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35
0002
.013
User’s Guide
2 User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05
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 Strømsø 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
User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05 3
Table of Contents
1 WELCOME 4
2 THE FLATPACK2 RECTIFIER ⎯ SHORT DESCRIPTION 4 2.1 GENERAL 4 2.2 MAIN FEATURES 4
3 INSTALLATION PROCEDURES 5 3.1 SAFETY PRECAUTIONS 5 3.2 HANDLES AND LOCKING MECHANISM 5 3.3 INSTALLATION OF RECTIFIERS 6 3.4 REMOVAL OF RECTIFIERS 6
4 OPERATING INSTRUCTIONS 7 4.1 GENERAL 7 4.2 FRONT PANEL INTERFACE 7 4.3 LED INDICATORS 7
5 CONNECTIONS 8
6 CAN BUS ADDRESSING (PLUG-AND-PLAY) 8
7 SPECIFICATIONS 9
4 User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05
1 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 provides important or critical information.
A note following this symbol clarifies or emphasises a recommendation.
2 The Flatpack2 Rectifier ⎯ Short Description
2.1 General 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 system’s Smartpack controller and other connected rectifiers. A wide range of features are implemented in the Flatpack2 rectifier, as mentioned below.
2.2 Main 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.
User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05 5
3 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
Figure 1 Flatpack2 Rectifier’s 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
When both handles are released, use them to pull the rectifier loose
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
Hole to release the handle’s spring mechanism
Handel in unlocked position
6 User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05
3.3 Installation of rectifiers
Installation of Flatpack2 Rectifier Modules
Step Comments
SLIDE THE MODULE INTO THE
POWER SHELF Slide the module 2/3 into the power shelf and open the handles
FASTEN THE MODULE
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
VERIFY THAT THE RECTIFIER IS
ON The green “ON” LED is lit and no alarm is activated
MOUNT BLIND PANELS ON EMPTY
RECTIFIER POSITIONS For safety reasons all vacant rectifier positions must be covered by blind panels
3.4 Removal of rectifiers
Removal of Flatpack2 Rectifier Modules
Step Comments
UNLOCK THE LEVERS Release the handles as described
PULL THE RECTIFIER LOOSE Using both handles pull the rectifier outwards to release it from the connector
SLIDE THE RECTIFIER OUT
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.
For safety reasons, blind panels must be mounted in all spare module locations to avoid contact with all conducting components
User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05 7
4 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
Figure 2 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
4.3 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 (+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 Flashing Rectifier is in Over-voltage Protection Mode OFF No abnormal situation is present Alarm (red)
ON
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
OFF No alarm situation is present
Table 1 Description of front LED indicators
Alarm LED Lamp (red)
Warning LED Lamp (yellow)
Power LED Lamp (green)
8 User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05
5 Connections All connections are implemented by plugging the Flatpack2 module to the power self’s back wiring card.
Figure 3 Flatpack2 module’s rear plug-in connections to power shelf’s back wiring card.
For details about other power shelf signals, please read the system specific documentation or contact your dealer or Eltek representative. 6 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 rectifier’s 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.
Flatpack2 rectifier(rear plug-in slot)
DC OutputPower shelf (-)
DC OutputPower shelf (+)
DC connectionModule (-)
DC connectionModule (+)
AC input connectionModule (L1)
AC input connectionModule (L2) Bus connection
Module (CAN-H)
Bus connectionModule (CAN-L)
User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05 9
7 Specifications
AC Input Voltage 85-290 VAC
(Nominal 185 – 275 VAC)
Frequency 45 to 66Hz
Maximum Current
9.7 Arms maximum at nominal input and full load
Power Factor
> 0.99 at 20% load or more
Input Protection
Varistors for transient protection Mains fuse in both lines Disconnect above 290 VAC
DC Output Voltage 53.5 VDC (adj. range: 45-56 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
±4.0% for 10-90% or 90-10% load variation, regulation time < 10ms
Hold up time > 20ms; output voltage > 44 VDC at full load
Ripple and Noise
< 100 mV peak to peak, 30 MHz bandwidth < 0.96 mV rms psophometric
Output Protection
Over-voltage shutdown Blocking diode Short circuit proof High temperature protection
Other Specifications Efficiency Typical 93%, min. 92% at 40-90%
load
Isolation 3.0 KVAC – input and output 1.5 KVAC – input earth 0.75 KVDC – output earth
Rectifier Alarms
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
Visual indications
Green LED: ON, no faults Red LED: rectifier failure Yellow LED blinking: no communication Yellow LED solid: derating power
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 regulated
MTBF > 250, 000 hours Telcordia SR-332 Issue I, method III (a)
Acoustic Noise < 55dBA
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)
Applicable Standards Electrical safety IEC 60950-1
UL 60950
EMC 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
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.
10 User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05
User’s Guide Flatpack2 Rectifier Module, Art. 350002.013, v1-2005-05 11
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. +852 28982689 +852 28983189 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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