19 Current Monitor
33 -V Out
Figure 10. TPCMQ24 Converter Module Pin Connections
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TPCMQ DC/DC CONVERTER SERIES
CORPORATION
OPERATING MANUAL
16.0 DESCRIPTION OF RACK/SHELF CONTROL AND SUPERVISORY SIGNALS
SIGNAL PIN DESCRIPTION
Inhibit 1
Overtemp. Warn. - 1
Overtemp. Warn. - 2
Overtemp. Warn. - 3
Current Monitor - 1
Current Monitor - 2
Current Monitor - 3
+5 Standby Supply 8
Current Share 10
A logic LO or short to Pin 23 turns off all converter modules
in the rack/shelf. This input is referenced to -Sense, Pin 23.
A logic HI indicates an overtemperature condition inside the
2
indicated module. The HI occurs a few milliseconds before
4
the unit shuts down. This signal is referenced to -Sense, Pin
6
23.
3
An analog output voltage of the indicated module is pro-
5
portional to its output current. This signal is referenced to
7
-Sense, Pin 23.
This is a +5V, 250mA output. It is referenced to the -Sense,
Pin 23.
This is an analog control signal made up of the current
share signals of all converter modules connected together.
This pin is used to connect to Pin 10 of another identical
converter shelf to share output currents. Output currents
between shelves are shared within an accuracy of 10% of
full load current over a 50% to 100% load range. This signal
is referenced to -Sense, Pin 23.
+ Sense
- Sense
Input Power Good - 1
Input Power Good - 2
Input Power Good - 3
Output Power Good - 1
Output Power Good - 2
Output Power Good - 3
11
23
14
16
18
15
17
19
These remote sense leads should be connected as a
twisted pair to the respective + and - load points to provide
regulation at the point of load. Removal of the sense leads
transfers regulation control to the output terminals of the
converter shelf. The correct polarities must be maintained.
A logic LO indicates the DC input is present at each indicated module. A logic HI indicates DC input failure. This signal
is referenced to -Sense, Pin 23.
A logic LO indicates that the indicated module is operating
properly with output voltage in its controllable range. A logic
HI indicates the output is outside the -25 to +10% output
range for the converter, the unit has failed or is in current
limit. This signal is referenced to -Sense, Pin 23.
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TPCMQ DC/DC CONVERTER SERIES
CORPORATION
OPERATING MANUAL
16.0 DESCRIPTION OF RACK/SHELF CONTROL AND SUPERVISORY SIGNALS
SIGNAL PIN DESCRIPTION
Module Present - 1
Module Present - 2
Module Present - 3
Remote Adjust - 1
Remote Adjust - 2
Remote Adjust - 3
-Sense 23 This is the reference pin for the above signals.
20
21
22
24
12
25
A logic LO means the indicated module is present; an open
indicates the module is absent. This signal is referenced to
-Sense, Pin 23.
These are analog voltage inputs to the designated converter modules by which the output voltage is adjusted. A zero
to + 5V input represents approximately -25 to +10% output
change for a converter. This input should be driven from a
source impedance less than 100 ohms and is referenced to
-Sense, Pin 23.
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17.0 INSTALLATION
17.1 Mounting. The TPCMQ Series converter rack/shelves are mounted in a
rack by means of mounting brackets on each side. One set of standard
brackets is supplied with each rack/shelf. The rack/shelf mounts in a 19inch rack, but brackets are available for mounting in a 23-inch rack (order
no. 775-1451-0000, set of two). There are seven different bracket positions
on the side of the rack/shelf, from front position to 6 inches from the front.
When mounting, the rack/shelf should fi rst be securely mounted to the rack,
then the converter modules inserted into the rack/shelf. The converter modules should be secured by tightening the jack screw on each module.
17.2 DC Input Connections. The DC input connections to the converter rack/
shelf are shown in Figure 4. As shown, there are separate bus bar connections for each converter module. The stud connections, labeled by converter module number, are no. 10-32 for TPCMQR1U3-48 and no.8-2 for
TPCMQR1U3-24. Shorting bars are available for each rack/shelf so that all
three inputs are in parallel. See data sheets in Appendix for ordering information.
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
17.3 DC Output Connections. The DC output connections are shown in Figure
4. The positive and negative output connections are made to the copper
bus bars as shown. The left bar is positive and the right one negative. Each
bus bar has a no. ¼ - 20 stud with nut. The output wires or bus bars should
be sized in accordance with the load current and length of conductor.
17.4 Contact Resistance. Connection to the input and output bus bars should
be clean and tight to minimize contact resistance.
17.5 Control and Supervisory Signal Connections. These connections
are made to J4, a subminiature D, 25-pin connector (Positronics No.
SD25F0S5OOX) by means of the mating connector. Details for these connections are given in Section 14.
17.6 Cooling. Each converter module is cooled by three 40 mm DC ball bearing
fans. For proper cooling, the area in front of the fan and around the air exits
should be kept clear for unimpeded air fl ow.
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TPCMQ DC/DC CONVERTER SERIES
CORPORATION
18.0 MAINTENANCE
No routine maintenance is required on the TPCMQ48 or TPCMQ24 Series except for periodic cleaning of dust and dirt around the fans. A small vacuum nozzle
should be used for this.
19.0 DC/DC CONVERTER AND RACK/SHELF SETUP AND TESTING
19.1 The converter modules and rack/shelf can be initially tested mounted in a
rack or on a test bench. The converter system is initially tested one converter module at a time.
19.2 Connect DC power wires to converter module no. 1 bus bar connector on
the back of the rack/shelf. Do not connect the DC wires to the DC source
yet.
OPERATING MANUAL
19.3 Connect a resistive power load across the DC output terminals. This load
can be a DC electronic load that is set to the resistive mode or a highpower resistor that has the proper power capacity and cooling. For this
test the load should be between 10% and 50% of the full load rating of the
converter
module.
19.4 Connect a color-coded, twisted pair (no. 22 or 24 AWG) from the remote
sense pins to the load. The +Sense lead (J4 Pin 11) must go to the positive side of the load and the - Sense lead (J4 Pin 23) must go to the negative side of the load.
19.5 Insert one of the converter modules into slot 1 of the rack/shelf (left-
most slot.) Connect the DC power wires to the appropriate source (24 or
48VDC) and measure the voltage across the load at the remote sense
points with a DC digital voltmeter. The voltage should be approximately
the specifi ed
voltage for the module (12, 13.6, 24, 27.2, 48 or 54.4VDC).
19.6 Checking the Front Panel LEDs. The Input Power Good and Output
Power Good LEDs should both be green.
19.7 Checking the Inhibit Input. Next, connect a wire going from J4 Pin 1 to
Pin 23. The converter output should turn off, giving zero volts across the
load. The Output Power Good LED should go off. Disconnect the wire.
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TPCMQ DC/DC CONVERTER SERIES
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OPERATING MANUAL
19.8 Checking the Input Power Fail and Output Power Good Signals. Mea-
sure the output voltage at both J4 Pins 14 and 15 with respect to -Sense
(Pin 23) with a DC digital voltmeter. Both voltages should be less than
0.5VDC, indicating a logic LO.
19.9 Checking the Remote Adjust Input. Connect a variable external power
supply as shown in Figure 8. With its output voltage set to zero, check
the output voltage of the converter module with a DC digital voltmeter.
The output voltage should be approximately 25% below its nominal value.
Disconnect the external 5V supply and disconnect the DC input to the
converter rack/shelf.
19.10 Checking the Other Converter Modules. Each converter module should
be tested in the above manner to verify its operation. Go back to Section
19.5 and proceed through the tests one by one until all converter modules
have been verifi ed.
19.11 Checking the Complete Converter Rack/Shelf. Confi rm that the output
voltages of the individual converter modules are all set to approximately
their specifi ed output voltages. Insert all three converter modules into
the rack/shelf. Connect a power load to the output–high-power resistor
or electronic load in resistive mode–to give 50% of the maximum output
current for the non-redundant mode of the modules shown in Table 13-1.
Connect the + and - Sense leads to the + and - sides of the load, respectively, as in Section 19.4.
Note that on the back of the rack/shelf each converter module has its own
DC power connection. Connect the rack/shelf inputs to the DC power
source: Shorting bars may be used for a single input correction. Check the
load voltage with a DC digital voltmeter. It should be close to the specifi ed value for the model tested. The Input Power Good and Output Power
Good LEDs should both be green on each converter module.
19.12 While the rack/shelf is operating, pull Module no. 1 out while monitoring
the output voltage with a DC digital voltmeter. It should remain the same.
Insert the module back into the rack/shelf. Repeat this for each of the
other modules. This test determines that hot-swapping is functioning properly in the N+1 redundant mode.
19.13 With all the modules inserted into the rack/shelf, check the Inhibit input for
the entire system. Connect a wire from J4 Pin 1 to Pin 23. The system
output should turn off, and the output voltage should go to zero. Reconnect the wire. This completes the rack/shelf setup and testing. Disconnect
the DC power source.
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20.0 TROUBLESHOOTING GUIDE
20.1 If you encounter diffi culties in getting the converter modules or rack/shelf
to operate properly, go through the following troubleshooting guide.
20.2 Table 20-1. TPCMQ48/TPCMQ24 Converter System Troubleshooting
SYMPTOM POSSIBLE CAUSE ACTION TO TAKE
TPCMQ DC/DC CONVERTER SERIES
OPERATING MANUAL
No output, Input Good and
Output Good LEDs off.
No output, Output Good
LED off, Input Good LED on.
No output, Output Good
LED off, Input Good LED on.
No output, Output Good
LED off, Input Good LED on.
No output, Output Good
LED off, Input Good LED on.
Low or no output, Output
Good LED off, Input Good
LED on.
No input power.
Inhibit in OFF
mode.
Check connection to DC source.
Check DC source circuit breakers.
Make sure J4 Pin 1 (Inhibit) is not
connected to Pin 23, -Sense, or to
ground.
Shorted output. Check for short and remove.
Overvoltage protection (OVP) has
latched.
Reset output by cycling the DC input
OFF and then back ON.
Overtemperature
protection is
activated on one
or more converter
Allow module to cool down for about
10 minutes. Check to see if the
cooling fans are operating.
modules.
Output load is too
great for the number of converter
Reduce load to proper level.
modules.
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