FlatpackS Modules. User's Guide. Rectifiers and Supervision. FlatpackS DC Power Supply Systems. Anatel Homolgation Numbers

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1 User's Guide FlatpackS Modules Rectifiers and Supervision FlatpackS DC Power Supply Systems Anatel Homolgation Numbers Rectifier Power System

2 aparecer aqui. Erro! Use a guia Página Inicial para aplicar Heading DC 1 Power ao texto Supply Systems que deverá aparecer SAFETY and aqui. 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! Device Hazard 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. G1 Electric Shock 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. G2 Environmental Precautions sss Ventilated Hot Surface 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. E1 Current Surge Protection 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 E2 Humidity & Dust Protection 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 E3 Precautions during Installation! Qualified Personnel 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. I1! EMC, NEC/CEC Regard 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. I2! Device Hazard Electric Shock 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. I3 I4 Electric Shock 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. I5 2 User s Guide Flatpack2 Rectifier & Supervision Modules,

3 Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek. 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. Copyright : Eltek, 2015 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 Anatel Label The folowing picture shows the Anatel label that is applied on bottom of the Rectifier. User s Guide FlatpackS Rectifier & Supervision Modules, 3

4 Table of Contents 1. Introduction 5 About this Guide... 5 System Diagrams Flatpacks DC Power Systems... 5 FlatpackS PS System ~ Telecom FlatpackS Rectifier & Supervision Modules 6 Key Features... 6 Typical Applications Installation of Flatpack2 Modules 7 Installing Rectifiers, Controller and Blind Panels... 7 Removing Flatpack S Rectifiers... 7 Mounting Flatpack S Rectifiers... 7 Mounting or Removing Blind Panels... 8 Removing Smartpack S Controller... 8 Mounting Smartpack S Controller... 8 Accessing the Controller s Ethernet Port... 9 Terminals and Pin-out Locations, Smartpack S Controller Location of Connector, Communication Ports Connection Drawing Operation 13 Front Panel Flatpack S Rectifier Module Front Panel Operation Smartpack S Controller Graphical Display Front Keys Software Menus Controller Access Via Stand-alone PC Technical Specifications 17 4 User s Guide Flatpack2 Rectifier & Supervision Modules,

5 1. Introduction The FlatpackS rectifier module is a powerful and cost-effective power supply used in Eltek s FlatpackS DC power systems. About this Guide This booklet provides users of FlatpackS DC power systems with the required information to install and operate the FlatpackS 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 FlatpackS DC power system. For detailed functionality description, browse and search through WebPower or PowerSuite Online Help. System Diagrams Flatpacks DC Power Systems The FlatpackS 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. FlatpackS PS System ~ Telecom The example in Figure 1 represents a typical FlatpackS 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 FlatpackS PS system for DC power supply of telecom equipment User s Guide FlatpackS Rectifier & Supervision Modules, 5

6 2. FlatpackS Rectifier & Supervision Modules The FlatpackS 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. FlatpackS 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 FlatpackS module, as mentioned below. Key Features Eltek Label Anatel Label 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 Flatpacks 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 Flatpacks 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. FlatpackS 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. 6 User s Guide Flatpack2 Rectifier & Supervision Modules,

3. Installation of Flatpack2 Modules Installing Rectifiers, Controller and Blind Panels CAUTION: The rectifiers may be warm, you may hand-carry them by their handle.

Device Hazard Removing Flatpack S Rectifiers To remove the Flatpack S rectifiers, do following: Unlock the rectifier by using a screwdriver to turn the locking screw ¼ of a turn clockwise to the

7 3. Installation of Flatpack2 Modules Installing Rectifiers, Controller and Blind Panels CAUTION: The rectifiers may be warm, you may hand-carry them by their handle. The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing.Device Hazard Removing Flatpack S Rectifiers To remove the Flatpack S rectifiers, do following: Unlock the rectifier by using a screwdriver to turn the locking screw ¼ of a turn clockwise to the unlocked position ( ) Remove the rectifier by using the rectifier s handle to pull the module loose. Support from underneath before the unit is completely free Mount blind panels in unused rectifier locations Mounting Flatpack S Rectifiers To mount the Flatpack S rectifiers, do following: Unlock the rectifier by using a screwdriver to turn the locking screw ¼ of a turn clockwise to the unlocked position ( ) Notice: the rectifiers may be inserted in the power shelf with the locking screw in both locked and unlocked positions Insert the rectifier by sliding it fully into the power shelf, so that it makes proper contact. Support from underneath Lock the rectifier by using a screwdriver to turn the locking screw ¼ of a turn counter clockwise to the locked position ( ). Then, the rectifier will be securely locked in the shelf, or ready for transport User s Guide FlatpackS Rectifier & Supervision Modules, 7

Mounting or Removing Blind Panels Always mount blind panels in unused Flatpack S rectifiers and Smartpack S controllers locations.

release the panel Removing Smartpack S Controller To remove the Smartpack S controller, do following: Unlock the controller by using a screwdriver to turn the locking screw ¼ of a turn clockwise to

Notice: in this position, the display is locked ( ), see Accessing the Controller s Ethernet Port on page <ET> Remove the controller by using the controller s handle to pull the module loose.

8 Mounting or Removing Blind Panels Always mount blind panels in unused Flatpack S rectifiers and Smartpack S controllers locations. Do following: To mount a blind panel insert the panel in an unused location until the panel engages and locks into position To remove a blind panel push the panel s handle downwards and pull out to release the panel Removing Smartpack S Controller To remove the Smartpack S controller, do following: Unlock the controller by using a screwdriver to turn the locking screw ¼ of a turn clockwise to the unlocked position (pos 2). Notice: in this position, the display is locked ( ), see Accessing the Controller s Ethernet Port on page <ET> Remove the controller by using the controller s handle to pull the module loose. Support from underneath before the unit is completely free Mount blind panels in unused module locations Mounting Smartpack S Controller To mount the Smartpack S controller, do following: Unlock the controller by using a screwdriver to turn the locking screw ¼ of a turn clockwise to the unlocked position (pos 2) Notice: the controllers may be mounted in the power shelf with the locking screw in both locked and unlocked positions Insert the controller by sliding it fully into the power shelf, so that it makes proper contact. Support from underneath 8 User s Guide Flatpack2 Rectifier & Supervision Modules,

9 Lock the controller by using a screwdriver to turn the locking screw ¼ of a turn counter clockwise to the locked position (pos 1). Then, the rectifier will be securely locked in the shelf, or ready for transport. Notice: in this position, the display is unlocked ( ), see Accessing the Controller s Ethernet Port on page <ET> Accessing the Controller s Ethernet Port The controller s Ethernet port can be accessed from the front (temporary connections) or from the rear (permanently connections. To access the Smartpack S controller Ethernet port from the front, do following: 1- Lock the controller (pos 1) 2- Slide the controller s display unit slightly out Pos 1= SP S and Display Pos 2= SP S and Display User s Guide FlatpackS Rectifier & Supervision Modules, 9

Terminals and Pin-out Locations, Smartpack S Controller Location of Connector, Communication Ports For a complete list of signals, pin-out, etc, refer to chapter Connection Drawing on page12 Location

10 Terminals and Pin-out Locations, Smartpack S Controller Location of Connector, Communication Ports For a complete list of signals, pin-out, etc, refer to chapter Connection Drawing on page12 Location of pluggable terminal blocks, RS232/RS485 port and Ethernet connector in the Smartpack S controller (the pluggable terminals may be black or green) All the controller s system connections to the system s backplane are implemented via an edge connector, when inserting the controller in the power system. Notice that when using the RS232 / RS485 port, you must configure RS232 to COM1 and RS485 to COM2, e.g. via PowerSuite. 10 User s Guide Flatpack2 Rectifier & Supervision Modules,

11 Connection Drawing Use this drawing as a customer connection reference for all cabling. You find the exact location of connection terminals, plugs, DIP switches, jumpers, etc. by referring to chapter Location of Connector, Communication Ports on page 11. Connection Drawing for Smartpack S controller The configurable inputs 1 through 4 operate in the range of max. 10 to +10VDC, and are intended for great accurate measurements, e.g. for temperature sensing using an external temperature NTC probe. Also, these inputs are suitable for monitoring other sensors (of pressure, humidity, etc.) that output 4mA to 20mA. An external 470 ohms resistor is then to be connected to the input s terminals on the controller, in parallel with the sensor s cables. The configurable inputs 5 and 6 operate in the range of 0 to 75VDC, and are intended for e.g. system voltage and battery symmetry measurements. User s Guide FlatpackS Rectifier & Supervision Modules, 11

All the 6 inputs may be configured as Auxiliary Switch (open/close, pull-up or pull-down), as temperature sense inputs with external NTC sensors, or as Clock inputs.

12 All the 6 inputs may be configured as Auxiliary Switch (open/close, pull-up or pull-down), as temperature sense inputs with external NTC sensors, or as Clock inputs. The SmartpackS controller also have a panel mounted version, that is shown in the picture below. Both controllers have the same hardware, but in different format. SmartpackS in the panel version. 12 User s Guide Flatpack2 Rectifier & Supervision Modules,

4. Operation Front Panel Flatpack S Rectifier Module The Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered).

similar major alarm) or OFF (OK, no alarm) Front Panel Operation Smartpack S Controller This chapter describes the Smartpack S controller s keys and indicators, and how to

13 4. Operation Front Panel Flatpack S Rectifier Module The Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered). Flatpack S HE rectifier s front lamps The Warning LED is ON (derating or similar minor warning), Flashing (over-voltage mode) or OFF (OK) The Alarm LED is ON (shutdown or similar major alarm) or OFF (OK, no alarm) Front Panel Operation Smartpack S Controller This chapter describes the Smartpack S controller s keys and indicators, and how to operate the Smartpack S-based DC power system from the controller s front panel. Smartpack S controller s front keys and indicators User s Guide FlatpackS Rectifier & Supervision Modules, 13

Graphical Display The Graphical Color Display 2.2 TFT is either in Status Mode (displays the system s status) or in Menu Mode (displays the menu structure).

14 Graphical Display The Graphical Color Display 2.2 TFT is either in Status Mode (displays the system s status) or in Menu Mode (displays the menu structure). The Smartpack S controller has the following LED indications: Description of the Smartpack S controller s LED illumination status Front Keys You can operate the power system navigating intuitively through the graphical menu structure via the following 4 front keys. We recommend using a pen or similar tool to press the keys, as they are small. The Enter or Left arrow key When entering numbers, a short press of this key navigates to the left. A long press of this key to enter and save data The Cancel or Right arrow key When entering numbers, a short press of this key navigates to the right. A long press of this key to cancel or abort data The Up and Down arrow keys to navigate up- or downwards the menu icons, point at options and increase and decrease values 14 User s Guide Flatpack2 Rectifier & Supervision Modules,

Software Menus The Smartpack S-based system s functionality is accessed via a network of software menus and submenus 1, enabling you to configure and control the

Editing parameters is password protected, (default pin code <0003> should be changed). The display can be in Status Mode or in Menu Mode.

15 Software Menus The Smartpack S-based system s functionality is accessed via a network of software menus and submenus 1, enabling you to configure and control the whole power system from the controller s front panel. When browsing the menus, the Menu Level Indicator shows the menu level you are in. Editing parameters is password protected, (default pin code <0003> should be changed). The display can be in Status Mode or in Menu Mode. 1 From a PC s web browser, via WebPower, or running the PowerSuite program, you can also access the complete system functionality, described in the programs Online Help User s Guide FlatpackS Rectifier & Supervision Modules, 15

Controller Access Via Stand-alone PC You can access the Smartpack S controller directly from a stand-alone computer, or via a Local Area Network (LAN) if available.

16 Controller Access Via Stand-alone PC You can access the Smartpack S controller directly from a stand-alone computer, or via a Local Area Network (LAN) if available. Each controller is shipped with a unique Eltek MAC address stored inside the controller and marked on the controller s label, and with the fixed IP address < >. Do following to access the controller: Start the Eltek Network Utility (ENU) program (or EVIPSetup.exe) Connect the computer to the controller (see Accessing the Controller s Ethernet Port on page 5). Check its MAC address is displayed Find the computer NIC s IP address and subnet mask (network card) Tip: using DOS command IPCONFIG, in a Command Prompt window e.g. computer s IP address < > Subnet mask < > Change the controller s IP address and Network Mask to be in the same range as the computer s Tip: Using the ENU program, 1. Select the controller, 2. Click in the Configuration button 3. Change e.g. from default < > < > to IP address < > < >, 4. Click on the Enable Static IP button Notice: Check that the IP address < > is not used, e.g. issuing the DOS command: Ping Access the controller s configuration pages in your Web browser, e.g. clicking the Web Interface button in the ENU program 6. Log in with the <admin> account 7. Change the controller s Device Name After accessing the controller, you can configure and monitor the power system using a standard web browser (via WebPower) or via the PowerSuite program. PowerSuite s newest version is always available on our FTP server. Contact your closest Eltek representative. For detailed functionality description, browse and search through the Functionality Description Help file (or ) or WebPower Online Help file. 16 User s Guide Flatpack2 Rectifier & Supervision Modules,

17 5. Technical Specifications Model 48/1000 HE 48/1800 HE Part number INPUT DATA Voltage (nominal) V AC / V DC 1) 195 2) V AC / 195 2) V DC 1) Voltage (operating range) V AC / V DC 1) 85 2) V AC / 85 2) V DC 1) Current nominal input, full load 5.9 A RMS 9.9 A RMS Frequency Hz / 0 Hz 1) Power Factor Protection OUTPUT DATA Voltage (default) Voltage (adjustable range) > 0.99 at 50% load or more Fuse in L & N Varistor Shutdown when input voltage is out of operating range 53.5 V DC V DC Power nominal input 1000 W 1800 W 85 VAC 420 W 700 W 2) Current nominal input 20.9 A (@V OUT < 48V DC) 37.5 A (@V OUT < 48V DC) Hold up time, maximum output power >20ms; output voltage > 41 V DC >10ms; output voltage > 42 V DC Current sharing (10-100% load) Static Voltage regulation (10-100% load) ±0.5% Dynamic Voltage regulation Ripple Protection OTHER SPECIFICATIONS ±5% of maximum current from 10 to 100% load ±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms < 150 mv PP, 30 MHz bandwidth ORing FET Short circuit proof High temperature protection Over voltage Shutdown Efficiency Up to 95.5 % Up to 95.8 % Isolation 3.0 kv AC - input to output 1.5 kv AC - input to earth 710 V DC - output to earth Alarms: Red LED Warnings: Yellow LED Normal operation: Green LED Low and high input voltage shutdown, High and low temperature shutdown, Rectifier Failure, Overvoltage shutdown on output, Fan failure, Low output voltage alarm, CAN bus failure Rectifier in power de-rate mode, Remote output current limit activated, Input voltage out of range, flashing at overvoltage, Loss of CAN communication with controller MTBF (Telcordia SR-332 Issue I method III (a)) > (@ T ambient : 25 C) > (@ T ambient : 25 C) Operating temperature (5-95% RH n.cond. hum.) Maximum output power de-rates above temp / to Storage temperature Dimensions[WxHxD] / Weight DESIGN STANDARDS -40 to + 85 C [-40 to +185 F] 45 C [113 F] / 85 C[185 F] -40 to + 85 C [-40 to +185 F] 45 C [113 F] / 85 C[185 F] -40 to +85 C (-40 to +185 F), humidity 0-99% RH non-condensing 72 x 41.5 x 217mm (2.83 x 1.63 x 8.54 ) / < 850 g (1.9 lbs) Electrical safety UL , EN EMC ETSI EN EN / -2 / -3 / -4 TS FCC CFR 47 Part 15 Environment ETSI EN : 2-1 (Class 1.2), 2-2 (Class 2.3) & 2-3 (Class 3.2) RoHS (2011/65/EU) and WEEE (2002/96/EC) compliant User s Guide FlatpackS Rectifier & Supervision Modules, 17

18 1) DC input only allowed when up-stream breaker is rated for the applicable DC input voltage and has a maximum current rating of 32A 2) For HW revisions , nominal range is VAC / VDC, maximum output power at 176 VAC/DC is 1180 W with further linear de-rating to 90W at 122 VAC/DC. Not to be used in applications with 110/120 VAC mains. 18 User s Guide Flatpack2 Rectifier & Supervision Modules,

19 Headquarters: Eltek Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway Phone: Fax:

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