Eltek Flatpack2 Manuale utente

350002.013

User's Guide

Rectifiers and Converters

Flatpack2 DC Power Supply Systems

Flatpack2 Modules

1 Introduction

2User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08

DC Power Supply Systems

SAFETY and ENVIRONMENTAL PRECAUTIONS

The product warranty becomes invalid if the following safety precautions are not followed during handling,

installation, commissioning and general use/operation of Eltek DC power supply system.

General Precautions

CAUTION: Even though the product incorporates protection circuitry and other safeguards, it can be damaged, perform

poorly or have a reduced lifetime if it is exposed to incorrect treatment during transport, installation or service.

Always handle the equipment using proper lifting techniques, do not roll, climb or drill hole in the cabinets or enclosures.

WARNING: Opening the equipment may cause terminal injury —even if the mains AC supply is disconnected.

Hazardous voltages may be present inside, as large capacitors may still be charged.

Device

Hazard

Electric

Shock

356800.183, 3v3

Environmental Precautions

CAUTION: To avoid damage the equipment, keep objects clear of system ventilation inlets, outlets and system

fans, if any, ensuring the airflow through the units is not obstructed, and that the fans rotate freely. Use caution with

rectifiers, as they can reach extreme temperatures under load and normal operation.

WARNING: The installer/user is responsible for ensuring that the DC power system is not damaged by current

surges, over-voltages, etc. caused by external transients, lightning, electrostatic discharge, etc. To avoid

damage and obtain the expected system reliability, it is mandatory to always install SPDs in Eltek’s power

supply systems. Follow the instructions given in “Guidelines for Lightning and Surge Protection”, doc. 2024623.

WARNING: The electronics in the power supply system are designed for indoor, clean environment. When

installed in outdoor enclosures, it is important to keep the door closed during operation, and replace the filters

on a regular basis. Indoor installations in dusty or humid areas require appropriate air filtering of the room, or

filtering of the air entering the DC power system. Follow the instructions given in “Generic Guidelines

Environmental Protection.”, doc. 2038879.

Ventilated

Hot Surface

Humidity & Dust

Protection

Current Surge

Protection

CAUTION: This product is tested and verified according to international safety, environmental and EMC standards. Any

non-Eltek equipment installed into this product after delivery might influence the performance and could infringe the

original approvals. The installer is responsible for ensuring that the environmental properties of this product/ system

do not deteriorate during installation, and that it is performed in accordance with applying regulations.

Installations in USA and Canada must comply with NEC/CEC requirements.

Precautions during Installation

CAUTION: Read the user documentation carefully before installing and using the equipment, as installation and

operation is to be performed as described in it. Always tighten screws and bolts with the torque values recommended in

the documentation. For safety reasons, the commissioning and configuration of the equipment is only to be

performed by Eltek’s personnel or by authorized and qualified persons.

CAUTION: Before you start the electrical installation, you must always disconnect all external AC supply fuses, as well as

internal battery and load fuses/ breakers, if any.

WARNING: For safety reasons (high leakage current / high touch current) you must always connect the AC

earth wire (PE) to the terminals, before you connect the AC input cable(s).

The batteries, if any, represent a major energy hazard. To avoid short-circuit of battery poles, you must always

remove metallic objects —uninsulated tools, rings, watches, etc. —from the vicinity of the batteries.

WARNING: 60V and higher DC power systems are only to be installed in Restricted Access Locations (RAL).

Access must be limited by use of tool, i.e. lock and key.

Device

Hazard

Qualified

Personnel

EMC, NEC/CEC

Regard

Electric

Shock

Electric

Shock

1 Introduction

User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08 3

Safety Precautions

 The equipment described in this manual must only be operated by Eltek

personnel or by persons who have attended a suitable Eltek 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 power system. As the modules

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

350002.013 Issue 8.1, 2013 August

Published 2013-08-26

Mafe

1 Introduction

4User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08

Table of Contents

1. Introduction 6

About this Guide .............................................................................................................6

System Diagrams Flatpack2 DC Power Systems ......................................................6

Flatpack2 PS System ~ Telecom ..............................................................................6

Flatpack2 PS System ~ Hybrid Solar ........................................................................7

Flatpack2 PS System ~ Industrial..............................................................................8

2. Flatpack2 Rectifier & Converter Modules 9

Key Features...................................................................................................................9

Typical Applications ........................................................................................................9

Module Options.............................................................................................................10

Heat Management ~ FB or BF Air Flow..................................................................................10

Rectifiers —Output Voltage Lower than 60VDC....................................................................11

Flatpack2 Rectifier 24V, 1800W HE........................................................................11

Flatpack2 Rectifier 24V, 2000W..............................................................................11

Flatpack2 Rectifier 24V, 2000W WOR....................................................................11

Flatpack2 Rectifier 48V, 1800W..............................................................................11

Flatpack2 Rectifier 48V, 2000W..............................................................................11

Flatpack2 Rectifier 48V, 2000W HE........................................................................11

Flatpack2 Rectifier 48V, 3000W..............................................................................12

Flatpack2 Rectifier 48V, 3000W HE........................................................................12

Flatpack2 Rectifier 48-60V, 2000W HE...................................................................12

Flatpack2 Rectifier 48V, 2000W BF ........................................................................13

Flatpack2 Rectifier 48V, 2000W HE, BF .................................................................13

Rectifiers —Output Voltage Higher than 60VDC...................................................................14

Flatpack2 Rectifier 110VDC, 2000W HE WOR - (Industrial)...................................14

Flatpack2 Rectifier 110-125VDC, 10A HE - (Industrial)..........................................14

Flatpack2 Rectifier 110-120VDC, 20A HE - (Industrial)..........................................14

Flatpack2 Rectifier 220VDC, 2000W HE WOR - (Industrial)...................................15

Flatpack2 Rectifier 220VDC, 5A HE - (Industrial) ...................................................15

Flatpack2 Rectifier 220VDC, 10A HE - (Industrial) .................................................15

Flatpack2 Rectifier 380VDC, 2500W HE - (Data Centres)......................................16

DC/DC Converters..................................................................................................................16

Flatpack2 DC/DC Converter 1350W, 18-75VDC, 24VDC.......................................16

Flatpack2 DC/DC Converter 1350W, 18-75VDC, 48VDC.......................................16

DC/DC Solar Chargers............................................................................................................17

Flatpack2 Solar Charger 24V, 1500W HE –(Solar)................................................17

Flatpack2 Solar Charger 48V, 1500W HE –(Solar)................................................17

3. Installation of Flatpack2 Modules 18

Safety Precautions........................................................................................................18

Mounting and Removing Modules .....................................................................18

Removing Blind Panels.................................................................................................18

Keying Scheme ~ Modules and Power Shelves ...........................................................19

Connections.........................................................................................................20

CAN Bus Addressing (plug-and-play) ...............................................................20

Correct Rectifier Position in Power Shelves ...........................................................................20

Firmware Upgrade of the Rectifier Modules ...........................................................................21

4. Operation 22

Front Panel Interface...........................................................................................22

LED Indicators .....................................................................................................22

5. Technical Specifications 23

Specifications Flatpack2 Rectifier 24V, 1800W HE ......................................................23

Specifications Flatpack2 Rectifier 24V, 2000W ............................................................24

1 Introduction

User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08 5

Specifications Flatpack2 Rectifier 24V, 2000W WOR...................................................25

Specifications Flatpack2 Rectifier 48V, 1800W ............................................................26

Specifications Flatpack2 Rectifier 48V, 2000W ............................................................27

Specifications Flatpack2 Rectifier 48V, 2000W HE ......................................................28

Specifications Flatpack2 Rectifier 48V, 3000W ............................................................29

Specifications Flatpack2 Rectifier 48V, 3000W HE ......................................................30

Specifications Flatpack2 Rectifier 48-60V, 2000W HE.................................................31

Specifications Flatpack2 Rectifier 48V, 2000W HE, BF................................................32

Specifications Flatpack2 Rectifier 110VDC, 2000W HE WOR - (Industrial).................33

Specifications Flatpack2 Rectifier 220VDC, 2000W HE WOR - (Industrial).................34

Specifications Flatpack2 Rectifier 380VDC, 2500W HE - (Data Centres) ....................35

Specifications Flatpack2 DC/DC Converter 1350W, 18-75VDC, 24VDC and 48VDC..36

Specifications Flatpack2 Solar Charger 24V, 1500W HE –(Solar) ..............................37

Specifications Flatpack2 Solar Charger 48V, 1500W HE –(Solar) ..............................38

1 Introduction

6User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08

1.Introduction

The Flatpack2 rectifier module is a powerful and cost-effective power supply used in

Eltek’s Flatpack2 DC power systems.

About this Guide

This booklet provides users of Flatpack2 DC power systems with the required information

to install and operate the Flatpack2 rectifier modules. The booklet also presents the

modules’technical specifications, such as input voltage range, output power, operating

temperature range, etc.

Read also the generic and site specific documentation that was delivered with your

Flatpack2 DC power system.

For detailed functionality description, browse and search through WebPower or

PowerSuite Online Help.

System Diagrams Flatpack2 DC Power Systems

The Flatpack2 modules are the building blocks of Flatpack2 PS systems, used for DC

power supply of telecom and industrial equipment, in grid-fed sites or hybrid solar sites.

Flatpack2 PS System ~ Telecom

The example in Figure 1 represents a typical Flatpack2 PS system for DC power supply of

telecom equipment. The system is fed from an external AC mains supply, and consists of

rectifiers in power shelves, a controller and DC distribution unit. Battery banks, LVD

contactors, etc. are typically also a part of the system. The system controller monitors

the whole system, and serves as the local user interface. You can configure the system

from a standard web browser, or installing the PowerSuite application in a computer.

Figure 1 Typical Flatpack2 PS system for DC power supply of telecom equipment

Flatpack2

Cabinetized

Battery string #1

AC mains

supply

selector

Symmetry

Alarm &

Temp. Sensor

LVLD

LVBD

Fuse Alarm

Telecom

equipment

Alarm Outputs NC-C-NO

Digital Inputs

Battery

Fuses

Load Fuses

& MCBs

Smartpack

controller

Flatpack2

rectifiers

PowerSuite

Application

CAN Bus

USB cable

distribution

Remote

Monitoring

AC Mains Grid

(230VAC or 400VAC

85-300VDC)

AC Supply

(Single- or 3-phase

or DC Input)

DC Supply

(24V, 48V or 60V)

1 Introduction

User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08 7

Flatpack2 PS System ~ Hybrid Solar

The example in Figure 2 represents a typical hybrid, solar Flatpack2 PS system for DC

power supply of telecom and industrial equipment.

The system is fed from strings of solar panels (DC feed), and uses a diesel generator as

AC feed backup at night and during cloudy days, thus ensuring extra battery charging.

Extra AC feed backup can also be supplied by wind turbines or from the Mains grid.

The hybrid, solar system consists of paralleled solar chargers and rectifiers in power

shelves, Smartpack2-based system controllers and DC distribution unit. Battery banks,

LVD contactors, etc. are typically also a part of the system.

The Smartpack2 Master controller serves as the local user interface, while the

Smartpack2 Basic controller monitors the system’s internal wiring. The I/O Monitor2 CAN

node provides the system with input monitoring and output controlling signals.

You can configure the system from a standard web browser, via WebPower, or installing

the PowerSuite application in a computer.

Figure 2 Typical hybrid, solar Flatpack2 PS system for DC power supply of telecom or

industrial equipment

Battery string #1

AC mains

supply

selector

Temp.

Sensors

LVLD

LVBD

Fuse Alarm

Battery

Fuses

Load Fuses

& MCBs

Flatpack2 HE

Rectifiers

CAN Bus

Distribution

DC Supply

(48V)

Flatpack2

Hybrid Solar

System

Ethernet

cable

Internet

Telecom and

Industrial

equipment

Smartpack2

Master Controller

Smartpack2

Basic Controller

Alarm Outputs NC-C-NO

Config. Inputs

WebPower

(web-based

user interface)

I/O Monitor2

CAN node

Flatpack2 HE

Solar Chargers

Wind Turbine

AC Mains Grid

(230VAC or 400VAC)

AC Generator

Solar Panels

AC Supply

(Single- or three-

phase)

DC Supply

(170-230VDC)

1 Introduction

8User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08

Flatpack2 PS System ~ Industrial

The example in Figure 3 represents a typical Flatpack2 PS system for DC power supply of

industrial equipment, in all areas of the industry, power generation and distribution.

The system is fed from an external AC mains supply, and consists of rectifiers in power

shelves, a system controller and DC distribution unit. Battery banks, LVD contactors, etc.

are typically also a part of the system.

The system controller monitors the whole system, and serves as the local user interface.

You can configure the system from computer, installing the MMT application.

Figure 3 Typical Flatpack2 PS system for DC power supply of industrial equipment

Flatpack2

Cabinetized

Battery string #1

AC mains

supply

selector

Symmetry

Alarm &

Temp. Sensor

LVLD

LVBD

Fuse Alarm

DC Load

Industrial

Equipment

Alarm Outputs NC-C-NO

Digital Inputs

Battery

Fuses

Load Fuses

& MCBs

UPC4

controller

MMT

Application

CAN Bus

USB cable

distribution

Remote

Monitoring

Flatpack2 HE

rectifiers

AC Supply

(Single- or 3-phase

or DC Input)

DC Supply

(24V, 48V, 60V,

110V, 125V, 220V)

AC Mains Grid

(230VAC or 400VAC

85-300VDC)

2 Flatpack2 Rectifier & Converter Modules

User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08 9

2.Flatpack2 Rectifier & Converter Modules

The Flatpack2 module is a hot-pluggable, digitally controlled switch mode power supply.

The module is designed for battery charging and supplying of high quality DC power to

telecom, industrial, solar hybrid equipment and similar applications.

The module works in stand-alone mode or in parallel with other modules, then

communicating via CAN bus with the system’s main controller and other connected

modules. Flatpack2 DC power systems are implemented by mounting the rectifiers in 23”

or 19” power shelves (4 modules across).

A wide range of features are implemented in the Flatpack2 module, as mentioned below.

Key Features

Highest efficiency in minimum space

Resonant topology makes the module efficiency industry leading, and

contributes to the module’s ultra compact dimensions.

Specially, the Flatpack2 HE module stands out with 96.5% efficiency.

Digital controllers

Primary and secondary controls are digitalized, enabling excellent monitoring

and control characteristics. Also, the number of components has been reduced

by 40% compared to previous module generation - for highly reliable, long

life, trouble free DC power systems.

Heat management

Front-to-back and back-to-front air flow modules, with chassis-integrated

heat sinks, gives the module the most suitable working environment and no

limitations in the scalability of the desired system solution.

CAN bus networked

The Flatpack2 module is connected in a CAN bus network for communication

with the controller and other modules.

Unique connection

A true plug-and-play connection system: reducing time-to-install related cost.

Global approvals

Flatpack2 is CE marked, UL recognized and NEBS certified for worldwide

installation

Typical Applications

Wireless, fiber and fixed line communication

Today’s communications demand state-of-the-art, cost efficient and compact DC power

systems. Flatpack2 modules deliver industry leading power density and superb reliability

at lowest lifetime cost.

Broadband and network access

Increasing network speed demands flexible and expandable DC power solutions. The

Flatpack2 module is your key building block for future needs.

Industrial and Solar Hybrid sites

Also appropriate for power supply facilities with or without battery in all areas of

industry, power generation and power distribution The solar charger option is suitable for

any telecom site with autonomous (solar only) or hybrid solar power.

Flatpack2 rectifier

Flatpack2 HE module

2 Flatpack2 Rectifier & Converter Modules

10 User’s Guide Flatpack2 Rectifier & Converter Modules, 350002.013, 8v1-2013-08

Module Options

The Flatpack2 modules are available in various options, offering different performance

and characteristics. Modules used in industrial applications are always keyed at

factory. Read also chapter “Keying Scheme ~ Modules and Power Shelves”, page 19.

Heat Management ~ FB or BF Air Flow

The Flatpack2 module options are always to be installed in power

systems designed for Front-to-Back Air Flow heat management,

except for modules specified for Back-to-Front Air Flow, e.g.

parts 241115.110 and 241115.115, refer to page 13.

CAUTION:

Never install Flatpack2 modules in power shelves with different output voltage than the module’s. The module’s

output voltage and the power system’s output voltage must always be the same.

A keyed power shelf will only allow modules that are keyed ( ) for this specific shelf, to be plugged in the shelf.

Device

Hazard

CAUTION:

Do not install modules with Back-to-Front heat management in power systems

designed for Front-to-Back heat management, or vice versa; otherwise the product

guaranty becomes invalidated.

Device

Hazard

Front-to-Back

Air Flow

Back-to-Front

Air Flow

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