Page 1
PRODUCTS MANUAL
R2G SERIES
Micro Redundant Power Supply For 2U Chassis
Page 2
INDEX
1.1 Introduction page 1
1.2 Packing page 2
1.3 Model Designation page 2
1.4 Features page 3
1.5 Pre-Installation page 4
1.6 Drawing page 4 ~ 13
1.7 Specification page 14 ~ 15
1.8 Installation & Testing page 16 ~ 17
1.9 Hot-Swap Procedures page 18 ~ 19
1.10 Pinouts and function of connectors page 20
1.11 Trouble shooting page 21
Page 3
1.1 INTRODUCTION
First of all, thank you for purchasing R2G Series – Micro Redundant power
supply for 2U chassis.
The R2G is an 1+1, Hot-swappable/Hot-pluggable, Micro Redundant power
supply set, it consists of:
(1) complete metal frame (nickel-plated)
(2) compact size (smaller than PSII form factor) 1+1 power modules
(3) backplane board
The R2G Series of hot swappable micro redundant power supply offer a
maximum 300/350 watts of output power. The R2G series provide Active
Power Factor correction (PFC) at full range AC Input complies with
IEC 1000-3-2/3 for critical applications.
The power unit’s size is compact which smaller than PS II form factor and both
power modules built an interior 40 m/m ball bearing DC fan for better ventilation.
Particularly an 80 m/m DC Fan built on the rear side of the whole system to make
sure a safe working unit. Each power module has designed with 6 outputs
including +3.3V, +5V, +12V, -12V, -5V & 5VSB circuits and higher current
availability based on Intel ATX12V / EPS12V standards. All you can see on the
backplane board is just passive components and this is the key point to a greater
Power Supply MTBF.
The unit features a warning sub-system, including LED display, buzzer alarm,
2
TTL signal, I
C interface device etc., at the same time, it guides user the fast way
to find out the power supply and DC fan Good or Fail conditions.
When all the power modules are at normal condition, it balances the load share
through its parallel design and results the power system increase reliability.
To really discover the power and ease in using these products, we recommend
that you read through this manual carefully.
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1.2 PACKING
Your R2G box package should consist of the following:
(A) R2G *1
(B) Accessory pack (included 1 holding bracket for shipment)*1
(C) Products’ manual *1
1.3 MODEL DESIGNATION
Model number identification:
R2G - 63ZZX
R --- Redundant (AC Input)
2G --- suit for 2U chassis (1U = 44.4 m/m)
6 --- for 6 DC outputs (5V/12V/-5V/-12V/3.3V/5VSB) for
ATX12V / EPS12V Spec.
3ZZ --- total output power, 3ZZ- 300,350 (unit: watt)
X --- can be P or F.
P for built in PFC (full range).
F for regular AC Input 115/230VAC (AVS, auto range)
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1.4 FEATURES
R2G Series --- Micro Redundant power supply (w/PFC / AVS versions)
1+1, Hot swappable, Hot pluggable, AC Input for 2U chassis
Easy fit into 2U , 300/350W +300/350W, PFC/AVS, ATX12V / EPS12V outputs
Dimension : 82 (H) x 101 (W) x 276/300 (D) m/m (2 housings optional)
True Redundant design (Passive backplane)
All circuit been designed in the power module
Hot swap, Hot plug ability
Full range / Auto range operations
Active Power Factor Correction (PFC) built in is optional
ATX 300/350W + 300/350W output power
Balance load sharing design
Remote sensing design
Meet FCC, CISPR EMI regulation
Faulty free - slide rail design
2
Smart I
C interface design (optional)
Compact size for 2U chassis
Space save / click type handle design
Dual EMI Line Filter inlets design
One piece 40 m/m ball bearing DC fan on power module design
A 80 m/m ball bearing DC fan on power system rear side (Optional)
1.5 PRE-INSTALLATION
Before installing the R2G unit into the system chassis, please review the
following drawings page 4 ~ 13 and find out the best way to match them.
1.6 DRAWING (page 4 ~ 13)
1.7 SPECIFICATIONS (page 14 ~ 15)
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INPUT CHARACTERISTICS: R2G-6300P
VOLTAGE: 95 ~264 VAC FULL RANGE
FREQUENCY : 47 ~ 63 Hz
INPUT CURRENT: 6.0 / 3.0 A FOR 115 / 230 VAC
INRUSH CURRENT: 60A / 80A MAX. FOR 115 / 230 VAC PER POWER MODULE
OUTPUT CHARACTERISTICS:
OUTPUT
VOLTAGE
5V 3.0 32
12V 2 16 20
-5V 0.05 0.5
-12V 0.05 0.8
3.3V 1.0 20
+5VSB 0.1 1.5
OUTPUT CURRENT REGULATION OUTPUT
RIPPLE & NOISE
MIN.[A] MAX.[A] PEAK(A) LOAD LINE
±
±
±
±
±
±
5%
6%
10%
10%
5%
5%
±
±
±
±
±
±
1%
1%
1%
1%
1%
1%
MAX. [P-P]
50mV
120mV
120mV
150mV
50mV
50mV
REMARKS: TOTAL CURRENT OF +5V AND + 3.3V NOT EXCEED 32 A
TOTAL +5V AND 3.3V AND 12V POWER NOT EXCEED 285 W
. TEMPERATURE RANGE : OPERATING 0
HOLD UP TIME: 16 ms MINIMUM AT FULL LOAD & NORMAL INPUT VOLTAGE
DIELECTRIC WITHSTAND: INPUT / OUTPUT 1500 VAC FOR 1 MINUTE
INPUT TO FRAME GROUND 1500 VAC FOR 1 MINUTE
EFFICIENCY: 63% TYPICAL, AT FULL LOAD
POWER GOOD SIGNAL: ON DELAY 100 ms TO 500 ms, OFF DELAY 1 ms
OVER LOAD PROTECTION: 110 ~ 160% MAX.
0
C --- 400C, STORAGE –200C --- 800C
OVER VOLTAGE PROTECTION:
+5V 5.7V ~ 6.5V, 3.3V 3.9 ~ 4.3V, 12V 13.3 ~ 14.3V
. OVER CURRENT PROTECTION : 5V, 12V, 3.3V 130% +/- 20% AT FULL LOAD
-5V, -12V SHORT CIRCUIT
EMI NOISE FILTER: FCC CLASS B, CISPR22 CLASS B
SAFETY: UL 1950, CSA 22.2 NO/ 950, TÜV IEC 950
REMOTE ON / OFF CONTROL
FAULTY ALARM METHODS : LED, BUZZER, TTL SIGNAL
HOT-SWAPPABLE / HOT-PLUGGABLE REDUNDANCY FUNCTION
BALANCE LOAD SHARING DESIGN
REMOTE SENSING DESIGN
ISOLATION: BUILT-IN IN THE POWER MODULE
MEET IEC-1000-3-2 CLASS D ( ACTIVE PFC )
DIMENSION: 82(H) X 101(W) X 300 (D) mm W Rear DC Fan
82(H) X 101(W) X 276 (D) mm W/O Rear DC Fan
COOLING : TWO 40 mm DC FANS ( ONE IN EACH MODULE )
ONE 80 mm DC FAN (REAR SIDE)
* I2C FEATURE (OPTIONAL )
Revision: A05
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INPUT CHARACTERISTICS: R2G-6350P
VOLTAGE: 90 ~ 264 VAC FULL RANGE
FREQUENCY : 47 ~ 63 Hz
INPUT CURRENT: 8.0 / 5.0 A FOR 115 / 230 VAC
INRUSH CURRENT: 60A / 80A MAX. FOR 115 / 230 VAC PER POWER MODULE
OUTPUT CHARACTERISTICS:
OUTPUT
VOLTAGE
5V 3.0 35
12V 2 22
-5V 0.1 0.5
-12V 0.1 0.8
3.3V 1.0 20
+5VSB 0.1 2.0
OUTPUT CURRENT REGULATION OUTPUT
MIN.[A] MAX.[A] PEAK(A) LOAD LINE
5%
±
5%
±
10%
±
10%
±
5%
±
5%
±
±
±
±
±
±
±
1%
1%
1%
1%
1%
1%
RIPPLE & NOISE
MAX. [P-P]
50mV
100mV
150mV
150mV
50mV
50mV
REMARKS: TOTAL CURRENT OF +5V AND + 3.3V NOT EXCEED 35 A
TOTAL +5V AND 3.3V AND 12V POWER NOT EXCEED 328 W
. TEMPERATURE RANGE : OPERATING 0
HOLD UP TIME: 16 ms MINIMUM AT FULL LOAD NORMAL INPUT VOLTAGE
DIELECTRIC WITHSTAND: INPUT / OUTPUT 1500 VAC FOR 1 MINUTE
INPUT TO FRAME GROUND 1500 VAC FOR 1 MINUTE
EFFICIENCY: 63% TYPICAL, AT FULL LOAD
POWER GOOD SIGNAL: ON DELAY 100 ms TO 500 ms, OFF DELAY 1 ms
OVER LOAD PROTECTION: 110 ~ 160% MAX.
0
C --- 400C, STORAGE –200C --- 700C
OVER VOLTAGE PROTECTION:
+5V 5.7V ~ 6.7V, 3.3V 3.7 ~ 4.7V, 12V 13.0 ~ 15.0V
. SHORT CIRCUIT : 5V,12V, 3.3V, AUTO-RECOVERED : 5VSB, -5V, -12V
EMI NOISE FILTER: FCC CLASS B, CISPR22 CLASS B
SAFETY: UL 1950, CSA 22.2 NO/ 950, TÜV IEC 950
REMOTE ON / OFF CONTROL
FAULTY ALARM METHODS : LED, BUZZER, TTL SIGNAL
HOT-SWAPPABLE / HOT-PLUGGABLE REDUNDANCY FUNCTION
N + 1 BALANCE LOAD SHARING DESIGN ON 5/12/3.3V CHANNEL
REMOTE SENSING DESIGN
ISOLATION: BUILT-IN IN THE POWER MODULE
MEET IEC-1000-3-2 CLASS D ( ACTIVE PFC )
DIMENSION: 82(H) X 101(W) X 276/300 (D) mm, 276mm -- W/O REAR DC FAN
COOLING : TWO 40 mm DC FANS ( ONE IN EACH MODULE )
ONE 80 mm DC FAN ( REAR SIDE )
I2C FEATURES ( OPTIONAL )
Revision: A02
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1.8 INSTALLATION & TESTING
Turn off (Remote off) the on/off switch.
Mount the power supply in the system chassis using the proper mounting tool,
the mounting holes in the power supply should match up with those in the case.
Attach the connectors to the M/B by following the M/B instructions, there are
various on connectors / pinouts in both power supply and M/B. They should
match each other; otherwise the connection will cause undetectable harms.
Attach all the remaining power supply connections to the various peripherals as
needed, these connectors are “keyed”, so there will be only one possible way to
connect them.
Before applying power to the system, make sure there are no loose or incorrect
connectors. You do not need to worry about the setting of AC Input because of
the units’ full range or auto voltage selecting features. Double check that all
connections to the M/B are matched properly. Maybe you would like to test the
redundancy function before you put back the cover of your system chassis.
Remote on the on/off switch, you will notice that if the power unit is operating
properly, then individual LEDs, external warning LEDs ( please refer to Sec. 1.10
for detail explanation) are lit Green, now remove one of the power modules by
pressing the click type handle, the warning buzzer in the power system will sound
and the external warning LED which display the status of the total power supply
system will change color to be Red, the individual LEDs (both on the rear side or
on the front control panel) indicating the power supply’s status will not light.
Meanwhile, the power supply will continue to backup the power output without
affecting the computer system’s operation.
The warning buzzer will continue sound, the user can reset the warning buzzer by
pressing the buzzer reset or use the reset switch which all can be found on the
front control panel of the system chassis, the reset switch can be connected by
wires lead provided from the power supply system (please refer to Sec. 1.10).
Insert the power module which is removed for testing earlier, the sound of the
warning buzzer will disappear, the external warning LED will turn Green again.
The LED indicating the status of the power supply will light again, test another
power supply by performing the similar procedure.
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If everything works out fine, then turn off (remote off) the power system, now put
back the cover of the case and tighten with the screws which you have retained
earlier. Now you have completed the installation of the R2G redundant power
supply system.
1.9 HOT-SWAP PROCEDURES
Please refer to the following when either power module or the fan found
defective.
A) Locate the defective power module by examining the individual LED (if LED
without light, it indicates the power module is defective).
***WARNING:
Please perform the above step carefully otherwise it may cause shut down the
whole system.
***WARNING:
Please do not remove the defective power module until you have worn gloves to
keep from be burned. This is due to the cover of the power module is been used as
heat sink for cooling, usually the temperature is around 50 ~ 60 degree Celsius
under full load condition.
B) Loosen the bracket screws of the power module
C) Remove the defective power module by pulling out method
***WARNING:
Please put aside the power module await for cooling down. Keep from other
people tough it until it is cool.
Page 20
D) Replace a new Good power module, insert the power module into the power
system to the end.
E) Check the LED of the power module light Green.
F) Check the LED which indicates the total power system status, that should be
from twinkle to Green.
G) Tighten the screws of the power module to fix it.
H) If you want to test this new power module in simulating defective situation.
Please refer to the Section 1.8 Installation & Testing Section.
Remarks: If the DC fan of the power module fail, you have to replace the power
module. Please follow with the Hot-Swap procedures of the power module.
1.10 PINOUTS AND FUNCTION OF THE CONNECTORS
*** Please be aware of the polarity***
THE LED CONNECTOR OF POWER#1 (300W ONLY)
PIN# COLOR VOLTAGE
1 GREEN +5V
2 BLACK GND
THE LED CONNECTOR OF POWER#2 (300W ONLY)
PIN# COLOR VOLTAGE
1 ORANGE +5V
2 BLACK GND
THE POWER SIGNAL CONNECTOR OF TOTAL POWER (300W ONLY)
PIN# COLOR CONDITION
1 RED POWER FAIL
2 BLACK GND
3 GREEN POWER OK
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THE BUZZER RESET SWITCH CONNECTOR (300W MODEL)
PIN# COLOR VOLTAGE
1 YELLOW +12V
2 BLACK GND
THE BUZZER RESET SWITCH CONNECTOR (350W MODEL)
PIN# COLOR VOLTAGE
1 YELLOW +5VSB(PULL HIGH)
2 BLACK GND
THE SIGNAL CONNECTOR OF POWER RESET
PIN# COLOR VOLTAGE
1 RED TTL SIGNAL
2 BLACK GND
TTL signal :
Sink current max. 5mA
Source current max. 50uA
Low Active --- Defective
High --- Normal
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1.11 TROUBLE SHOOTING
If you have followed these directions correctly, there should be no problem
occurred. Some common symptoms are: the system doesn’t work, buzzer sound,
work for a very short period, etc., please try the following steps to verify and
correct it:
1. Check all the connections (correct pinouts, loose connections, wrong direction,
etc).
2. Check for short-circuits or defective peripherals by unhooking each peripheral
once at a time. When the systems functions again, you have solved the
problem.
3. Once you hear the buzzer sound or see the LED with RED light, please be
aware of :
a. If the load is under the minimum / over the maximum
load of each channel
(please refer the Sec. 1.7 specification)?
b. If each power cord been well plugged into the inlet?
Suppose the above condition been happened, please unplug the power cords, wait
for 2 ~ 3 minutes for releasing the protection state, then test it again.
c. If buzzer still sound or the LED shows power module is defective, please
locate which power module is defective, perform hot-swap procedure (please
refer to the Sec. 1.9 Hot-swap procedures), sent the defective power module to
your vendor for RMA operation.
d. If you can not fix the problem, please contact with your vendor for supporting.
Page 23
The “RELIABILITY “ solution to E-application
新巨企業股份有限公司
ZIPPY TECHNOLOGY CORP.
POWER DIVISION
HEADQUARTERS
10F, NO. 50, MIN CHYUAN RD., SHIN-TIEN CITY,
TAIPEI HSIEN, TAIWAN, R.O.C.
TEL: 886-2-29188512 FAX: 886-2-29134969
WEB SITE: http://www.zippy.com.tw
E-mail：power@zippy.com.tw
USA OFFICE
U.S. East (Atlantic)
11 Melanie Lane, Unit 1B East Hanover, NJ 07936
TEL：1-973-463-9499 FAX：1-973-453-8014
E-mail：edward@zippy.com
U.S. W est (Pacific)
961 CALLE NEGOCIO, SAN CLEMENTE CA 92673, USA
TEL: 1-949 366 9525 FAX: 1- 949 366 9526
EMAIL: powerusa@zippy.com
CANADA OFFICE
ZIPPY TECHNOLOGY CANADA INC.
Unit3-3671 Viking Way Richmond, B.C V6V 2J5 Canada
TEL：1-604-278-6615 FAX：1-604-278-6624
CELL: 1-778-288-9622 E-mail：ian@zippy.com
Note:
*The description stated herein is subject to change without prior notice.
*All brand names and trademarks are the property of their respective owners
702-10034
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