Flatpack 2 Rectifier

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: [email protected] 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


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.


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


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


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)


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)


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.



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: [email protected]

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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Flatpack 2 Rectifier