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Users Guide

Flatpack Rectifier Module


FP1500, 24V748V/60V FP700&1800, 48V

351400.013

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 2006

Certificate no: 900005E

Certificate no: 900005Q

351400.013 Issue 7.2, 2006 June Published 2006-09-27 Mfm

Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

Table of Contents
1 2 SCOPE MAIN FEATURES 2.1 GENERAL 2.2 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 RECTIFIER ALARM 4.4 OUTPUT VOLTAGE ADJUSTMENT 4.4.1 Internal adjustment (stand alone use) 4.4.2 Remote control of output voltage 4.5 CONNECTIONS ERROR STATE TABLE AND FAULT-FINDING SPECIFICATIONS 6.1 INPUT 6.1.1 Start / stop voltages and input voltage range 6.1.2 High voltage disconnect 6.2 OUTPUT 6.3 OTHER SPECIFICATIONS 6.3.1 Efficiency 6.3.2 Safety 6.4 ENVIRONMENT 6.4.1 Temperature Range 6.4.2 Humidity 6.4.3 Acoustic Noise 6.5 APPLICABLE STANDARDS 6.6 MECHANICAL DIMENSIONS 4 4 4 4 5 5 5 6 6 7 7 7 7 8 8 8 8 9 10 10 10 10 10 10 10 11 11 11 11 11 11 11

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Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

1 Scope
This document describes the installation procedures and operating instructions of the Flatpack Rectifier Module, as well as technical specifications such as input voltage range, output power and operating temperature range. Before you start using a Flatpack 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 Flatpack Rectifier Module is a switch mode power supply designed for battery charging and supplying high quality DC power to telecom equipment and similar applications. A wide range of features is integrated, as mentioned below.

2 Main features 2.1 General

2.2 Features

Front LED indicators, load current LED bargraph and output voltage adjustment point for stand-alone control and monitoring Active current sharing between modules independent of any monitoring unit Wide input voltage range, ranging from 85 VAC to 300 VAC Automatic shutdown for input voltages above 300VAC Surges Protection Power factor close to unity and low input current THD High efficiency Temperature monitoring and over heat protection Short circuit protection Constant power charging during battery recharge True hot plug-in

Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

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

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

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

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 Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

3.3 Installation of rectifiers


Installation of Flatpack 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 Flatpack Rectifier Modules Step Unlock the levers Pull the rectifier loose Comments Release the handles as described Using both handles pull the rectifier forward 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. If the unit has been in use for some time it 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 Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

4 Operating instructions 4.1 General

The Flatpack Rectifier Module is designed for both stand-alone and parallel operation in a system. When used as a stand-alone unit, the output voltage can be adjusted via a front accessible potentiometer. The front panel LEDs provide information regarding the rectifier status and an LED bar-graph shows how much current the unit is delivering, 0-100%. A potential free alarm relay (form-C contacts) provides a signal if there is any internal failure. The alarm relay operates in failsafe-mode, i.e. the relay coil is energized when there is no alarm.

4.2 Front panel interface


LED bar graph Voltage adjustment potentiometer

Alarm LED Figure 1

On LED Example of a Flatpack Rectifier Modules front panel

4.3 Rectifier Alarm


Event
Input voltage out of range

The Flatpack Rectifier Module has the following LED indications: On (green) indicates that the power supply is ON Alarm (red) indicates an alarm situation LED bargraph (10 yellow LEDs) shows the output current

The following events will trig the Alarm LED and the alarm relay:

Description
The input voltage is either below minimum (85Vac) or above maximum (310Vac) The module has shut down due to high output voltage. The rectifier will automatically shut itself down if it produces an output voltage above the OVS limit. Unplug the rectifier from the system, let it discharge for 1 minute and insert the module in the system again. If the alarm is still activated, the rectifier has probably an internal fault and needs repairing The module has shutdown due to high internal temperature One or both fans has been stopped or failed Internal failure Table 1 Alarm events

Over voltage Shutdown

High temperature shutdown Fan Failure Internal malfunction

Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

4.4 Output voltage adjustment


The Flatpack Rectifier Module has a front accessible potentiometer that can be used to adjust the output voltage of the rectifier. If more than one rectifier is to be installed in the system, it is advisable to install and adjust one rectifier at a time. On completion, all the rectifiers may then be installed. The rectifiers will only share the current equally if the output voltage is adjusted equally. This adjustment is set at the factory during testing. It is advisable to avoid making un-necessary re-adjustments, due account should be taken of the effect this procedure may have on the customers equipment. This adjustment shall not be done on rectifiers installed in a system with a Flatpack MCU. Set the output voltage from the MCU`s front panel if installed.

4.4.1 Internal adjustment (stand alone use)

When used in a Flatpack power system containing a Flatpack MCU, the output voltage is controlled by the MCU via a 0-5V control signal.

4.4.2 Remote control of output voltage

4.5 Connections

The Flatpack rectifier includes an AC input connector, DC output connections and a signal interface connector for monitoring and control signals.

Signal connector

AC input (L)

AC input (N)

PE

DC Output positive (+)

DC Output negative (-)

Figure 2 Rear connections The signal connector is for internal use only, and contains signals such as current share bus, output voltage regulation bus, alarm relay outputs and others. For details about the signals please contact your dealer or Eltek representative.

Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

5 Error state table and fault-finding


A summary of operating and failure modes of the module is given in table 2 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


No AC or batteries Both input and output are disconnected from power sources present The rectifier system may have been switched OFF via the External shutdown Monitoring & Control Unit (MCU). Refer to the Flatpack MCU user manual for operation instructions. Normal operation - To verify that the module is OK: Check the output voltage which should be slightly below the float voltage. Measure Power or current the current, it should read more than the nominal current limit during charging Derating 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. Measure the input voltage. Be aware that the output power is derated for low input voltages. See specification for details. Check all system input fuses or circuit breakers. Measure the input voltage. If only one module has failed check the internal fuses in the rectifier. If modules act differently, the most likely error is internal over voltage protection. Remove the rectifier from the system and let it rest for 1 minute, and then reconnect it. If the green LED lights up and the alarm LED is OFF, the rectifier has assumed normal operation. If the module fails again it should be removed for repair. Observe the ambient temperature. At temperatures above shut down temperature levels, see page 11, the rectifier may shut down to avoid internal damage. Verify that both fans are running. If not, replace the rectifier with a new module, and send the malfunctioning module for servicing. None of the above solved the problem probably module fault. Call service. This mode may occur for a short time only during power-up or power-down. Otherwise, call service.

All LED's off

Power LED on, LED Bargraph shows max. reading Or Low output voltage

De-rating due to low input voltage Loss of input voltage Over voltage protection

Alarm LED on All other LEDs off

High temperature shutdown Fan failure

Module failure

Power LED on, Alarm LED on

Module error

Table 2 Error states

Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

6 Specifications 6.1 Input


Flatpack 1500 24V 48V 60V
Input voltage, operating range Frequency Maximum Current Power Factor Total Harmonic Distortion Input protection

Flatpack 1800 48V


85-275 Vac*

Flatpack 700 48V

8.3 Arms

9.3 Arms

45 to 66Hz 9.2 Arms 11.1 Arms > 0.99 at 50% load or more typical 5% Surge protection Internal fuses (L & N) Disconnect above 300Vac

7.5 Arms

* The module will disconnect itself from the mains for voltages above 300Vac. For voltages between 275 and 300Vac, the module will operate with reduced power factor.

6.1.1 Start / stop voltages and input voltage range


Condition Low Mains Shutdown 150 VAC De-rate Point 185 VAC De-rate Point 300 VAC Shut down Hysteresis Range 75 VAC 90 VAC 145 VAC 150 VAC 180 VAC 185 VAC 300 5 VAC - latching

High voltage disconnect occur at 300 VAC 5 VAC. The rectifier will disconnect itself from the mains supply and then automatically restart. The module will run in hick-up mode until the mains voltage is within the operating range. NB! The module may be damaged for input voltages above 350VAC.

6.1.2 High voltage disconnect

6.2 Output

Flatpack 1500 24V 48V


Output voltage 21.5 29VDC preset 26.8VDC 50A at Output current 27Vdc max Over voltage 30.0Vdc shutdown 85-150VAC 560W Output 150-185VAC 1250W power 185-310VAC 1350W Hold-up time Voltage regulation Dynamic response 44 - 58VDC 53.5VDC 31.0A at 48Vdc max 59.5Vdc 550W 1100W 1500W

60V
55 - 73VDC 66.8VDC 25.0A at 60Vdc max 74.5Vdc

Flatpack 1800 48V


44 - 58VDC 53.5VDC 37.5A at 48Vdc max 59.5Vdc

Flatpack 700 48V


44 - 58VDC 53.5VDC 15.0A at 48Vdc max 59.5Vdc 600W (85-99VAC) 700W (99-310VAC)

550W 500W 1100W 1200W 1500W 1800W 20ms at full load Static 0.5 % 4.0 %

6.3 Other specifications


6.3.1 Efficiency Flatpack 1500 24V 48V 60V
Efficiency (100% load, 230 Vac input) >89.1% >90.0% >91.3

Flatpack 1800 Flatpack 700 48V 48V


>90.0 >90.0

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Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

6.3.2 Safety
Mobility Protection class Intended site and usage IEC protection class Isolation Voltages Fixed, for building in, direct plug-in 1 (permanent connection to protective earth) For use in restricted access locations - service access area. An external primary circuit breaker must be used in the input line. IP20. Current from AC inputs to safety earth: < 3.5 mA at 50 Hz. Discharge time of module connector pins to safe level: < 1 second. Input Output: 3.0kVac Input ground: 1.5kVac Output ground: 1.0kVdc

6.4 Environment
6.4.1 Temperature Range
Storage: 40C to +85C (-40F to +185F) Recommended long-term storage temperature: +10C to +30C (+50F to +86F) Operation (stand alone usage):

Flatpack 1500
Normal Operation Output power derated Shut down -40C to +70C
(-40F to +158F)

Flatpack 1800 Flatpack 700


-40C to +50C
(-40F to +122F) (+122F to +158F)

-40C to +70C
(-40F to +158F) (+185F to +203F)

+70C to + 95C
(+158F to +203F)

+50C to + 70C +85C to + 95C > 70C


(>+158F)

> 95C
(>+203F)

> 95C
(>+203F)

6.4.2 Humidity

Storage: 099 % RH non-condensing (recommended: 10-30 % RH) Operation: 095 % RH non-condensing Sound pressure < 55 dBA for stand alone module at 1m distance

6.4.3 Acoustic Noise

6.5 Applicable standards


Electrical safety EMC EN 60950 UL 60950 ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) Telcordia GR1089 CORE class B EN 61000-3-2 ETSI EN 300 019-2 ETSI EN 300 132-2 Telcordia GR63 CORE Zone 4

Harmonics Environment

6.6 Mechanical dimensions


Dimensions Weight W:214mm D:243mm H:41.5mm W:.43 D:9.57 H:1.64 2.8 Kg / 6.17 lbs

Users Guide Flatpack Rectifier Module,

Art. 351400.013, v7.2-2006-06

11

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e-mail:

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