351400.0

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User’s Guide

Flatpack Rectifier Module FP1500, 24V748V/60V

FP700&1800, 48V

2 User’s Guide Flatpack Rectifier Module, Art. 351400.013, v7.2-2006-06

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

User’s Guide Flatpack Rectifier Module, Art. 351400.013, v7.2-2006-06 3

Table of Contents

1 SCOPE 4

2 MAIN FEATURES 4 2.1 GENERAL 4 2.2 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 RECTIFIER ALARM 7 4.4 OUTPUT VOLTAGE ADJUSTMENT 8

4.4.1 Internal adjustment (stand alone use) 8 4.4.2 Remote control of output voltage 8

4.5 CONNECTIONS 8

5 ERROR STATE TABLE AND FAULT-FINDING 9

6 SPECIFICATIONS 10 6.1 INPUT 10

6.1.1 Start / stop voltages and input voltage range 10 6.1.2 High voltage disconnect 10

6.2 OUTPUT 10 6.3 OTHER SPECIFICATIONS 10

6.3.1 Efficiency 10 6.3.2 Safety 11

6.4 ENVIRONMENT 11 6.4.1 Temperature Range 11 6.4.2 Humidity 11 6.4.3 Acoustic Noise 11

6.5 APPLICABLE STANDARDS 11 6.6 MECHANICAL DIMENSIONS 11

4 User’s 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 provides important or critical information.

A note following this symbol clarifies or emphasises a recommendation.

2 Main features 2.1 General 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.

2.2 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

User’s Guide Flatpack Rectifier Module, Art. 351400.013, v7.2-2006-06 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 Flatpack Rectifier Module incorporates handles that serve two purposes; to lock the module into position, and serve as pull-out handles

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

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

6 User’s Guide Flatpack Rectifier Module, Art. 351400.013, v7.2-2006-06

3.3 Installation of rectifiers Installation of Flatpack 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 Flatpack Rectifier Modules

Step Comments

Unlock the levers Release the handles as described

Pull the rectifier loose Using both handles pull the rectifier forward 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. If the unit has been in use for some time it may be hot.

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

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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

Figure 1 Example of a Flatpack Rectifier Module’s front panel

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

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

Event Description

Input voltage out of range The input voltage is either below minimum (85Vac) or above maximum (310Vac)

Over voltage Shutdown

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

High temperature shutdown

The module has shutdown due to high internal temperature

Fan Failure One or both fans has been stopped or failed Internal malfunction Internal failure

Table 1 Alarm events

LED bar graph

Alarm LED “On” LED

Voltage adjustment potentiometer

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4.4 Output voltage adjustment 4.4.1 Internal adjustment (stand alone use)

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.

4.4.2 Remote control of output voltage 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.

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

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.

DC Output positive (+)

DC Output negative (-)

Signal connector

AC input (L)

AC input (N)

PE

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.

User’s Guide Flatpack Rectifier Module, Art. 351400.013, v7.2-2006-06 9

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

All LED's off

No AC or batteries present

External shutdown

Both input and output are disconnected from power sources

The rectifier system may have been switched OFF via the Monitoring & Control Unit (MCU). Refer to the Flatpack MCU user manual for operation instructions.

Normal operation - Power or current limit during charging

To verify that the module is OK: Check the output voltage which should be slightly below the float voltage. Measure the current, it should read more than the nominal current

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

Derating due to high internal temperature

De-rating due to low input voltage

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.

Loss of input voltage

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.

Over voltage protection

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.

High temperature shutdown

Observe the ambient temperature. At temperatures above shut down temperature levels, see page 11, the rectifier may shut down to avoid internal damage.

Fan failure Verify that both fans are running. If not, replace the rectifier with a new module, and send the malfunctioning module for servicing.

Alarm LED on All other LEDs off

Module failure None of the above solved the problem – probably module fault. Call service.

Power LED on, Alarm LED on

Module error This mode may occur for a short time only during power-up or power-down. Otherwise, call service.

Table 2 Error states

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6 Specifications 6.1 Input

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

6.1.2 High voltage disconnect 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.

6.2 Output

6.3 Other specifications 6.3.1 Efficiency

Flatpack 1500 Flatpack 1800 Flatpack 700 24V 48V 60V 48V 48V Input voltage, operating range

85-275 Vac*

Frequency 45 to 66Hz Maximum Current 8.3 Arms 9.3 Arms 9.2 Arms 11.1 Arms 7.5 Arms Power Factor > 0.99 at 50% load or more Total Harmonic Distortion typical 5%

Input protection Surge protection

Internal fuses (L & N) Disconnect above 300Vac

Flatpack 1500 Flatpack 1800 Flatpack 700 24V 48V 60V 48V 48V Output voltage

preset21.5 – 29VDC

26.8VDC 44 - 58VDC

53.5VDC 55 - 73VDC

66.8VDC 44 - 58VDC

53.5VDC 44 - 58VDC

53.5VDC

Output current 50A at

27Vdc max 31.0A at

48Vdc max 25.0A at

60Vdc max 37.5A at

48Vdc max 15.0A at

48Vdc max Over voltage shutdown

30.0Vdc 59.5Vdc 74.5Vdc 59.5Vdc 59.5Vdc

Output power

85-150VAC

150-185VAC

185-310VAC

560W 1250W 1350W

550W 1100W 1500W

550W 1100W 1500W

500W 1200W 1800W

600W (85-99VAC)

700W (99-310VAC) Hold-up time 20ms at full load Voltage regulation Static ± 0.5 % Dynamic response ± 4.0 %

Flatpack 1500 Flatpack 1800 Flatpack 700 24V 48V 60V 48V 48V Efficiency (100% load, 230 Vac input)

>89.1% >90.0% >91.3 >90.0 >90.0

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6.3.2 Safety

Mobility Fixed, for building in, direct plug-in Protection class 1 (permanent connection to protective earth)

Intended site and usage For use in restricted access locations - service access area. An external primary circuit breaker must be used in the input line.

IEC protection class 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.

Isolation Voltages Input – Output: 3.0kVac Input – ground: 1.5kVac Output – ground: 1.0kVdc

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

Operation (stand alone usage):

6.4.2 Humidity Storage: 0–99 % RH non-condensing (recommended: 10-30 % RH) Operation: 0–95 % RH non-condensing

6.4.3 Acoustic Noise Sound pressure < 55 dBA for stand alone module at 1m distance

6.5 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) Telcordia GR1089 CORE class B

Harmonics EN 61000-3-2 Environment

ETSI EN 300 019-2 ETSI EN 300 132-2 Telcordia GR63 CORE Zone 4

6.6 Mechanical dimensions Dimensions W:214mm D:243mm H:41.5mm

W:.43” D:9.57” H:1.64” Weight 2.8 Kg / 6.17 lbs

Flatpack 1500 Flatpack 1800 Flatpack 700 Normal Operation -40°C to +70°C

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

-40°C to +70°C (-40°F to +158°F)

Output power derated +70°C to + 95°C (+158°F to +203°F)

+50°C to + 70°C (+122°F to +158°F)

+85°C to + 95°C (+185°F to +203°F)

Shut down > 95°C (>+203°F)

> 70°C (>+158°F)

> 95°C (>+203°F)

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