NewMar RM2048HE User manual

Rectifier Installation Manual Page 1 of 10
POWERING THE NETWORK
www.poweringthenetwork.com | 800.854.3906
Costa Mesa, CA
Installation Manual
RM2048HE 48V Rectifier
Product Compliance
RoHS
Copyright © Newmar 2021 All rights reserved.
Release Date: 26 AUG 2021
Disclaimer: Newmar reserves the right to make changes to the information within this document without notice
M-RM2048HE 020623

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1. Introduction
1.1. Indicators 3
1.2. Power and Current Limit 3
1.3. Output Over-Voltage Shut Down 3
1.4. Input Over/Under Voltage Shut Down 3
1.5. Rectifier Soft Start and Inrush Current 4
1.6. Over Temperature Turn Down/Shutdown 4
1.7. Reverse Polarity Protection 4
1.8. Active Load Share 4
1.9. Fan Cooling 4
1.10. Serial Alarm and Control Interface 4
1.10.1. Voltage Control 4
1.10.2. Rectifier Alarm states 4
1.10.3. Rectifier Shutdown 4
1.11. Post-mate Connection 5
1.12. 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 7
2.5 Rectifier Addressing 7
2.6 Commissioning the Rectifier 7
3. Specifications 8
3.1. AC Input 8
3.2. DC Output 8
3.3. Environmental 9
3.4. Mechanical 9
3.5. Compliances 9
4. Servicing 9
4.1. Warnings 9
4.2. Troubleshooting 10
4.3. Fuses 10
5. Ventilation Details 10
6. Warranty 10

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1 Principles of Operation
1.1 Introduction
The RM2048HE is a telecommunications grade rectifier with the following features:
High Efficiency
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.
This green LED indicates that mains power is connected to the unit and that the primary stages of the
rectifier are operating.
This LED flashes during power save mode.
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
No communications address (LED is flashing in this state)
Brownout
Postmate open
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.
1.3 Power and Current Limit
The rectifier automatically limits its output as load demand reaches it maximum capacity.

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1.4 Output Over-Voltage Shut Down
The rectifier will automatically shut down 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 7
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 45°C.
The rectifier will operate in ambient temperatures up to 70°C 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 self-protect the rectifier. The
rectifier will continue to operate if the internal temperature stays within allowable limits.
1.11 Serial Alarm and Control Interface
The rectifier, when installed in an Newmar rectifier shelf or system, 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 and current share will revert to the rectifier current share bus. The voltage set point reverts to the default
setting after 8 minutes of no monitor communications.

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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 43V and 60V. The monitor operates in several 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.
Equalize Voltage Mode
The monitor sets the system voltage to an elevated level (e.g. 56V) 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 recharged, 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 capacity 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 writing to
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 shut down, 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.

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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.
1.13 Interface – Rear Connector
The rear connector on the rectifiers is a Positronic® 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.
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.

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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
2.2 Rectifier Shelf
The RM2048HE rectifier must only be used in conjunction with an appropriate Newmar designed or Newmar
approved system or rectifier shelf.
2.3 AC Supply Surge Protection
The AC supply that feeds the rectifiers must 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. Rectifiers that
exhibit transient surge damage are not covered under warranty.
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 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 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 must be operated in a low dust environment.
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.
• Push the rectifier into the rectifier shelf until the connector is fully engaged.
• There will be an audible click as the rectifier locks itself in position using the plastic spring retainer on
the right side of the front panel.
• Rectifier removal is achieved by pressing and holding the unlock button then gently pulling on the front
panel.
3) Once the rectifier is installed into the rectifier shelf, the AC power can be turned on. After the initial startup
period the rectifier will be set to the desired system parameters by the monitor module via the serial
communications.
3 Specifications
3.1 AC Input
Nominal
230 V

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Voltage Range
85 – 300 V AC (reduced power below 190 V)
Frequency Range
45 – 65 Hz
Power Factor
> 0.99
Efficiency
> 96.3% (peak)
Input Fuses
HRC Fuses in phase and neutral
Maximum Input Current
Protection
12 A
Input Voltage
Automatic shutdown, restarts when correct voltage restored.
Input Inrush
3.2
DC Output
< 2x maximum input current
Nominal
48 V
Rated Voltage
54 V
Adjustable Voltage Range
43 V – 60 V
Maximum Rated Current
41.7 A
Maximum Rated Power
Regulation
2.0 kW
Line
±0.1%
Load
±0.5% no load to full load
Hold-up time
>15ms for 20% output voltage drop
Start-up time
Protection
Start-up delay 1 second (varies with AC supply voltage) Walk-in delay
6 seconds at full output (varies with DC output voltage)
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
Noise
Adjustable limit
Ripple
Below 100 Hz <10 mV
RMS
Unweighted
Voice band
100 Hz to 5 kHz <2 mV
RMS
Psophometric
Wide band
5 kHz to 1MHz <10 mV
RMS
Unweighted
Peak to Peak
0 to 20 MHz <100 mV Peak to peak
Isolation

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Input to Output
4000 V DC
Input to Chassis
3500 V DC (VDR to chassis removed)
Output to Chassis
2100 V DC
3.3 Environmental
Operating Ambient Temperature
Rated
25 ± 5 ºC
Range
-20 ºC to 70 ºC (maximum power derates above 45 ºC)
Humidity
5 – 98% RH (non-condensing)
Altitude
3.4
Mechanical
<2000 m above sea level
Dimensions (W, H, D)
111.5 mm, 44 mm (1U), 282 mm overall (260 mm shelf)
Weight
1.5 kg
Shipping Dimensions (W, H, D) 120 mm, 52 mm, 325 mm
Shipping Weight
3.5 Compliances
1.6 kg
Safety
EN 60950
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 continual product development, specifications are subject to change without prior notice.
4 Servicing
If the rectifier develops an operational fault, or is damaged in any way, an Authorized Service Center should service
it immediately.
4.1 Warnings
This rectifier contains no user serviceable components. Do not disassemble the rectifier.
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

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4.2 Troubleshooting
If the red LED is illuminated:
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 illuminated:
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:
FH101 15 A 250 V ceramic slow blow wire end Fuse FH102 15 A 250 V
ceramic slow blow wire end Fuse
5 Ventilation Details
The rectifier has an outlet area of 3.26 in2/2100 mm2. Any custom mounting tray shall not obstruct these openings
and requires a minimum opening area of 3.26 in2/2100 mm2.
Refer to additional information in section 2.4 Ventilation above.
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 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.