NewMar CM Series User manual

POWERING THE NETWORK
www.poweringthenetwork.com | 800.854.3906
Costa Mesa, CA
Installation Manual
CM Series DC-DC Converter
Product Compliance
Low Voltage Directive (LVD) 2014/35/EU
Electromagnetic Compatibility Directive (EMC) 2014/30/EU
EN 55022 (CISPR 22) Information technology equipment - Radio disturbance characteristics -
Limits and methods of measurement 2010/AC: 2011
EN 55024 (CISPR 24) Information technology equipment - Immunity characteristics - Limits and
methods of measurement 2010
EN 60950-1 Information technology equipment – Safety – Part 1: General requirements 2001
Copyright © NewMar 2022 All rights reserved.
Release Date: 27 SEP 2022
Disclaimer: NewMar reserves the right to make changes to the information within this document without notice
M-CMDCCONV 092722

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Table of Contents
1Safety ............................................................................................................................................................... 6
2Receiving
Instructions .................................................................................................................................... 6
2.1 Package Inspection................................................................................................................................ 6
2.2 Equipment Inspection............................................................................................................................
6
2.3 Handling .................................................................................................................................................. 6
2.4 Identification Labels.............................................................................................................................. 7
3Scope................................................................................................................................................................ 7
4Principles of Operation ................................................................................................................................. 7
4.1 Introduction ............................................................................................................................................ 7
4.2 Front Panel Indicators........................................................................................................................... 7
5Features (User Adjustable) ........................................................................................................................... 8
5.1 Output Voltage ...................................................................................................................................... 8
5.2 Default Output Voltage........................................................................................................................ 8
5.3 Current Limit
(Output) ........................................................................................................................... 8
5.4 Power
Limit ............................................................................................................................................. 8
5.5 Over-Voltage Shut Down
(Output) ..................................................................................................... 8
5.6 Current Share ......................................................................................................................................... 8
5.7 Shutdown Latch Enable........................................................................................................................ 9
5.8 Default Output Settings........................................................................................................................
9
6Features (Factory Set) ................................................................................................................................... 9
6.1 Input Over/Under-Voltage Shut Down............................................................................................. 9
6.2 Input/Output Inrush Current Limiter................................................................................................. 9
6.3 Over-Temperature Shutdown............................................................................................................. 9
6.4 Reverse Polarity Protection................................................................................................................. 9
6.5 Parallel Converter Operation .............................................................................................................. 9
6.6 Converter Fail Relay............................................................................................................................ 10
6.7 Rear
Connector .....................................................................................................................................10
6.7.1 Pin descriptions............................................................................................................................10
6.7.2 Positronix Connector.................................................................................................................. 11
7Installation .....................................................................................................................................................11
7.1 Positioning of Converter....................................................................................................................11
7.2 Mounting the Converter into the Rack ........................................................................................... 11
7.3 Cabling...................................................................................................................................................12
7.4 Multiple Converters ............................................................................................................................
12
7.5 Commissioning the Converter ..........................................................................................................
12
8Servicing ........................................................................................................................................................ 12
8.1 Warnings ............................................................................................................................................... 12
8.2 Troubleshooting ...................................................................................................................................
13

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1 SAFETY
All installation and maintenance must be carried out by suitably qualified
personnel.
For your protection, the product manual should be read and thoroughly
understood before unpacking, installing, and using the equipment.
2 RECEIVING INSTRUCTIONS
Newmar provides all equipment to the delivering carrier securely packed and in perfect condition.
Upon acceptance of the package from Newmar, the delivering carrier assumes responsibility for its
safe arrival. Once the equipment is received, it is the recipient’s responsibility to document any
damage the carrier may have inflicted, and to file the claim promptly and accurately.
2.1 Package Inspection
Examine the shipping crate or carton for any visible damage: punctures, dents, and any other signs of
possible internal damage.
Describe any damage or shortage on the receiving documents and have the carrier sign their full
name.
2.2 Equipment Inspection
Open the crate or carton and inspect the contents for damage. While unpacking, be careful not to
discard any equipment, parts, or manuals. If any damage is detected, call the delivering carrier to
determine the appropriate action. They may require an inspection.
IMPORTANT: Save all the shipping materials for the inspector to see.
After the inspection has been made, if damage has been found, contact Newmar. We will determine
if the equipment should be returned to our plant for repair or if some other method would be more
expeditious. If it is determined that the equipment should be returned to us, ask the delivering
carrier to send the packages back at the delivering carrier’s expense.
If repair is necessary, we will invoice you for the repair so that you may submit the bill to the
delivering carrier with your claim forms.
It is your responsibility to file a claim with the delivering carrier. Failure to properly file a claim for
shipping damages may void warranty service for any physical damages later reported for repair.
2.3 Handling
Handle the equipment with care. Do not drop or lean on front panel or connector. Keep away from
moisture.

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2.4 Identification Labels
Model number and serial number are clearly marked on all equipment. Please refer to these numbers
in all correspondence with Newmar. Ideally provide a photograph of the product label for reference.
3 SCOPE
This document details the Newmar CM series of DC-to-DC converters: features, functions,
specifications, and installation.
4 PRINCIPLES OF OPERATION
4.1 Introduction
The CM series of fan cooled flat-mount DC-DC converters consist of the following models:
Table 1: CM series converter specifications
Model
Nominal
Input
Voltage
Input
Voltage
range
Nominal
Output
Voltage
Output
Voltage
Range
Maximum
Output
Current
Power
Rating
CM-12-40 48V 40-60V 12V 10.5-15V 40.0A 600W
CM-24-40 48V 40-60V 24V 21-30V 40.0A 600W
The features of the converters are:
•Fan cooled
•Thermal protection
•Input/output voltage and current protected
•Active load sharing when operated in parallel with another converter
•External alarm and control interface
•1U rack height
4.2 Front Panel Indicators
There are 3 LED indicators on the front panel indicate the operational state of the converter.
: This green LED indicates that input power is connected to the unit and that the primary
stages of the converter are operating.
: This yellow LED indicates a non-urgent alarm state within the converter.
This could be caused by the following:
•Converter in output power/current limit
•Converter over temperature
•Fan failed
•Converter soft starting
: This red LED indicates an urgent alarm state within the converter.
This could be caused by the following:
•Converter failed
•The DC input voltage is outside the operating range.
•Converter shut down due to output over-voltage or over-temperature

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5 FEATURES (USER ADJUSTABLE)
The following converter features are adjustable by the user. Features must be adjusted using the
serial communications interface using the EM4x energy manager.
5.1 Output Voltage
The output voltage is set through the serial interface by an external controller (e.g., System monitor).
This setting is volatile and is not saved when the converter powers down. If this setting is not set,
then the converter will use the Default Output Voltage. The adjustment range is indicated in table1.
5.2 Default Output Voltage
The default output voltage will be the output voltage if no serial connection is made to the converter
while in operation.
5.3 Current Limit (Output)
The converter automatically limits the converter output current. The maximum output current is
preset in the factory but may be adjusted down.
5.4 Power Limit
The output power is factory set and model-specific it may be set at a lower limit if desired.
5.5 Over-Voltage Shut Down (Output)
The converter will automatically shut down if the output voltage exceeds the preset value. The
Over- Voltage Shutdown voltage is preset in the factory at the value indicated in Table 2.
The over-voltage set point will reduce with increased output current by to 2% at full load. This is to
ensure that the converter producing the over-voltage is shutdown first and any other converters
operating in parallel remain operating.
5.6 Current Share
Current share is normally always enabled, but it is possible to temporarily disable current share to
investigate system operation issues.

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5.7 Shutdown Latch Enable
When the converter is shut down due to either over-voltage or over-temperature, it will
automatically restart when the voltage or temperature returns to normal levels. However, this
setting, when enabled, ensures the converter is latched off when either or both conditions occur.
5.8 Default Output Settings
In the factory the converters output settings are set as follows:
Table 2: CM series converter factory settings
Model Default Voltage Over Voltage
Shutdown Current Limit Power Limit
CM-12-40 13V 16.0V 40.0A 600W
CM-24-40 26V 32.0V 40.0A 600W
6 FEATURES (FACTORY SET)
6.1 Input Over/Under-Voltage Shut Down
If the input voltage moves outside the specified range, the converter may shut down until the input
voltage returns to within this specified range.
6.2 Input/Output Inrush Current Limiter
On start-up, the peak input and output inrush currents are limited. They are both limited so as not to
exceed their normal operating level.
6.3 Over-Temperature Shutdown
When the converter reaches its maximum operating temperature, the converter will progressively
reduce the output current to attempt to reduce the heat within the unit. In extreme circumstances,
the converter will totally shutdown.
The operating ambient temperature range is: -20 to 70ºC. Maximum output power is de-rated at
temperatures above 50ºC.
6.4 Reverse Polarity Protection
The converter has an internal reverse polarity protection fuse and crowbar diode fitted to the input
and output of the converter. These parts are not user serviceable, and the converter will require to be
returned to an authorized service center for repair.
6.5 Parallel Converter Operation
The converters may be connected in parallel to source more current, or to provide a degree of
redundancy.

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The converters connected in parallel must all be of the same model, voltage, and power rating.
If multiple converters are used, they may be housed in one or more converter shelves with dedicated
backplane circuit boards. The converters should have the load share signal connected between the
converters. This is achieved by connecting the load share signal line on the back plane on each
converter (Note: with a common backplane this can be done on the backplane itself).
When load share is connected, the converters with the higher voltage output will automatically
adjust their output voltage down so that all converters take a uniform share of the load. If using
more than one shelf of converters the link between the shelves should be connected.
6.6 Converter Fail Relay
The converter fail relay output appears on pins 12 and 15 of the rear connector. The relay is
normally energized while the converter is operating. If the converter fails, the relay will be de-
energized, and the contacts change state. The contacts can be set to be either Normally Open (NO)
or Normally Closed (NC) using the header next to the main rear connector. If the header link bridges
the two pins closest to the main connector the relay contacts will be NC. If the header links the two
pins furthest from the main connector, the relay contacts will be NO.
Note: The contact states normally open (NO) or normally closed (NC) refer to the status of the relay
contacts when it is de-energized. Hence, this is the state that the contacts will be when the converter has
failed.
6.7 Rear Connector
The power input/output and monitor connection are made through the Positronix goldfish GFSH109
series on the rear of the converter. Pin identification table is below:
6.7.1 Pin descriptions
Table 3: CM series converter rear connector output pin descriptions
Pin # Description
Pin 1,2,4 Positive Input – Always connect in parallel.
Pin 3,5,6 Negative Input – Always connect in parallel.
Pin 7 Serial Communication Bus (SBI)
Pin 8 Rack Position - horizontal
Pin 9 Rack Position - vertical
Pin 10 Post-mate – connected to 0V
Pin 11 Load Share
Pin 12 Fail Alarm isolated relay. 100V, 100mA max (jumper determines contact
state)
Pin 13 SBI – Power (+)
Pin 14 SBI – Power (-)
Pin 15 Fail Alarm isolated relay. 100V, 100mA max (jumper determines contact
state)
Pin 16,17 Negative Output – Always connect in parallel.
Pin 18,19 Positive Output – Always connect in parallel.

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6.7.2 Positronix Connector
Figure 1: CM series converter rear connector output pin locations
7 INSTALLATION
7.1 Positioning of Converter
The converter should be positioned close to the load supply, to keep the length of the low voltage
cables to a minimum. These cables are carrying high currents, and voltage drop in the cables must be
kept to a minimum.
CM series converters can be mounted 4 across a 1U 19” shelf. The shelves may also be stacked on
top of each other.
Care should be taken to ensure that air entering the front of the converter is cool
air and has not been heated by other equipment.
7.2 Multiple Converters
The converters may be operated in parallel to provide greater current capability and to provide
redundancy.
When converters are connected in parallel (and load sharing), alarm outputs on the converters give
the status of all the units.
Any fuses or circuit breakers on the output of the converter must be placed after the converter
outputs have been connected.
7.3 Commissioning the Converter
1. Ensure the polarity of the load and battery cables to the backplane is correct
2. Plug the converter into the converter shelf using the following steps:
•Locate the metal tag (at the bottom/rear of the converter) into the chosen slot in the backplane
•Push the converter into the converter shelf until the connector is fully engaged.
•There will be an audible clock as the converter locks itself in position using the plastic spring
retainer on the right side of the front panel.
• Converter removal is achieved by pressing and holding the unlock button then gently
pulling on the front panel.
3. Once the converter is installed into the converter shelf, the AC power can be turned on.
After the initial startup period the converter will be set to the desired system parameters by

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DANGER
Do not operate the converter if the covers are removed or damaged in any
way.
WARNING
The converter contains voltages that may be lethal even after the input
supply has been removed.
WARNING
The converter contains components at high temperature that may burn if
touched.
the monitor module via serial connection. If there is more than one converter connected in
parallel, then follow the above procedure for each converter in turn (with the other
converters all disconnected). Ensure all converters are adjusted to the same output voltage.
Finally check that all converters are indicating near equal current (should be better than
10% of full load).
8 SERVICING
If the converter develops an operational fault or is damaged in any way an authorized service center
should service, it immediately.
8.1 Warnings
This converter contains no user serviceable components. Do not disassemble the
converter. To isolate the converter from the power supply, simply unplug it from the shelf.
8.2 Troubleshooting
Basic operation checks:
•Check power to the converter
•Check that the DC input LED is on
•Check and resolve any fault conditions indicated by the converter
•Disconnect load leads. Check the voltage across the load is as expected
•Connect a current meter in series with the load. Adjust the load and check the current
delivered by the converter is as expected (if not recheck each converters output
voltage)
Load Checks:
•Connect a load to the converter output. Turn the input volts on and check that the
current drawn by the load is as expected, and within the capabilities of the converter.
8.3 EM4x Shelf Configuration
The EM4x Web UI is used to configure DC-DC converter shelves under IO Configuration>IO
Boards> Shelf Configuration.

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Figure 9: EM4x Shelf Configuration
Enter the number of DC-DC converter modules in a shelf into the appropriate shelf field, starting at
Shelf 7 and decrementing for each DC-DC converter shelf in the system. That is, the number of DC-
DC converter modules in a second shelf is entered into the Shelf 6 field, then Shelf 5 field, and so
on.
Note: that the Shelf Configuration section of the IO Boards page shows all the shelves of the system.
Where ‘Shelf’ in this instance is each dedicated module backplane (a 12-way 3U rectifier backplane = ‘one
shelf’) and the shelf number is determined by the module type:
•Rectifier shelves (including Renewable shelves) start their numbering at Shelf 1 and increment.
•DC-DC converter shelves start numbering at Shelf 7 and decrement.
Note: the maximum number of shelves per IO board is 7. For shelf numbers greater that 7 an IO expansion
board is included in the system.
Warranty
NewMar warrants that this product is free from defects in material and workmanship and agrees to remedy
any defect (or at its option replace the product) for a period of two years from the date of purchase. This
warranty covers both parts and labor. Parts may be replaced under this warranty with new or
remanufactured parts.
This warranty will not apply to any product that has been improperly installed (as described in the installation
manual), misused, abused, used in ways the product was not designed, altered, or repaired in any way which
may affect the performance or reliability of operation, sustained damage by power surges or electrical
storms, or sustained shipping damage, or repaired by any unauthorized repair center.
Please contact NewMar Customer Service to obtain a Returned Materials Authorization (RMA) prior to
shipping any products for repair. All shipments must be shipped prepaid and include proof of the date of
your original purchase. Please include your name, address, phone number, email address and a brief
description of the problem.
NewMar makes no other warranties, express or implied, including any warranty of fitness for a particular
purpose. In no event shall NewMar be responsible for indirect or consequential damages or lost profits even
if NewMar has been advised of the possibility of such damages. NewMar sole obligation to you shall be the
repair or replacement of a non-conforming product.