350002.013
User’s Guide
Rectifier Module
Flatpack2 DC Power Supply Systems
1 Welcome
2
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
Information in this document is subject to change without notice and does not represent
a commitment on the part of Eltek Energy.
No part of this document may be reproduced or transmitted in any form or by any means
— electronic or mechanical, including photocopying and recording — for any purpose
without the explicit written permission of Eltek Energy.
Copyright ©: Eltek Energy, Norway 2006
Certificate no: 900005E
Certificate no: 900005Q
Safety Precautions
The equipment described in this manual must only be operated by
Eltek Energy personnel or by persons who have attended a suitable
Eltek Energy training course
The equipment represents an energy hazard and failure to observe this
could cause terminal injury and invalidate our warranty
There are hazardous voltages inside the power system. As the modules
incorporate large charged capacitors, it is dangerous to work inside the
system even if the mains supply is disconnected
Products into which our components are incorporated have to comply with a
number of requirements. Installation is to be in accordance with the
recommendations herein
Please read the manual carefully before using the equipment
350002.013 Issue 5, 2006 Nov
Published 2006-11-25
Mfm
1 Welcome
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
3
Table of Contents
1. Welcome 4
About this Guide .............................................................................................................4
System Diagram ⎯ Flatpack2 DC Power System ..........................................................4
2. Flatpack2 Rectifier 5
Key Features................................................................................................................... 5
Typical Applications ........................................................................................................5
3. Installation of Flatpack2 Rectifiers 6
Safety Precautions.......................................................................................................... 6
Mounting and Removing Rectifiers .....................................................................6
Removing Blind Panels................................................................................................... 6
Connections...........................................................................................................7
CAN Bus Addressing (plug-and-play) .................................................................7
Correct Rectifier Position in Power Shelves .............................................................................7
4. Operation 8
Front Panel Interface.............................................................................................8
LED Indicators .......................................................................................................8
5. Technical Specifications 9
Specifications Flatpack2 Rectifier 48V, 1800W ..............................................................9
Specifications Flatpack2 Rectifier 48V, 2000W ............................................................10
Specifications Flatpack2 Rectifier 24V, 2000W ............................................................11
1 Welcome
4
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
1. Welcome
The Flatpack2 rectifier module is a powerful and cost-effective power supply used in
Eltek’s Flatpack2 DC power system.
About this Guide
This booklet provides users of Flatpack2 DC power systems with the required information
to install and operate the Flatpack2 rectifier modules. The booklet also presents the
rectifier’s technical specifications, such as input voltage range, output power, operating
temperature range, etc.
Read also the generic and site specific documentation that was delivered with your
Flatpack2 DC power system.
System Diagram ⎯ Flatpack2 DC Power System
The Flatpack2 rectifier modules are the building blocks of Flatpack2 PS systems, see
Figure 1. The Smartpack controller monitors and controls the whole system, and serves
as the local user interface between you and the system. The PowerSuite application
enables you to configure and operate system from a personal computer.
Figure 1 Example of a typical Flatpack2 PS system for DC power supply of telecom
equipment. The system is fed from an external AC mains supply, and consists of
rectifiers in power shelves, a control unit and DC distribution unit. Battery banks,
LVD contactors, etc. are typically also a part of the system.
Flatpack2
Cabinetize
d
Battery string #1
A
C mains
supply
selector
Symmetry
Alarm &
Temp. Senso
r
LVLD
LVBD
Fuse Alarm
AC Fuses,
external
(230VAC or
400VAC
Telecom
equipment
AC Suppl y
(Single- or
three-
p
hase)
A
larm Outputs NC-C-NO
Digital Inputs
Batte
r
y
Fuses
Load Fuses
& MCBs
Smartpack
ctrl. unit
Flatpack
2
rectifiers
PowerSuite
A
pplication
CAN Bus
USB cable
DC
distribution
DC Supply
(24V, 48V
or 60V*
)
*Available from 2007
Remote
Monitorin
g
2 Flatpack2 Rectifier
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
5
2. Flatpack2 Rectifier
The Flatpack2 rectifier module is a hot-pluggable, digitally controlled switch mode power
supply. The module is designed for battery charging and supplying of high quality DC
power to telecom equipment and similar applications.
The rectifier works in stand-alone mode or in parallel with other rectifiers, then
communicating via CAN bus with the system’s Smartpack controller and other connected
rectifiers. Flatpack2 DC power systems are implemented by mounting the rectifiers in 23”
or 19” power shelves (5 or 4 rectifiers across, respectively).
A wide range of features are implemented in the Flatpack2 rectifier, as mentioned below.
Key Features
Highest efficiency in minimum space
Resonant topology makes the module efficiency industry leading, and
contributes to the rectifier’s ultra compact dimensions.
Digital controllers
Primary and secondary controls are digitalized, enabling excellent
monitoring and control characteristics. Also, the number of
components has been reduced by 40% compared to previous rectifier
generation - for highly reliable, long life, trouble free DC power
systems.
Heat management
Front-to-back air flow, with chassis-integrated heat sinks, gives the
module the most suitable working environment and no limitations in
the scalability of the desired system solution.
CAN bus networked
The Flatpack2 rectifier is connected in a CAN bus network for
communication with the controller and other rectifiers.
Unique connection
A true plug-and-play connection system: reducing time-to-install
related cost.
Global approvals
Flatpack2 is CE marked, UL recognized and NEBS certified for world
wide installation.
Typical Applications
Wireless, fiber and fixed line communication
Today’s communications demand state-of-the-art, cost efficient and compact DC power
systems. Flatpack2 rectifiers deliver industry leading power density and superb reliability
at lowest lifetime cost.
Broadband and network access
Increasing network speed demands flexible and expandable DC power solutions. The
Flatpack2 rectifier is your key building block for future needs.
3 Installation of Flatpack2 Rectifiers
6
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
3. Installation of Flatpack2 Rectifiers
Safety Precautions
Get acquantied with the satety precautions on page 2, before installing or handling
the equipment.
Mounting and Removing Rectifiers
The Flatpack2 rectifiers incorporate handles that serve both to lock the modules
into position and to pull them out of their housings.
Mounting the Flatpack2 rectifier (hot-pluggable)
1. Open the handles
(insert a screwdriver into the holes to release the
spring mechanism)
2. Insert the module fully into the power shelf
3. Lock the handles
(push the handles up into their housings (locked
position), so that the module is securely locked)
Removing the Flatpack2 rectifier
1. Open the handles
(insert a screwdriver into the holes to release the
spring mechanism)
2. Remove the module
(use both handles to pull the module loose from the
connector; support from underneath)
Figure 2 Flatpack2 rectifiers’s locking mechanism
Removing Blind Panels
Release the panel’s upper left and right corners by inserting a small screwdriver
into the panel’s upper left gap, and carefully press down and out to release the
locking tabs. Repeat on the upper right gap. Refer to the Flatpack2 system’s quick
start guide for more information.
Handle in locked position
Hole to release the
handle’s spring
mechanism
Handle in
unlocked
p
osition
Flatpack2
rectifier
Device
hazard
CAUTION: The rectifiers may be warm, but do not hand-carry them by their
handles. Open the handles before inserting them into the power shelves (hotpluggable).
Mount blind panels in unused module locations.
Electric
shock
Device
hazard
CAUTION: Do not relocate already hot-plugged rectifiers to other positions in
the power shelf.
New Flatpack2 rectifiers must be hot-plugged in the power shelf, one at time,
starting with position 1, 2, 3 and so on. This is usually performed before shipment
of the system. Read your system’s quick start guide for more information.
CAUTION: Double Pole / Neutral Fusing. There is a Mains fuse in each line.
3 Installation of Flatpack2 Rectifiers
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
7
Connections
All connections are implemented by inserting the Flatpack2 module fully into the power
shelf, thus plugging the rectifier to the self’s back wiring card (hot-pluggable).
Figure 3 Flatpack2 module’s rear plug-in connections to power shelf’s back wiring card
For details about other power shelf signals, type of power shelf, etc., please read the
system’s generic and specific documentation, or contact your dealer or Eltek
representative.
CAN Bus Addressing (plug-and-play)
When a Flatpack2 rectifier is hot-plugged in the power shelf the first time, the Smartpack
controller automatically assigns the rectifier with the next available ID number (CAN bus
address).
The rectifier will retain its ID (and serial number), even after removing and reinserting it
in the power shelf.
The rectifiers’ IDs are assigned from 1 and upwards. When a module is plugged in, the
Smartpack controller automatically increases the number of communicating rectifiers in
the CAN network.
Correct Rectifier Position in Power Shelves
Flatpack2 DC power systems are usually shipped from factory with the rectifier modules
already installed in the correct position in the power shelves, with respect to their CAN
bus address or ID number.
This relationship is very important for the correct monitoring of the mains three phases,
as the Smartpack controller always uses rectifier ID 01, 02 and 03 to monitor mains
phase L1, L2 and L3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and
06 will automatically take over.
For example: accidentally inserting a rectifier with ID 02 in a power shelf position
internally connected to mains phase L1, will cause the controller to monitor L1 “thinking“
it monitors L2.
Flatpack2 rectifie
r
(rear plug-in slot)
DC Output
Power shelf (-
)
DC Output
Power shelf (+
)
DC connection
Module (-)
DC connection
Module (+)
AC input
connection
Module (L1)
AC input
connection
Module (L2)
Bus connection
Module (CAN-H)
Bus connection
Module (CAN-L)
4 Operation
8
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
4. Operation
The Flatpack2 Rectifier Module is designed for parallel operation in a system. The front
panel LEDs provide information about the rectifier status and CAN bus activity.
Front Panel Interface
Figure 4 Example of a Flatpack2 Rectifier
Module’s front panel
The Flatpack2 Rectifier Module has the following LED indications:
•
“Power” (green) indicates that the power supply is OFF, ON and communicating
•
“Alarm” (red) indicates an alarm situation
•
“Warning” (yellow) indicates an abnormal situation
LED Indicators
The following events will activate the Flatpack2 rectifier’s front LEDs:
LED Status Description
Power
(green)
ON Rectifier is powered
Flashing Smartpack controller accessing information on the rectifier
OFF Mains are unavailable
Warning
(yellow)
ON
Rectifier is in Derating Mode (reduced output power) due to
high internal temperature, or
low input voltage, or
fan failure
The remote Battery Current Limit is activated
AC input voltage is out of range
Rectifier in stand-alone mode (or loss of communication
with the Smartpack controller
Flashing Rectifier is in Over-voltage Protection Mode (AC input)
OFF No abnormal situation is present
Alarm
(red)
ON
Rectifier is in Shut-down Mode due to
low mains, or
high internal temperature, or
high output voltage
Internal rectifier failure (malfunction)
Fan failure (single or double fan malfunction)
Low output voltage
CAN bus failure
OFF No alarm situation is present
Refer also to chapter “Technical Specifications”, page 9.
Alarm
LED Lamp (red)
Warning
LED Lamp (yellow)
Power
LED Lamp (green)
5 Technical Specifications
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
9
Applicable Standards
Electrical safety IEC 60950-1
UL 60950-1
CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (telecommunication network)
EN 61000-6-4 (emission, industry)
EN 61000-6-3 (emission, light industry)
EN 61000-6-2 (immunity, industry)
EN 61000-6-1 (immunity, light industry)
Telcordia NEBS GR1089 CORE
Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2
ETSI EN 300 132-2
Telcordia NEBS GR63 CORE Zone 4
RoHS compliant (pending)
Specifications are subject to change without notice 241115.001.DS3 v.05
5. Technical Specifications
Specifications Flatpack2 Rectifier 48V, 1800W
AC Input
Voltage 85-290 VAC
(Nominal 185 – 275 VAC)
Frequency 45 to 66Hz
Maximum
Current
10.7 A
rms
max.
at nominal input and full load
Power Factor > 0.99 at 20% load or more
Input
Protection
o Varistors for transient protection
o Mains fuse in both lines
o Disconnect above 290 VAC
DC Output
Voltage 53.5 VDC
(adj. range: 43.5-56.0 VDC)
Output Power 1800 W at nominal input
Maximum
Current
37.5 Amps
at 48 VDC and nominal input
Current Sharing ±3% from true average current
between modules
Static voltage
regulation
±0.5% from 10% to 100% load
Dynamic voltage
regulation
±5.0% for 10-90% or 90-10%
load variation, regulation time
< 50ms
Hold up time > 20ms; output voltage > 43.5
VDC at 1500W load
Ripple and Noise o < 100 mV peak to peak,
o 30 MHz bandwidth
o < 0.96 mV rms psophometric
Output Protection o Over-voltage shutdown
o Blocking diode
o Short circuit proof
o High temperature protection
Other Specifications
Efficiency Typical 92%,
min. 91% at 40-90% load
Isolation o 3.0 KVAC – input and output
o 1.5 KVAC – input earth
o 0.5 KVDC – output earth
Alarms:
Warnings:
o Low mains shutdown
o High temperature shutdown
o Rectifier Failure
o Over-voltage shutdown on output
o Fan failure, one or two fans.
o Low voltage alarm at 43.5V
o CAN bus failure
o Rectifier in power derate mode
o Remote battery current limit
activated
o Input voltage out of range, flashing
at over-voltage
o Loss of CAN communication with
control unit, stand alone mode
Visual
indications
o Green LED: ON, no faults
o Red LED: rectifier failure
o Yellow LED : rectifier warning
Operating
temp
-40 to +70°C (-40 to +158°F)
Storage
temp
-40 to +85°C (-40 to +185°F)
Cooling 2 fans (front to back airflow)
Fan Speed Temperature and load regulated
MTBF > 250, 000 hours Telcordia SR-332
Issue I, method III (a)
Acoustic
Noise
< 50dBA at nominal input and 70%
load (T
ambient
< 30°C)
Humidity Operating: 5% to 95% RH non-
condensing
Storage: 0% to 99% RH non-
condensing
Dimensions 109 x 41.5 x 327mm (wxhxd)
(4.25 x 1.69 x 13”)
Weight 1.8 kg (3.97 lbs)
5 Technical Specifications
10
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
Applicable Standards
Electrical safety IEC 60950-1
UL 60950-1
CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (telecommunication network)
EN 61000-6-1 (immunity, light industry)
EN 61000-6-2 (immunity, industry)
EN 61000-6-3 (emission, light industry)
EN 61000-6-4 (emission, industry)
Telcordia NEBS GR1089 CORE
Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2 (-1, -2, -3)
ETSI EN 300 132-2
Telcordia NEBS GR63 CORE Zone 4
RoHS compliant (pending)
Specifications are subject to change without notice 241115.100.DS3 v.02
Specifications Flatpack2 Rectifier 48V, 2000W
AC Input
Voltage 85-300 VAC
(Nominal 185 – 275 VAC)
Frequency 45 to 66Hz
Maximum Current 12.5 A
rms
maximum
at nominal input and full load
Power Factor > 0.99 at 20% load or more
Input Protection o Varistors for transient protection
o Mains fuse in both lines
o Disconnect above 300 VAC
DC Output
Voltage 53.5 VDC
(adj. range: 43.5-57.6 VDC)
Output Power 2000 W at nominal input
Maximum
Current
41.7 Amps
at 48 VDC and nominal input
Current Sharing ±3% from true average current
between modules
Static voltage
regulation
±0.5% from 10% to 100% load
Dynamic voltage
regulation
±5.0% for 10-90% or 90-10%
load variation, regulation time
< 50ms
Hold up time > 20ms; output voltage > 43.5
VDC at 1500W load
Ripple and Noise o < 100 mV peak to peak,
o 30 MHz bandwith
o < 0.96 mV rms psophometric
Output Protection o Over-voltage shutdown
o Blocking diode
o Short circuit proof
o High temperature protection
Other Specifications
Efficiency Typical 92%, min. 91% at 40-90%
load
Isolation o 3.0 KVAC – input and output
o 1.5 KVAC – input earth
o 0.5 KVDC – output earth
Alarms:
Warnings:
o Low mains shutdown
o High temperature shutdown
o Rectifier Failure
o Over-voltage shutdown on output
o Fan failure, one or two fans.
o Low voltage alarm at 43.5V
o CAN bus failure
o Low temperature shutdown
o Rectifier in power derate mode
o Remote battery current limit
activated
o Input voltage out of range, flashing
at over-voltage
o Loss of CAN communication with
control unit, stand alone mode
Visual
indications
o Green LED: ON, no faults
o Red LED: rectifier failure
o Yellow LED : rectifier warning
Operating
temp
-40 to +75°C (-40 to +158°F)
Storage
temp
-40 to +85°C (-40 to +185°F)
Cooling 2 fans (front to back airflow)
Fan Speed Temperature and current regulated
MTBF > 350, 000 hours
Telcordia SR-332 Issue I, method
III (a) (T
ambient
: 25°C)
Acoustic
Noise
< 55dBA at nominal input and full load
(T
ambient
< 30°C)
Humidity Operating: 5% to 95% RH non-
condensing
Storage: 0% to 99% RH non-
condensing
Dimensions 109 x 41.5 x 327mm (wxhxd)
(4.25 x 1.69 x 13”)
Weight 1.9 kg (4.19lbs)
5 Technical Specifications
User’s Guide Flatpack2 Rectifier Module,
350002.013, v5-2006-11
11
Applicable Standards
Electrical safety IEC 60950-1
UL 60950-1
CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (telecommunication network)
EN 61000-6-4 (emission, industry)
EN 61000-6-3 (emission, light industry)
EN 61000-6-2 (immunity, industry)
EN 61000-6-1 (immunity, light industry)
Telcordia NEBS GR1089 CORE (pending)
Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2
ETSI EN 300 132-2
Telcordia NEBS GR63 CORE Zone 4 (pending)
RoHS compliant (pending)
Specifications are subject to change without notice 241115.200.DS3 v.01
Specifications Flatpack2 Rectifier 24V, 2000W
AC Input
Voltage 85-290 VAC
(Nominal 176 – 275 VAC)
Frequency 44 to 66Hz
Maximum
Current
13.4 A
rms
maximum
at nominal input and full load
Power Factor > 0.99 at 50% load or more
Input
Protection
o Varistors for transient protection
o Mains fuse in both lines
o Disconnect above 290 VAC
DC Output
Voltage 26.7 VDC
(adj. range: 21.0-29.0 VDC)
Output Power 2000 W at nominal input
Maximum
Current
84.0 Amps
at 24 VDC and nominal input
Current Sharing ±5% from true average current
between modules
Static voltage
regulation
±0.5% from 10% to 100% load
Dynamic voltage
regulation
±5.0% for 10-90% or 90-10%
load variation, regulation time
< 50ms
Hold up time > 20ms; output voltage > 21 VDC
at 1000W load
Ripple and Noise < 100 mV peak to peak
< 0.96 mV rms psophometric
Output Protection o Over-voltage shutdown
o Blocking diode
o Short circuit proof
o High temperature protection
Other Specifications
Efficiency Typical 89%
Isolation o 3.0 KVAC – input and output
o 1.5 KVAC – input earth
o 0.5 KVDC – output earth
Alarms:
Warnings:
o Low mains shutdown
o High temperature shutdown
o Rectifier Failure
o Over-voltage shutdown on output
o Fan failure, one or two fans.
o Low voltage alarm at 21.5V
o CAN bus failure
o Rectifier in power derate mode
o Remote battery current limit
activated
o Input voltage out of range, flashing
at over-voltage
o Loss of CAN communication with
control unit, stand alone mode
Visual
indications
o Green LED: ON, no faults
o Red LED: rectifier failure
o Yellow LED : rectifier warning
Operating
temp
-40 to +75°C (-40 to +167°F)
Storage
temp
-40 to +85°C (-40 to +185°F)
Cooling 2 fans (front to back airflow)
Fan Speed Temperature and load regulated
MTBF > 200, 000 hours Telcordia SR-332
Issue I, method III (a)
Acoustic
Noise
< 65dBA at nominal input and 70%
load (T
ambient
< 30°C)
Humidity Operating: 5% to 95% RH non-
condensing
Storage: 0% to 99% RH non-
condensing
Dimensions 109 x 41.5 x 327mm (wxhxd)
(4.25 x 1.69 x 13”)
Weight 1.9 kg (3.97 lbs)
www.eltekenergy.com
ELTEK Energy
P-O- BOX 2340 StØmsØ
N-3003 DRAMMEN
NORWAY
Phone: +47 32203200
Telefax: +47 32203210
Internet: http://www.eltekenergy.com
e-mail:
eltek@eltekenergy.com
Location Company Telephone Fax
Norway Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10
Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118
Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602
China Eltek Energy Ltd. +769 22651108
Europe Eltek Energy UK Ltd. +44 1442 219355 +44 1442 245894
Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175
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