Power Systems Design Guide

Transcription

1 Power Systems Design Guide R Series AC-DC Bulk Power Systems

2 CONTENTS ANR1 Overview 3 ANR2 Safety Considerations 4 ANR3 A Series Bulk Power Front End Cartridges 6 ANR3.01 OUTLINE SPECIFICATION 6 ANR3.02 OPERATION 8 ANR3.03 INSTALLATION 12 ANR3.04 MECHANICAL DETAILS 14 ANR3.05 TROUBLESHOOTING 15 ANR4 R Series Bulk Power Front End 1U Racks 17 ANR4.01 OUTLINE SPECIFICATION 17 ANR4.02 OPERATION 18 ANR4.03 INSTALLATION 20 ANR4.04 MECHANICAL DETAILS 23 ANR4.05 TROUBLESHOOTING 24 ANR5 R Series Multiple Racks 26 ANR5.01 OUTLINE SPECIFICATION 26 ANR5.02 OPERATION 26 ANR5.03 INSTALLATION 28 ANR5.04 MECHANICAL DETAILS 31 ANR5.05 TROUBLESHOOTING 32 ANR6 SCM-R Control & Monitor Unit 34 ANR6.01 OUTLINE SPECIFICATION 34 ANR6.02 OPERATION 34 ANR6.03 INSTALLATION 35 ANR6.04 MECHANICAL DETAILS 36 ANR6.05 TROUBLESHOOTING 37 ANR7 Accessories 38 ANR8 Start up sequence - Power Module Hot Plug-in 40 ANR9 Contact Details 41

3 ANR1 Overview The Powerstax Bulk Power Front End Systems are built up from a number of modules. The basic building blocks being the A Series Bulk Power Front End Cartridges. These are a range of power factor corrected units providing 750 to 1000W of output power with a wide range of output voltages from 24V to 56.2V. Module Power Input Voltage A W VAC A W VAC A W VAC Output Voltages 48.0, 54.5, 56.2 VDC 48.0, 54.5, 56.2 VDC 24.0 & 28.0 VDC For systems where in excess of 1000W is required or system redundancy is required then the R series range of power shelves are available. These high power density 1U racks take up to 3 of the A Series modules and can be staked up to 4 racks (4U) high to provide up to 12,000W. Range Description Total Power R3000 1U, 19 Rack for up to 3 x 3000W A1000 Modules R2400 1U, 19 Rack for up to 3 x 2400W A0800 Modules R2250 1U, 19 Rack for up to 3 x A0750 Modules 2250W The A Series modules provide an I 2 C interface for control, diagnostics and power management. The SCM-R is a 1U 19 Rack Mount Control & Monitor Unit designed for use with the A Series Modules used in the R Series racks. The digital controller communicates with the power modules by means of the I 2 C buss and allows adjustment of the system voltage in 100mV steps. Up to 12 hot swap power modules can be used in parallel and the controller can be used to read the current (with 100mA resolution) of the selected module. As an option a card can be fitted to the R Series racks to provide volt free relay contacts for the alarms from the individual power modules in the rack. The connection for the SCM-R module is passed through this card allowing the card and SCM-R to be used together.

4 ANR2 Safety Considerations Warnings This section contains important warnings relating to: AC Inputs Equipment Classification DC Outputs Modules Location and Environment Servicing EMC Compliance Batteries (if applicable) Inspecting the Equipment and Reporting Damage UL Approval AC Inputs - The AC power cords must be suitably rated for the environment and AC power distribution system. In addition, these AC power cords must be approved and installed to comply with local wiring regulations. The maximum length of each AC power cord should not exceed 3 m (9.84 feet), unless local wiring regulations permit otherwise. - Ensure that the AC supply is disconnected from those fused AC power sockets before checking or replacing their respective fuses. - The maximum earth leakage current of each power module is 1.7 ma. Ensure that any upstream Residual Current Devices (RCDs) is appropriately rated. - Power modules and single racks have been approved and tested on a 20A branch circuit. Alternative protection would need to consider discrimination with module input fuse. Equipment Classification Power modules and power systems are classified as Class 1 equipment that must be provided with an earth connected to the Protective Earthing Conductor in the building wiring. The earth conductor of each AC power cord must be connected to the Protective Earthing Conductor in the building wiring. DC Outputs - The DC output of a module is floating with respect to earth, in customer applications either the positive or negative output of the DC output may be referenced to earth if required. Modules - The modules are designed to operate at elevated temperature and may become hazardous to touch. Care must be exercised by the system designers to prevent possible contact. - Do not attempt to disassemble the module. Return them, (in their original packaging) along with the completed Return Materials Authorization, to your local Powerstax product representative for replacement or repair. Location and Environment - The modules are intended for use within suitable enclosures and safety must be considered in positioning the modules. - The location must provide adequate airflow around the modules and racks, in an atmosphere free from excessive dust, corrosive fumes or conductive contaminants. - Dust build-up around the modules or rack may cause premature failure. In dusty environments, either install the module in a sealed and airconditioned equipment room, or provide fan assisted filtered air to create a positive pressure environment inside the equipment room. Both options require regular cleaning of the air filters. - Do not allow water or any foreign object to enter the module. Do not place objects containing liquid on top of or near the unit. - To reduce the risk of electric shock and maintain optimum system cooling, always cover empty slots with blanking panels. To avoid electrical shock, do not place hands inside the shelf. Servicing - The DC modules contain hazardous voltages. Do not attempt to disassemble or service the unit if you are not qualified. Only service personnel of Powerstax Plc or their authorized service agents are permitted to service the unit. EMC Compliance - The power modules & racks may be used in close proximity to other electronic equipment provided installation is carried out according to instructions in this guide. However, proper installation and compliance with EMC standards does not guarantee that the power modules or racks will not respond to electromagnetic disturbances, or will not cause interference to other equipment in a particular installation.

5 Batteries (if applicable) If the outputs of the modules or racks are connected to a battery system extra precautions need to be considered. - Always install the batteries according to the relevant battery manufacturer s instructions. - Batteries are powerful sources of energy and present a potential electrical shock and energy hazard. The energy hazard is always present, even if the batteries are not connected. Avoid short circuiting terminals of opposite polarity. Remove or cover rings, wristwatch and other metal jewellery that might be exposed to battery terminals, before installing batteries. Always use insulated tools. - Ensure protection devices (fuses etc) in series with the battery are suitable for the potential short circuit current. Inspecting the Equipment and Reporting Damage - Unpack the power module, rack or controller and inspect it carefully for possible damage that may have occurred while in transit. Next, check the equipment against the packing list (supplied with the equipment) and ensure that you have received the correct type of modules etc. - Report any damage or incorrect shipment immediately to your local Powerstax product representative. - Keep the original packaging. You will need it if any equipment needs to be returned to your local Powerstax product representative. UL Approval The range of the power modules and racks are UL recognized under file number E Under this file there are a number of conditions of acceptability which are covered in the relevant parts of this guide. Those relevant to the end user are detailed below: For use in or with complete equipment where the acceptability of the combination is determined by Underwriters Laboratories Inc. When installed in an end-product, consideration must be given to the following: - A suitable Electrical & Fire enclosure shall be provided in the end product. - The products were tested on a 20A branch circuit. If used on a branch circuit greater than this, additional testing may be required. - All secondary output circuits are SELV. - The secondary output circuit exceed 240VA at a voltage of 2V or more and are hazardous energy levels. - The input and output connectors are suitable for factory wiring only. - The equipment has been evaluated for use in a pollution degree 2 environment. - A suitable Earth/Bonding shall be provided in the end product.

6 ANR3 A Series Bulk Power Front End Cartridges ANR3.01 OUTLINE SPECIFICATION ANR Input Units A0750 & A0800 A1000 Min Nom/Typ Max Min Nom/Typ Max Input Voltage VAC Input Frequency Hz Inrush Current A Power Factor Efficiency % Input Leakage Current ma Hold up time 3 ms An internal fuse is provided for input protection in compliance with safety agency requirements. Notes 1 400Hz input frequency available (with safety approvals) contact Powerstax for details. 2 Power factor at output load 50% of full load. 3 Hold up time for A0750 at 24V, 600W, for A0800 at 48V, 800W. ANR Output A XXX Units Min Norm/Typ Max Set point -240 Volts Volts 28.0 Rated current -240 Amps Amps Regulation (load, line, temp & set point) % Remote sense drop Volts 0.5 Over current limit Amps 40 Overvoltage set point Volts Ripple (20MHz bandwidth) mvp-p 150 Noise (20MHz bandwidth) mvp-p 300 Output rise time ms Transient Response % Active current sharing differential A ±3.2 Efficiency, full 120VAC % load & ORing Diode 264VAC % Start up delay S Turn on delay ms 250

7 Set point A XXX A XXX Units Min Norm/Typ Max Min Norm/Typ Max -480 Volts Volts Volts Amps Amps Rated current -562 Amps Regulation (load, line, temp & set point) % Remote sense drop Volts Over current limit Amps Overvoltage set point Volts Ripple & Noise (20MHz mvp-p bandwidth) Output rise time ms Transient Response % Active current sharing differential A ±1.7 ±2.1 Efficiency, full 120VAC % (180VAC) load & ORing Diode 264VAC % Start up delay S Turn On delay ms 200 ANR Environmental Characteristics Units Min Norm/Typ Max Storage temperature C A C 0 60 Operating A C 0 60 temperature Acoustic noise A C 0 70 A0750 dba A0800 dba A1000 dba 60 Humidity (non-condensing) % 5 95 Altitude 4 Feet ,000 ESD IEC Level 3 stand-alone Electromagnetic Immunity IEC Level 2 stand-alone Primary to Secondary VAC 3000 Isolation Voltage Primary to chassis GND VAC 1500 Secondary to chassis GND Input 80% load, T A = 30 C Vibration Shock VAC 500 hours 4x10 5 Meets IEC Meets IEC

8 Notes: 1 Derating 5%/ C from 50 C to 60 C 2 Derating 5%/ C from 50 C to 60 C 3 Derating 2.5%/ C from 50 C to 70 C 4 Derating 2 C/1000ft above 8000ft. ANR Mechanics The mechanics for the three types of A series power modules are identical and the detailed drawings are shown in Section ANR3.04. The outline details are given below Depth - 276mm (10.87 ) excluding front panel handles Width 144.8mm (5.70 ) Height 40.8mm (1.61 ) Weight 2.2kg (4.84lb) typical unpacked ANR3.02 OPERATION The Powerstax A series of front-end power module is specifically designed to operate as an integral part of a complete distributed power system, with or without battery backup. The module can also be used in stand alone situations. A full complement of protection, alarm and control features has been incorporated into the power unit to provide the versatility of applications. The flexible feature set is described in the sections below. ANR Visual Indicators Each power module has two LEDs to provide visual status information. The table below describes the function of these LEDs. Colour Meaning Illumination LED 1 Input voltage Green AC OK OK Powered up Green and operating LED 2 normally Output Internal fault or OK Amber overload condition ANR Output Current Over current protection In the event of an overload condition, the power supply limits the output current. The graph shows the typical voltage current characteristics of an A0800. Output Characteristics 55 Output Voltage Output Current

9 Dependent upon the output voltage set the characteristics follow a near flat characteristic until the over current limit point is reached. The over current characteristic allows the output current to increase as the voltage falls; this allows the units to power modules with a constant power requirement. At a voltage of approx 39V the unit will operate in a trip and restart (or hic-up) mode. On removal of the overload the unit automatically recovers. Overvoltage & Overtemperature Protection The power unit turns itself off before the output voltage reaches the OVP threshold. In the event of an overtemperature condition, the power unit protects itself by shutting off, restarting automatically after cooling down. ANR Remote Sense (RS+, RS-) Remote sensing allows for the power module to provide a constant voltage at the load despite voltage drops in the connecting cables. When not in use the remote sense pins should be connected to the output pins at the power module or left disconnected. This provides a stabilized voltage at the output pins. To compensate for the voltage drops on the output cable the remote sense leads should be connected as close to the load as possible. To avoid noise pick up the sense leads should either be screened or twisted or run parallel. Care should be taken to ensure that the correct polarity sense is connected at the load. A Series Power module V+ RS+ RS- V- The maximum volt drop that can be compensated for is defined in the specification for each module, 0.5V for standard modules. It should be noted that this is the total voltage drop in both the positive and negative lines (i.e. 0.25V in each). Potential break points in the load leads should not be included in the sense circuit. This LOAD particularly applies to switches, circuit breakers or fuses. The opening of the device would remove the connection between output and sense and remove the compensation. Clearly where this is impractical the output should be connected as local sense and the output increased to compensate for the loss in the device. Alternatively where the potential break point is close to the load, the remote sense could be taken to the module side of this break point ANR I²C Serial Bus Interface support The power module provides an I²C serial bus interface to receive/transmit data. The module voltage and current can be monitored on this I²C and is used by the SMC-R to control the output voltage and adjust the current share between modules. The I²C serial bus consists of 3 lines, SDA: Data signal I/O for I²C functionality. SCL: Clock signal input for I²C functionality. RTN: Return for I²C bus. ANR Current Share The parallel connection of power modules is frequently required in order to boost the output power level. The modules provide a single-wire interface between each of the power units which forces them to share the load current equally. The output current can be reported through the I²C bus. A simple connection between the current share pins CS, RS+ and RS- pins between the Power Modules is all that is required. Use of a twisted pair for the connection between the RS± pins is recommended. A diode is included in the output of the power unit to protect the DC bus during a power supply failure or hot plugging of the power unit. In the R series racks these interconnections are made within the rack, the remote sense and current share pins etc are bought out to the DSB25 connector on the rear of the rack. These are then connected for multiple racks in the same way as individual modules. Note: The power modules should be mounted close to one another to make the connection +Vout and - Vout between power modules as short as practicable.

10 Only one set of RS± connections is required to be connected to the load when operating modules in parallel as the RS± connections between modules is adequate. A Series Power module V+ RS+ CS RS- V- V+ RS+ CS RS- V- LOAD A Series Power module ANR Remote On/Off This is an input signal referenced to the negative output. Shorting this signal to the negative output will turn on the power unit. Delay between this signal going high and the output falling out of regulation is between 1 and 4 ms. After the On/Off signal is again shorted to negative output there is a delay of a maximum of 200ms before the output is in regulation again. Note: the 0V reference ground for the ON/OFF pin is the signal return of the module ANR Status Signals The following are the optically isolated opencollector signals, for both the logic low level is lower than 0.6V with the sink current of the photo-transistor less than 1mA. The output transistors are in NPN configuration with a max collector voltage of 40V and max forward current of 80mA. Max power dissipation in these devices is 150mW at 25 deg C derating by 1.5mW/deg C. DC FAIL: This signal indicates the output fail. It becomes low with a turn on delay of 100 to 600mS after the output voltage reaches in the regulation window. It will go to a high level at least 1mS before output voltage falls outside of the regulation window. OTP: This signal indicates fan fail or over temperature. It becomes low with a turn on delay of 100 to 600mS after the output voltage reaches in the regulation window. It will go to a high level 200mS before the unit shuts down if a fan fails or an over temperature is sensed. ANR INT. bus The intermediate DC bus is a DC output from the power module for shelf internal usage. There is a reserved slot for a DC/DC converter on the back plane of the power shelf. The DC/DC may transfer DC bus voltage to a standby DC output that may be customized upon request. ANR Input / Output Connector The input / output connector is a Positronic PCIB24W9M400A1 with 9 power pins and 15 signal pins. 3 out of the 9 power pins are for the AC input. A0 A3 are address lines for the I²C serial bus, these are set to either 0 or 1 external to the module to define the address. This is done within the rack on the R series.

11 ANR Output timing The rise and fall of the output with respect to the input supply and DC ON/OFF is shown in the diagrams below:- T1 T2 T3 T4 T5 Start up delay Hold up time Turn on delay Min ~ 20 min Typ dependent on Max output voltage 200 Units ms ms ms ms ms

12 ANR3.03 INSTALLATION ANR Prior to installation The safety section of this guide must be carefully read to ensure that the module is correctly installed, if in any doubt please contact Powerstax. - Unpack the DC module and inspect it carefully for possible damage that may have occurred while in transit. Next, check the equipment against the packing list (supplied with the equipment) and ensure that you have received the correct type of DC modules. - Report any damage or incorrect shipment immediately to your local Powerstax product representative. - Keep the original packaging until the modules have been fully integrated and tested. You may need it for any onward shipment or if any equipment needs to be returned to your local Powerstax product representative. ANR Fusing & Surge suppression As the Power Modules have internal protection against excessive input current, an external input fuse is needed only to protect the input cabling etc, from an electrical safety point of view. This fuse should be selected to withstand the maximum input current at low input voltage. However fuse selection should take into account that fuses de-rate with temperature and time and may therefore open under normal conditions. If more than one module is to be supplied through a single protection device, care must be taken to ensure correct discrimination is provided. If this upstream device is too fast acting, or rated too low then it could fail before the module fuse removing the supply to more than just the failed module. In the case of a single module this is less of a problem however care should be taken that the upstream device does not cause nuisance tripping. When sizing the fuse, consideration should be made of the wide input range of the power modules and that the current at these lower input voltages will be significantly higher than at higher inputs. It is possible for the input voltage to drop during a brown-out or during a power failure or recovery. If the protection device is not suitably sized it could open preventing the module from operating once the input supply has recovered. The input of the power module has a number of devices designed to protect the unit from the affects of surges and spikes on the input of the module. Clearly there is a limit as to the level of spikes etc the module can withstand without damage. The modules will meet the levels defined in IEC Level 3 & IEC Level 3 with damage free operation. Input surges or spikes above these levels may cause damage to the modules, as may operation above the maximum input voltage. Operation below the minimum input voltage may cause the module to shut down due to over temperature but should not give rise to any damage. ANR Connection details The connector on the A series power modules is a Positronics PCIB24W9M400A1 that has 9 power pins and 15 signal pins. 3 out of the 9 power pins are for the AC input, the pinout is shown above. The mating half of the connector is a Positronics PCIB24W9FXXX, where the XXX denotes options for the different connection methods (i.e. pcb, pressfit etc.) In making the connections to the connector a number of issues must be considered:

13 Safety The connector carries ac input, dc output and signals. The signals and output are all secondary and so care should be taken the creepage and clearance distances are not reduced in the wiring or pcb used to connect to the output connector. Conductors (cables or pcb tracks) should be sized to withstand the maximum current available at the connection, i.e. for the ac input all three connections should be able to withstand the current of the upstream protection, the power conductors should be sized and marked in accord with local wiring regulations. Cooling The connector is in the cooling air path that flows from the fans at the front to the grill at the back. Care should be taken to ensure that any wiring or pcb used to connect to the output connector does not significantly impede air flow. Required pins Irrespective of the load current expected to be drawn all of the output connectors should be used, under fault conditions the power module could still supply the full current and so over run the connector if not all poles are used. Not all of the signal pins may be required; indeed for stand alone operation it may be that none of the signal pins would be required. Those likely to be used would be the remote sense pins (9 & 10), the remote ON/OFF pin (7) and the alarm pins OTP (16) and DC Fail (19). All of these pins are referenced to the signal return (14). ANR Cooling The power modules are fitted with two fans to provide cooling for the module; however care must be taken not to adversely effect this cooling. The modules sense the internal temperature of the unit and will protect themselves from excessive temperature. The cooling may be adversely affected due to a number of causes: - Objects preventing the fans from turning, this may be an accidental effect. The power module monitors the fan rotation and if a fan becomes locked the module will shut down. - Blocking the air from entering the module. Clearly for the cooling to operate correctly the fans must be able to draw the air in easily, this means that there should be no obstructions around the front of the module. In general a space of approx 50mm is sufficient to allow the fans to draw the air in provided that there are not obstructions on all sides. - Blocking the air from exiting the module. As described previously the warm exhaust air must be able to exit the module without any significant impedance, as with the front of the module care must be taken to ensure that there are no obstructions to the air flow. - Heat from other devices. If the power module is fitted in a system with other heat generating sources care must be taken that the hot exhaust air from these modules is not drawn into the fans of the power module. - Ambient temperature too high. Clearly if the ambient around the power module is too high then the fans will not be able to cool the module correctly. Care needs to be taken with the system as a whole to ensure that its maximum ambient does not exceed that of the module or that insufficient cooling within the system causes that internal ambient to exceed that of the module. ANR Zero load operation The power module is fitted with a switched dummy load hence if the output load falls to zero this dummy load is connected ensuring that the module still sees a small load. This has a number of advantages as it prevents the PWM circuit from trying to control the output at zero load, which in many units means operation in the audible region. This also improves the transient response of the module at light load as the PWM circuit does not have to recover from being fully off load. This is an automatic feature and does not affect any other parts of the modules operation. ANR Start up sequence For single power modules the start up process is as detailed below: - Connect power and signal connections with reference to the safety and installation sections. - Apply AC power to module - Check both front panel LED s light green and that the voltage at the load is correct.

14 ANR3.04 MECHANICAL DETAILS Notes - Tolerances are ± 0.1mm unless otherwise stated.

15 ANR3.05 TROUBLESHOOTING The table below shows a number of common points that should be considered before concluding that a module may be damaged. Problem Possible Cause Required Action No output voltage Output voltage too high Output voltage too low Regulation (Load or Line) to high Input voltage outside operating range Input or output connections not made correctly ON / OFF pin incorrect Sense terminals incorrect Ambient or module temperature too high Output overload Sense terminals incorrect External voltage applied Input voltage outside operating range Input or output connections not made correctly Sense terminals incorrect Output in current limit Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct. High impedance joints can result in incorrect operation. The ON / OFF pin should be pulled low (>0.8V) to ensure correct operation Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. Check that the ambient temperature does not exceed the maximum or that the cooling has not been adversely affected i.e. fans blocked. An output short circuit will cause the module to enter a trip & restart (hic-up) mode that may appear as no output. Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. If an external voltage has been applied to the module either disconnect it or reduce the level to within specification. Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct, incorrect polarity connection could result in the output appearing low. High impedance joints can result in incorrect operation. Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. Check that the output current is not in excess of the rated level, the current limit will reduce the output voltage. Reduce the output current and check that the output voltage returns to the correct level. Input voltage outside operating Check the input voltage is within the specified range limits. Input or output connections not Check that the input and output connections are made correctly correct. High impedance joints can result in incorrect operation. Sense terminals incorrect Check that the sense terminals have been

16 Module produces audible noise Input or output cables cross section area insufficient. Output in current limit External voltage source connected to the output connected correctly as described above. Specific attention should be paid to any components within the remote sense path. If the input and output cables (or pcb tracks) are not of a sufficient cross sectional area they appear as a series resistance. This will add to the level of regulation in either the input or output. Check that the output current is not in excess of the rated level. When operating in current limit the module may produce an audible noise. Reduce the output current and check that the output voltage returns to the correct level. An external voltage source connected to the output could take over the load from the module hence appearing as a zero load. If the external source is above the overvoltage level of the unit then the OVP circuit will operate the unit in a trip & restart mode producing an audible noise. Removing or reducing the level of this external voltage should prevent this. This will still occur even with the zero load board fitted as the external supply will provide the current for this load as well. Returns Procedure If after these checks have been made, the module still appears to have a fault, please contact your local Powerstax product representative. A Returns Material Authorization number will be issued. This will be used to track the module on its return and any further action that may be required can be considered. When contacting your local Powerstax product representative please include as much information as possible, including product type & serial number, details of suspected fault, details of application including load, input voltage, heatsinking etc.

17 ANR4 R Series Bulk Power Front End 1U Racks ANR4.01 OUTLINE SPECIFICATION ANR General The part number of the R series racks defines the modules to be used within it and the rack options as shown below: The power modules are designed with ORing diodes at the output to prevent the module from bringing down the bus voltage either during hot insertion or as the result of a module fault. The connectors between the power module and shelf are selected to provide blind mating and support hot insertion and removal. Active current sharing between paralleled modules and shelves distribute the load evenly between multiple power units. The A series power modules provide a number of status report and remote control features. Those signals are aggregated on the host interface on the back of the shelf. RXXXX X X X X Output Power Output connector option 2250 = 2250W (3x750W) 1 = Terminal Block 2400 = 2400W (3x800W) 3000 = 3000W (3x1000W) AC Input connector, 1 = IEC320 connector for each module Rack mount position Interface connector On/off 1,2,3 AC Fail 1,2,3 Vaux 0 = Flush (standard) 0 = N.C. N.C. N.C. 1 = 127mm back from front panel 1 = On (default) N.C. N.C. ANR Input The R series racks as a default have an IEC320 socket for each module. This means that the rating for each input is as per the module fitted. As described below the basic details are Rack Modules Fitted Input voltage range R x A VAC R x A VAC R x A VAC Max input current (full load, min input voltage). 11.6A 11.9A 7.0 The currents given are for each individual unit, the max per rack could be three times this level. Clearly this has to be considered when providing a supply for the rack. An internal fuse is provided in each power module, external fusing may be required for input protection in compliance with safety agency requirements. Care should be taken if a single protection device (fuse or mcb) is used for all the inputs of the rack that discrimination is allowed for between this device and the power module fuse. ANR Output As with the input, the output of the rack is dependent upon the modules fitted to it. The modules and racks can be used either as a bulk power system or as an N+1 redundancy system. The total powers for a single rack are given below

18 R2250 R2400 R3000 Bulk Power System N+1 Redundant System Max Power Max Current Max Power Max Current A W 93.75A 1500W 62.50A A W 80.36A 1500W 53.57A A W 50.00A 1600W 33.33A A W 44.04A 1600W 29.36A A W 42.70A 1600W 28.47A A W 62.50A 2000W 41.67A A W 55.05A 2000W 36.70A A W 53.38A 2000W 35.59A ANR Environmental Characteristics As the only active components on the racks are monitoring circuits the environmental specifications for the R series racks are as for the A series modules used within them. The shelf will meet CISPR Class B, conducted emissions EN55022 stand-alone. ANR Mechanics The mechanics for the three types of R series racks are identical and the detailed drawings are shown in Section ANR4.04. The outline details for a single rack are given below, (without power modules fitted) Depth 335.5mm (13.2 ) Width 482.6mm (19.0 ) at front of rack, (17.32 ) at rear Height 43.5mm (1.71 ) Weight XXkg (YYlb) typical unpacked ANR4.02 OPERATION Clearly all of the features detailed for the power modules are also available from the R series racks. The signals are bought out to the 25 way D connector on the rear of the rack. Common features such as remote sense or current share are bought out as a connection for the complete rack. Other features, such as the alarms, are bought out per module so that the module producing the alarm can be identified if required. Input Connector The R series power shelves can be used with any standard global line voltages. The standard AC input connection to the shelf is through three IEC320 type connector rated at 10A / 250Vac in Europe/Asia and 15A /120Vac in North America. Output Connector The shelf has two terminal blocks for DC output (each with three M4 screws). They are labelled V+ and V-, respectively, on the body of the shelf next to the terminal block. The V+ and V- are floating with respect to frame GND. Frame GND may be connected to either bus depending upon the customer requirements for positive bus or negative bus, or the output can be floated with respect to frame GND. Interface Connector The power shelf has a 25-pin, D-type female interface connector on the back. The power system can be monitored and controlled through this interface. The table below shows the pin allocation and function. Pin Number Signal Name Description 1 DC Fail 2 DC fail signal of module 2 2 A2 I 2 C address bit 2 3 A3 I 2 C address bit 3 4 ON SYNC (optional) Power on synchronization for multi shelf operation

19 5 SDA I 2 C serial data bus 6 SCL I 2 C clock 7 NC Do not use, internal shelf supply 8 On/Off 1 (optional) Remote ON/OFF control of module 1 9 OTP 1 Fan fail or over temp signal of module 1 10 On/Off 2 (optional) Remote ON/OFF control of module 2 11 Vaux (optional) Aux voltage for customer usage 12 DC Fail 1 DC fail signal of module 1 13 AC Fail 3 (optional) AC fail signal of module 3 14 OTP 3 Fan fail or over temp signal of module 3 15 DC Fail 3 DC fail signal of module 3 16 INT BUS Intermediate DC bus for internal shelf use 17 AC Fail 1 (optional) AC fail signal of module 1 18 On/Off 3 (optional) Remote ON/OFF control of module 1 19 SRTN Signal & Vaux return 20 RS- Remote sense ve 21 OTP 2 Fan fail or over temp signal of module 2 22 RS+ Remote sense +ve 23 AC Fail 2 (optional) AC fail signal of module 2 24 CS Single wire, current share interface 25 V- V- ANR Addressing Unless a SMC-R control & monitor unit is to be used with a rack the addressing of the units is not important. The I 2 C serial bus uses 4 address lines A0 to A3 to determine the address of the individual modules; A0 & A1 are set within the rack. A2 & A3 can either be left disconnected or connected to V-, if connected to V- then the modules will be reported as 1, 2 & 3, if not connected then the modules will be reported as 10, 11, & 12. Clearly if a SMC-R module is not being used then the connection of the address lines has no affect the operation of the rack. ANR N+1 Redundancy As previously mentioned the racks can be connected to provide N+1 redundancy. That is in a single rack, the load equivalent to two power modules can be supplied and by adding a third module, should one module fail, or the supply to that module fail, then the load is still supported. In practice the modules share the load equally between them and in the event of a failure the remaining modules share the extra load equally. The modules have output ORing diodes built in to prevent failure of a module causing the system to fail, however there are a number of issues that must be considered to prevent complete failures of a redundant system. Input protection Each module is fitted with an ac input fuse; in the case of a failure in the module this fuse will protect the module from excessive current. If more than one module is to be supplied through a single protection device, care must be taken to ensure correct discrimination is provided. If the upstream device is too fast acting, or rated too low then it could fail before the module fuse removing the supply to more than just the failed module. Input supply current During normal operation the output load of the rack would be shared equally by the modules connected however under certain conditions (fault conditions or battery recharge) all the connected modules may operate at full power. The input supply must be sized to allow all the connected modules to operate at full power, not just the expected system load. Output load Because the system has an extra module connected, it is possible for the load to draw more power than expected. If this exceeds the rating of the modules without the redundant module (i.e. the N number of modules) then in the event of a module failure the load would not be supported. Particular care should be taken in situations where extra equipment can be added after initial installation that may increase the overall load.

20 A number of features are shown here that do not appear on the individual power modules. ANR AC Fail Option This signal warns of a failure of the ac input and provides an optically isolated open-collector signal. The logic low level is lower than 0.6V with the sink current of the photo-transistor less than 1mA. This signal will change state prior to the DC Fail signal from the module. ANR Power on synchronization option This option allows for synchronisation of the start up of multiple racks, connecting the pin between racks ensures that the modules of all of the racks start together. With this option fitted the ON/OFF control of individual racks is disabled. The option codes for DC ON/OFF and AC Fail are shown below: RXXXX-X-011 Power on synchronisation not fitted, power module ON/OFF can be controlled by system. RXXXX-X-111 Power on synchronisation fitted, power module ON/OFF cannot be controlled by system. RXXXX-X-211 AC Fail fitted, power on synchronisation not fitted, power module ON/OFF can be controlled by system. ANR Vaux Option It is possible to provide an optional house keeping output derived from the main output, for systems supplying batteries this output would be battery backed. Contact Powerstax for details of the output available. ANR4.03 INSTALLATION ANR Prior to installation The safety section of this guide must be carefully read to ensure that the rack and modules are correctly installed, if in any doubt please contact Powerstax. - Unpack the rack and DC modules and inspect them carefully for any possible damage that may have occurred while in transit. Next, check the equipment against the packing list (supplied with the equipment) and ensure that you have received the correct type of rack and DC modules. - Report any damage or incorrect shipment immediately to your local Powerstax product representative. - Keep the original packaging until the rack & modules have been fully integrated and tested. You may need it for any onward shipment or if any equipment needs to be returned to your local Powerstax product representative. ANR Fusing & Surge suppression As the Power Modules have internal protection against excessive input current, an external input fuse is needed only to protect the input cabling etc, from an electrical safety point of view. This fuse should be selected to withstand the maximum input current at low input voltage. Fuse selection should also take into account that fuses de-rate with temperature and time and may therefore open under normal conditions. If more than one module is to be supplied through a single protection device, care must be taken to ensure correct discrimination is provided. If the upstream device is too fast acting, or rated too low then it could fail before the module fuse removing the supply to more than just the failed module. When sizing the fuse, consideration should be made of the wide input range of the power modules and that the current at these lower input voltages will be significantly higher than at higher inputs. It is possible for the input voltage to drop during a brown-out or during a power failure or recovery. If the protection device is not suitably sized it could open preventing the module from operating once the input supply has recovered. The maximum earth leakage current of each power module is 1.7mA, multiple power modules may be required to be connected to separate building branch circuits. Consideration should be given to any upstream Residual Current Devices (RCDs). The input of the power module has a number of devices designed to protect the unit from the

21 affects of surges and spikes on the input of the module. Clearly there is a limit as to the level of spikes etc the module can withstand without damage. The modules will meet the levels defined in IEC Level 3 & IEC Level 3 with damage free operation. Input surges or spikes above these levels may cause damage to the modules, as may operation above the maximum input voltage. Operation below the minimum input voltage may cause the module to shut down due to over temperature but should not give rise to any damage. ANR Connection details The R series racks provide separate connections for the ac input, dc output and the signals. The ac input is made via 3 IEC320 connectors, one for each module. The connectors used are rated at 10A for high input voltage and UL recognised for 15A, care should be taken that the mating connector used is also rated correctly. Optional clips are available to ensure the IEC connector does not become disconnected. The DC output is available by two terminal blocks on each rack, one for the positive and one for the negative. Options are available to provide alternatives to the screws terminals. In making the connections to the connector a number of issues must be considered: Safety Although the ac input, dc output and signals connectors are separate, care should be taken to ensure the creepage and clearance distances are not reduced in the wiring. Conductors should be sized to withstand the maximum current available at the connection, i.e. for the ac input the live, neutral and earth cables should be able to withstand the current of the upstream protection, the power conductors should be sized and marked in accord with local wiring regulations. The output cables should be designed for the full current capacity of the rack, under fault conditions the power modules could still supply the full current and so over run the cables. Cooling The connectors are in the cooling air path care should be taken to ensure that any wiring used to connect to the input or output connectors does not significantly impede air flow. Required signal pins Not all of the signal pins may be required; indeed for stand alone operation none of the signal pins may be required. Those likely to be used would be the remote sense pins (20 & 22), the remote ON/OFF pins (8, 10 & 18) and the alarm pins OTP (9, 14 & 21) and DC Fail (1, 12 &15). All of referenced to the signal return (19). For multiple racks, or for use with the SMC-R other connections would be required the table below outlines the recommended connections for a number of applications. Pin No Signal Single stand alone rack Single rack with SMC-R 1 DC Fail 2 Monitor if required Monitor if required 2 A2 Leave open or connect to V- Connect to V- 3 A3 Leave open or connect to V- Connect to V- 4 ON SYNC (optional) N.C. N.C. 5 SDA N.C. Connect between racks and to SMC-R 6 SCL N.C. Connect between racks and to SMC-R 7 NC Do not use, internal shelf supply connect between racks 8 On/Off 1 (optional) RXXXX-X-0(or 2), connect to V- if not used, or TTL L to power on TTL H to power off. RXXXX-X-1 leave open. 9 OTP 1 Add a resistor to Vcc if monitored or leave open if not used. 10 On/Off 2 (optional) RXXXX-X-0(or 2), connect to V- if not used, or TTL L to power on TTL H to power off. RXXXX-X-1 leave open. 11 Vaux (optional) Aux voltage for customer usage, where fitted. 12 DC Fail 1 Add a resistor to Vcc if monitored or leave open if not used. 13 AC Fail 3 (optional) Add a resistor to Vcc if monitored or leave open if not used. 14 OTP 3 Add a resistor to Vcc if monitored or leave open if not used. 15 DC Fail 3 Add a resistor to Vcc if monitored or leave open if not used. 16 INT BUS Intermediate DC bus for internal shelf use, leave open.

22 17 AC Fail 1 (optional) Add a resistor to Vcc if monitored or leave open if not used. 18 On/Off 3 (optional) RXXXX-X-0(or 2), connect to V- if not used, or TTL L to power on TTL H to power off. RXXXX-X-1 leave open. 19 SRTN Use as signal reference if required Connect between racks and to SMC-R 20 RS- Connect to load ve if used or leave open if not used. 21 OTP 2 Add a resistor to Vcc if monitored or leave open if not used. 22 RS+ Connect to load +ve if used or leave open if not used. 23 AC Fail 2 (optional) Add a resistor to Vcc if monitored or leave open if not used. 24 CS Leave open 25 V- Ref for remote On/Off if used ANR Addressing In a system where the I 2 C bus is not being used then there is no requirement to set the addresses of the racks. If however the I 2 C bus is to be used, i.e. the SMC-R controller is fitted, it is important that the addressing is set. The table below shows the A2 & A3 settings to provide the rack addressing, A0 & A1 are set within the rack To provide a logic 1 the pins should be pulled high through a resistor to 5V (with respect to V-), care should be taken to ensure that this signal does not exceed 5V. To provide a logic 0 the pins should be pulled low to V-. Shelf Module No A3 A2 A1 A ANR Cooling The power modules are fitted with two fans to provide cooling for the module; care must be taken not to adversely effect this cooling. The modules sense the internal temperature of the unit and will protect themselves from excessive temperature. The cooling may be affected due to a number of causes: - Fans locked, this may be an accidental effect. The power module monitors the fan rotation and if a fan becomes locked the module will shut down. - Blocking the air from entering the module. For the cooling to operate correctly the fans must be able to draw the air in easily, hence there should be no obstructions around the front of the rack. In general a space of approx 50mm is sufficient to allow the fans to draw the air in provided that there are not obstructions on all sides. - Blocking the air from exiting the rack. The warm exhaust air must be able to exit the module without any significant impedance; care must be taken to ensure that there are no obstructions to the air flow. - Heat from other devices. If the rack is fitted in a system with other heat generating sources care must be taken that the hot exhaust air from these modules is not drawn into the fans of the power modules. - Ambient temperature too high. Care should be taken with the system as a whole to ensure that insufficient cooling within the system does not cause the internal ambient to exceed that of the rack. ANR Zero load operation As each power module is fitted with a switched dummy load, there are no requirements to draw a minimum load. It is possible however that at light loads the sharing between modules will not be accurate. ANR Start up sequence Without SMC-R For single power racks without SMC-R the start up process is as detailed below: - Connect power and signal connections on the rack with reference to the safety and installation sections. - Insert Power Modules into shelf

23 - Plug AC power cords into AC inputs - Apply AC power to modules - Check both front panel LED s light green and that the voltage at the load is correct. With SMC-R For single power racks with SMC-R the start up process is as detailed below: - Connect power and signal connections on the rack with reference to the safety and installation sections. - Connect power and signal connections to the SMC-R with reference to the safety and installation sections. - Insert Power Modules into shelf - Plug AC power cords into AC inputs - Apply AC power to modules - Check both front panel LED s light green and that the voltage at the load is correct. - Check the LED s on the SMC-R light correctly and toggle through the modules fitted to ensure that the voltage & current shown is correct. ANR4.04 MECHANICAL DETAILS Notes - Tolerances are ± 0.1mm unless otherwise stated. - Mounting ears can be mounted 100.8mm from front of rack (option)

24 ANR4.05 TROUBLESHOOTING The table below shows a number of common points that should be considered before concluding that a module may be damaged. Problem Possible Cause Required Action No output voltage Output voltage too high Output voltage too low Regulation (Load or Line) to high Input voltage outside operating range Input or output connections not made correctly ON / OFF pin incorrect Sense terminals incorrect Ambient or module temperature too high Output overload Sense terminals incorrect External voltage applied Input voltage outside operating range Input or output connections not made correctly Sense terminals incorrect Output in current limit Input voltage outside operating range Input or output connections not made correctly Sense terminals incorrect Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct, high impedance joints can result in incorrect operation. The ON / OFF pins (if available) should be pulled low (>0.8V) to ensure correct operation Check that the sense terminals have been connected correctly as described. Specific attention should be paid to polarity and any components within the remote sense path. Check that the ambient temperature does not exceed the maximum Check that the cooling has not been adversely affected i.e. fans blocked. An output short circuit will cause the module to enter a trip & restart (hic-up) mode that may appear as no output. Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. If an external voltage has been applied to the module either disconnect it or reduce the level to within specification. Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct, high impedance joints can result in incorrect operation. Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. Check that the output current is not in excess of the rated level, the current limit will reduce the output voltage. Reduce the output current and check that the output voltage returns to the correct level. Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct, high impedance joints can result in incorrect operation. Check that the sense terminals have been

25 Module produces audible noise Input or output cables cross section area insufficient. Output in current limit External voltage source connected to the output connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. If the input and output cables are not of a sufficient cross sectional area they appear as a series resistance. This will add to the level of regulation in either the input or output. Check that the output current is not in excess of the rated level. When operating in current limit the module may produce an audible noise. Reduce the output current and check that the output voltage returns to the correct level. An external voltage source connected to the output could take over the load from the module hence appearing as a zero load. If the external source is above the overvoltage level of the unit then the OVP circuit will operate the unit in a trip & restart mode producing an audible noise. Removing or reducing the level of this external voltage should prevent this. Returns Procedure If after these checks have been made, the module still appears to have a fault, please contact your local Powerstax product representative. A Returns Material Authorization number will be issued. This will be used to track the module on its return and any further action that may be required can be considered. When contacting your local Powerstax product representative please include as much information as possible, including product type & serial number, details of suspected fault, details of application including load, input voltage, heatsinking etc.

26 ANR5 R Series Multiple Racks ANR5.01 OUTLINE SPECIFICATION ANR General The basic specification for a number of multiple racks is as for the individual rack but with higher input and output powers Up to 4 racks can be connected in parallel to increase the available power, detailed description of how to interconnect these racks is provided in the Installation section of this guide. The available power & current from these multiple racks is shown below 1 Rack 2 Racks 3 Racks 4 Racks R V o/p VAC i/p R V o/p VAC i/p R V o/p VAC i/p Bulk Power N+1 Bulk Power N+1 Bulk Power N W 1500W 2400W 1600W 3000W 2000W 93.75A 62.5A 50A 33.33A 62.5A 41.67A 4500W 3750W 4800W 4000W 6000W 5000W 187.5A A 100A 83.33A 125A A 6750W 6000W 7200W 6400W 9000W 8000W A 250A 150A A 187.5A A 9000W 8250W 9600W 8800W 12000W 11000W 375A A 200A A 250A A ANR5.02 OPERATION All of the features detailed for the power modules are also available from the R series racks. The signals are bought out to the 25 way D connector on the rear of the rack. Common features such as remote sense or current share are bought out as a connection for the complete rack. Other features, such as the alarms, are bought out per module so that the module producing the alarm can be identified if required. Input Connector The R series power shelves can be used with any standard global line voltages. The standard AC input connection to the shelf is through three IEC320 type connector rated at 10A / 250Vac in Europe/Asia and 15A /120Vac in North America. Output Connector Each shelf has two terminal blocks for DC output (each with three M4 screws). They are labelled V+ and V-, respectively, on the rack next to the terminal block. The V+ and V- are floating with respect to frame GND. Frame GND may be connected to either bus depending upon the customer requirements for positive bus or negative bus, or the output can be floated with respect to frame GND. Interface Connector Each power shelf has a 25-pin, D-type female connector on the back. The power system can be monitored and controlled through this interface. The table below shows the pin allocation and function. Pin Number Signal Name Description 1 DC Fail 2 DC fail signal of module 2 2 A2 I 2 C address bit 2 3 A3 I 2 C address bit 3 4 ON SYNC (optional) Power on synchronization for multi shelf operation 5 SDA I 2 C serial data bus 6 SCL I 2 C clock 7 NC Do not use, internal shelf supply 8 On/Off 1 (optional) Remote ON/OFF control of module 1

27 9 OTP 1 Fan fail or over temp signal of module 1 10 On/Off 2 (optional) Remote ON/OFF control of module 2 11 Vaux (optional) Aux voltage for customer usage 12 DC Fail 1 DC fail signal of module 1 13 AC Fail 3 (optional) AC fail signal of module 3 14 OTP 3 Fan fail or over temp signal of module 3 15 DC Fail 3 DC fail signal of module 3 16 INT BUS Intermediate DC bus for internal shelf use 17 AC Fail 1 (optional) AC fail signal of module 1 18 On/Off 3 (optional) Remote ON/OFF control of module 1 19 SRTN Signal & Vaux return 20 RS- Remote sense ve 21 OTP 2 Fan fail or over temp signal of module 2 22 RS+ Remote sense +ve 23 AC Fail 2 (optional) AC fail signal of module 2 24 CS Single wire, current share interface 25 V- V- ANR Addressing The I 2 C serial bus uses 4 address lines A0 to A3 to determine the address of the individual modules; A0 & A1 are set within each rack. A2 & A3 need to be set for each rack; details are shown in section ANR If a SMC-R is not being used then the addressing of the units does not affect the operation of the rack. ANR N+1 Redundancy The racks can be connected to provide N+1 redundancy. That is in multiple rack, the load is equivalent to a number of power modules, by adding an extra module, should one module fail, or the supply to that module fail, the load is still supported. In practice the modules share the load equally between them and share the extra load equally in the event of a failure. The modules have output ORing diodes built in to prevent failure of a module causing the system to fail, however there are a number of issues that must be considered to prevent complete failures of a redundant system. Input protection Each module is fitted with an ac input fuse, if more than one module is to be supplied through a single protection device, correct discrimination must be provided. If this upstream device is too fast acting, or rated too low then it could fail before the module fuse removing the supply to more than just the failed module. Input supply current During normal operation the output load of the rack would be shared equally by the modules connected however under certain conditions (fault conditions or battery recharge) all the connected modules may operate at full power. The input supply must be sized to allow all the connected modules to operate at full power, not just the expected system load. Output load Because the system has an extra module connected, it is possible for the system to provide more power than expected. If this exceeds the rating of the modules without the redundant module (i.e. the N number of modules) then in the event of a module failure the load would not be supported. Particular care should be taken in situations where extra equipment can be added after initial installation, increasing the overall load. ANR AC Fail Option This signal warns of a failure of the ac input and provides an optically isolated open-collector signal. The logic low level is lower than 0.6V with the sink current of the photo-transistor less than 1mA. This signal will change state prior to the DC Fail signal from the module. ANR Power on synchronization option This option allows for synchronisation of the start up of multiple racks, connecting the pin between racks ensures that the modules of all of the racks start together. With this option fitted the ON/OFF control of individual racks is disabled. The option codes for DC ON/OFF and AC Fail are shown below:

28 RXXXX-X-011 Power on synchronisation not fitted, power module ON/OFF can be controlled by system. RXXXX-X-111 Power on synchronisation fitted, power module ON/OFF cannot be controlled by system. RXXXX-X-211 AC Fail fitted, power on synchronisation not fitted, power module ON/OFF can be controlled by system. ANR Vaux Option It is possible to provide an optional house keeping output derived from the main output, for systems supplying batteries this output would be battery backed. Contact Powerstax for details of the output available. ANR Current share The R series racks have two methods of current sharing, an analogue and a digital system, the later only available if the system includes an SMC-R. In a rack the current share pins of the modules are interconnected via the backplane, for multiple rack systems the current chare pins on the D connector must be connected between racks. To ensure that the current share operates correctly systems without the SMC-R controller ensure that all the modules are set to the same output voltage and that the racks are connected together as close as possible to the rack. In a system including an SMC-R the modules each report the output current and the controller adjust their output voltage to share the output current. To prevent problems between the two systems the digital system operates over a limited range and the analogue system provides the fine balancing. ANR5.03 INSTALLATION ANR Prior to installation The safety section of this guide must be carefully read to ensure that the rack and modules are correctly installed, if in any doubt please contact Powerstax. - Unpack the rack and DC modules and inspect them carefully for possible transit damage. Check the equipment against the packing list (supplied with the equipment) and ensure that you have received the correct type of rack and DC modules. - Report any damage or incorrect shipment immediately to your local Powerstax product representative. - Keep the original packaging until the rack & modules have been fully integrated and tested. You may need it for any onward shipment or if any equipment needs to be returned. ANR Fusing & Surge suppression As the Power Modules have internal protection against excessive input current, an external input fuse is needed only to protect the input cabling etc, from an electrical safety point of view. This fuse should be selected to withstand the maximum input current at low input voltage. Fuse selection should take into account that fuses de-rate with temperature and time. If more than one module is to be supplied through a single protection device, correct discrimination must be provided. If the upstream device is too fast acting, or rated too low then it could fail before the module fuse removing the supply to more than just the failed module. When sizing the fuse, consideration should be made of the wide input range of the power modules as the current at these lower input voltages will be significantly higher than at higher inputs. It is possible for the input voltage to drop during a brown-out, a power failure or recovery. If the protection device is not suitably sized it could open preventing the module from operating once the input supply has recovered. The maximum earth leakage current of each power module is 1.7mA, multiple power modules may be required to be connected to separate building branch circuits. Consideration may be required to be given to upstream Residual Current Devices (RCDs). The input of the power module has a number of devices designed to protect the unit from the affects of surges and spikes on the input of the module. Clearly there is a limit as to the level of spikes etc the module can withstand without damage. The modules will meet the levels

29 defined in IEC Level 3 & IEC Level 3 with damage free operation. Input surges or spikes above these levels may cause damage to the modules, as may operation above the maximum input voltage. ANR Connection details The R series racks provide separate connections for the ac input, dc output and the signals. The ac input is made via IEC320 connectors, one for each module. The connectors used are rated at 10A for high input voltage and UL recognised for 15A, the mating connector used must be rated correctly. Optional clips are available to ensure the IEC connectors are not vulnerable. The DC output is available by two terminal blocks on each rack, one each for the positive and negative. Options are available to provide alternatives to the screw terminals. In making the connections to the connector a number of issues must be considered: Safety Although the ac input, dc output and signals connectors are separate, care should be taken to ensure the creepage and clearance distances are not reduced in the wiring. Conductors must be sized to withstand the max current available at the connection, i.e. for the ac input the live, neutral and earth cables should be able to withstand the current of the upstream protection, the power conductors should be sized and marked in accord with local wiring regulations. The output cables must be designed for the full current capacity of the rack; under fault conditions the power modules supply the full current. Cooling The connectors are in the cooling air path that flows from the fans at the front to the grill at the back. Ensure that any wiring connected to the output connector does not impede air flow. Required signal pins Not all of the signal pins may be required; for stand alone operation none of the signal pins may be required. Those likely to be used would be the remote sense pins (20 & 22), the remote ON/OFF pins (8, 10 & 18) and the alarm pins OTP (9, 14 & 21) and DC Fail (1, 12 &15); all referenced to the signal return (19). For multiple racks, or for use with the SMC-R other connections would be required the table below outlines the recommended connections for a number of applications. Pin No Signal Multiple racks, no SMC-R Multiple racks, with SMC-R 1 DC Fail 2 Monitor if required Monitor if required 2 A2 Leave open or connect to V- Set addressing as required for shelf 3 A3 Leave open or connect to V- number 4 ON SYNC (optional) Connect between racks if option fitted Connect between racks if option fitted 5 SDA N.C. Connect between racks and to SMC-R 6 SCL N.C. Connect between racks and to SMC-R 7 NC Do not use, internal shelf supply connect between racks 8 On/Off 1 (optional) RXXXX-X-0(or 2), connect to V- if not used, or TTL L to power on TTL H to power off. RXXXX-X-1 leave open. 9 OTP 1 Add a resistor to Vcc if monitored or leave open if not used. 10 On/Off 2 (optional) RXXXX-X-0(or 2), connect to V- if not used, or TTL L to power on TTL H to power off. RXXXX-X-1 leave open. 11 Vaux (optional) Aux voltage for customer usage, where fitted. 12 DC Fail 1 Add a resistor to Vcc if monitored or leave open if not used. 13 AC Fail 3 (optional) Add a resistor to Vcc if monitored or leave open if not used. 14 OTP 3 Add a resistor to Vcc if monitored or leave open if not used. 15 DC Fail 3 Add a resistor to Vcc if monitored or leave open if not used. 16 INT BUS Intermediate DC bus for internal shelf use, leave open. 17 AC Fail 1 (optional) Add a resistor to Vcc if monitored or leave open if not used. 18 On/Off 3 (optional) RXXXX-X-0(or 2), connect to V- if not used, or TTL L to power on TTL H to power off. RXXXX-X-1 leave open. 19 SRTN Use as signal reference if required Connect between racks and to SMC-R 20 RS- Connect between racks and to load ve if used or leave open if not used.

30 21 OTP 2 Add a resistor to Vcc if monitored or leave open if not used. 22 RS+ Connect between racks and to load +ve if used or leave open if not used. 23 AC Fail 2 (optional) Add a resistor to Vcc if monitored or leave open if not used. 24 CS Connect between racks 25 V- Connect between racks, ref for remote On/Off if used ANR Addressing In a system where the I 2 C bus is not being used then there is no requirement to set the addresses of the racks. If the I 2 C bus is to be used, i.e. the SMC-R controller is fitted, it is important that the addressing is set. The table below shows the A2 & A3 settings to provide the rack addressing, A0 & A1 are set within the rack To provide a logic 1 the pins should be pulled high through a resistor to 5V (with respect to V-), care should be taken to ensure that this signal does not exceed 5V. To provide a logic 0 the pins should be pulled low to V-. Shelf Module No A3 A2 A1 A ANR Cooling The power modules are fitted with two fans to provide cooling for the module; care must be taken not to effect this cooling. The modules sense the internal temperature of the unit and will protect themselves from excessive temperature. The cooling may be affected due to a number of causes: - Fan locked, this may be an accidental effect. The power module monitors the fan rotation and if a fan becomes locked the module will shut down. - Blocking the air from entering the module, for the cooling to operate correctly the fans must be able to draw the air in easily, this means that there should be no obstructions at the front of the rack. A space of approx 50mm is sufficient to allow the fans to draw the air in provided that there are not obstructions on all sides. - Blocking the air from exiting the rack, the warm exhaust air must be able to exit the module without any significant impedance; care must be taken to ensure that there are no obstructions to the air flow. - Heat from other devices, if the rack is fitted in a system with other heat generating sources the hot exhaust air from these modules must not be drawn into the fans of the power modules. - Ambient temperature too high, if the ambient around the rack is too high then the fans will not be able to cool the modules correctly. Sufficient cooling within the system is required to ensure that the internal ambient does not exceed that of the rack. ANR Zero load operation As each power module is fitted with a switched dummy load, there are no requirements to draw a minimum load. It is possible however that at light loads the sharing between modules will not be as accurate. ANR Start up sequence Without SMC-R For multiple power racks without SMC-R the start up process is as detailed below: - Connect power and signal connections on the rack with reference to the safety and installation sections. - Insert Power Modules into shelf - Plug AC power cords into AC inputs - Apply AC power to modules - Check both front panel LED s light green and that the voltage at the load is correct. With SMC-R For multiple power racks with SMC-R the start up process is as detailed below:

31 - Connect output power and signal connections on the rack with reference to the safety and installation sections. - Connect power and signal connections to the SMC-R with reference to the safety and installation sections. - Insert Power Modules into shelf - Plug AC power cords into AC inputs of first shelf (this is the shelf with modules addressed 1, 2 & 3) - Apply AC power to modules of first shelf - Check both front panel LED s light green and that the voltage at the load is correct. - Plug AC power cords into AC inputs of remaining shelves. - Apply AC power to modules of remaining shelves. - Check the LED s on the SMC-R light correctly and toggle through the modules fitted to ensure that the voltage & current shown is correct. ANR5.04 MECHANICAL DETAILS Notes - Tolerances are ± 0.1mm unless otherwise stated - Mounting ears can be mounted 100.8mm from front of rack (option)

32 ANR5.05 TROUBLESHOOTING The table below shows a number of common points that should be considered before concluding that a module may be damaged. Problem Possible Cause Required Action No output voltage Output voltage too high Output voltage too low Regulation (Load or Line) to high Input voltage outside operating range Input or output connections not made correctly ON / OFF pin incorrect Sense terminals incorrect Ambient or module temperature too high Output overload Sense terminals incorrect External voltage applied Input voltage outside operating range limits. Input or output connections not made correctly Sense terminals incorrect Output in current limit Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct, high impedance joints can result in incorrect operation. The ON / OFF pins (if available) should be pulled low (>0.8V) to ensure correct operation Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. Check that the ambient temperature does not exceed the maximum or that the cooling has not been adversely affected i.e. fans blocked. An output short circuit will cause the module to enter a trip & restart (hic-up) mode that may appear as no output. Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. If an external voltage has been applied to the module either disconnect it or reduce the level to within specification. Check the input voltage is within the specified Check that the input and output connections are correct, high impedance joints can result in incorrect operation. Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path. Check that the output current is not in excess of the rated level, the current limit will reduce the output voltage. Reduce the output current and check that the output voltage returns to the correct level. Input voltage outside operating Check the input voltage is within the specified range limits. Input or output connections not Check that the input and output connections are made correctly correct, high impedance joints can result in incorrect operation. Sense terminals incorrect Check that the sense terminals have been connected correctly as described above. Specific attention should be paid to polarity and any components within the remote sense path.

33 Module produces audible noise Input or output cables cross section area insufficient. Poor current sharing Addressing incorrect Output in current limit External voltage source connected to the output If the input and output cables are not of a sufficient cross sectional area they appear as a series resistance. This will add to the level of regulation in either the input or output. Check that the current share connection is made between multiple racks. If the system is fitted with an SMC-R check that the addressing is correct and that the SCM-R can register all the modules fitted. Check that the output current is not in excess of the rated level. When operating in current limit the module may produce an audible noise. Reduce the output current and check that the output voltage returns to the correct level. An external voltage source connected to the output could take over the load from the module hence appearing as a zero load. If the external source is above the overvoltage level of the unit then the OVP circuit will operate the unit in a trip & restart mode producing an audible noise. Removing or reducing the level of this external voltage should prevent this. Returns Procedure If after these checks have been made, the module still appears to have a fault, please contact your local Powerstax product representative. A Returns Material Authorization number will be issued. This will be used to track the module on its return and any further action that may be required can be considered. When contacting your local Powerstax product representative please include as much information as possible, including product type & serial number, details of suspected fault, details of application including load, input voltage, heatsinking etc.

34 ANR6 SCM-R Control & Monitor Unit This unit is designed to control and monitor the Powerstax 19" rack mount PSU systems: R3000, R2400, and R2250. The controller is digital and communicates with the power modules by means of an I 2 C bus. It offers adjustment of the system voltage in 100mV steps over the range 23-29V for the A0750 powers units and 46-58V in the A0800 & A1000 power units. Up to 12 hot swap power units can be used in parallel and the controller can be used to select a particular power unit position and read the current being drawn from that unit with a resolution of 100 ma. The address of individual power cartridge is set in hardware using the cable assembly to the controller. The Powerstax SCM-R does not require an external power source and is powered from the bus voltage of the system. The control & Monitor Unit is a 1U high, 19" chassis with read-outs on the front panel, input and output at the rear. ANR6.01 OUTLINE SPECIFICATION ANR Power supply The controller s power supply is derived from the system output bus voltage. Supply voltage: Supply current: +22Vdc to +62Vdc up to 250mA A 2 way terminal block is fitted on the back panel to allow the bus voltage to be connected. A 1A fuse is fitted internally to protect against faults. ANR PSU module current measurement and display The output current of the psu module being addressed is displayed to one place of decimals by a 3 digit seven segment LED. ANR System voltage measurement and display The output voltage of the system bus is displayed to one place of decimals by a 3 digit seven segment LED. The SMC-R can control the system voltage over the ranges shown below: Nominal 24V Nominal 48V Adjustment 23.5Vdc to 28.5Vdc Adjustment 47.0Vdc to 57Vdc ANR Mechanics The detailed drawings are shown in Section ANR6.04. The outline details are given below, Depth 84.3mm (3.3 ) Width 482.6mm (19.0 ) Height 43.5mm (1.71 ) Weight XXkg (YYlb) typical unpacked ANR6.02 OPERATION The front panel has mounting tabs and has the following displays and controls: Seven segment LED displays - Two digits for power module address - Three digits for module output current (one place of decimals) - Three digits for system output voltage (one place of decimals) The rocker switch next to the two digit display allows module address selection and the second rocker switch to allow system bus voltage adjustment. The interface to the shelf/modules is by means of an I 2 C serial data bus. The controller enclosure is fitted with a 25 way female D connector to allow connection of the controller to up to 4 racks. Output voltage control The output bus voltage is used to supply the controller, but is also measured by the controller

35 for display on the front panel LED as the system output voltage. Next to the display is a momentary action rocker switch (mom-off-mom) which allows the bus voltage to be adjusted. The switch is normally at its central off position. Rocking it upwards and holding it will cause the bus voltage to nudge upwards, likewise rocking and holding it down causes the bus voltage to nudge downwards. This is achieved by the controller addressing each of the psu modules in turn and nudging the output upwards or downwards. Note that the address display does not change while this is happening. The psu modules operate in the range: Nominal 24V Nominal 48V Adjustment 23.5Vdc to 28.5Vdc Adjustment 47.0Vdc to 57Vdc The controller automatically recognises which nominal output voltage is being produced (by measurement of the bus voltage). The psu modules may then be adjusted to the limits shown. ANR Current sharing The power modules operate an analogue sharing bus. This operates best when the output voltage of individual modules is set close together. The controller is required to optimise the current share by measuring the output current of individual modules, and then nudging the output voltage of individual modules upwards or downwards. At the same time, the overall bus voltage must be controlled. Thus, the bus voltage is kept within regulation whilst the current share control adjusts each individual power module. ANR Rack & Module Addressing For the controller to monitor and adjust each module the racks must set up an individual address for each module. The address for each module within a rack is set within the rack but the address of each rack has to be set in multi rack systems. Details of this are provided in the installation section. ANR6.03 INSTALLATION ANR Prior to installation The safety section of this guide must be carefully read to ensure that the rack and modules are correctly installed, if in any doubt please contact Powerstax. - Unpack the SMC-R and inspect it carefully for possible damage that may have occurred while in transit. Check the equipment against the packing list (supplied with the equipment) and ensure that you have received the correct equipment. - Report any damage or incorrect shipment immediately to your local Powerstax product representative. - Keep the original packaging until the SMC-R has been fully integrated and tested. You may need it for any onward shipment or if any equipment needs to be returned to your local Powerstax product representative. ANR Connection details The SMC-R is powered direct from the dc bus; connection is to the two way terminal block on the rear of the unit. This input is fuse protected but care must be taken in connecting not to produce any risk of shorting of the dc bus (loose cable strands etc). The signal connections are made from the racks to the controller via the 25 way D connector on the rear of the unit. The main connections that need to be made from the racks to the SMC-R are Pin 5 Pin 6 Pin 19 SDA SCL SRTN ANR Addressing The addressing of the racks should have been completed during installation of the rack systems, however the details below show the addressing systems used.

36 Shelf Module No A3 A2 A1 A ANR6.04 MECHANICAL DETAILS Notes - Tolerances are ± 0.1mm unless otherwise stated.

37 ANR6.05 TROUBLESHOOTING The table below shows a number of common points that should be considered before concluding that a module may be damaged. Problem Possible Cause Required Action No LED s light Cannot register all of the modules fitted Cannot change the output voltage Returns Procedure Input voltage outside operating range Input connections not made correctly Signal connections not made correctly Addressing incorrect Signal connections not made correctly Addressing incorrect Output in current limit Check the input voltage is within the specified limits. Significant overvoltage (above the absolute maximum level) could result in damage to the module requiring replacement. Check that the input and output connections are correct, incorrect polarity connection could result in damage to the module requiring replacement. High impedance joints can result in incorrect operation. Check that the signal connections have been made correctly as described. Specific attention should be paid to the SDA, SCL & SRTN connections. Check that the addressing is correct and that there are no duplications. Check that the signal connections have been made correctly as described. Specific attention should be paid to the SDA, SCL & SRTN connections. Check that the addressing is correct and that there are no duplications. Check that the output current is not in excess of the rated level. The output current limit will reduce the output voltage. Reduce the output current and check that the output voltage returns to the correct level. If after these checks have been made, the module still appears to have a fault, please contact your local Powerstax product representative. A Returns Material Authorization number will be issued. This will be used to track the module on its return and any further action that may be required can be considered. When contacting your local Powerstax product representative please include as much information as possible, including product type & serial number, details of suspected fault, details of application including load, input voltage, heatsinking etc.

38 ANR7 Accessories ANR Dummy front panel ZBLP-001 For racks that are not fully populated with power modules a dummy front panel should be fitted. This protects the user from any possible contact with the rear terminals and improves the airflow in the overall system. Notes - Tolerances are ± 0.1mm unless otherwise stated. ANR Power Ports Power ports can be fitted to the 25 way D connector of the R series racks and provide a range of options not available on the standard rack. Each of these are fitted with a second 25 way D connector to allow the connection to an SMC-R. ZPPA The ZPPA series of power ports provide a range of features. The alarm signals from the A series power modules are open collector alarms, the ZPPA modules are fitted with relays to provide volt free relay contact alarms. In these modules the DC fail and OTP alarms are combined to give a single DC alarm. The AC fail alarms are also converted to volt free relay outputs. Two versions are available, either providing individual relays for each alarm or series connection providing a single alarm if any alarm condition is produced. These relay contacts are bought out onto a separate connector that can be easily disconnected if it is required to be removed. On this connector is a position for the bus voltage to be connected to supply the drive for the relays. The ZPPA modules also provide jumper positions to set the A2 & A3 connections on the racks. Fitting the jumper provides a logic 0, leaving the jumper off provides a logic 1. The modules also connect the bus voltage to an otherwise unused pin on the 25 way D connector allowing the SMC-R to be power from the D connector and not requiring a separate connection to be made. ZRPA The ZRPA provides the volt free relay option for the DC fail alarm as above but not the OTP or AC fail alarm. However in this case it provides both the normally open NO and normally closed NC connections of the relay. It does provide the

39 A2 & A3 jumpers but not the connection of the bus to the controller. Mechanical details The ZPPA & ZRPA are the same mechanically and the outline details are given below. Depth 27.6mm (1.09 ) Width 106mm (4.17 ) Height 40mm (1.57 ) Weight XXkg (YYlb) typical unpacked The outputs of the relays etc are bought to the connector CON3, the mating half (Weidmuller BLZF 3.5/10) is as standard supplied with the ZPPA or ZRPA. ANR Ribbon Cable An optional ribbon cable, part number is available. It provides connection for up to 4 shelves to an SMC-R with sufficient cable for the shelves and controller to be positioned on top of each other. All of the 25 connections are made between racks and controller and can be used even if less than 4 racks were to be used. Alternative versions (differing lengths and rack connections) are available on request. ANR Input & Output connection options A range of options are available although the most common are detailed below. Input The IEC320 connectors used are a widely used range but the option of a retention clip is available which prevents the cable from accidentally being removed. Output The screw terminals can be replaced or converted into stud terminals. A standard version of this is M10 studs that can be used to provide high current interconnection. Paralleling busbars can be provided to make contact between racks positioned next to each other.

40 ANR8 Start up sequence - Power Module Hot Plug-in For single or multiple power racks with or without an SMC-R the Power Module Hot Plug-in process is as detailed below: - Locate module in required slot and push module slowly and smoothly into position until contact is felt with the rear connector. - Once the first set of pins are connected the AC OK LED will light green. - Once this LED is green push home fully and the PWR OK LED will light green Locate module in required slot and push module slowly and smoothly into position until contact is felt with the rear connector. Once the first set of pins are connected the AC OK LED will light green. Once this LED is green push home fully and the PWR OK LED will light green.