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Operation Guide

Flatpack Rectifier Module

FP1500, 24V/48V/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 2005

Certificate no: 900005E Certificate no: 900005Q


Head Office:
Phone: (+47) 32 20 32 00
Eltek Energy
Fax: (+47) 32 20 32 10
P.O. Box 2340
E-Mail: eltek@eltekenergy.com
Strømsø
Internet: http://www.eltekenergy.com
N-3003 DRAMMEN
Norway

351400.013 Issue 7.1, 2005 August

Published 2005-08-09

Mfm

2 Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08


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

Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08 3


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
þ important or critical information.
A note following this symbol clarifies or
ü 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

4 Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08


3 Installation procedures
3.1 Safety precautions

þ 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
þ The equipment represents an energy hazard and failure to observe this
could cause terminal injury and invalidate our warranty
þ 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
þ 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
þ 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

R Do not hold or hand-carry the rectifier by its handles


R Use gentle force, when releasing the handles from their locked position
R Open the handles before inserting the module fully into the power shelf

Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08 5


3.3 Installation of rectifiers
Installation of Flatpack Rectifier Modules

Step Comments

1. SLIDE THE MODULE INTO THE Slide the module 2/3 into the power shelf and open the
POWER SHELF handles
Push the module fully into the power shelf and push
the handles into their slots to lock the rectifier into
2. FASTEN THE MODULE
position. Make sure the module is fully inserted before
locking the handles
3. VERIFY THAT THE RECTIFIER IS ON The green “ON” LED is lit and no alarm is activated

4. MOUNT BLIND PANELS ON EMPTY For safety reasons all vacant rectifier positions must be
RECTIFIER POSITIONS covered by blind panels

3.4 Removal of rectifiers


Removal of Flatpack Rectifier Modules

Step Comments

1. UNLOCK THE LEVERS Release the handles as described


Using both handles pull the rectifier forward to release
2. PULL THE RECTIFIER LOOSE
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
3. SLIDE THE RECTIFIER OUT
removed. If the unit has been in use for some time it
may be hot.

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

6 Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08


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 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

Voltage adjustment
LED bar graph potentiometer

Alarm LED “On” LED

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
The input voltage is either below minimum (85Vac) or
Input voltage out of range
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
Over voltage Shutdown 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 The module has shutdown due to high internal temperature
shutdown
Fan Failure One or both fans has been stopped or failed
Internal malfunction Internal failure
Table 1 Alarm events

Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08 7


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.

P 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.

P 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.

Signal
connector

AC AC PE DC Output DC Output
input input positive (+) negative (-)
(L) (N)

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.

8 Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08


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
All LED's off 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
Power or current which should be slightly below the float voltage. Measure
limit during the current, it should read more than the nominal current
Power LED on, charging
LED Bargraph
shows max. Derating due to To verify temperature de-rating: Determine the maximum
reading high internal rectifier current of the system. Read the measured rectifier
temperature current in the display of the monitoring units. If the value
Or shown by the monitoring unit is less than the maximum
rectifier current, the rectifier(s) have most likely de-rated
Low output the output power due to high temperature.
voltage
De-rating due to Measure the input voltage. Be aware that the output power
low input voltage is derated for low input voltages. See specification for
details.

Loss of input Check all system input fuses or circuit breakers. Measure
voltage the input voltage. If only one module has failed check the
internal fuses in the rectifier.

Over voltage If modules act differently, the most likely error is internal
protection 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.
Alarm LED on
All other LEDs
off High temperature Observe the ambient temperature. At temperatures above
shutdown 70°C (1500W & 700W) and 50°C (1800W), 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.

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

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

Table 2 Error states

Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08 9


6 Specifications
6.1 Input
Flatpack 1500 Flatpack 1800 Flatpack 700
24V 48V 60V 48V 48V
Input voltage,
85-275 Vac*
operating range
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%
Surge protection
Input protection Internal fuses (L & N)
Disconnect above 300Vac

* 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
Flatpack 1500 Flatpack 1800 Flatpack 700
24V 48V 60V 48V 48V
Output voltage 21.5 – 29VDC 44 - 58VDC 55 - 73VDC 44 - 58VDC 44 - 58VDC
preset 26.8VDC 53.5VDC 66.8VDC 53.5VDC 53.5VDC
50A at 31.0A at 25.0A at 37.5A at 15.0A at
Output current
27Vdc max 48Vdc max 60Vdc max 48Vdc max 48Vdc max
Over voltage
30.0Vdc 59.5Vdc 74.5Vdc 59.5Vdc 59.5Vdc
shutdown
85-150VAC 560W 550W 550W 500W
Output
150-185VAC 1250W 1100W 1100W 1200W 600W (85-99VAC)
power
185-310VAC 1350W 1500W 1500W 1800W 700W (99-310VAC)
Hold-up time 20ms at full load
Voltage regulation Static ± 0.5 %
Dynamic response ± 4.0 %

6.3 Other specifications


6.3.1 Efficiency
Flatpack 1500 Flatpack 1800 Flatpack 700
24V 48V 60V 48V 48V
Efficiency >89.1% >90.0% >91.3 >90.0 >90.0
(100% load, 230 Vac input)

10 Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08


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


Flatpack 1500 Flatpack 1800 Flatpack 700
Normal Operation -40°C to +70°C -40°C to +50°C -40°C to +70°C
(-40°F to +158°F) (-40°F to +122°F) (-40°F to +158°F)

Output power derated +70°C to + 95°C +50°C to + 70°C +85°C to + 95°C


(+158°F to +203°F) (+122°F to +158°F) (+185°F to +203°F)

Shut down > 95°C > 70°C > 95°C


(>+203°F) (>+158°F) (>+203°F)

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

Operation Guide Flatpack Rectifier Module, Art. 351400.013, v7.1-2005-08 11


ELTEK Energy
P-O- BOX 2340 StØmsØ
N-3003 DRAMMEN
NORWAY

Phone: +47 32203200


Telefax: +47 32203210
Internet: http://www.eltekenergy.com
e-mail: eltek@eltekenergy.com

Location Company Telephone Fax


Norway Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10
Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118
Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602
China Eltek Energy Ltd. +852 28982689 +852 28983189
Europe Eltek Energy UK Ltd. +44 1442 219355 +44 1442 245894
Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175

www.eltekenergy.com