Users Guide

350002.013

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 2005

Certificate no: 900005E

Certificate no: 900005Q

Head Office: Eltek Energy P.O. Box 2340 Strms N-3003 DRAMMEN Norway

Phone: (+47) 32 20 32 00 Fax: (+47) 32 20 32 10 E-Mail: eltek@eltekenergy.com Internet: http://www.eltekenergy.com

350002.013

Issue 1, 2005 May

Published 2005-05-19 Mfm

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Table of Contents
1 2 WELCOME THE FLATPACK2 RECTIFIER SHORT DESCRIPTION 2.1 GENERAL 2.2 MAIN FEATURES INSTALLATION PROCEDURES 3.1 SAFETY PRECAUTIONS 3.2 HANDLES AND LOCKING MECHANISM 3.3 INSTALLATION OF RECTIFIERS 3.4 REMOVAL OF RECTIFIERS OPERATING INSTRUCTIONS 4.1 GENERAL 4.2 FRONT PANEL INTERFACE 4.3 LED INDICATORS CONNECTIONS CAN BUS ADDRESSING (PLUG-AND-PLAY) SPECIFICATIONS 4 4 4 4 5 5 5 6 6 7 7 7 7 8 8 9

5 6 7

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Welcome

This document describes the installation procedures and operating instructions of the Flatpack2 Rectifier Module, as well as technical specifications such as input voltage range, output power and operating temperature range. Before you start using a Flatpack2 Rectifier Module, it is essential to read this manual first. The manual employs consistent visual cues to help you locate and interpret information easily. Important information is outlined according to the table below. Symbol Meaning A note following this symbol important or critical information. provides

A note following this symbol clarifies or emphasises a recommendation.

The Flatpack2 Rectifier Short Description

The Flatpack2 Rectifier Module is a hot-pluggable, digitally controlled switch mode power supply 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 systems Smartpack controller and other connected rectifiers. A wide range of features are implemented in the Flatpack2 rectifier, as mentioned below.

2.1 General

2.2 Main Features

Highest efficiency in minimum space Resonant topology makes the module efficiency industry leading and contributes to the rectifiers 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.

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Installation procedures

3.1 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 rectifier system. As the rectifier units 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

3.2 Handles and locking mechanism

The Flatpack2 Rectifier Module incorporates handles that serve two purposes; to lock the module into position, and serve as pull-out handles

Hole to release the handles spring mechanism

To unlock and release the handles, insert a small screw driver into the holes in the upper corners of the rectifier front panel to release the spring mechanism. Do not use excessive force. The handle will release and pop out

Handel in locked position When both handles are released, use them to pull the rectifier loose

Handel in unlocked position Figure 1 Flatpack2 Rectifiers locking mechanism

Do not hold or hand-carry the rectifier by its handles Use gentle force, when releasing the handles from their locked position Open the handles before inserting the module fully into the power shelf

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

3.3 Installation of rectifiers

Installation of Flatpack2 Rectifier Modules Step SLIDE THE MODULE INTO THE
POWER SHELF

Comments Slide the module 2/3 into the power shelf and open the handles Push the module fully into the power shelf and push the handles into their slots to lock the rectifier into position. Make sure the module is fully inserted before locking the handles The green ON LED is lit and no alarm is activated For safety reasons all vacant rectifier positions must be covered by blind panels

FASTEN THE MODULE VERIFY THAT THE RECTIFIER IS

ON

MOUNT BLIND PANELS ON EMPTY

RECTIFIER POSITIONS

3.4 Removal of rectifiers

Removal of Flatpack2 Rectifier Modules Step UNLOCK THE LEVERS PULL THE RECTIFIER LOOSE Comments Release the handles as described Using both handles pull the rectifier outwards to release it from the connector Take hold of the rectifier unit and pull it out from its slot. Support the unit from below as it is being removed. Warning: If the unit has been in use for some time, rectifier body may be hot.

SLIDE THE RECTIFIER OUT

For safety reasons, blind panels must be mounted in all spare module locations to avoid contact with all conducting components

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Operating instructions

4.1 General

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.

4.2 Front panel interface

Warning LED Lamp (yellow) Alarm LED Lamp (red)

Figure 2

Example of a Flatpack2 Rectifier Modules front panel

Power LED Lamp (green)

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

4.3 LED indicators

The following events will activate the Flatpack2 rectifiers front LEDs:

LED
Power (green)

Status
ON Flashing OFF

Description
Rectifier is powered Smartpack controller accessing information on the rectifier Mains are unavailable Rectifier is in Derating Mode (reduced output power) due to high internal temperature (+45 to 75 C) or low input voltage (lower than 185VAC) 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 Rectifier is in Over-voltage Protection Mode No abnormal situation is present Rectifier is in Shut-down Mode due to low mains (0 85VAC) or high internal temperature (+75 C or higher) or high output voltage (higher than 59.5 VDC) Internal rectifier failure (malfunction) Fan failure (single or double fan malfunction) Low output voltage (0 to 43.5VDC) CAN bus failure No alarm situation is present Table 1 Description of front LED indicators

Warning (yellow) ON

Flashing OFF Alarm (red) ON

OFF

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Connections

All connections are implemented by plugging the Flatpack2 module to the power selfs back wiring card.
Flatpack2 rectifier (rear plug-in slot) AC input connection Module (L2) AC input connection Module (L1) DC connection Module (+) DC connection Module (-)

Bus connection Module (CAN-L) Bus connection Module (CAN-H)

DC Output Power shelf (+)

DC Output Power shelf (-)

Figure 3

Flatpack2 modules rear plug-in connections to power shelfs back wiring card. the system specific

For details about other power shelf signals, please read documentation or contact your dealer or Eltek representative.

CAN bus addressing (plug-and-play)

When a Flatpack2 rectifier is plugged in the power shelf the first time, the Smartpack controller automatically assigns the rectifier with the next available ID number. 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. When a previously installed rectifier is plugged in the power shelf again, it always sends its previous ID and serial number to the Smartpack controller.

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Specifications

AC Input
Voltage Frequency Maximum Current Power Factor Input Protection 85-290 VAC (Nominal 185 275 VAC) 45 to 66Hz 9.7 Arms maximum at nominal input and full load > 0.99 at 20% load or more Varistors for transient protection Mains fuse in both lines Disconnect above 290 VAC

Other Specifications
Efficiency Isolation Typical 93%, min. 92% at 40-90% load 3.0 KVAC input and output 1.5 KVAC input earth 0.75 KVDC output earth Low mains alarm High mains alarm Low output voltage alarm Over voltage shutdown alarm Current limit alarm Current sharing alarm Fan Alarm Temperature alarm Rectifier failure alarm Green LED: ON, no faults Red LED: rectifier failure Yellow LED blinking: no communication Yellow LED solid: derating power -40 to +70C (-40 to +158F) -40 to +85C (-40 to +185F) 2 fans (front to back airflow) Temperature regulated > 250, 000 hours Telcordia SR-332 Issue I, method III (a) < 55dBA Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing 109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13) 1.8 kg (3.97 lbs)

Rectifier Alarms

DC Output
Voltage Output Power Maximum Current Current Sharing Static voltage regulation Dynamic voltage regulation Hold up time 53.5 VDC (adj. range: 45-56 VDC) 1800 W at nominal input 37.5 Amps at 48 VDC and nominal input 3% from true average current between modules 0.5% from 10% to 100% load

Visual indications

Operating temp Storage temp Cooling

4.0% for 10-90% or 90-10% load variation, regulation time < 10ms > 20ms; output voltage > 44 VDC at full load < 100 mV peak to peak, 30 MHz bandwidth < 0.96 mV rms psophometric Over-voltage shutdown Blocking diode Short circuit proof High temperature protection

Fan Speed MTBF Acoustic Noise Humidity

Ripple and Noise Output Protection

Dimensions Weight

Applicable Standards
Electrical safety EMC IEC 60950-1 UL 60950 ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) Telcordia NEBS GR1089 CORE EN 61000-3-2 ETSI EN 300 019-2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant (pending)

Harmonics Environment

Specifications are subject to change without notice.

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

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Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

Users Guide Flatpack2 Rectifier Module,

Art. 350002.013, v1-2005-05

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ELTEK Energy
P-O- BOX 2340 Stms N-3003 DRAMMEN NORWAY Phone: Telefax: Internet: +47 32203200 +47 32203210 http://www.eltekenergy.com eltek@eltekenergy.com

e-mail:

Location Norway Americas Asia/Pacific China Europe Middle East

Company Eltek Energy AS Eltek Energy, LLC Eltek Energy Pte Ltd. Eltek Energy Ltd. Eltek Energy UK Ltd. Eltek Middle East

Telephone +47 32 20 32 00 +1 815 459 9100 +65 6 7732326 +852 28982689 +44 1442 219355 +971 4 887 1176

Fax +47 32 20 32 10 +1 815 459 9118 +65 6 7753602 +852 28983189 +44 1442 245894 +971 4 887 1175

www.eltekenergy.com