PRICE: $25.00 OPERATING MANUAL PCM/TPCM SERIES PowerCassette® FRONT-END SWITCHERS www.unipowercorp.com © 2003 UNIPOWER Corp. All Rights Reserved Manual No. TPCM-Man-602-4 PCM-TPCM-Man 06/11/03 UNIPOWER Corporation NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: +1 954-346-2442 • Fax: +1 954-340-7901 • sales@unipower-corp.
CONTENTS SECTION TOPIC PAGE 1.0 Introduction 1 2.0 PowerCassette Features 1 3.0 Summary of Product Line 3 4.0 Safety Warnings 4 5.0 Warranty 4 6.0 Unpacking and Inspection 5 7.0 Front Panel Description 5 8.0 PowerCassette Specifications 5 9.0 Description of Features and Options 8 10.0 Mechanical Specifications 9 11.0 Safety and Industry Standards 9 12.0 Operating Information 10 13.0 Parallel Operation 14 14.0 Compatible 19-Inch Racks 14 15.
ILLUSTRATIONS FIGURE TITLE PAGE 1 PowerCassette Front End Models PCM and TPCM 2 2 Front Panel of the PowerCassette Front End 2 3 IEC Input Version 6 4 Mechanical Dimensions of PowerCassette 6 5 Connectors and Pin Connections 11 6 Output Voltage Adjustment 12 7 Rated Total Output Power vs.
POWERCASSETTE FRONT-END OPERATING MANUAL OPERATING MANUAL PCM/TPCM SERIES PowerCassette® NEXT GENERATION FRONT-END SWITCHER 1.0 INTRODUCTION This operating manual should be read through carefully before installing and operating the PCM/TPCM Series PowerCassette®. The PowerCassette is an advanced-design, front-end switching power supply that employs a unique, new architecture which permits quick factory programming of its output.
POWERCASSETTE FRONT-END OPERATING MANUAL PCM Series (Chassis Mount) TPCM Series (Hot-Swap) Figure 1. PowerCassette Front-End Models PCM and TPCM AC POWER FAIL LED DC POWER GOOD LED HANDLE 4 4 4 Figure 2.
POWERCASSETTE FRONT-END OPERATING MANUAL u u u u u u u u u u u u u u u u u Hot-Swap or Chassis Mount Versions IEC 60320 Input Option with Switch 12, 24, or 48 VDC Outputs Integral LED Status Indicators Up to 10 Watts/Cubic Inch Power Density Power Factor Corrected Low Profile: 1.
POWERCASSETTE FRONT-END OPERATING MANUAL 3.3 19-Inch Compatible Racks. These racks hold two or three TPCM units. Rack Model No.: 4.0 5.0 TPCMR1U2 for Two Units TPCMR1U3 for Three Units SAFETY WARNINGS 4.1 These power supplies have hazardous external and internal voltages. They should be handled, tested and installed only by qualified 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.
POWERCASSETTE FRONT-END OPERATING MANUAL 6.0 7.0 UNPACKING AND INSPECTION 6.1 This PowerCassette was carefully tested, inspected and packaged for shipment from our factory. Upon receipt of the unit it should be carefully unpacked and inspected for any damage in shipment. 6.2 If there is evidence of damage, do not attempt to test the unit. The freight carrier should be notified immediately and a claim for the cost of the power supply should be filed with the carrier for direct reimbursement.
POWERCASSETTE FRONT-END OPERATING MANUAL Figure 3. IEC Input Version (Option E) NOTE: The TPCM Model is shown. The PCM version does not have handle or mounting bracket with bolt. Maximum torque on the threaded inserts is 6 inch-pounds. Figure 4.
POWERCASSETTE FRONT-END OPERATING MANUAL Standby Output ................................................................ +5V, 250mA DC Power Good Signal ........................................................ Logic Low AC Power Fail Signal .......................................................... Logic High Inhibit .................................................................................... Logic Low Enable ..................................................................................
POWERCASSETTE FRONT-END OPERATING MANUAL 9.0 DESCRIPTION OF FEATURES & OPTIONS DESCRIPTION FEATURE / OPTION Power Factor Correction Wide Range AC Input 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. The AC input range is continuous from 85 to 265VAC, 47-63Hz, for worldwide operation. EMI Input Filter This filter suppresses conducted noise from the supply back onto the AC line.
POWERCASSETTE FRONT-END OPERATING MANUAL DESCRIPTION FEATURE / OPTION Hot-Swap Connectors The hot-swap connectors used in both the PowerCassette and rack are specifically designed for hot-swap applications. They have staged pin engagement for safety and optimum operation. The ground (common) and AC pins make first contact and the enable pin makes last contact, turning the unit on (provided it is not “inhibited”).
POWERCASSETTE FRONT-END OPERATING MANUAL 12.0 11.2 The PowerCassette is CE marked to indicate conformance to the European Union’s Low Voltage Directive. 11.3 Input conducted EMI meets FCC20780 part 15J Curve B and EN55022 Curve B. 11.4 The input immunity, conducted, meets the following. Input fast transients, lineto-line, meet EN61000-4-4 Level 3; input surges, line-to-line, meet EN610004-5 Level 3; and input surges, line-to-ground, meet EN61000-4-5 Level 4. OPERATING INFORMATION 12.
POWERCASSETTE FRONT-END OPERATING MANUAL CONNECTOR: POSITRONICS PCIB24W9M400A1 MATE: PCIB24W9F400A1 PIN CONNECTIONS PIN 1 2 3 4 5 6 7 8 9 10 11 12 FUNCTION +V Out +V Out +V Out V Return V Return V Return Enable* + Sense - Sense Inhibit Spare/ SDA* Spare/ SCL* MATING CONNECTOR KIT PIN FUNCTION 13 14 15 16 17 18 19 20 21 22 23 24 Spare DC Power Good/ ADD GA1* AC Power Fail V Trim Overtemp.
POWERCASSETTE FRONT-END OPERATING MANUAL (b) (a) OUTPUT 12V 24V 48V R1* 12K 33K 75K * Resistors are 5%, 1/8W. % of Rated Total Output Power Figure 6. Output Voltage Adjustment Methods Figure 7. Rated Total Output Power vs. Ambient Temperature Figure 8.
POWERCASSETTE FRONT-END OPERATING MANUAL 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. PowerCassette incorporates a “straight line” method of current limiting.
POWERCASSETTE FRONT-END OPERATING MANUAL 13.0 14.0 PARALLEL OPERATION 13.1 Parallel Connection. Two or more PowerCassettes can be operated in parallel by connecting their outputs in parallel and connecting their current share terminals, together (pin 18). The PowerCassette racks permit conveniently operating two or three units in parallel in either a 1+1 or 2+1 redundant mode or non-redundant mode. 13.2 Redundant Operation.
POWERCASSETTE FRONT-END OPERATING MANUAL TPCMR1U2 FRONT VIEW t t 17.19 (437) OUTPUT - + t 1.72 (43.7) t A J1 J2 J3 B BACK VIEW J3 PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 OUTPUT: ANDERSON-TYPE CONNECTORS ANDERSON No. 5916 WITH 5952 CONTACTS RED = + Output BLACK = - Output J3 PIN CONNECTIONS FUNCTION PIN FUNCTION Inhibit 14 AC Power Fail - A Overtemp. Warning - A* 15 DC Power Good - A* Current Monitor - A* 16 AC Power Fail - B Overtemp.
POWERCASSETTE FRONT-END OPERATING MANUAL TPCMR1U3 t t 17.19 (437) t FRONT VIEW 1.72 (43.7) t B A C BACK VIEW J4 +V -V OPTION E J3 J2 J1 FRONT VIEW BACK VIEW J4 +V -V OUTPUT: Copper bus bars with no. 1/4-20 studs with nuts. J4 PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 J4 PIN CONNECTIONS FUNCTION PIN FUNCTION Inhibit 14 AC Power Fail - A Overtemp. Warning - A* 15 DC Power Good - A* Current Monitor - A* 16 AC Power Fail - B Overtemp.
POWERCASSETTE FRONT-END OPERATING MANUAL Up to 800W or 1600W N+1 Redundant Current-Shared Outputs IEC60320 AC Inputs Front or Rear Access I2C Serial Data Bus Option Optional 23-Inch Mounting (with brackets) Module Present Signal 14.2 Ordering Guide RACK MODEL NO. MAX. NO. MODULES TPCMR1U2 TPCMR1U3 TPCMR1U3-E 2 3 3 CONNECTIONS All Front Entry All Rear Entry AC Front Entry DC Rear Entry Signals Rear Entry MAX.
POWERCASSETTE FRONT-END OPERATING MANUAL 14.4 14.3.5 For details on I2C data (J3 pins 9 and 13) see Appendix. 14.3.6 The Module Present outputs (J3 pins 20 and 21) are grounded (to -Sense) when the module is plugged in and open when the module is out. Three-Unit Rack. The three-unit 19-inch rack is shown in Figure 10 together with connectors and pin designations. The AC input connectors are IEC60320. All connections are at the rear of the rack for the standard model.
POWERCASSETTE FRONT-END OPERATING MANUAL 15.0 DESCRIPTION OF CONTROL AND SUPERVISORY SIGNALS SIGNAL PINS Enable 7 ± Sense 8&9 Inhibit 10 DESCRIPTION A logic LO or short to Pin 9 enables (turns on) the unit. A logic HI or open inhibits (turns off) the unit. This input is referenced to - Sense, Pin 9. This pin must be activated to a logic LO or short for the PowerCassette to operate.
POWERCASSETTE FRONT-END OPERATING MANUAL 16.0 17.0 INSTALLATION 16.1 Mounting. The PowerCassette can either be mounted in the 19-inch rack (model TPCM) and secured by means of the jack screw or it can be mounted (model PCM) on another metal chassis by means of no. 4-40 screws into the four threaded inserts on the bottom of the PowerCassette. It can also be mounted by the two no. 8-32 inserts on either side of the case. Maximum penetration for each is 3/16-inch.
POWERCASSETTE FRONT-END OPERATING MANUAL tested in Position A (left side) of the rack. 18.2 With the input power source turned off, connect input power wires to the PowerCassette mating connector or in case of the rack to the input connector on the A side of the rack. Make sure that the safety ground wire is connected. Do not touch the output terminals when AC input power is present. 18.3 Connect a resistive power load across the proper output pins.
POWERCASSETTE FRONT-END OPERATING MANUAL approximately +5V. Disconnect the wire from the Inhibit to - Sense. The DC Power Good green LED should turn on. Check the output voltage on the DC Power Good pin as described above. The voltage should be a logic LO, +0.5V or less. 18.9 Testing the Other Power Cassettes. For a rack with two or three PowerCassettes, the other PowerCassettes should be plugged into Position A in the rack and tested in the same manner as above in Sections 18.2 to 18.8. 18.
POWERCASSETTE FRONT-END OPERATING MANUAL 19.0 TROUBLESHOOTING GUIDE 19.1 If you encounter difficulties in getting the PowerCassettes or the complete rack to operate properly, go through the following troubleshooting guide. 19.2 Table 19-1. PowerCassette and Rack Troubleshooting SYMPTOM 19.3 POSSIBLE CAUSE ACTION TO TAKE No output, AC Fail and DC Good LEDs off. No AC power. Check connection to AC power source. Check source circuit breakers. No output, DC Good LED off, AC Fail LED on.
C O R P O R A T I O N North America: 954-346-2442 • sales@unipower-corp.com Europe: +44(0)1903 768200 • info@unipower-europe.com PowerCassette®: I2C SERIAL BUS INTERFACE FOR PCM/TPCM Status Indication of system critical power supply parameters FEATURES Industry Standard Communication Interface Inventory Control Information Status Indication PCM Series (Chassis Mount) Management of System Load Imminent Failure Warning TPCM Series Fully Integrated with Standard PSU Package (Hot-Swap) 1U HIGH 1.
North America: 954-346-2442 • sales@unipower-corp.com Europe: +44(0)1903 768200 • info@unipower-europe.com C O R P O R A T I O N SPECIFICATIONS, PowerCassette®: I2C SERIAL BUS INTERFACE FOR PCM/TPCM ELECTRICAL INTERFACE Addressing (GA0, GA1 and GA2) Three external address lines are employed allowing up to eight PowerCassette modules to be addressed on a single I2C bus.
