FLATPACK

Rev.5
September 2002

Updated versions may be available

 Flatpack 1500

The rectifier module in the new Eltek Medium Range Systems

Power Density

SMPS 1000 SI SMPS 1000 SI Flatpack 1500

1000W, convection vs. Flatpack 1500 1400W, fan cooled
cooled

Power density
Power density
230 VAC: 0.648 W/cm3
230 VAC: 0.26 W/cm3 10.58 W/inch3
4.23 W/inch3
120 VAC: 0.278 W/cm3
4.53 W/inch3
W x D x H=66.8 x 220 x 264 (mm)
2.63 x 8.66 x 10.39 (inches) W x D x H=214 x 243 x 41.5 (mm)
8.43 x 9.57 x 1.64 (inches)
 Flatpack 1500

Key parameters:
Maximum output power 1400 W
Global input range: 85 – 300 VAC
Automatic disconnect at input voltages > 300 VAC
Wide temperature range: -40°C to +70°C
(-40°F to +158°F)
Compact and flexible (1U high/2 rectifiers in 19” width)
Vertical or Horizontal mounting
Hot swap (output diode)
Fan cooled
Cost efficient
Automatic de-rating of output power at low input
voltage and/or high ambient temperatures
Easy and quick mounting and removal
Flatpack 1500 Input Voltage
vs. Output Power

1600

1400

1200
Output Power (W)

1000 185
800

600
150
400

200
85 312
0
0 50 100 150 200 250 300 350
Input Voltage (VAC)
Power Derate with Respect to
Temperature (230VAC Input)

1600

1400
Maximum Available Power (Watts)

1200

1000

800

600

400

200

0
60 65 70 75 80 85 90 95 100

Ambient Temperature (degC)

Comment: Measured on a stand-alone rectifier module

 Flatpack 1500 (48V)

MODULE DATA
Input voltage: 0-85 VAC no output
85-150 VAC 500 W at 48 VDC
150-185 VAC 1100 W at 48 VDC
185-300 VAC 1400 W at 48-59 VDC
> 275 VAC - reduced power factor
> 300 VAC - disconnection from mains
and automatic reconnect
Power Factor: > 0.99
Efficiency: > 90%
Output power: 1400 W from 48V to 59V (230 VAC input)
(de-rated in lower input range)
Output current: 29 Amps at 48V
Ripple/noise: < 100mVp-p
< 0.96mV psophometric noise
Hold-up time: > 10ms
Ambient temp: -40°C to 70°C (-40°F to +158°F)
(Power limiting may occur > 40°C (104°F))
Dimensions: 214 x 243 x 41.5mm (8.8” x 9.8” x 1.64”) (WxDxH)
Approvals: IEC/EN 60950, UL 1950
IEC/EN 60215, BS3192
FCC 68, GR-1089-CORE
Flatpack 1500 (48V)

LED bargraph
10 green LED’s indicate output
current from 0 Amps to 29 Amps 2 fans

Alarm LED Power LED

Internal Rectifier On
rectifier failure No fault
Flatpack 2U Power System
19” horizontal mounting

1U high building blocks: 44.45mm (1.75”)

Allows optimal utilisation of rack height
The 1U Power Shelf accommodates 2 Flatpack rectifiers
The 1U DC-distribution and monitoring unit is mounted on top
Flatpack 1U System Components
for 19” rack mounting

”Flatpack MCU” Monitoring ”Flatpack DCD 125A”

& Control Unit (1U)
125A DC Distribution (1U)

2 ”Flatpack 1500” rectifiers in

a 1U high power shelf
 19” horizontal mounting

The capacity is increased by adding more power shelves

 19” horizontal mounting

Two rectifiers mounted in a 1U Power Shelf

 19” horizontal mounting

1U Power Shelf rear view

RJ45 connectors
Mains for internal
input system
terminals communication

DC
output
terminals
 19” horizontal mounting
with 3U distribution

The distribution on top will vary in size, depending on

maximum current and the number of circuit breakers/fuses
required
19” horizontal mounting
with 3U distribution

Mains input Load MCB’s Battery MCB’s

Sample Flatpack
Distribution Option

Common Alarm
positive outputs
bar max 2.5 mm2

DC output on
top of MCB’s.
Max 25 mm2
19” horizontal mounting
with 3U distribution

Mains input Load MCB’s Battery Fuses

19” horizontal mounting
with 3U distribution

Front
Side

Top
Rear
19” horizontal mounting
with 3U distribution

Mains input Load MCB’s Load Fuses Battery Fuses

Sample Flatpack in Cabinet
Application
Intermediate PRS Solution

A comprehensive amount of PRS 700 system solutions have been

made to fulfill many different customer and regional requirements.
Compared with today's system solutions the Flatpack 1500 has the
following improvements:

Improved operating temperature range (some old system

designs may experience power de-ration at temperatures < 40°C
(104°F))

Improved power density (convection cooled rectifiers require a

lot of open space above and underneath to achieve a good airflow)

Wider input voltage range (De-rated output power at input

voltages below 205 VAC and no high voltage disconnect)

New important features are added when replacing the SMPS 1000
with the Flatpack 1500 rectifier. A large range of existing system
designs with various distribution solutions can be used.
Intermediate PRS Solution

Implement Flatpack 1500 rectifiers into existing Power Rack Systems

7 kW 16.8 kW
AL 175 NT

Flatpack 1500
Intermediate PRS Solution

Highly competitive systems can be made by replacing SMPS 1000

with Flatpack 1500 in standard PRS 700
Advantages
Current system solutions are made highly competitive
Short development time and short time to market
More than twice the power density of a standard PRS 700
Utilizes existing distribution, monitoring and cabinet solutions
Wider operating temperature range
Wider input voltage range with high voltage disconnect

Functionality which is not included

Digital inputs for monitoring of external equipment
Individual control of two contactors
Single/several rectifier alarms
Future Flatpack Systems

New cabinet designs based on the Flatpack 1500 rectifier, various rack
mountable distribution units and the Flatpack MCU will be made. The
main improvements will be:
Increased flexibility (the systems can be designed with a
building block approach)

Improved monitoring & control features using the Flatpack MCU

Reduced cost as more parts of the system can be manufactured

in high volumes

Increased power density (the system designs will be even more

compact, since the height of the monitoring unit including
interface PCB is only 1U as opposed to today's 5U)

The rectifiers can be mounted vertically to achieve even higher

power density in ETSI cabinets (15.4 kW in only 5U height)
Future Flatpack Systems

A common MPSU solution

Future Flatpack Systems
Future Flatpack Systems

Outdoor Cabinets
Flatpack Solutions

19” horizontal mounting Power Tower

Different distribution units

for different needs

1U Power Shelf
Highlights Flatpack MCU

Front panel LCD and keypad for on-site service

RS-232 for PC connection or remote monitoring & control via modem / SNMP
Up to 11 configurable alarm relay outputs for traditional remote monitoring
4 configurable digital inputs for monitoring of other equipment on site
Battery monitoring and testing (manual & automatic)
Temperature Compensated Charging for increased battery lifetime
Hot Plug-In
Password protected operator access levels
Alarm/event log with time and date
Windows based software for easy access and configuration (WinPower Silver)
Remote Monitoring & Control

Options for remote monitoring & control

Potential free relays (6 or 11 form C contacts)
Modem with call-back functionality
SNMP
direct connection to TCP/IP network
connection using micro-wave

WinPower Silver through TCP/IP

Web browser (future option)