Unipower TPCMQ48 SERIES User manual

OPERATING MANUAL
TPCMQ48 SERIES
48VDC INPUT DC/DC CONVERTERS
www.unipowerco.com
Manual No. tpcmq48-4 © 2016 UNIPOWER LLC
All Rights Reserved
tpcmq48-man-rev4-0116.indd
NORTHAMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: [phone] • Fax: [phone] • [email protected]
EUROPE • Parkland Business Centre, Chartwell Road, Lancing BN15 8UE, ENGLAND • Tel: [phone] • [email protected]

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
Contents
1.0 INTRODUCTION ...............................................................................................................4
2.0 STANDARD FEATURES ...................................................................................................5
3.0 SUMMARY OF PRODUCT LINE .....................................................................................5
4.0 SAFETY WARNINGS.........................................................................................................6
5.0 WARRANTY (summary) ....................................................................................................6
6.0 UNPACKING AND INSPECTION.....................................................................................6
7.0 MODULE SPECIFICATIONS............................................................................................7
8.0 FRONT PANEL DESCRIPTION........................................................................................7
9.0 DESCRIPTION OF OPERATION......................................................................................8
10.0 MECHANICAL SPECIFICATIONS.................................................................................10
11.0 SAFETYAND INDUSTRY STANDARDS......................................................................11
13.0 PARALLEL OPERATION ................................................................................................15
14.0 MODULE INSTALLATION.............................................................................................16
15.0 COMPATIBLE 19-INCH POWER SHELVES .................................................................17
16.0 MECHANICAL DIMENSIONS .......................................................................................19
17.0 SHELF INSTALLATION..................................................................................................21
18.0 MAINTENANCE..............................................................................................................22
19.0 SETUPAND TESTING ....................................................................................................22
20.0 OPTIONAL I²C SERIAL BUS INTERFACE...................................................................24
21.0 TROUBLESHOOTING GUIDE.......................................................................................28

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
FIGURES
Figure 1 - Module & Power Shelf....................................................................................................4
Figure 2 - Front Panel View.............................................................................................................7
Figure 3 - Module Dimensions......................................................................................................10
Figure 4 - Module Rear Views showing connection details ..........................................................11
Figure 5a - Signal Connections – 12, 24 & 27.2V Models............................................................12
Figure 5b - Signal Connections – 48 & 54.4V Models..................................................................12
Figure 6 - Connection Diagram for Parallel Operation .................................................................15
Figure 7 - Power Self Front & Rear Views....................................................................................17
Figure 8a - TPCMQR1U3-48 Power Shelf Outline.......................................................................19
Figure 8b - TPCMQR1U3-48H Power Shelf Outline....................................................................20

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
OPERATING MANUAL
TPCMQ48 SERIES
48VDC INPUT DC/DC CONVERTERS
1.0 INTRODUCTION
This Operating Manualshould be readthrough carefully beforeinstalling and operatingtheTPCMQ48
Series DC/DC converters.
TPCMQ48 is a family of high density hot-swappable, modular DC/DC converters producing up
to 1000 watts output power from a nominal 48VDC source. There are 6 standard models with
dierent output voltages and power levels. The modules are ultra-compact with power density up
to 12.5 watts per cubic inch. The modules have automatic load sharing and active output ORing
circuit so they can be hot-swapped while the system is operating. When using the optional I²C serial
communications interface, status and control data can be passed between the module and a host
system or power management unit.
Front panel mounted LEDs indicate input and output condition and a +5Vstandby output is also
included. Operating temperature range is -20°C to +70°C.
TPCMQ48 modules can be fully integrated into an OEM host system or alternatively installed into
a matching 1U high 19” rack-mount power shelf. Multiple power shelves may be connected in
parallel for increased system capacity.
Figure 1 below shows a TPCMQ48 module and three modules installed into a power shelves.
.
Figure 1 - Module & Power Shelf

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
2.0 STANDARD FEATURES
Isolated 5V, ¼ A Standby Output
Hot-Swap Operation
12, 24 or 48 VDC Output
Up to 3000 Watts Shelf Output
Remote Output Adjustment
Wide Range 40 to 60VDC Input
Integral LED Status Indicators
-20°C to +70°C Operating
I²C Serial Data Bus Option
Upto12.5Watts/Cubic InchPowerDensity
 Low Prole: 1.6 Inches High
Single Hot-Swappable Connector
Reverse Air Flow Option
Staged Pin Engagement
ORing Diode on Output
1U, 19” Rack/Shelf Holds 3 Units
19- or 23-Inch Rack Mounting
Active Current Sharing
Optimized Thermal Management
No Minimum Load
Control & Monitoring Features
3.0 SUMMARY OF PRODUCT LINE
3.1 Standard Modules & Shelves
STANDARD MODULES
OUTPUT
POWER OUTPUT VOLTAGE OUTPUT CURRENT INPUT CURRENT MODULE NUMBER RACK/SHELF NUMBER
650W 12VDC 54.2A 16.5A @ 48VDC TPCMQ48-12/54 TPCMQR1U3-48
700W 24VDC
27.2VDC 29.2A 25.7A 16.6A @ 48VDC 19.9A @ 40VDC TPCMQ48-24/29 TPCMQ48-27/26
1000W 48VDC
54.4VDC 20.8A 18.4A 20.8A @ 48VDC 25.0A @ 40VDC TPCMQ48-48/21
TPCMQ48-54/18 TPCMQR1U3-48H
3.2 Options
OPTIONS
CODE DESCRIPTION OUTPUT
DERATING APPLICABILITY
RReverse Air Flow
(Back to Front) 20% All modules
Z I2C Serial Data Bus N/A All modules
TPCMQR1U-48
NOTE: TPCMQR1U3-48H will accept modules both with and without the I²C
option, but modules should not be mixed.

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
4.0 SAFETY WARNINGS
4.1 These power supplieshave hazardous externaland internal voltages. They should behandled,
tested and installed only by qualied technical persons who are trained in the use of power
systems and are well aware of the hazards involved.
4.2 The input terminals are at hazardous voltage potentials. Do not touch this area when power
is applied.
4.3 When operating this power supply, the chassis ground terminal must be connected to safety
ground by means of a three-wireAC power line to minimize electrical shock hazard and to
ensure low EMI (electromagnetic interference).
4.4 The internal voltages are at hazardous potentials. The power supply cover should not be
removed. There are no user-serviceable components in these units. Removing the cover
of the power supply will void the warranty.
5.0 WARRANTY (summary)
TPCMQ48 Series DC/DC Converters are warranted for two (2) years from date of shipment against
defects in material and workmanship. This warranty does not extend to products which have been
opened, altered or repaired by persons other than persons authorized by the manufacturer or to
products which become defective due to acts of God, negligence or the failure of customer to fully
follow instructions with respect to installation, application or maintenance.
For a complete text of UNIPOWER’s warranty conditions please request a copy from your local
Sales Oce.
6.0 UNPACKING AND INSPECTION
6.1 This unit was carefully tested, inspected and packaged for shipment from our factory. Upon
receipt the unit should be carefully unpacked and inspected for any damage in shipment.
6.2 If there is evidence of damage, donotattemptto install the unit. The freight carrier should
be notied immediately and a claim for the cost of the unit should be led with the carrier
for direct reimbursement. Be sure to include the model and serial number of the damaged
unit in all correspondence with the freight carrier. Also save the shipping carton and packing
material as evidence of damage for the freight carrier’s inspection.
6.3 UNIPOWER LLC will cooperate fully in case of any shipping damage investigation.
6.4 Always save the packing materials for later use in shipping the unit. Never ship this unit
without proper packing.

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
7.0 MODULE SPECIFICATIONS
The following specications are typical at 25°C unless otherwise noted.
OUTPUT SPECIFICATIONS
Total Output Power, Continuous, Max................see table page 1
Voltage Adjustment Range, Min. ........................... -25% to +10%
Total Regulation1...................................................................2.0%
Total Regulation, Standby Supply ........................................5.0%
Ripple & Noise, Pk-Pk2......................................................200mV
Voice Band Noise.........................................................<32dBrnC
Dynamic Response3...........................................................300µS
Temperature Coe󰀩cient ..............................................±0.02%/°C
Minimum Load..........................................................................0A
Current Limit................................................105% Rated Current
Overload Protection...............................................Auto Recovery
Overvoltage Protection................................... Latched Shutdown
Remote Sense............................................Up to 0.25V Per Wire
Current Share...........................................±10% Full Load Rating
Standby Output..........................................................+5V, 250mA
Output Power Good Signal...........................................Logic Low
Input Power Fail Signal................................................Logic High
Inhibit............................................................................Logic Low
Enable ..........................................................................Logic Low
Thermal Warning.........................................................Logic High
INPUT SPECIFICATIONS
Input Voltage Range.................................................... 40-60VDC
Inrush Current Limiting..................................................10A Peak
Input EMI Filter...............................................................Standard
Analog Voltage Adjust......................................................0 to +5V
Input Immunity, Conducted
Fast Transients, Line-Line.....................±500V (EN61000-4-4)
Surges, Line-Line ..................................±500V (EN61000-4-5)
Surges, Input Ground............................±500V (EN61000-4-5)
Input Protection 12/24Vout..............................Internal Fuse, 30A
48Vout .................. requires external protection
GENERAL SPECIFICATIONS
E󰀩ciency 4
12/24Vout ................................................82-88% at Full Load
48Vout .................................................up to 90% at Full Load
Switching Frequency..........................................210kHz Nominal
Isolation, Class I, min.5
Input-Output..............................................................2121VDC
Input-Ground ............................................................1000VDC
Output-Ground.........................................................................
100VDC..............................................................................MTBF
(Bellcore)...............................................................200,000 Hours
Safety Standards....................UL60950-1, CSA22.2 No.60950-1
EN60950-1
ENVIRONMENTAL SPECIFICATIONS
Operating Temperature.............................-20°C to 70°C Ambient
Derating....................................................2.5%/°C, 50°C to 70°C
Storage Temperature............................................-40°C to +85°C
Cooling ................................................Integral Ball Bearing Fans
PHYSICAL SPECIFICATIONS
Case Material, Module & Rack/Shelf............................Aluminum
Dimensions, Inches(mm)
Module.................................................1.6 H x 5.0 W x 10.0 D
(40.6 x 127 x 254)
Rack/Shelf....................................1.72H x 19.00 W x 11.56 D
(44 x 483 x 294)
Weight
Module....................................................... 3.15 lbs. (1.43 kg.)
Rack/Shelf.................................................4.15 lbs. (1.88 kg.)
NOTES:
1. No load to full load, including line regulation and load regulation.
2. Whichever is greater. 20MHz bandwidth. Measure with 0.1µF ceramic and 10µF
tantalum capacitors in parallel across the output.
3. <4% deviation recovering to within 1% for 25% load change.
4. Typical e󰀩ciency is at low end of range for 12V output and at high end of range
for 24V output.
5. Input-output isolation gure is for isolation components only. 100% production
Hipot tested input to ground.
8.0 FRONT PANEL DESCRIPTION
INPUT POWER
GOOD
OUTPUT POWER
GOOD
HANDLE
JACKING
SCREW
Figure 2 - Front Panel View

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
8.1 FRONT PANEL INDICATORS
The two green front panel indicators together indicate the status of the power module.
LED Status Condition
INPUT POWER GOOD ON DC input within limits
OFF DC input outside limits
OUTPUT POWER GOOD ON DC Output is on and within limits
OFF DC Output is o󰀨
9.0 DESCRIPTION OF OPERATION
9.1 Power Outputs
The power output terminals provide the main output power of the unit. The output voltage
is adjustable by means of a potentiometer accessible through the top cover of by using the
analogue remote adjust pin. Note that all of the powerpins must be used for correctoperation
and to avoid overheating of the connector. The power output terminals are isolated from
chassis ground to a maximum voltage of 100VDC.
9.2 I/O Signals
The # symbol in the following text is used to denote an active low signal.
9.2.1 Sense +Ve, Sense –Ve
The sense signals are intended to be connected to the point of load so that voltage drop in
the load cables can be compensated for. The amount of compensation is limited to 0.25V
per wire. Care must be taken when using the sense signals as if the power connections to
the load are interrupted by disconnection or circuit breaker with the senses still connected
then damage may occur to the power supply and sense wiring. Sense +Ve and Sense -Ve
are internally connected to the module output power terminals using 10 Ohm resistors so
that if the senses are not connected the output will still be regulated.
Sense -Ve is also used as the return path for the other I/O signals.
9.2.2 Current Share
This signal is connected between all modules required to share a load. This signal is capable
of driving up to 16 modules. The return path for this signal is Sense -Ve and that signal
should also be connected between all modules for correct sharing operation.
9.2.3 Current Monitor
This analogue signal provides avoltage proportional to the outputload current of the module.
The full scale voltage for nominal full load current is 3.0V.
9.2.4 Standby Return
This is the return path for the +5V standby supply.

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TPCMQ48 SERIES
INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
9.2.5 Remote Adjust
An analogue voltage from 0 to +5V controls approximately -25 to +10% output range. This
input can be controlled externally by a power control system. Multiple inputs can also be
connected together so that the external control voltage adjusts multiple module outputs
simultaneously.
9.2.6 +5V Standby
The 5V supply is always present when the DC input is within the operating range of the
module. The maximum current available from 5VSB pin is 25mA The return for this power
rails is standby return. The standby supply has an internal ORing diode so that it can be
connected to the same outputs of additional units directly on the backplane.
9.2.7 Input Power Fail
This signal provides an open drain output that indicates the status of the DC input. The
signal is low for the OK state. The output is capable of supporting voltages of up to 30V
and will sink current up to 30mA.
9.2.8 Output Power Good
This signal provides an open drain output that indicates that the DC output voltage outside
the -25 to +10% output range for the converter, the unit has failed or is in current limit. The
signal is low for the OK state. The output is capable of supporting voltages of up to 30V
and will sink current up to 30mA.
On the 12/24V model this pin is used for I²C address GA1 when the I²C option is tted.
9.2.9 Overtemp. Warning
This signal provides an open drain output that indicates that the power supply internal
temperature is within a safe operating range. The signal is low for the OK state and goes
high a few milliseconds before the unit shuts down. The output is capable of supporting
voltages of up to 30V and will sink current up to 30mA.
On the 12/24V model this pin is used for I²C address GA0 when the I²C option is tted.
9.2.10 Module Present (48V/54V output units only)
This signal can be used to detect if a module is present. It is connected to standby return
when the module is present. This signal should be driven from a source impedance of less
than 100 Ohms.
9.2.11 Enable
This signal is used to enable the unit. This pin engages after the power terminals when
plugging in the module and disengages before the power terminals when unplugging the
module. It is intended to control hot-plugging to avoid burning connector pins caused by
arcing of high currents. This pin should be connected to Sense -Ve on the backplane for
correct operation.

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INSTALLATION & OPERATING MANUAL
Manual No. tpcmq48-4 tpcmq48-man-rev4-0116.indd
9.2.12 Inhibit
This signal can be used to control the main output of the unit in order to turn it on and o.
A low signal on this pin will turn the main output o. This behavior can allow a system to
be setup so that the main output will not come on until commanded by a supervisory circuit.
The driving circuit should be capable of sinking and sourcing at least 0.5mA.
9.2.13 SCL, SDA
These are the I²C serial data bus signals used for digital communication. They require pull-
up resistors or active pull-up circuits to 3.3V or 5V.
9.2.14 GA0, GA1, GA2
These are the I²C interface address lines. They are used to set the hardware address of each
module on the backplane. Each module should have a unique address when connected using
the same serial bus.
The address lines should either be tied high (to 5VSB) for ‘1’ or low (standby return) for
‘0’.
10.0 MECHANICAL SPECIFICATIONS
The mechanical dimensions of the TPCMQ48 Series module are shown.
Note that while TPCMQ48 Series modules are designed for hot-swap applications, xing points are
provided for applications not requiring this capability.
Figure 3 - Module Dimensions