Operation Guide

Flatpack 2500, 48V

351410.013

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Energy AS. 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 AS. Copyright : Eltek Energy AS, Norway 2005

Certificate no: 900005E

Certificate no: 900005Q

351410.013
Published 2005-11-16 Mfm

Issue 2, 2005 Nov

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

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 (AC) 6.1.1 Start / stop voltages and input voltage range 6.1.2 High voltage disconnect 6.2 OUTPUT (DC) 6.3 MECHANICAL DIMENSIONS 6.4 OTHER SPECIFICATIONS 6.4.1 Efficiency 6.4.2 Safety 6.4.3 Environment 6.4.4 Applicable standards 4 4 4 4 5 5 5 6 6 7 7 7 7 8 8 8 8 9 10 10 10 10 10 11 11 11 11 11 11

5 6

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

Scope

This document describes the installation procedures and operating instructions of the Flatpack 2500 rectifier module, as well as technical specifications such as input voltage range, output power and operating temperature range. Before you start using a Flatpack 2500, 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.

Main features

2.1 General
The Flatpack 2500 is a 48V switch mode power supply designed for battery charging and supplying high quality DC power to telecom equipment and similar applications. The Flatpack 2500 rectifier is intended to be used as a module in larger power supply systems, as well as a stand-alone rectifier. 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

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

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

Release hole The Flatpack 2500 rectifier incorporates handles that serve two purposes: to lock the module into position and to serve as pull-out handles.

Handle in locked position

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 Handle in released position

5 Do not hold or hand-carry the rectifier by its handles 5 Use gentle force, when releasing the handles from their locked position 5 Open the handles before inserting the module fully into the power shelf

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

3.3 Installation of rectifiers

Installation of Flatpack 2500 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

FASTEN THE MODULE

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 2500 modules Step UNLOCK THE LEVERS PULL THE RECTIFIER LOOSE SLIDE THE RECTIFIER OUT 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.

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

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

Operating instructions

4.1 General
The Flatpack 2500 rectifier 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 bargraph 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

On LED (green) Alarm LED (red) LED bar graph

Fan

Voltage adjustment potentiometer Figure 1 Flatpack 2500 front panel

The Flatpack 2500 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
INPUT VOLTAGE OUT OF
RANGE

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 all three fans has been stopped or failed Internal failure Table 1 Alarm events

OVER VOLTAGE SHUTDOWN

HIGH TEMPERATURE
SHUTDOWN

FAN FAILURE INTERNAL MALFUNCTION

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

4.4 Output voltage adjustment

4.4.1 Internal adjustment (stand alone use) The Flatpack 2500 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.

4.4.2 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.

AC input (L) AC input (N) PE

DC output (+) DC output (-) Figure 2 Rear connections

Signal connector

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.

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

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 70 degrees, 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 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, Module error ALARM LED ON

Table 2 Error states

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

Specifications

6.1 Input (AC) Type

Input voltage:

Electrical Data
85-275 VAC operating range (higher than 250VAC only for a short time, not continuously) Reduced PF between 275-310 VAC Frequency: Maximum Current: Power Factor: 45 to 66Hz Max. 16 Arms > 0.99 5%, typical Surge protection (varistors) Internal fuses (L & N) Protective shutdown > 310 VAC at 174 VAC, 2500 W output at 50% load or more

Total Harmonic Distortion: Input protection:

6.1.1 Start / stop voltages and input voltage range Condition Low Mains Shutdown 150 VAC De-rate Point 174 VAC De-rate Point 300 VAC Shut down 6.1.2 High voltage disconnect High voltage disconnect occur at 310 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. Hysteresis Range 75 VAC 80 VAC 145 VAC 150 VAC 170 VAC 174 VAC 310 5 VAC - latching

6.2 Output (DC) Type

Output voltage: Output current: Output Protection: Output power:

Electrical Data
40 59.5 VDC Max. 52 A 59.5 VDC 800 W 2000 W 2500 W Hold-up time >10ms at full load 0.5% 4.0 % from 0 to full load 53.5 VDC preset at 48VDC (230 V) shutdown level (OVS) at 85-150 VAC at 150-174 VAC at 174-310 VAC

Blocking diode, short circuit proof and high temperature protection

Static Voltage regulation Dynamic response

10

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

6.3 Mechanical dimensions

Dimensions: W:214 mm D:343mm H:43 mm Weight: 3.82 Kg W8.43 D:13.5 H:1.69 8.42 lbs

6.4 Other specifications

6.4.1 Efficiency

Type
Efficiency: 6.4.2 Safety

Electrical Data
> 91% at 230 VAC and full load

Type
Mobility: Protection class: Intended site and usage:

Electrical Data
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 < 3.5 mA at 50 Hz. < 1 second (connector pins to safe level) 3.0 KVAC input and output 1.5 KVAC input earth 1.0 KVDC input earth

IEC protection class: Current from AC inputs to safety earth: Discharge time: Isolation Voltages:

6.4.3 Environment

Type
Storage Temperature: Storage Humidity: Operating Temperature: (stand alone) Operating Humidity: Acoustic Noice:

Data
-40 to +85C (-40 to +185F) +10 to +30C (+50 to +86F) 0% to 99% RH non-condensing 10-30 % RH -25 to +55C (-13 to +131F) +55 to + 70C (+131 to +158F) > 70C (>158F) 5% to 95% RH non-condensing < 55 dBA (sound pressure)
For stand alone module at 1m distance Output power derated to avoid damage Shut down to avoid possible damage Recommended Recommended long-term storage temp.

6.4.4 Applicable standards Electrical safety: EMC: Harmonics: Environment: EN 60950 ETSI EN 300 386 V.1.3.1 EN 61000-3-2 ETSI EN 300 019-2 ETSI EN 300 132-2 (telecommunication network)

Operation Guide Flatpack 2500 Rectifier Module,

351410.013, v2-2005-11

11

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

e-mail:

Location Norway Americas Asia/Pacific China Europe Middle East

Company Eltek Energy AS Eltek Energy, LLC Eltek Energy Pte Ltd. Eltek Energy Tech. Ltd. Eltek Energy UK Ltd. Eltek Middle East

Telephone +47 32 20 32 00 +1 815 459 9100 +65 6 7732326 + 86 769 2651108 +44 1442 219355 +971 4 887 1176

Fax +47 32 20 32 10 +1 815 459 9118 +65 6 7753602 + 86 769 2296797 +44 1442 245894 +971 4 887 1175

www.eltekenergy.com