PF2500
Power Supplies
2500 Watt Hot-Swap/Redundant Front-End Switching Power Supply
48V Primary Output with 5VSB @ 250mA
Features
- 2500 Watt Output Power over the 180 to 264VAC Input Range
- Active PFC for EN61000-3-2 Class D Compliance
- Full Load operating temperature range from –10 to +50°C
- 1U x 3U form factor (1.6 x 4.83 x 15.6”)
- Excellent combination of both High Reliability and Low Cost
- Up to 7,500w in 1U 19” Rack
- Up to 22,500W in 3U 19” Rack
- Full hot-swap capability, with low insertion/extraction force
- Front panel LED’s for AC OK and DC OK
- Temperature controlled fan speed, for low noise and long life
- Configurable I2C interface status and control
- Single wire active current share
- Operating Parameters adjustable via Analog or Digital Interface
- N+1 or N+M Redundancy
- Integral isolation (OR-ing) mosfets
- Stand-by power of 5V @ 250mA
- Full array of status & control signals (digital and analog)
- Remote sense: up to 0.5V cable losses compensation
- No minimum load required
- 48V Main Output may referenced as positive or negative
- RoHS compliant
- 2 Year Warranty
Introduction
The PF2500-4801 Front-End Modules from SAE Power deliver 2100W of highly reliable isolated 48VDC with 5V standby power. These supplies are ideal for usage in today’s distributed power architectures.
These suppplies offer state-of-the-art status and control functions in both analog (TTL) and Digital (I2C) signal sets. This feature allows engineers more flexibilty and control in their system designs. The functions include remote on/off control, power sup- ply present, voltage adjustment, current monitor, AC OK, DC OK, remote sense, current share, fan fail and overtemperature warning. Multiple racks may be interconnected for additional power and redundancy.
These supplies have been mechanically designed to accomodate 1U (horizontal) or 3U (vertical) mounting. Measuring only 15.60 x 4.86 x 1.60”, these supplies are designed to fit the majority of today’s distributed power applications. Customers may mount these supplies in SAE Power’s standard off-the-shelf 1U or 3U high 19” rack mount chassis or directly into the OEM system. The hot-swap / blind-mate connectors enable customers fast and easy integration of these supplies with no down-time.
Typical Applications
- Distributed Power Architectures
- Server Equipment
- LAN / WAN / SAN Applications
- Network Equipment
- Automated Test Equipment
- Network Attached Storage
Certifications
Input Specifications
| PARAMETER | MIN | TYP | MAX | UNIT | NOTE |
|---|---|---|---|---|---|
| Input Voltage | 180 | - | 264 | VAC | Brownouts below input range will not damage the supply |
| Turn-On Voltage | - | - | 180 | VAC | |
| Turn-Off Voltage | 170 | - | - | VAC | |
| Input Transient (Operational) | - | - | 300 | VAC | Not to exceed 20ms |
| Input Frequency | 47 | - | 63 | Hz | ETSI 300132-1 Compliant |
| Inrush Current | - | - | 30 | Amps | Measured at 25°C for all line conditions, cold start, half cycle average |
| Input Current | - | - | 13.20 | Amps | Maximum |
| Input Protection | - - | - - | 15 250 | Amps VAC | Dual Fused (Both Line & Neutral), Type 3AB Axial |
| Operational Efficiency | - | 90% | - | % | Full Load and 230 VAC Operation including OR-ing function |
| Power Factor | 0.98 | - | - | PF | Meets IEC61000-3-2 Limits for Harmonic Current Emission |
| Leakage Current | - | - | 1.0 | mArms | at 230VAC / 60Hz Operation per module |
| Hold-Up Time | 20 | - | - | ms | Assuming 180 VAC, 25°C and Full Load Operation |
Output Specifications
| PARAMETER | MIN | TYP | MAX | UNIT | NOTE |
|---|---|---|---|---|---|
| Output (Setpoint) 48V: 5VSB: | 47.5 4.75 | 48.0 5.0 | 48.5 5.25 | VDC VDC | Consult Factory for unique setpoint requirement |
| Adjustment Range 48V: 5VSB: | -5 -2 | - | +5 +15 | % % | Apply analog volatage between VoAdj Pin and Standby Return Pins of 0~2.5V (OV = -5% / 1.25V = 48V / 2.5V = +5%) |
| Output Power | - | - | 2500 | Watts | |
| Output Current 48V: 5VSB: | - - | - - | 52.00 0.250 | Amps | |
| Current Share | - | - | 10 | % | Single Wire Current Share Accuracy in % of full load |
| Regulation 48V: 5VSB: | - - | - - | 1 5 | % % | Maximum for any combination of line, load and temperature regulation |
| Ripple Noise | - | 0.5 | 1 | % | 20MHz bandwidth |
| Transient Response | - - | - - | 5 300 | % μs | Maximum Deviation for a 50% step load (<1Aμs) for load conditions >10% of Iout |
| Turn-On Over-Shoot | - | - | None | - | Monotonic start-up to 48V with no overshoot |
| Turn-On Delay | - | - | 1.5 | Secs | Applying AC Input (Cold Start) |
| Remote On Delay Time | - | - | 500 | ms | AC present >2 seconds and output is enabled |
| Remote Off Delay Time | - | - | 10 | ms | Output in regulatioon >2 seconds and output is inhibited |
| Over-Current Protection | 110 | - | - | % | Constant Current Foldback. Current limit is adjustable via digital signal (auto-reset). Contact factory for custom setpoint. |
| Over-Voltage Protection | - | - | 56 | VDC | Latched Off - Recycle AC Input or Apply Remote Off/On to reset |
| Over-Temp Protection | - | - | 85 | °C | Self protecting shutoff and auto-recovery and hysteresis |
Environmental Specifications
| PARAMETER | MIN | TYP | MAX | UNIT | NOTE |
|---|---|---|---|---|---|
| Operating Temperature | -10 | - | 70 | °C | Derate Output Power 2.5% per °C above 50°C |
| Cooling | - | - | - | - | Temperature controlled ball bearing fans for low noise and long life |
| Storage Temperature | -40 | - | 85 | °C | |
| Operating Humidity | 10 | - | 95 | % | Non-Condensing |
| Storage Humidity | 10 | - | 95 | % | Non-Condensing |
| Operating Altitude | - | - | 2,250 | Meters | 700-1100mbar |
| Storage Altitude | - | - | 10,000 | Meters | 300-1100mbar |
| Shock & Vibration | 6 | - | - | G rms | Designed to meet NEBS GR-63-CORE Level 3 (20-200Hz, 30 min, 6 G rms acceleration), TELECORDIA GR-63-CORE, GR-487-CORE Seismic Zone 4. |
| Reliability - Bellcore RPP | - | 250,000 | - | Hours | Assuming Full Load and 50°C Operation |
Isolation Specifications
| Parameter | Description |
|---|---|
| Input to Output | 4200 Vrms (Dielectric Factory Test) |
| Input to Ground | 2120 VAC per EN60950 |
| Output to Ground | 500 VDC per IEEE802 |
Electromganetic Compatibility
| Parameter | Description |
|---|---|
| Electrostatic Discharge | EN61000-4-2, +/- 4kV Contact, +/- 8kV Air Discharge |
| Radiated Susceptibility | EN61000-4-3, 26-1000MHz, 10V/M, 80% AM |
| EFT / Bursts | EN61000-4-4, ± 2KV |
| Surges | EN61000-4-5, ±2KV Line-Earth, ±1KV Line-Line |
| Conducted Immunity | EN61000-4-6, 0.15 - 800MHz, 10V, 80% AM |
| Voltage Dips | EN61000-4-11, 95% Dip & 10ms, 30% Dip & 500ms |
| Voltage Interruptions | EN61000-4-11, 20% Reduction, 5s |
| Radiated Emissions | EN55022 Class B, EN61204 Class B (In Rack or customer enclosure) |
| Conducted Emissions | EN55022 Class B, EN61204 Class B |
| Harmonic Current | EN61000-3-2 Class D |
| Fluctuations / Flicker | EN61000-3-3 |
International Standards
| Parameter | Description |
|---|---|
| Safety Approvals | cTUVus EN60950, CE Mark (LVD) |
Status & Control Signals
These 1U power modules contain a microprocessor control circuit that provides active control of the power conversion, cooling and external digital and analog interface. The microprocessor control employes a SMBus interface, compatible with I2C signaling, at the power unit and optionally at sub-racks levels. This control is implemented using flash memory, which is in-system reprogrammable over the SMBus interface. The signals provided at the power unit connector are described in the physical interface section. The logical interface section provides a brief description of the available SMBus interface and protocol.
Sub-Rack Physical and Logical Interface
The sub-rack interface exposes the features of the power unit interface to the outside world. and is available as both a passive-backplane and a modular digital/analog backplane incorporating a microprocessor-controlled IO Bridge board. The passive-backplane provides for communication using the SMBus and or physical signals as described later. The use of SMBus is optional as the system will run without it. The IO Bridge configuration provides the ability to connect the sub-rack to other racks or networks such as RS485-based, Ethernet or other physical and logical protocols, at the same time providing selected power unit control signals such as remote sense, PSON, alarms etc.
Power Unit Physical Interface
Each signal available at the connector is described below. Where indicated, an internal pull-up resistor is present. The pull-up is a combination of the VSB supply and an internal source of +5V diode OR-ed together. All of the control signals are referred to STANDBYRTN except the +SENSE and –SENSE, +VOUT and –VOUT. The output is floating +/- 60V with respect to the controls permitting arbitrary output polarity. The output and controls are not DC referenced internally to protective earth by high-value resistors to bleed off any accumulated charge on bypass capacitors.
SDA
- SMBus I2C compatible serial data line
- 5V and 3V compatible
- no internal pull-up on this line
SCL
- SMBus I2C compatible serial clock line
- 5V and 3V compatible
- Internal pull-up on this line.
A0
- Power Unit address input bit 0 (least significant bit)
- Sets the address for SMBus and LS_BUS communications
- Internal pull-up
OTWN/ALT
- Normally low output goes high to indicate over-temperature alarm
- Open-collector signal
- No internal pull-up
- Active state may be changed (reversed) as firmware option
- Alternatively used as SMBus alert signal as firmware option
+SENSE
- Positive remote sense connection (local regulation operates without connection of sense leads)
-SENSE
- Negative remote sense connection (local regulation operates without connection of sense leads)
A1
- Power Unit address input bit 1
- Sets the address for SMBus and LS_BUS communications
- Internal pull-up
ACOK/A2
- Normally low output which goes high to indicate loss of AC input
- Open-collector signal
- Internal pull-up may be de-populated as factory hardware option
- Active state may be changed (reversed) as firmware option
- Alternatively used as address bit A2 input as firmware option
PSMODE
- Power Unit input used to activate optional interface features
- Firmware option determines physical and logical interface configuration so power units may be used in different sub-racks or systems without change
- Internal pull-up
5VSB
- +5V 0.25A standby supply output
- Operates independently of main outputs
VSB12
- +12-14V 0.2A unregulated output
- Internal sub-rack use only to power paralleled controller
- circuits during fault
VOADJ
- Analog input to adjust output margin +/- 5% by applying a voltage from 0-2.5V (0 = -5% / 1.25=12V / 2.5 = +5%)
- Input impedance >50K ohms
STANDBYRTN
- Common return
- Return for all control signals except +SENSE, -SENSE
- Should be tied to PE ground in system for ESD and SELV reasons as with any logic signals.
PWOK/A3
- Normally low output goes high to indicate output voltage alarm
- Open-collector signal
- Internal pull-up may be de-populated as factory hardware option
- Active state may be changed (reversed) as firmware option
- Alternatively used as address bit A3 input as firmware option
LS_BUS
- Open collector bidirectional digital signal
- Internal pull-up may be de-populated as factory hardware option
- Used for communication directly between Power Units for load
- share control
FANFAIL
- Normally low output which goes high to indicate fan failure alarm
- Open-collector signal
- No internal pull-up
- Active state may be changed (reversed) as firmware option
CURMON
- Internally connected to STANDBYRTN to indicates PS presence
- Internal impedance is 10 ohms
PSPRESENT
- Analog output from 0 to 5V proportional to main output current
PSKILL
- Input connected to STANDBYRTN to enable the power unit
- Short last-mate/first-break pin on PS connector for hot-plug
- Open connecion disables PS and microprocessor controls
- Signal has internal pull-up to voltage that is between 5-8V
PSON
- Input when driven high (+5V) will enable the power unit
- No internal pull-up
- When driven from low to high will reset internal watchdog circuit
- if activated, restarting microprocessor controls
- When driven from low to high will enable recovery from
- over-voltage latch off
Power Supply Logical Interface
The logical interface consists of the discrete signals described above. All of the digital inputs and outputs are defined in firmware hence their use is configurable and changeable as a firmware option. For example additional address bits may be defined or alert signals to send to a system controller. The SMBus interface which is compatible with I2C implements messaging based on the SMBus specification. The SDA and SCL lines comply with the requirements of SMBDAT and SMBCLK. The microprocessor controller has control of the power converters. It takes inputs from output voltage and current sensors, controls fan speed and can report all of these inputs for monitoring purposes. There is additional logic providing for monitoring of temperatures and voltages including the input voltage in the primary circuits of the supply. The control capabilities are limited only by the firmware applied – arbitrary timing of output voltage shutdown, turn-on, alarm warning times etc. is available as a firmware option. The most basic configuration has the following commands available, all using SMBus messaging protocols. The data format for voltages, temperatures and currents is a scaled 16-bit signed 2’s complement integer.
Check Present
– SMBus quick command is used to determine power unit presence
Get Output Status
– Output voltages and currents are returned using an SMBus block read protocol
Get Temperature Status
– Temperature status including hot spot temperature(s) is returned using an SMBus block read protocol
– Warning and shutdown levels and timing may be adjusted to a particular application as a firmware option
Get Fan Status
– Fan operating or failed status including operating speeds are returned using an SMBus block read protocol
Get Input Status
– Input voltage status and measurement of input voltage is returned using an SMBus block read protocol
Get Firmware Information
– Returns the firmware revision information using the SMBUS block read protocol
Get Factory Information
– Returns the power unit model, serial number and date code information using the SMBus block read protocol
Other Functions
Additional functions exist to place the power unit controller in a so-called bootstrap mode. In this mode additional commands exist to enable the verification (CRCs) and loading of firmware. As a factory firmware option additional nonvolatile memory may be accessible for customer-applied inventory or other data.
The upgrade of firmware over the SMBus incorporates additional security and error detection to prevent inadvertent modification or failed firmware upgrades, incorporating a 16-bit CRC and binary firmware image transfer.
Please request the 1U Family Interface brochure for additional details.
Mechanical Drawing
See Engineering Specification for complete details including connector and pin assignments.
Mechanical Details
| Parameter | Description |
|---|---|
| Module | 15.60” (L) x 4.86” (W) x 1.60” (H). *Extraction handle extends 1.60”, connector extends 0.41” |
| Faceplate | 5.22” (W) x 1.72” (H) |
| Material | Aluminum, gold chromate |
| Connector | FCI PowerBlade Series # 51939-147, mates with FCI # 51915-062 |
| Weight | Each module weighs 5.00lbs /2.29kg |
Pin Assignments
| Signal Name | Pin | Description |
|---|---|---|
| GND | PA1 | AC Ground (Chassis Ground) |
| ACN | PA2 | AC Input (Neutral) |
| ACL | PA3 | AC Input (Line) |
| +V | PB1, PB2 | +V1 (Main) Output |
| -V | PB3, PB4 | -V1 (Main) Return |
| VSB12 | A1 | +12VDC / 500mA Standby Power (Internal use only, redundantly powers paralleled supply microprocessors) |
| 5VSB | A2 | +5VDC / 250mA Standby Power |
| N/C | A3 | No Connection |
| PSON | A5 | Power Supply Enable (TTL Active High) |
| PSKILL | A6 | Hot-Swap Enable / Disable via mechanical short pin |
| STANDBYRTN | B1, B2 | Signals & 5VSB Return (Isolated from output voltage) |
| PSPRESENT | B3 | Power Supply is Present (Internally connected to GND2) |
| VOADJ | B4 | Analog Output Voltage Adjustment |
| CURMON | B5 | Analog Output Current Monitor |
| AO | C1 | I2C Power Unit Address Input bit 0 |
| A1 | C2 | I2C Power Unit Address Input bit 1 |
| AC OK/A2 | C3 | AC Present (TTL Active Low), Alternatively used as addres bit A2 input as firmware option |
| PWOK/A3 | C4 | Output Power OK (TTL Active low), Alternatively used as addres bit A3 input as firmware option |
| +SENSE | C5 | +Remote Sense Connection (compensates for <500mV drop) |
| -SENSE | C6 | -Remote Sense Connection (compensates for <500mV drop) |
| SCL | D1 | SMBus I2C compatible serial clock line |
| SDA | D2 | SMBus I2C compatible serial data line |
| PSMODE | D3 | Input used to active optional interface features |
| LS_BUS | D4 | Digital Current Share Bus / Single Wire Current Share (no customer connection is permitted) |
| FANFAIL | D5 | Fan Failure Signal (TTL Active High) |
| OTWN/ALT | D6 | Overtemperature warning, Alternatively used as SMBus alert signal as firware option |
1U150LA
Optional 1U High 19” Rack Mount Chassis
Mechanical Drawing
Pin Assignments
| Pin | Function |
| 1 | PW0K/A3_3 |
| 2 | PW0K/A3_2 |
| 3 | PWOK/A3_1 |
| 4 | ACOK/A2_1 |
| 5 | ACOK/A2_3 |
| 6 | ACOK/A2_2 |
| 7 | -SENSE |
| 8 | +SENSE |
| 9 | SPARE PIN |
| 10 | SCL |
| 11 | OTWN/ALT * |
| 12 | CUR MON 3 |
| 13 | PSPRESENT_3 |
| 14 | SDA |
| 15 | VSB |
| 16 | CUR MON 1 |
| 17 | CUR MON 2 |
| 18 | VO ADJ 1 |
| 19 | VO ADJ 2 |
| 20 | VO ADJ 3 |
| 21 | LS_BUS |
| 22 | PSON * |
| 23 | PSPRESENT_1 |
| 24 | PSPRESENT_2 |
| 25 | STANDBY RTN |
Specifications subject to change.