Unipower Quick-Set PowerCassette PCHS Series User manual

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OPERATING MANUAL
PCHS/TPCHS SERIES
Quick-Set PowerCassette®
ADVANCED MULTI-OUTPUT
SWITCHER AND RACKS
www.unipowerco.com
Manual No. TPCHS-2 © 2014 UNIPOWER LLC
All Rights Reserved
pchs-tpchs-man-rev2-1214.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] • Fax: [phone] • [email protected]
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
Contents
1.0 INTRODUCTION................................................................................................................4
2.0 QUICK-SET POWERCASSETTE FEATURES .................................................................5
3.0 SUMMARY OF PRODUCT LINE......................................................................................6
4.0 SAFETY WARNINGS.........................................................................................................6
5.0 WARRANTY (summary).....................................................................................................7
6.0 UNPACKING AND INSPECTION.....................................................................................7
7.0 DESCRIPTION OF OPERATION.......................................................................................7
8.0 FRONT PANEL DESCRIPTION ........................................................................................ 8
9.0 MODULE SPECIFICATIONS ............................................................................................8
10.0 DESCRIPTION OF FEATURES & OPTIONS...................................................................9
11.0 MECHANICAL SPECIFICATIONS................................................................................. 11
13.0 OPERATING INFORMATION......................................................................................... 12
14.0 PARALLEL OPERATION.................................................................................................15
15.0 COMPATIBLE 19-INCH RACKS.....................................................................................16
16.0 DESCRIPTION OF CONTROLAND SUPERVISORY SIGNALS.................................21
17.0 INSTALLATION................................................................................................................22
18.0 MAINTENANCE...............................................................................................................23
19.0 SETUPAND TESTING.....................................................................................................23
20.0 TROUBLESHOOTING GUIDE........................................................................................25
APPENDIX 1..................................................................................................................... 26
APPENDIX 2..................................................................................................................... 28
APPENDIX 3..................................................................................................................... 30
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
FIGURES
Figure 1 - Quick-Set PowerCassette Models (hot-swap model shown)..........................................4
Figure 2 - PowerCassette Simplied Block Diagram (AC Input) ...................................................5
Figure 3 - Front Panel of the Quick-Set PowerCassette..................................................................8
Figure 4 - Mechanical Dimensions of PowerCassette...................................................................11
Figure 5 - Connectors and Pin Connections to PowerCassette......................................................12
Figure 6 - Output Voltage Adjustment (V1 & V2).........................................................................13
Figure 7 - Rated Total Output Power vs. Ambient Temperature....................................................13
Figure 8 - Remote Sensing Connection for Each V1, V2 or V3 Output........................................14
Figure 9 - 19-Inch Racks for Two or Three PowerCassettes.........................................................16
Figure 10 - Two-Unit Rack with Connections...............................................................................18
Figure 11 - Three-Unit Rack with Connections.............................................................................20
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
OPERATING MANUAL
PCHS/TPCHS QUICK-SET PowerCassette®
ADVANCED, MULTI-OUTPUT SWITCHER
1.0 INTRODUCTION
This operating manual should be read through carefully before installing and operating the PCHS/
TPCHS Quick-Set PowerCassette®.
The Quick-Set PowerCassette is an advanced-design, multi-output switching power supply that
employs a unique, new cellular architecture which permits quick factory programming of its outputs
by means of internal DIP switches to meet virtually any requirement. There are up to six outputs,
including a 5VDC 250 mAindependent standby output. Maximum continuous output power is 600
watts, and available voltages are from 1.2VDC to 12VDC.
The PowerCassette is ultra-compact, only 1.6 inches high, 5 inches wide and 11 inches deep, giving
6.8 watts per cubic inch power density. The unit comes in two versions: the PCHS model which is
the standard, non-hot-swap version; and the TPCHS model, which is the hot-swap version with a
handle and mounting bracket with jackscrews. See Figure 1. There are also bothAC and DC input
models available.
PowerCassette incorporates control and monitoring features including enable and inhibit inputs,
input power fail and output power good signals, overtemperature warning and remote sensing onV1,
V2 and V3. The front panel has two LED status indicators: one for Input Power Good and the other
for Output Power Good. The V1, V2 and V3 outputs have single-wire, current sharing capability.
19-inch, 1U-high racks are available to hold either two or three PowerCassette units connected in
parallel to give 600 or 1200 watts with redundancy or 1200 watts with non-redundant operation.
The racks feature a number of input connection options.
There is also an I²C serial bus interface option which gives the status of system critical operating
parameters..
Figure 1 - Quick-Set PowerCassette Models (hot-swap model shown)
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
Figure 2 - PowerCassette Simplied Block Diagram (AC Input)
2.0 QUICK-SET POWERCASSETTE FEATURES
The following is a summary of the important features of the Quick-Set PowerCassette
Outputs Set by Internal DIP Switches
Advanced “Cellular Power”™ Architecture
Up to 5 Outputs Plus 5V 250 mAStandby
508 Different Models
Hot-Swap or Chassis Mount Versions
Compatible 19-Inch Racks Available
Integral LED Status Indicators
AC or DC Input
I²C Serial Data Bus Option
6.8 Watts/Cubic Inch Power Density
Power Factor Corrected (AC Version)
 Low Prole: 1.6 Inches High (1U)
Hot-Swappable Connector
Staged Pin Lengths
Output ORing Diodes on All Outputs
Active, Single-Wire Current Sharing on V1, V2 & V3
Universal 85-264 VAC Input
Wide Range 36-72 VDC Input
DC Input Reverse Polarity Protected
Class B EMI Input Filter (AC Version)
No Minimum Load on Any Output
Control and Monitoring Signals
Optimized Thermal Management
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
3.0 SUMMARY OF PRODUCT LINE
3.1 The Quick-Set PowerCassette product line consists of 254 AC input models and 254 DC
input models, or 508 different models total. There is a choice of ve outputs plus a 5V, 250
mA standby output, giving a total of up to six outputs.
3.2 The following Ordering Guide with examples gives the conguration of model numbering.
ORDERING GUIDE
SERIES AC or DC
INPUT V1 OUTPUT I²C OUTPUT V1 to V5 OUTPUTS
PCH = Chassis Mount
TPCH = Hot Swap Q = DC B* = AC 29332-S = 1.8-5V Out 32332-S = 12V Out Z = I²C B* = No I²C Use 5 Letters From Tables: -XXXXX (Appendix 1)
*NOTE: B means “leave blank” (no letter)
Examples: Model TPCH29332-S-DBFGE is a Hot-Swap version with AC input, no I²C,
V1 = 5V/70A, V2 = 2.5V/50A, V3 = 12V/10A, V4 = -12V/3A and V5 = -5V/3A
Model PCHQ32332-SZ-FCOGE is a Chassis Mount version with DC input, I²C output,
V1 = 12V/35A, V2 = 3.3V/50A, V3 = No Output, V4 = -12V/3A and V5 = -5V/3A
3.3 The outputs are designated by ve sufx letters taken from the tables in Appendix 1.
3.4 The 19-Inch compatible racks are designated as follows:
Two-Unit Rack: TPCHR1U2 for AC input
TPCHQR1U2 for DC input
Three-Unit Rack: TPCHR1U3 for AC input
TPCHQR1U3 for DC input
4.0 SAFETY WARNINGS
4.1 These power supplieshave hazardousexternal andinternal voltages. They shouldbe handled,
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.
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
5.0 WARRANTY (summary)
PowerCassette Seriesare warrantedfor two (2)years fromdate ofshipment againstdefects inmaterial
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 Of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, donot attemptto installtheunit. 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.
7.0 DESCRIPTION OF OPERATION
7.1 A simplied block diagram of a Quick-Set PowerCassette unit with AC input is shown in
Figure 2. PowerCassette employs a new, advanced CellularPower™ architecture onsisting
of standardized power cells. The diagram shows that there are four power cells employed.
7.2 The rst cell contains (for the AC input version shown) an input EMI lter, rectier and
power factor converter. Cells two and three each have a precongured, high-current, single-
output DC-to-DC converter. Cell four has a pre-congured triple output DC-to-DC converter;
this cell produces one medium current output and two low current outputs. The individual
DC-to-DC converter cells are quickly and simply programmed at the factory to the required
output voltages by means of internal DIP switches on the circuit board. The result is ve
DC outputs plus a 5V 250 mAstandby output, giving up to six outputs in total.
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
8.0 FRONT PANEL DESCRIPTION
The front panel of the Quick-Set PowerCassette is shown in Figure 3. On the left bottom of the
panel is the Input Power Good LED (green) and on the right bottom is the Output Power Good LED
(green). For the TPCHS and TPCHQS models there is a handle between the two LEDs. Also for
these models there is a mounting bracket on the right side of the front panel. This has a jackscrew
(Allen bolt) for securing the unit.
Figure 3 - Front Panel of the Quick-Set PowerCassette
9.0 MODULE SPECIFICATIONS
OUTPUT SPECIFICATIONS
Total Output Power, Continuous, Max.........................................600 Watts
Voltage Adjustment Range, Min ...........................................................±5%
Total Regulation1, V1, V2, V3..............................................................2.0%
Total Regulation1, V4, V5.....................................................................3.0%
Ripple & Noise, Pk-Pk2............................................................1% or 50mV
Holdup Time ...................................................................................... 20mS
Dynamic Response3.........................................................................300μS
Temperature Coefcient .............................................................±0.02%/°C
Minimum Load, Any Output.....................................................................0A
Overload Protection.............................................................Auto Recovery
Overvoltage Protection, V1, V2, V3...............................Latched Shutdown
Remote Sense, V1, V2, V3........................................Up to 0.25V Per Wire
Current Share, V1, V2, V3...................................... ±10% Full Load Rating
Standby Output........................................................................ +5V, 250mA
Output Power Good Signal.........................................................Logic High
Input Power Fail Signal...............................................................Logic High
Global Inhibit................................................................................Logic Low
Enable .........................................................................................Logic Low
Thermal Warning.........................................................................Logic Low
AC INPUT SPECIFICATIONS
Input Voltage Range................................................................. 85-264VAC
Power Factor........................................................................................0.99
Input Frequency.............................................................................47-63Hz
Inrush Current Limiting................................................................ 30A Peak
Input EMI Filter6..............................................................EN55022 Curve B
FCC20780 pt. 15J Curve B
Harmonic Distortion............................................................... EN61000-3-2
Input Immunity, Conducted
Fast Transients, Line-Line........................±2kV (EN61000-4-4 Level 3)
Surges, Line-Line .....................................±2kV (EN61000-4-5 Level 3)
Surges, Line-Ground................................±4kV (EN61000-4-5 Level 4)
Input Protection ..............................................................Internal Fuse, 15A
DC INPUT SPECIFICATIONS
Input Voltage Range...................................................................36-72VDC
Inrush Current Limiting................................................................ 10A Peak
Input EMI Filter......................................................................Standard
Input Immunity, Conducted
Fast Transients, Line-Line........................±2kV (EN61000-4-4 Level 3)
Surges, Line-Line ...................................±500V (EN61000-4-5 Level 1)
Surges, Line-Ground..............................±500V (EN61000-4-5 Level 1)
Input Protection .........................................................Internal Fuse, 25A
GENERAL SPECIFICATIONS
Efciency4.........................................................................75% at Full Load
Switching Frequency
PFC Converter (AC Input)..........................................................48-110kHz
Output Converters............................................................ 275kHz Nominal
Isolation, Class I, min.5
Input-Output (AC Input/DC Input)...........................3000VAC/1500VDC
Input-Ground (AC Input/DC Input)..........................1500VAC/1500VDC
Output-Ground (AC Input/DC Input)...............................50VDC/50VDC
MTBF (Bellcore.........................................200,000 HoursSafety Standards
EN60950, UL1950, CSA22.2 No.950
ENVIRONMENTAL SPECIFICATIONS
Operating Temperature...............................................0°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 ..............................................................................Aluminum
Dimensions, Inches(mm).........................................1.6 H x 5.0 W x 11.0 D
(40.6 x 127 x 279)
Weight ...............................................................................3.3 lbs. (1.5 kg.)
NOTES:
1. No load to full load, including line regulation and load regulation.
2. Whichever is greater. 20MHz bandwidth. Measure with 0.1μFceramic
and 10μF tantalum capacitors in parallel across the output. For outputsof
2.5V or lower, the gure is 2% maximum.
3. <4% deviation recovering to within 1% for 25% load change.
4. Typical efciency for 4 output unit with one high-current output of 5V
or lower. Efciency can vary 5% or more depending on combination of
outputs.
5. Input-output isolation gure is for isolation components only. 100%
production Hipot tested.
6. When installed in compatible rack. Consult factory.
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
10.0 DESCRIPTION OF FEATURES & OPTIONS
FEATURE / OPTION DESCRIPTION
Power Factor Correction The input current is a sine wave in-phase with the input voltage to
give a power factor of 0.99. Input current total harmonic distortion
meets EN61000-3-2. This is forAC input models.
Wide Range AC Input The AC input range is continuous from 85 to 265VAC, 47-63Hz,
for worldwide operation.
EMI Input Filter This lter suppresses conducted noise from the supply back onto the
AC line. The lter meets FCC20780 part 15J Curve B and EN55022
Curve B when the PowerCassette is installed in a compatible rack.
Wide Range DC Input The DC input range is 36 to 72VDC with 48VDC as the nominal
input. The DC input also has an EMI input lter.
Reverse Polarity Protection The DC input models are reverse polarity protected by means of an
input diode.
Inrush Current Limiting When the unit is turned on, the initial input current is limited to a
peak value of 30 amperes (AC input) or 10 amperes (DC input).
This is accomplished by an active current limiting circuit (not a
thermistor).
Thermal Protection If the PowerCassette overheats internally, it will automatically
shut down. The Output Good LED turns off. The Overtemperature
Warning and Output Power Good signals both go LO. After a few
minutes the unit will cool down and automatically start up again.
Current Sharing The PowerCassette will automatically current share with another
identical PowerCassette. A single-wire connection for V1, V2,
and V3 provides this. The outputs actively current share with an
accuracy of 10% of their full load output current for total loads of
50% to 100%. V4 and V5 also current share but employ the droop
method.
ORing Diodes A diode in series with each output protects the outputs of parallel
connectedPowerCassettes. Ifoneoutput failstoa shortorto alower
than normal output voltage, the other output is not affected. Also
when hot-swapping units in the rack, the diode prevents a glitch
in the output voltage while the output is still rising on the inserted
supply. The 5V, 1A standby output also has an ORing diode.
5V, ¼A Standby Output This is an independent output which is not controlled by the Enable
or Inhibit inputs. The output also has an ORing diode and can be
paralled with another PowerCassette Standby Output.
Overvoltage Protection V1, V2 and V3 outputs are protected from overvoltage due to
fault conditions in the supply. Overvoltage protection is set at
approximately 10% above the nominal output voltage level. The
result is a latched shutdown of the supply. It is reset by cycling the
input off and then back on.
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
FEATURE / OPTION DESCRIPTION
No Load Operation All PowerCassette outputs can be operated down to zero load while
maintaining output regulation.
Hot-Swap Connectors The hot-swap connectors used in both the PowerCassette and rack
are specically designed for hot-swap applications. They have
staged pin lengths for safety and optimum peration. The ground
(common) and AC pins make rst contact and the enable pin makes
last contact, turning the unit on (provided it is not “inhibited”).
Hot-Swap Operation Hot-swap operation means that a PowerCassette can be removed
and replaced while the rack is powering the load. If the rack is
operated in an N+1 redundant mode, hot-swap replacement will not
affect the output voltage.
Output Protection Output current limiting protects the output of the PowerCassette
from damage due to an overload or short circuit condition. This
protectioniscontinuous,withoutdamage, and recoveryis automatic
when the overload is removed. Current limiting begins at about
105% of rated output current.
LED Indicators The Input Power Good indicator is a green LED, showing that input
power is present. The Output Power Good indicator is a green LED
showing that the output voltage is present and within operating
range.
I²C Serial Data Bus This data bus provides output data on V1, V2 and V3 voltages;
V1, V2 and V3 currents; internal temperature; fan speed; and part
number, serial number and date code of the PowerCassette. For
further details on this Option, see the AppendixA1 and A2.
Rack Input Options There are two input versions: An IEC320 connector (for AC) or a
terminal block connector (for AC or DC).
Control and Monitoring
Signals For detailed descriptions of Enable/Inhibit, Current Share, Remote Sense, Input Fail and Output Good signals, see Section 16,
Description of Control and Supervisory Signals.
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
11.0 MECHANICAL SPECIFICATIONS
The mechanical dimensions of the Quick-Set PowerCassette are shown in Figure 4.
Figure 4 - Mechanical Dimensions of PowerCassette
12.0 SAFETY AND INDUSTRY STANDARDS
12.1 The Quick-Set PowerCassette meets the following safety certications:
STANDARD AGENCY
UL1950 UL
CSA22.2 No.950 CUL
EN60950 DEMKO
12.2 The PowerCassette is CE marked to indicate conformance to the European Union’s Low
Voltage Directive.
12.3 Input conducted EMI meets FCC20780 part 15J Curve B and EN55022 Curve B when the
unit is installed in either of the compatible 19-inch racks.
12.4 For the AC input models, input fast transients, line-to-line, meet EN61000-4-4 Level 3;
input surges, line-to-line, meet EN61000-4-5 Level 3; and input surges, line-to-ground,
meet EN61000-4-5 Level 4. For the DC input models, input fast transients, line-to-line,
meet EN61000-4-4 Level 3; input surges, line-to-line, meet EN61000-4-5 Level 1; and input
surges, line-to-ground, meet EN61000-4-5 Level 1
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
13.0 OPERATING INFORMATION
13.1 Input Voltage and Connection. TheAC versionof thePowerCassette operates offworldwide
AC input voltagesin therange of85 to264VAC at 47to 63Hz.The three-wireAC connection
is made to pins 45-47 on the large Positronics connector. Mating connector kits for both
AC and DC inputs are available. See the connector diagram and Pin Connections table in
Figure 5. Also available is a Mating Interface Board with screw terminal connections. See
AppendixA5. The DC version of PowerCassette operates from a wide range 36 to 72 VDC
input. The three-wire DC connection is made to pins 48 to 50 of the small, separate DC
input connector shown in Figure 5.
13.2 OutputConnections.The output voltages areprovided onpins 1to 24of thelarge Positronics
connector. V1 and V2, the highest current outputs, use a series of paralleled pins for the
currents.All output returns are connected together internally, but each return should be run
separately to its respective load.
MATING INTERFACE BOARD MATING CONNECTOR KIT PIN STAGING
For single PCHS/TPCHS
PowerCassette (AC or DC)
Order No: 009-3708-0000
AC Input: Order Kit No.
775-1429-0000
DC Input: Order Kit No.
775-1445-0000
PINS LENGTH
1-20 .300”
21-26 .250”
27 .150”
28-44 .250”
45-47 .450”
48-50 .250”
PIN CONNECTIONS
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
1 +V1 Out 11 V1 & V2 Return 21 V4 Out 31 -V1 Sense 41 V2 Current Share
2 +V1 Out 12 V1 & V2 Return 22 Signal Ground 32 V2 External Trim 42 Input Power Fail
3 +V1 Out 13 V1 & V2 Return 23 V5 Out 33 +V2 Sense 43 Spare/Interrupt*
4 +V1 Out 14 +V2 Out 24 V4 & V5 Return 34 -V2 Sense 44 V3 Current Share
5 +V1 Out 15 +V2 Out 25 Spare/ADD GA0* 35 V1 Current Share 45 Chassis Ground
6 +V1 Out 16 +V2 Out 26 +5V, 1A Standby 36 +V3 Sense 46 AC Line
7V1 & V2 Return 17 +V2 Out 27 Enable* 37 -V3 Sense 47 AC Neutral
8V1 & V2 Return 18 +V2 Out 28 Spare/ADD GA1* 38 Output Power Good/SDA* 48 +DC Input
9V1 & V2 Return 19 V3 Return 29 V1 External Trim 39 Global Inhibit 49 -DC Input
10 V1 & V2 Return 20 +V3 Out 30 +V1 Sense 40 Overtemp. Warning/SCLK* 50 Chassis Ground
*NOTES: For unit to operate, pin 27 must be at logic LO or shorted to pin 22. Pin 39 should be connected through a 10k ohm resistor to Pin 26.
Pins 25, 28, 38, 40 and 43 function as I²C outputs when that option is present. All returns and signal ground are connected together.
Figure 5 - Connectors and Pin Connections to PowerCassette
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
13.3 Output Voltages. Each output voltage is factory set to its nominal value to an accuracy of
±1%. The V1 and V2 output voltages can be more accurately adjusted to a value within a
±5% range by means of external components as shown in Figure 6. Also be aware of he
output voltage polarities as shown in the Model Sufx Selector in Appendix 1.
Figure 6 - Output Voltage Adjustment (V1 & V2)
13.4 Output Power. The maximum continuous output power from all outputs is 600 watts. The
maximum combined current or power for V1 and V2 on any model must not exceed 120
amperes or 500 watts; for V3, V4 and V5 combined, 171 watts; and for the total unit, 600
watts. The maximum output power of a PowerCassette may be drawn up to 50°C ambient
temperature. Above 500C the total output power must be derated by 2.5%/°C. See Figure
7. The maximum operating ambient temperature is 70°C, at which the total output power
must be derated by 50%.
Figure 7 - Rated Total Output Power vs. Ambient Temperature
13.5 Output Overload Protection. PowerCassette outputs are protected from damage due to
an overload or short circuit condition. This protection is continuous and without damage;
recovery is automatic when the overload or short circuit condition is removed. PowerCas-
sette incorporates a “straight line” method of current limiting. When the output current
reaches an overload threshold, the voltage begins to drop sharply so that the current, with
a given overload impedance, forces the voltage to a level which maintains the current at an
equilibrium point.
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PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
13.6 Remote Sensing. Remote sensing connections for V1, V2 and V3 are made to the desig-
nated pins on the large Positronics connector. Remote sensing is not available on the low
current V4 and V5 outputs or on the Standby +5V, 250 mA output. Remote sensing is used
to regulate the output voltage at the point of load by compensating for the voltage drop in
the wires to the load. Each +Sense lead must be connected to the + side of the load and each
-Sense lead to the -side of the load. The sense leads should be color-coded, twisted pairs of
AWG no. 22 or 24 copper wire. See Figure 8. Remote sensing can compensate for a total
voltage drop of 0.5V, or 0.25V per load wire. The sense leads should not exceed 10 feet (3
meters) in length. If remote sensing is not required, the sense leads may be left open for
local sensing at the output terminals. Be careful not to reverse the sense lead connections,
as this could damage the output.
Figure 8 - Remote Sensing Connection for Each V1, V2 or V3 Output
13.7 Control & Supervisory Signals. All control and supervisory signals are accessible at the
large Positronics connector on the back of the unit. See Figure 5.The Global Inhibit (Pin 39)
should be connected through a 10k ohm resistor to the +5V Standby (Pin 26).See Section
16 for a complete description of these input and output signals.
13.8 Alarm Signals. Among the control and supervisory signals are three logic alarms: Input
Power Fail, Output Power Good and Overtemperature Warning. These are logic signals
referenced to Signal Ground, Pin 22 on the large Positronics connector. Input Power Fail is
a logic LO when AC or DC input power is present. This signal goes to a HI 4 milliseconds
before the outputs go out of regulation and stays HI for typically 15 msec. Output Power
Good is a HI when V1 to V3 outputs are present and in regulation. Overtemperature Warning
is normally a logic HI but goes to a LO when the internal air temperature reaches a critical
level just prior to the unit shutting down. These logic signals are provided from transistor
interfaces with internal pull-up resistors to an internal +5V level.
13.9 AC and DC Inputs. It should be noted that the AC and DC input pins are mutually
exclusive. In other words, an AC input PowerCassette does not have the small Positronic
DC input connector (pins 48 to 50). Likewise the DC input PowerCassette has no connec-
tions to the AC input terminals on the large Positronics connector (pins 46 and 47).
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Page 15
PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
13.10 I²C Option. This option provides an industry standard I²C serial data bus interface which
provides the status of system-critical operating parameters. This permits the montoring of
these parameters on demand by a host system or computer.
Three forms of data are available from the PowerCassette by means of its I²C capability:
inventory control information, operating status indication and system load data. Inventory
control information consists of model number, manufacturing part number, serial num-
ber, etc., to identify the specic PowerCassette. Operating status indicators include input
power fail, output power good, temperature warning and alarm, and fan good for each of
three cooling fans. System load data includes V1 to V3 output voltages and currents, and
internal temperature.
For further details on the I²C serial data bus, see Appendix 2.
14.0 PARALLEL OPERATION
14.1 Parallel Connection.PowerCassettes can be operated inparallel by connecting theiroutputs
in parallel, connecting their V1, V2 and V3 current share terminals, respectively, together
(pins 35 together, pins 41 together and pins 44 together) and connecting the Signal Grounds
together (pins 22). The PowerCassette racks permit conveniently operating units in parallel
in either a redundant or non-redundant mode.
14.2 Redundant Operation. Connecting two PowerCassettes in parallel, with or without the
compatible 19-inch rack, so that the full output load current can be carried by one unit
results in 1+1 redundant operation. While operating normally, the load current is shared
approximately equally between the two units. Should one PowerCasssette fail, or even if
one of its outputs fails, the full load is then maintained by the other unit. The failed unit can
then be replaced (hot-swap) without affecting the load current. This operation is facilitated
by the ORing diode on each output. In similiar fashion three PowerCassettes in parallel with
the full output load current carried by two of the units results in 2+1 redundant operation.
Redundancy with quick replacement of a failed unit results in virtually innite MTBF.
14.3 Non-Redundant Operation. Higher output load currents can be realized by operating
two units in the non-redundant mode to achieve 1200 watts output power . The units are
connected in parallel the same as before. In this case if one unit or one output fails, the load
will lose power since only part of the load current can now be supplied by the remaining
unit which will go into current limit. The failed unit can be quickly replaced without turning
the power off (hot-swap) to restore load current. In the 19-inch compatible racks there is a
limit of 1200 watts output for both the two- and three-unit versions. Three units therefore
cannot be operated in non-redundant mode.
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Page 16
PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
15.0 COMPATIBLE 19-INCH RACKS
15.1 Figure 9 shows the two 19-inch compatible racks holding two or three PowerCassette units
These racks have the following features:
• Standard 19-Inch Rack-Mounting
• Only 1U High
• Hot-Swap Operation
• Holds 2 or 3 PowerCassette Modules
• AC or DC Input Versions
• Class B EMI Input Filter
• 1200W Non-Redundant
• 600W or 1200W Redundant
• Current-Shared Outputs
• IEC60320 or Terminal Block Inputs
• Front or Rear Inputs
• I²C Serial Data Bus Option
• Optional 23-Inch Mounting (with brackets)
• Optional Rear Plastic Cover
• Module Present Signal
Figure 9 - 19-Inch Racks for Two or Three PowerCassettes
Ordering Guide
MODEL NO.: TPCHR1U2 -
TPCHQR1U2 -
TPCHR1U3 -
*TPCHQR1U3 -
C: For clear plastic rear safety cover.
Sufx for input connector(s) (See Table).
Two Unit Rack
Three Unit Rack
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Page 17
PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
15.2 Two-Unit Rack. The two-unit, 19-inch rack is shown in Figure 10 with connections and
pin designations. There is a choice of single or dual IEC60320 AC input connectors or
single or dual terminal block AC or DC input connectors. The various connector versions
are summarized in the following table.
Table 15-1. Input Connector Designation
INPUT
CONNECTOR SINGLE/ DUAL
CONN.
CONNECTOR
POSITION AC INPUT TPCHR1U2 DC INPUT TPCHQR1U2 MODEL NO.
SUFFIX
IEC60320
IEC60320
IEC60320
IEC60320
Dual
Dual
Single
Single
Front
Rear
Front
Rear
4
4
4
4
A
B
C*
D*
Terminal Block
Terminal Block
Terminal Block
Terminal Block
Dual
Dual
Single
Single
Front
Rear
Front
Rear
4
4
4
4
4
4
4
4
E
F
G
H
*See paragraph 15.2.1
15.2.1 Maximum output power rating is 1200 watts for all models except Model Sufxes C
and D (for input connector designation). For these two models the maximum output
power is 600 watts for 100- 120VAC input or 1000 watts for 200-240VAC input. Thus
for 100-120 VAC input the two PowerCassette models can be employed in a 1+1
redundant conguration or for 200-240VAC they can be employed in a non-redundant
conguration but only up to 1000 watts output power. There are no limitations for DC
input models all of which can produce up to 1200 watts output with 36-72VDC input.
15.2.2 All outputs from the two PowerCassette modules are connected in parallel in the
rack except the +5V 250 mA Standby outputs which must be externally paralleled by
connecting P2 pins 3 and 11 together.
15.2.3 The rack depth is 14.00 inches (356mm). The clear plastic rear cover (Option C) adds
2.09 inches (53.1mm) to the depth for a total of 16.09 inches (409mm).
15.2.4 The V1 and V2 Returns and V3, V4 and V5 Commons are all connected together in
the rack. It is recommended, however, that the Returns and Commons be separately
connected to their respective loads.
15.2.5 The front view arbitarily shows dual IEC60320 connectors; the back view shows dual
terminal block connectors.
15.2.6 Module Ais on the left; module B is on the right (as seen from the front).
15.2.7 For dual input racks, each input goes separately to the PowerCassette on the same side
of the rack.
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Page 18
PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
15.2.8 For details on control signals, see Section 16 and Figure 10.
FRONT VIEW
BACK VIEW
V1 & V2 Connections are to No. ¼ - 20 bolts
P2
113
1425
P1
P2 PIN CONNECTIONS P1 PIN CONNECTIONS
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
1 Inhibit-B 14 Input Power Fail-B A1 V3 Common 5 V4 Out
2 Output Good/Data-B 15 Overtemp./Serial Clock-B A2 +V3 Out 6 -V3 Sense
3 +5V Standby-B 16 Interrupt-B A3 +V3 Out 7 -V2 Sense
4 Module Present-B 17 Common 1 +V3 Sense 8 -V1Sense
5 Spare 1 18 +V3 Sense 2 +V2 Sense 9 V5 Common
6 Spare 2 19 -V3 Sense 3 +V1 Sense 10 V5 Out
7 Spare 3 20 +V2 Sense 4 V4 Common
8 -V1 Sense 21 -V2 Sense P2 Note: Inhibits A and B (pins 13 and 1) should
each be connected to +5V Standbys A and B,
respectively, (Pins 11 and 3) through 10k ohm
resistors. Pins 2, 12, 15, 16, 23 and 24 function
as I2C outputs when that option is present.
9 +V1 Sense 22 Module Present-A
10 Common 23 Interrupt-A
11 +5V Standby-A 24 Overtemp./Serial Clock-A
12 Output Good/Data-A 25 Input Power Fail-A
13 Inhibit-A
Figure 10 - Two-Unit Rack with Connections
15.2.9 For details on I²C data (P2 pins 2, 12, 15, 16, 23 & 24), see Appendix 2. The module
address (A or B) is jumper programmable in the rack.
15.2.10 The module Present outputs (P2 pins 4 & 22) are grounded when the module is plugged
in; otherwise they are open circuit.
15.2.11 Dual-feed input isolation diodes can be provided for DC input models. Please contact
factory.
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Page 19
PCHS/TPCHS SERIES Quick-Set PowerCassette®
INSTALLATION & OPERATING MANUAL
Manual No. tpchs-2 pchs-tpchs-man-rev2-1214.indd
15.3 Three-Unit Rack. The three-unit, 19-inch rack is shown in Figure 11 with connections
and pin designations. For AC input there is a choice of an IEC60320 or a terminal block
connector. The connector comes only on the rear panel. For information on the DC input
connector, contact the factory. The input connector versions are summarized in the following
table.
Table 15-3. Input Connector Designation
INPUT
CONNECTOR CONNECTOR POSITION MAX. POWER AC INPUT VOLTAGE MODEL NO.
SUFFIX
IEC60320, C14 Rear 1200W 200-240VAC D
Terminal Block Rear 1200W 100-240VAC H
For information on DC input rack, contact factory.
15.3.1 Maximum output power rating is 1200 watts for allAC and DC input, three-unit racks.
This means that three modules can operated in a 2+1 redundant conguration to produce
1200 watts output not in non-redundant conguration for more than 1200 watts.
15.3.2 All outputs from the three PowerCassette modules are connected in parallel in the rack
except the +5V 1AStandby outputs which must be externally paralleled by connecting
P2 pins, 2, 7 and 11 together.
15.3.3 The rack depth is 15.06 inches (384mm). The clear plastic rear cover (Option C) adds
2.09 inches (53.1 mm) to the depth for a total of 17.15 inches (436mm).
15.3.4 The V1 and V2 Returns and V3, V4 and V5 Commons are all connected together in
the rack. It is recommended, however, that the Returns and Commons be separately
connected to their respective loads.
15.3.5 Module Ais on the left and module C is on the right as seen from front.
15.3.6 For details on control signals, see Section 16 and Figure 11.
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