NewMar C2R-2000 User manual

Powering the Network
www.newmartelecom.com • 800-854-3906 Newport Beach, CA USA
Centurion II Power System
24 VDC, 1000 Watt/
48 VDC, 2000 Watt Rectier
Installation / Operation Manual
Model:
C2R-2000
Newmar
2911 W. Garry Ave.
Santa Ana, CA 92704
Tel: [phone]
Fax: [phone]
M-C2R-2000
Oct 2010

Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
1Principles of Operation..................................................................................................................... 2
1.1Introduction........................................................................................................................ 2
1.2Indicators........................................................................................................................... 2
1.3Power and Current Limit.................................................................................................... 3
1.4Output Over-Voltage Shut Down........................................................................................ 3
1.5Input Over/Under Voltage Shut Down................................................................................ 3
1.6Rectifier Soft Start and Inrush Current............................................................................... 3
1.7Over Temperature Turn Down/Shutdown .......................................................................... 3
1.8Reverse Polarity Protection ............................................................................................... 3
1.9Active Load Share ............................................................................................................. 3
1.10Fan Cooling....................................................................................................................... 3
1.11Serial Alarm and Control Interface..................................................................................... 3
1.11.1Voltage Control .................................................................................................................. 4
1.11.2Rectifier Alarm states......................................................................................................... 4
1.11.3Rectifier Shutdown............................................................................................................. 4
1.12Post-mate Connection ....................................................................................................... 4
1.13Interface - Rear Connector ................................................................................................ 5
2Installation......................................................................................................................................... 6
2.1General Warnings..............................................................................................................6
2.2Rectifier Shelf .................................................................................................................... 6
2.3AC Supply Surge Protection.............................................................................................. 6
2.4Ventilation.......................................................................................................................... 6
2.5Rectifier Addressing........................................................................................................... 7
2.6Commissioning the Rectifier.............................................................................................. 7
3Specifications.................................................................................................................................... 8
3.1AC Input............................................................................................................................. 8
3.2DC Output – Software Switchable...................................................................................... 8
3.3Environmental.................................................................................................................... 9
3.4Mechanical ........................................................................................................................ 9
3.5Compliances...................................................................................................................... 9
4Servicing.......................................................................................................................................... 10
4.1Warnings ......................................................................................................................... 10
4.2Troubleshooting............................................................................................................... 10
4.3Fuses............................................................................................................................... 10
5Ventilation Details........................................................................................................................... 11
6Warranty .......................................................................................................................................... 12

2
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
1 Principles of Operation
1.1 Introduction
The C2R-2000 is a telecommunications grade rectifier with the following features:
Hot pluggable
Forced Air Cooled
Thermally Protected
Power Factor Corrected
Wide input AC Voltage
Constant Power Output Limit
Input/Output Voltage and Current Protected
Active Load Sharing
Serial alarm and control interface
Microprocessor controlled
1.2 Indicators
There are 3 LED indicators on the front panel indicate the operational state of the rectifier.
AC: This green LED indicates that mains power is connected to the unit and that the primary stages of
the rectifier are operating.
:This yellow LED indicates a Non-Urgent alarm state within the rectifier. This could be caused by
the following:
Rectifier in output power/current limit
Rectifier over temperature
Fan failed
Rectifier soft starting
:This red LED indicates an Urgent alarm state within the rectifier. This could be caused by the
following:
Rectifier Failed
The AC input voltage is outside the operating range.
Rectifier shut down due to output over voltage or over temperature.

3
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
1.3 Power and Current Limit
The rectifier automatically limits its output as load demand reaches it maximum capacity.
1.4 Output Over-Voltage Shut Down
The rectifier will automatically shutdown if the output voltage exceeds the preset value. The Over Voltage
Shut Down point reduces by about 1V at full load to ensure the rectifier producing the Over Voltage Shut
Down turns off first. The Over Voltage Shutdown voltage is preset in the factory but may be adjusted.
1.5 Input Over/Under Voltage Shut Down
If the input voltage is outside the specified range, the rectifier may shut down until the voltage returns
within the specified range.
1.6 Rectifier Soft Start and Inrush Current
On start-up, the peak mains inrush current is limited to twice the maximum operating current. The output
voltage and current will rise slowly from zero during start-up. This means that the AC input power slowly
increases over a 2 second period, providing a gentle load characteristic for any standby generators.
1.7 Over Temperature Turn Down/Shutdown
When the rectifier reaches its maximum operating temperature (internal), the rectifier will progressively
reduce the output current to attempt to reduce the heat within the unit. In extreme circumstances, the
rectifier internal temperature may continue to rise even with reduced output current. In this case the
rectifier will totally shutdown and will restart when the internal temperature returns within limits.
The maximum ambient operating temperature range at full power is: -10 to 50 ºC.
The rectifier will operate in ambient temperatures up to 70ºC but the rectifier will de-rate its output power to
keep internal temperatures within the allowable range.
1.8 Reverse Polarity Protection
The rectifier has an internal reverse polarity protection fuse and crowbar diode fitted. These parts are not
user serviceable, and the rectifier will require returning for servicing if incorrect polarity is applied to the
output.
1.9 Active Load Share
The rectifier will actively current share with other rectifiers in the same DC system. The rectifiers are
interconnected through pin 11 of their connector. The hardware in each rectifier looks at this current share
bus and adjusts its output current to align with other rectifiers. In addition to this control, the monitor can
compare rectifier output currents and adjust individual rectifiers to achieve current share. The rectifier
current share bus is generally used within one rack of rectifiers and the monitor control is used to make
separate racks share with each other.
1.10 Fan Cooling
The rectifier constantly monitors its internal temperature, ambient temperature and output current, then
adjusts fan speed to ensure continued operation. This control of fan speed ensures that rectifier acoustic
noise and dust accumulation are minimized.
If the fan fails and cannot be restarted then the current limit will further reduce to 10A. The rectifier will
continue to operate as long as the internal temperature stays within allowable limits.
1.11 Serial Alarm and Control Interface
The rectifier, when installed in a Newmar C2RS rectifier shelf, is controlled via the serial interface by the
system monitor. The system monitor can set up control parameters and receive alarm information via this
interface.
If this interface is disconnected or fails for some reason the rectifier will operate with the parameters last
sent from the monitor. Current share will revert to the rectifier current share bus.

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
1.11.1 Voltage Control
The rectifier voltages are set by the system monitor via the serial communications bus. The rectifier
voltage can be set to any value between 21.5V-30V (24V mode), 43V-60V (48V mode). The monitor
operates in a number of modes that will affect the rectifier voltage setting.
Float Voltage Mode (AVC Off)
The monitor sets the float voltage to its target level at start up, and then resends this same level at
regular intervals thereafter. The voltage control is open loop.
Float Voltage Mode (AVC On)
The monitor sets the system voltage to its target float voltage, then monitors the system voltage
and adjusts rectifier voltages to maintain the system voltage at the desired float voltage.
Equalise Voltage Mode
The monitor sets the system voltage to an elevated level (e.g. 28V) for a fixed period, and then
resets the system voltage to the float voltage setting.
Fast Charge Mode
The monitor sets the system voltage to an elevated level after a battery discharge. This keeps the
rectifiers in current limit for a longer period, leading to a faster battery recharge. When the battery
is recharge the monitor resets the system voltage to the float voltage level.
1.11.2 Rectifier Alarm states
The rectifier will report the following states to the monitor via the serial communications:
AC Fail The AC supply is not present at the rectifier.
Rectifier Fail The rectifier is not functioning. This could be due to high output voltage, AC failure
or a fault with the rectifier internally.
Over Temperature The internal temperature of the rectifier is too high and the rectifier has begun to limit
its output to control this temperature.
Fan Fail The fan has ceased to work.
Current Limit The rectifier output has reached maximum and the output current is being limited.
Shutdown The rectifier has been shutdown by the monitor. It will restart again in 5 minutes
unless the shutdown instruction is repeated.
EEPROM Fault The rectifier microprocessor has encountered an error while reading from EEPROM.
Soft Start The rectifier has just turned on and is slowly increasing its output.
1.11.3 Rectifier Shutdown
The rectifier can be remotely forced to shutdown, via the serial communications, by the system monitor
and/or remote supervisory software. The rectifier will shut down for 5 minutes then restart. If a further
shutdown signal is received by the rectifier before the 5 minutes is up, the timer will reset to 5 minutes.
Hence, if a rectifier is to be kept shutdown a shutdown signal must be sent to it at regular intervals.
1.12 Post-mate Connection
The rectifier is “hot plug” capable. This is achieved by having one pin on the rear connector that mates
after the other pins. This pin must be connected to negative bus volts and the rectifier will not start until
this pin engages. If a rectifier will not start, ensure the rectifier is fully engaged in the Goldfish connector in
the rectifier shelf.

5
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
1.13 Interface - Rear Connector
The rear connector on the rectifiers is a Positronix Goldfish GFSH109 series.
Pin descriptions
Pin # Description
Pin 1,2,3 Positive Output
Pin 4,5,6 Negative Output
Pin 7 Serial Communication Bus
Pin 8 Rack Position - horizontal
Pin 9 Rack Position - vertical
Pin 10 Post-mate – connected to negative output
Pin 11 Load Share
Pin 12 Not Assigned
Pin 17 AC protective Earth
Pin 18 AC live (phase) conductor
Pin 19 AC neutral conductor
Note: Unassigned pins should not be connected to anything and should
be left isolated and voltage free.

6
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
2 Installation
2.1 General Warnings
This rectifier contains no user serviceable components. Do not disassemble the rectifier.
To isolate the rectifier from the mains power, simply unplug from the rack or switch off at the distribution
panel.
2.2 Rectifier Shelf
The C2R-2000 rectifier is designed to be used with the Newmar C2RS rectifier shelf or approved
alternative. This shelf will accommodate up to 4 C2R-2000 modules giving a total output capacity of
4.0kW.
Note: C2R-2000 rectifier (48/24 VDC) should not be connected together with ordinary C2R-1000 rectifier
as they have different output voltages and damage may result.
2.3 AC Supply Surge Protection
The AC supply that feeds the rectifiers should have surge protection installed to meet levels defined for
terminal equipment. Newmar recommend that IEC 62305-4(Protection against lightning - Part 4: Electrical
and electronic systems within structures) be used to give guidance on the design of surge suppression
systems.
2.4 Ventilation
The performance of the rectifier can be limited if the ventilation is restricted. The rectifier is cooled by
drawing air into the front of the unit with a single fan. This air passes through the rectifier cooling the
electronics and exiting the rectifier at the rear. To ensure this happens as efficiently as possible ensure the
following:
•The air at the front of the rack is at ambient temperature and not being heated by other equipment.
•Ensure the rectifier shelf has at least 75mm (3”) clear horizontal space behind it. This space must
be clear of cables and any other components that may restrict air movement.
(Note: if multiple rectifier shelves are installed then there should be at least 75mm (3”) clear
horizontal space per shelf.)
•The free space in the rack should continue vertically to the exhaust point at the top of the rack,
without impediment.
•The hot exhaust air should not be allowed to re-circulate to the front of the rack as this will be
drawn into the rectifiers again, in effect raising the apparent ambient temperature.
The rectifier should be operated in a low dust environment. If this cannot be guaranteed, then the rack
should be fitted with air filters to prevent dust passing into the rectifier units. These filters need to be
designed for adequate air volume and regularly maintained.
Note: If you are designing your own rectifier shelf, then particular care must be taken to ensure that any
metalwork, cable or printed circuit boards are placed to maximise the flow of cooling air. To assist in this a
drawing of the rear area of the rectifier, show air flow areas, has been included in appendix 5.
DANGER
Do not operate the rectifier if the covers are damaged or removed in any way
-The rectifier contains voltages that may be lethal even after the
input supply has been removed
-The rectifier contains components at High Temperatures that may
burn if touched

7
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
2.5 Rectifier Addressing
Each rectifier in the system has a unique address which identifies it to the monitor. This address is set by
the position in the rectifier shelf and the number of the shelf. It is read by the rectifier from the backplane
PCB and will change if the rectifier is moved to a new location. This address structure is set up when the
system is built by the system manufacturer.
2.6 Commissioning the Rectifier
1) Ensure the polarity of the load and battery cables to the backplane is correct.
2) Plug the rectifier into the rectifier shelf using the following steps:
•Locate the metal tag (at the bottom/rear of the rectifier) into the chosen slot in the backplane.
•Engage the plastic front panel into the slot at the front of the rectifier shelf.
•Push the rectifier into the rectifier shelf until the connector is fully engaged.
•Lock the rectifier in position using the plastic retainers in the front panel.
3) Once the rectifier is installed into the rectifier shelf, the AC power can be turned on. After the initial
start up period the rectifier will be set to the desired system parameters by the monitor module via
the serial communications.

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
3 Specifications
Due to ongoing product development specifications are subject to change without prior notice
3.1 AC Input
Nominal 230V or 115V (Reduced output @ 115V)
Voltage Range 90 – 300V AC (reduced power below 175V)
Frequency Range 45 – 66Hz
Power Factor > 0.99
Efficiency > 91% (>50% output power)
Input Fuses HRC Fuses in phase and neutral
Maximum Input Current 13A
Protection
Input Voltage Automatic shutdown, restarts when correct voltage restored.
Input Inrush < 2x maximum input current
3.2 DC Output – Software Switchable
Nominal 48V 24V
Rated Voltage 58V 29V
Adjustable Voltage Range 43V – 60V 21V – 30V
Maximum Rated Current 41.7A* 41.7A*
Maximum Rated Power 2.0kW 1.0kW
* 21A maximum below 175 VAC Input
Regulation
Line ±0.1%
Load ±0.5% no load to full load
Hold-up time >15ms for 20% output voltage drop
Start-up time Start-up delay 1 second. (varies with AC supply voltage)
Walk-in delay 6 seconds at full output. (varies with DC output voltage)
Protection
Power Limit Adjustable to 50 – 100% of maximum rated current
Over Temperature Automatic current turndown, backup shutdown protection
Polarity Reversal Output Fuse with Crowbar diode
Over Voltage Adjustable limit

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
Noise
Ripple Below 100Hz <1mVRMS Unweighted
Voice band 100Hz to 5 kHz <1mVRMS Psophometric
Wide band 5 kHz to 1MHz <5mVRMS Unweighted
Peak to Peak 0 to 20MHz <50mV Peak to peak
Isolation
Input to Input 4000V DC
Input to Chassis 3500V DC (VDR to chassis removed)
Output to Chassis 2100V DC
3.3 Environmental
Operating Ambient Temperature
Rated 25± 5 ºC
Range -10ºC to 70ºC
Storage Temperature -20ºC to 70ºC
Humidity 5 – 95% RH (non-condensing)
Altitude <2500m above sea level
De-rate maximum ambient temperature by 4ºC
per 1000m above sea level.
3.4 Mechanical
Dimensions (W, H, D) 111.5mm (4.39”), 44mm (1.73” or 1U), 282mm overall
jajljafjlajflkajlfjalfjaljflajdfljasdlfjaljf(260mm/10.23” shelf)
Weight 1.5kg (3.31 lbs.)
Shipping Dimensions (W, H, D) 120mm (4.7”), 52mm (2.05”), 325mm (12.8”)
Shipping Weight 1.6kg (3.53 lbs.)
3.5 Compliances
Safety EN60950
Electrostatic Discharge CISPR 24
Radiated Radio Frequency CISPR 22
AC Harmonics EN 61000-3-2
AC Flicker and Fluctuation EN 61000-3-3
Other CE & RoHS compliant
Due to ongoing product development specifications are subject to change without prior notice.

10
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
4 Servicing
If the rectifier develops an operational fault, or is damaged in any way, an Authorised Service Centre
should service it immediately.
4.1 Warnings
This rectifier contains no user serviceable components. Do not disassemble the rectifier.
4.2 Troubleshooting
If the red LED is alight:
Unplug the rectifier and re-engage.
Check AC power to the rectifier.
Check for rectifier alarms in the monitor Urgent Alarm list.
If symptoms persist, contact a service agent.
If the yellow LED is alight:
Check the monitor Non-Urgent Alarm list.
4.3 Fuses
Although there are fuses inside the rectifier, these are rated such that their failure indicates a fault requiring
qualified service. Do not attempt to repair these fuses.
However for IEC 60950 the fuse ratings are required to be specified. The following fuses are soldered to
the PCB:
FH183 FST 250mA 250V EFT/MET PCB Fuse
FH100 15A 250V ceramic slow blow wire end Fuse
FH101 15A 250V ceramic slow blow wire end Fuse
DANGER
Do not operate the rectifier if the covers are damaged or removed in any way.
-The rectifier contains voltages that may be lethal even after the input supply
has been removed
-The rectifier contains components at High Temperatures that may cause
burns if touched

11
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
5 Ventilation Details

12
Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [email protected]
6 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 one year from the date of purchase. This
warranty covers both parts and labour. 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 unauthorised repair centre.
Please contact Newmar Customer Service to obtain a Returned Materials Authorisation (RMA), by calling
714-751-0488, 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’s shipping address:
2911 W. Garry Ave., Santa Ana, CA 92704.
Newmar Ltd 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 Ltd 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.