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Operation Guide

Flatpack DC/DC 24/48 and Flatpack DC/DC 48/24

351550.013

1 Scope
Information in these documents is subject to change without notice and does not represent a commitment on the part of Eltek Energy AS. No part of these documents 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 AS.

Copyright : Eltek Energy AS, Norway 2006 EMC


Generic Immunity Standard
EN50082-1 Residential, Commercial and Light Industry EN50082-2 Industrial Environment LVD73/23/EEC Low Voltage Directive

LVD

Generic Emission Standard


EN50081-1 Residential, Commercial and Light Industry EN50081-2 Industrial Environment

NS-EN ISO 9001:1994 Certificate no: 900005Q NS-EN ISO 14001:1996 Certificate no: 900005E. This product holds a CE mark and satisfies all requirements covering relevant standards and directives.

Certificate no: 900005E

Certificate no: 900005Q

Eltek Energy AS
PO Box 2340 Strms, N-3003 Drammen Grterudveien 8, N-3036 Drammen Norway Tel: Fax:
E-mail:

+47 32 20 32 00 +47 32 20 32 10
eltek@eltekenergy.com www.eltekenergy.com

Internet:

Art. No.: 351550.013


Published 2006-07-31
mfm

Issue 3, 2006 July

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

1 Scope

Contents
1. Scope System Precautions Main Features 4 4 5

2. 3.

General....................................................................................................................... 5 Features ..................................................................................................................... 5

4.

Installation Procedures

Safety Precautions............................................................................................6 Handles and Locking Mechanism....................................................................7 Installation of Modules .....................................................................................8


Signal Connections .................................................................................................... 9

Removal of Units...............................................................................................9

5.

Operating Instructions

10

General..................................................................................................................... 10 Front Panel LED Indications..................................................................................... 10

System Operation Flatpack DC/DC Converters............................................11

6.

Interface

12

Visual Interface................................................................................................12 User Interface ..................................................................................................12 Converter Alarm ..............................................................................................14 Error State Table and Fault-Finding ..............................................................14 Replacement of Fans ......................................................................................16

7.

Technical Specifications

17

Technical Specification Flatpack DC/DC 48/24.............................................17 Technical Specification Flatpack DC/DC 24/48.............................................18

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

1 Scope

1. Scope
The Flatpack DC/DC 24/48 and the Flatpack DC/DC 48/24 Converter Modules are designed for stand-alone use, or for working in parallel, as part of a DC-DC rack system. The converters are hot pluggable and have a blocking diode on the output for true redundancy. High frequency switch mode technology is used to minimise volume and weight and to obtain fast output voltage regulation. The module has soft start power up. When working in parallel the converters provide active current sharing via CAN-bus. An internal blocking diode allows hot plug-in and isolates any faults in the converters output the DC bus.

This manual includes a specification of the environmental limits of the converters, with regards to temperature range, humidity and acoustic noise.
Elteks Part Name Flatpack DC/DC 48/24 Flatpack DC/DC Converter Description Flatpack 48/24 DC/DC Converter Module Flatpack 24/48 DC/DC Converter Module

2. System Precautions
Before you start using a Flatpack DC/DC converter, it is essential you read this manual first. The manual employs consistent visual cues to help you locate and interpret information easily.

Symbol

Meaning
A note following this symbol provides important or critical information. A note following this symbol clarifies or emphasises a recommendation.

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

3 Main Features

3. Main Features

General
The Flatpack DC/DC converters are designed for use in telecom systems. The Flatpack DC/DC 24/48V and 48/24V converters are intended to receive power from a 24V or a 48V telecom rectifier system and to deliver a fixed output voltage (for exact output values, please see chapter 7 in this manual). The converters are hot pluggable and have blocking diodes on the output for true redundancy. Parallel operation is possible, with active current sharing via CAN-bus. The converters are intended for stand-alone operation, but some control and information retrieval will be possible when connected to a control unit with CAN-bus. The typical application will be that the DC/DC converters are installed into a 24V or a 48V telecom rectifier system and communicate with this systems control unit. In a typical application, the input side will have the negative leg connected to earth, and the output side will have the positive leg connected to earth. These connections will be made on system level. The converter design is independent of system earthing, i.e. with floating input and output and with isolated CANbus. Modern, yet well-proven technology makes the Flatpack DC/DC 24/48 and the Flatpack DC/DC 48/24 compact and reliable modules. In addition, a wide range of features is integrated, as mentioned below.

Features
Front LED indicators, current LED bar graph and output voltage adjustment point for stand-alone control and monitoring. Information regarding the modules status will, at all times, be accessible from the front. Wide input voltage ranges Low voltage shutdown Temperature monitoring and automatic power limitation and shutdown at high internal temperatures True hot plug-in

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

4 Installation Procedures

4. Installation Procedures
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 module. As the modules incorporate large charged capacitors, it is dangerous to work inside them even if the DC 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.

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

4 Installation Procedures

Handles and Locking Mechanism


The Flatpack DC/DC 24/48 and 48/24 converter modules are equipped with handles that serve two purposes:

1. To lock the module into position


When the module is plugged into its slot, it is then locked into position using the handles on either side of the front panel. Once the module is in position the handles must be rotated into their housings and firmly pushed home; failure to do so will prevent the module from making proper contact.

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

Figure 1 Releasing the modules handles

2. To pull the module loose

When both handles are released, use them to pull the module loose.

Figure 2 Module with released handles

5 Do not hold or hand-carry the module by its handles. 5 Use gentle force, when releasing the handles from their locked position

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

4 Installation Procedures

Installation of Modules

Figure 3 Connections accessible from the rear of Flatpack DC/DC 24/48 and DC/DC 48/24

Output +ve Output ve CAN bus connector

Input +ve Input ve

Installation of Flatpack DC/DC 24/48 & 48/24 Converter Modules


Step 1. PLUG IN THE NEW
UNIT

Comments

OK

Insert a small screwdriver into the holes in the upper corners of the unit front panel and carefully rotate each lever downwards. Do not use excessive force The lever will release and pop out. Make sure that the levers are fully open and insert the unit into its slot in the system. Push the levers into their slots to lock the unit into position. The green ON LED is lit and no alarm is activated. For safety reasons all vacant unit positions must be covered by blind panels

2. FASTEN THE MODULE 3. VERIFY THAT THE


UNIT IS ON

4. MOUNT BLIND PANELS


ON EMPTY UNIT POSITIONS

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

4 Installation Procedures

Signal Connections

Figure 4 Signal connector as seen from the back of the unit

Plug no. / pin A5 B5 C5 C2 D1 C1 B1 D2 A4 B4 C6 D6 B6 A6

Name CanH CanL CanGnd +5v P1 - Reset P2 - PTA0 - DIG1 P3 - IRQ - DIG2 Signal reference Shutdown + Shutdown Module alarm C Module alarm NO Module alarm NC Module alarm NC critical

Comments Opto isolated Opto isolated Opto isolated Used for programming the C Used for programming the C Used for programming the C and output voltage selection Used for programming the C and output voltage selection Used for programming the C and output voltage selection Opto isolated Opto isolated Alarm: common Alarm: Normally open Alarm: Normally closed Alarm: Normally closed via 2k2 resistor

Removal of Units
Removal of Flatpack DC/DC 24/48 & 48/24 Converter Modules
Step UNLOCK THE LEVERS Comments OK

PULL THE UNIT LOOSE SLIDE THE UNIT OUT

Insert a small screwdriver into the holes in the upper corners of the unit front panel and carefully rotate the lever downwards. Do not use excessive force The lever will release and pop out (see chapter Handles and Locking Mechanism, page 7 ). Using both handles pull the unit forward to release it from the connector Take hold of the unit and pull it out from its slot. Support the unit from below as it is being removed (If the unit has been in use for some time it may be hot!) Do not carry the unit by its levers.

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

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

5 Operating Instructions

5. Operating Instructions
General
The Flatpack DC/DC 24/48 and 48/24 converter modules are designed for both stand-alone and parallel operation in a system. When used as a stand-alone unit, the output voltage is adjusted on insertion to the back plane.

Front Panel LED Indications


The front panel LEDs provide information regarding unit status and an LED bar graph shows how much current the unit is delivering (on a scale from 0 to 100%). A unit alarm signal provides an alarm, if there is any internal failure. When operating in a system, local and remote monitoring can be achieved via the AEON monitoring & control unit. The unit is installed in a power shelf that provides parallel connection of several units and/or power shelves, either in 19, ETSI or 21 wide cabinets. Various DC distribution solutions provide connectivity for different amounts of load circuits and battery strings.
ON / Alarm LED (Green in normal operation)

Bar graph showing % power output

Figure 5 View showing front panel LED indicators in normal operation

Shorter bar graph indicates the module outputs lower power

Figure 6 View showing 4 units in normal operation (All green LEDs ON and equal number of bar graph LEDs ON)

Figure 7 View showing 4 units in asymmetric operation (All green LEDs ON and unequal number of bar graph LEDs ON)

The bar graphs show that the individual units are delivering different power outputs. This shows that the current sharing subsystem is inoperable, and may indicate a fault on the CAN-bus. It does not stop the system from delivering full load.

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Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

Art. 351550.013, v3-2006-07

Warning yellow LED ON

5 Operating Instructions

Figure 8 View showing Warning LED illuminated

When the warning LED is lit one of the following warnings has occurred: LED bar graph (10 green LEDs) shows the output current on a scale from 0 to100%, each LED representing 10% output current. The unit delivers more than 23A, when all LEDs are lit, when the unit is in current limit operation the warning LED will be illuminated. Single fan failure High temperature derating activated


Alarm red LED ON

Figure 9 View showing Alarm (red) Led illuminated

Status (red) indicates one of the following fault conditions: DC input voltage out of range High temperature shutdown Unit shutdown due to high internal temperature Fan Failure Both fans has been stopped, or failed Internal malfunction Internal failure Over voltage shutdown The output voltage has been above safe level

The internal alarm relay is made failsafe, i.e. the relay coil is energized, when there is no alarm. The alarm relay is energized when the green LED, and only the green LED is lit.

System Operation Flatpack DC/DC Converters


In a system configuration, the units are mounted in dedicated power shelves that provide parallel DC connection, DC feed and signal interconnection via a communication bus to the AEON unit. The modules exhibit active load sharing when connected in parallel. Current sharing has the advantage that the MTBF will be equally distributed throughout the system.

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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6 Interface

6. Interface
Visual Interface
INDICATORS TYPE OF ALARM

Red/Green LED Yellow LED

Red: Module alarm Green: Power OK Module warning: Single fan failure High temperature / derating activated Current limit Module alarm: DC input voltage out of range No output voltage Over voltage shutdown Both fans failed High temperature shutdown

Bar graph

Output current, 2.3A per segment

User Interface
Voltage adjustment: The module will read two digital inputs: DIG1 and DIG2, (shorted to signal ref. = 0, open = 1). The output voltage will be set according to the table:
DIG1 DIG2

OUTPUT VOLTAGE

48Vdc 53,5Vdc 55Vdc 56Vdc

0 1 1 0

1 0 1 0

Shutdown: Alarms:

Information:

Shutdown is possible both from an opto-isolated digital input and via the CAN bus. The alarm relay shall be activated by both Module failure and Module warning Detailed alarm info shall be available on the CAN bus. When communicating with a CAN-based Eltek control module, it shall be possible to retrieve detailed module information according to the generic Eltek CAN-bus protocol (to be determined).

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Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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6 Interface
The following production data is stored in the module, and can be retrieved on demand:
INFORMATION LIMITATIONS

Main Board Serial Num Unit Serial Num Main Board HW Revision Main Board Article No. Unit HW Revision Unit Article No. Main Board Tested By Main Board Tested Date Unit Tested By Unit Tested Date Burn In By Burn In Date

Maximum 6 characters. Character set: 0-9, A-D and period. Maximum 16 characters. Character set: 0-9, A-D and period. Maximum 6 characters. Character set: 0-9, A-D and period. Maximum 16 characters. Character set: 0-9, A-D and period. Up to 4 ASCII characters Up to 4 ASCII characters Up to 4 ASCII characters

In addition, the following information can be retrieved on demand Converter type Version number SW Manufacturer (part of serial number) Hour counter Max. current Max. temperature Current limit operation High temperature derating /warning High temperature failure Internal temperature Output current Output voltage Fan failure alarm OVP alarm Low input voltage alarm High input voltage alarm Module failure SW download: It is possible to download new software via the signal connector. Addressing : Automatic (Plug and Play)

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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6 Interface

Converter Alarm
If the Flatpack DC/DC converters operating environment (input voltage or temperature) is outside limits, or if the units have suffered an internal component failure, the Flatpack DC/DC converters will give an alarm via a common internal alarm relay. Also, the red alarm LED in the front panel will be lit. Some of these alarms are automatically reset as soon as the source of the alarm is no longer present. The following circumstances may cause such an alarm: Input voltage below limit (auto-recovery when input voltage is high enough) High temperature shutdown

Other alarms are caused by more severe circumstances and a manual reset, or repair of the module might be necessary. The following circumstances will cause damage that will require repair of the module: Input fuse(s) blown due to component failure. Fan failure. One or both fans have been stopped or failed Loss of internal supply voltage(s) due to internal component failure

The following circumstance can be manually reset on site Over voltage shutdown. The unit will automatically shut itself down if its output is above the OVS limit. Unplug the rectifier from the system, let it discharge until all the bar-graph LEDs are dark and the warning LED should now be dark. If the alarm is still activated when the rectifier is reinstalled it probably has an internal fault and needs repairing

Error State Table and Fault-Finding


A summary of operating and failure modes of the module is given in table 1 below which includes information for error recovery and verification. "Call service" means you should contact your dealer or Eltek representative for assistance.
SYMPTOM POSSIBLE ERROR HOW TO FAULT-FIND, RECOVER OR RESTART

GREEN LED ON ALARM (RED)


AND WARNING (YELLOW) OFF

Normal operation

No fault

ANY NUMBER OF
BAR GRAPH LEDS ON

ALL LEDS OFF

Normal disconnect

Input is disconnected from power source

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Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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6 Interface
SYMPTOM POSSIBLE ERROR HOW TO FAULT-FIND, RECOVER OR RESTART

LOW OUTPUT
VOLTAGE

De-rating due to high internal temperature

To verify temperature de-rating: Determine the maximum rectifier current of the system. Read the measured rectifier current in the display of the monitoring units. If the value shown by the monitoring unit is less than the maximum rectifier current, the rectifier(s) have most likely de-rated the output power due to high temperature. Observe the system. If all modules act equal, most likely errors are: Line input voltage failure. The modules may have entered input voltage low protect mode. Check all system line input voltage fuses or circuit breakers. Measure line voltage, and check that it is not below the limit. See specifications If modules act differently, the most likely errors are: Over voltage protection. Each unit monitors its own voltage and shuts down if an internal error makes the output voltage go above the legal level. Remove the rectifier from the system and let it rest for one minute, and then reconnect it. If the green LED lights up and the alarm LED is OFF, the rectifier has assumed normal operation. If rectifier goes back to failure condition it should be removed for repair.

ALARM LED (RED) ON ALL OTHER LED'S OFF

Module alarm:

Loss of input voltage

Internal shutdown: Over voltage protection

High temperature shutdown

Observe the ambient temperature. At temperatures above the specified limit, the rectifier may shut down to avoid internal damage. Verify that both fans are running. If not, remove the rectifier from the system and replace the fan(s) according to the description in chapter Replacement Of Fans. None of above solved problem probably module fault. Call service. Observe the system. If all modules act equal, most likely errors are: Normal operation - current limit To verify that the module is OK: Reduce load and verify that the yellow LED goes off

Fan failure, both fans

Module failure

GREEN LED AND WARNING LED (YELLOW) ON, LED BAR


GRAPH SHOWS MAX. READING

Overload

WARNING LED (YELLOW) ON, LED BAR


GRAPH SHOWS LESS THAN MAX. READING

Fan failure, single fan

Verify that both fans are running. If not, remove the rectifier from the system and replace the fan(s) according to the description in chapter Replacement Of Fans. Observe the ambient temperature. At temperatures above the specified limit, the rectifier may derate to avoid internal damage.

High temperature derating activated

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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6 Interface

Replacement of Fans
The Flatpack DC/DC modules incorporate two fans that are located in the front of the converters. This procedure describes how to replace fans in the event of failure.
Unscrew the screws on the sides, top and back of the converter. Remove the top cover and the front panel Note the orientation of the fan(s), unscrew and remove them Plug in the new fan(s) and fasten them in the same orientation. Fit the plastic front panel into the bottom cover Fit the top cover and ensure that the plastic front fits into all the slots making sure that the front is not mounted up side down. Fasten the chassis screws on the sides, the top and back.

REMOVE THE CONVERTERS


TOP COVER

REPLACE DAMAGED FAN(S)

ASSEMBLE THE FRONT


PANEL AND COVER

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Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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7 Technical Specifications

7. Technical Specifications
Technical Specification Flatpack DC/DC 48/24
INPUT
Input Voltage range Maximum Current Protection 40.0-60 VDC 32 Amps at 40.0 VDC input Soft start Internal fuse Automatic shutdown for input voltages < 40 VDC and > 62 VDC 24-28 VDC 1100 W at 27.5 VDC 40 Amps at 24 VDC 2 Amps 0.5% from 0 to full load 4.0% for 10-90% or 90-10% load variation <100 mV peak to peak, 30 MHz bandwidth Blocking diode Non-destructive short circuit operation and selective high output voltage shutdown (30 V)

OTHER SPECIFICATIONS
Isolation Voltages Converter alarms Input/ Earth: 600 VDC Input/ Output: 1000 VDC Output/ Earth: 600 VDC No output voltage Overvoltage shutdown Dual fan failure High temperature shutdown Short circuit/ fold back activated DC input voltage out of range Single fan failure High temperature/ derating activated Current limit Green LED: ON, no faults Red LED: No output, converter failure Yellow LED bargraph: measuring output current (0-100%) 90% typical -40 to +65C (-40 to +149F) +65 to +75 C (+149 to +167F): Temperature dependent power limiting may occur -40 to +85 C (-40 to +185F) Temperature controlled fans 6.3 Bels 218 x 43 x 240mm (wxhxd) (8.58 x 1.69 x 9.45) < 3kg (< 6.6lbs) IEC 60950-1, UL 60950-1 ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-4 (emission, industry) EN 61000-6-1 (immunity, light industry) ETSI EN 300 019-2 ETSI EN 300 132-1 ETSI EN 300 132-2 ETSI EN 300 753 class 3.1 (acoustic noise)

OUTPUT
Output Voltage Output Power Output Current Current Share Static Voltage Regulation Dynamic Voltage Regulation Ripple and Noise Protection Converter warnings

Visual indications

Efficiency Operating Temp

Storage Temp Cooling Acoustic Noise Dimensions Weight Electrical safety EMC

APPLICABLE STANDARDS

Environment

Specifications are subject to change without notice.

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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7 Technical Specifications

Technical Specification Flatpack DC/DC 24/48


INPUT
Input Voltage range Maximum Current Protection 19.8-32 VDC 73 Amps at 19.8 VDC input Soft start Internal fuse Automatic shutdown for input voltages < 19.5 VDC and > 30 VDC 55 VDC (43-59 VDC adjustable) 1250 W 23 Amps 1 Amp 0.5% from 0 to full load 1.0% for 10-90% or 90-10% load variation <100 mV peak to peak, 30 MHz bandwidth Blocking diode Non-destructive short circuit operation and selective high output voltage shutdown (59.5V)

OTHER SPECIFICATIONS
Isolation Voltages Input/ Earth: 600 VDC Input/ Output: 600 VDC Output/ Earth: 600 VDC Converter No output voltage alarms Overvoltage shutdown Fan failure High temperature shutdown Short circuit/ fold back activated Converter DC input voltage out of range warnings Single fan failure High temperature/ derating activated Current limit Visual Green LED: ON, no faults indications Red LED: No output, converter failure Yellow LED bargraph: measuring output current (0-100%) Efficiency 90% at full load Operating -40 to +65C (-40 to +149F) Temp +65 to +75 C (+149 to +167F): Temperature dependent power limiting may occur Storage Temp -40 to +85 C (-40 to +185F) Cooling Speed controlled fans Acoustic Noise <60dBA Dimensions 218 x 43 x 240mm (wxhxd) (8.58 x 1.69 x 9.45) Weight < 3kg (< 6.6lbs)

OUTPUT
Output Voltage Output Power Output Current Current Share Static Voltage Regulation Dynamic Voltage Regulation Ripple and Noise Protection

APPLICABLE STANDARDS
Electrical safety EN 60950, UL 60950 EMC ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-4 (emission, industry) EN 61000-6-1 (immunity, light industry) Telcordia GR1089 CORE Environment ETSI EN 300 019-2 ETSI EN 300 132-1 ETSI EN 300 132-2 Telcordia GR63 CORE Zone 4 ETSI EN 300 753 class 3.1 (acoustic noise) Specifications are subject to change without notice.

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Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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7 Technical Specifications

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules

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

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 +769 22651108 +44 1442 219355 +971 4 887 1176

Fax +47 32 20 32 10 +1 815 459 9118 +65 6 7753602 +44 1442 245894 +971 4 887 1175
www.eltekenergy.com