351410 013 opergde flatpack 2500 rectifier pdf

7/28/2019 351410 013 OperGde Flatpack 2500 Rectifier PDF

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351410.0

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Operation Guide

Flatpack 2500, 48V


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2 Operation Guide Flatpack 2500 Rectifier Module, 351410.013, v2-2005-11

Information in this document is subject to change without notice and does not representa commitment on the part ofEltek 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 purposewithout the explicit written permission ofEltek Energy AS.

Copyright : El t e k E n e r g y A S , Norway 2005

Certificate no: 900005E Certificate no: 900005Q

351410.013 Issue 2, 2005 Nov

Published 2005-11-16

Mfm


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Operation Guide Flatpack 2500 Rectifier Module, 351410.013, v2-2005-11 3

Table of Contents

1 SCOPE 42 MAIN FEATURES 4

2.1 GENERAL 42.2 FEATURES 4

3 INSTALLATION PROCEDURES 53.1 SAFETY PRECAUTIONS 53.2 HANDLES AND LOCKING MECHANISM 53.3 INSTALLATION OF RECTIFIERS 63.4 REMOVAL OF RECTIFIERS 6

4 OPERATING INSTRUCTIONS 74.1 GENERAL 74.2 FRONT PANEL INTERFACE 74.3 RECTIFIER ALARM 74.4 OUTPUT VOLTAGE ADJUSTMENT 8

4.4.1 Internal adjustment (stand alone use) 84.4.2 Remote control of output voltage 8

4.5 CONNECTIONS 85 ERROR STATE TABLE AND FAULT-FINDING 96 SPECIFICATIONS 10

6.1 INPUT (AC) 106.1.1 Start / stop voltages and input voltage range 106.1.2 High voltage disconnect 10

6.2 OUTPUT (DC) 106.3 MECHANICAL DIMENSIONS 116.4 OTHER SPECIFICATIONS 11

6.4.1 Efficiency 116.4.2 Safety 116.4.3 Environment 116.4.4 Applicable standards 11


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1 Scope

This document describes the installation procedures and operating instructions of theFlatpack 2500 rectifier module, as well as technical specifications such as input voltagerange, output power and operating temperature range.

Before you start using a Flatpack 2500, it is essential to read this manual first. Themanual employs consistent visual cues to help you locate and interpret informationeasily. Important information is outlined according to the table below.

Symbol Meaning

A note following this symbol providesimportant or critical information.

A note following this symbol clarifies oremphasises a recommendation.

2 Main features

2.1 General

The Flatpack 2500 is a 48V switch mode power supply designed for battery charging andsupplying high quality DC power to telecom equipment and similar applications. TheFlatpack 2500 rectifier is intended to be used as a module in larger power supplysystems, as well as a stand-alone rectifier. A wide range of features is integrated, asmentioned below.

2.2 Features

Front LED indicators, load current LED bargraph and output voltage adjustmentpoint 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


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3 Installation procedures

3.1 Safety precautions

The equipment described in this manual must only be operated by EltekEnergy personnel or by persons who have attended a suitable Eltek Energytraining course

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

There are hazardous voltages inside the rectifier system. As the rectifierunits incorporate large charged capacitors, it is dangerous to work insidethe system even if the mains supply is disconnected

Products into which our components are incorporated have to comply with anumber 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 2500 rectifier incorporates handles that servetwo purposes: to lock the module into position and to serveas pull-out handles.

5Do not hold or hand-carry the rectifier by its handles

5Use gentle force, when releasing the handles from their locked position

5Open the handles before inserting the module fully into the power shelf

To unlock and release the handles, insert a small screwdriver into the holes in the upper corners of the rectifierfront panel to release the spring mechanism. Do notuse excessive force. The handle will release and popout

When both handles are released,use them to pull the rectifier loose

Handle inreleasedposition

Releasehole

Handle inlocked position


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3.3 Installation of rectifiers

Installation of Flatpack 2500 modules

Step Comments

SLIDE THE MODULE INTO THE

POWER SHELFSlide the module 2/3 into the power shelf and open thehandles

FASTEN THE MODULE

Push the module fully into the power shelf and pushthe handles into their slots to lock the rectifier intoposition. Make sure the module is fully inserted beforelocking the handles

VERIFY THAT THE RECTIFIER IS ON The green ON LED is lit and no alarm is activated

MOUNT BLIND PANELS ON EMPTYRECTIFIER POSITIONS

For safety reasons all vacant rectifier positions must becovered by blind panels

3.4 Removal of rectifiers

Removal of Flatpack 2500 modules

Step Comments

UNLOCK THE LEVERS Release the handles as described

PULL THE RECTIFIER LOOSEUsing both handles pull the rectifier forward to releaseit from the connector

SLIDE THE RECTIFIER OUT

Take hold of the rectifier unit and pull it out from itsslot. Support the unit from below as it is beingremoved. If the unit has been in use for some time itmay be hot.

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


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4 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 frontaccessible potentiometer. The front panel LEDs provide information regarding the rectifierstatus and an LED bargraph shows how much current the unit is delivering, 0-100%. Apotential free alarm relay (form-C contacts) provides a signal if there is any internalfailure. The alarm relay operates in failsafe-mode, i.e. the relay coil is energized whenthere is no alarm.

4.2 Front panel interface

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 Description

INPUT VOLTAGE OUT OFRANGE

The input voltage is either below minimum (85Vac) orabove 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 anoutput voltage above the OVS limit. Unplug the rectifierfrom the system, let it discharge for 1 minute and insert themodule in the system again. If the alarm is still activated,the rectifier has probably an internal fault and needsrepairing

HIGH TEMPERATURESHUTDOWN

The module has shutdown due to high internal temperature

FAN FAILURE One or all three fans has been stopped or failed

INTERNAL MALFUNCTION Internal failure

Table 1 Alarm events

LED bar graph

Voltage adjustment potentiometer

Alarm LED (red)

On LED (green)

Fan


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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 theoutput voltage of the rectifier.

If more than one rectifier is to be installed in the system, it is advisable to install andadjust one rectifier at a time. On completion, all the rectifiers may then be installed. Therectifiers 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 iscontrolled 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 signalinterface connector for monitoring and control signals.

Figure 2 Rear connections

The signal connector is for internal use only, and contains signals such as current sharebus, output voltage regulation bus, alarm relay outputs and others.

For details about the signals please contact your dealer or Eltek representative.

3 This adjustment is set at the factory during testing. It is advisable to avoidmaking un-necessary re-adjustments, due account should be taken of theeffect this procedure may have on the customers equipment.

3 This adjustment shall not be done on rectifiers installed in a system with aFlatpack MCU. Set the output voltage from the MCU`s front panel ifinstalled.

AC input (L)

AC input (N)

PE

DC output (+)

DC output (-)

Signalconnector


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5 Error state table and fault-finding

A summary of operating and failure modes of the module is given in table 2 below, whichincludes information for error recovery and verification. "Call service" means you shouldcontact your dealer or Eltek representative for assistance.

Symptom Possible error How to fault-find, recover or restart

ALL LED'S OFF

No AC or batteriespresent

External shutdown

Both input and output are disconnected from power sources

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

Normal operation -Power or currentlimit duringcharging

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

POWERLEDON,

LEDBARGRAPHSHOWS MAX.READING

OR

LOW OUTPUTVOLTAGE

Derating due tohigh internaltemperature

De-rating due tolow input voltage

To verify temperature de-rating: Determine the maximumrectifier current of the system. Read the measured rectifiercurrent in the display of the monitoring units. If the valueshown by the monitoring unit is less than the maximumrectifier current, the rectifier(s) have most likely de-ratedthe output power due to high temperature.

Measure the input voltage. Be aware that the output poweris derated for low input voltages. See specification fordetails.

Loss of inputvoltage

Check all system input fuses or circuit breakers. Measurethe input voltage. If only one module has failed check the

internal fuses in the rectifier.

Over voltageprotection

If modules act differently, the most likely error is internalover voltage protection. Remove the rectifier from thesystem and let it rest for 1 minute, and then reconnect it. Ifthe green LED lights up and the alarm LED is OFF, therectifier has assumed normal operation. If the module failsagain it should be removed for repair.

High temperatureshutdown

Observe the ambient temperature. At temperatures above70 degrees, the rectifier may shut down to avoid internaldamage.

Fan failure Verify that both fans are running. If not, remove the rectifierfrom the system and replace the fan(s) according to thedescription in chapter Replacement Of Fans.

ALARM LEDON

ALL OTHERLEDSOFF

Module failure None of the above solved the problem probably modulefault. Call service.

POWERLEDON,

ALARM LEDON

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

Table 2 Error states


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6 Specifications

6.1 Input (AC)

Type Electrical Data

Input voltage: 85-275 VAC operating range(higher than 250VAC only for a short time, notcontinuously)

Reduced PF between 275-310 VAC

Frequency: 45 to 66Hz

Maximum Current: Max. 16 Arms at 174 VAC, 2500 W output

Power Factor: > 0.99 at 50% load or more

Total Harmonic Distortion: 5%, typical

Input protection: Surge protection (varistors)

Internal fuses (L & N)

Protective shutdown > 310 VAC

6.1.1 Start / stop voltages and input voltage range

Condition Hysteresis Range

Low Mains Shutdown 75 VAC 80 VAC150 VAC De-rate Point 145 VAC 150 VAC174 VAC De-rate Point 170 VAC 174 VAC300 VAC Shut down 310 5 VAC - latching

6.1.2 High voltage disconnect

High voltage disconnect occur at 310 VAC5 VAC. The rectifier will disconnect itself fromthe mains supply and then automatically restart. The module will run in hick-up modeuntil the mains voltage is within the operating range.

NB! The module may be damaged for input voltages above 350VAC.

6.2 Output (DC)

Type Electrical DataOutput voltage: 40 59.5 VDC 53.5 VDC preset

Output current: Max. 52 A at 48VDC (230 V)

Output Protection: 59.5 VDC shutdown level (OVS)

Blocking diode, short circuit proof and high temperature protection

Output power: 800 W at 85-150 VAC

2000 W at 150-174 VAC

2500 W at 174-310 VAC

Hold-up time >10ms at full load

Static Voltageregulation

0.5% from 0 to full load

Dynamic response 4.0 %


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6.3 Mechanical dimensions

Dimensions: W:214 mm D:343mm H:43 mm W8.43 D:13.5 H:1.69

Weight: 3.82 Kg 8.42 lbs

6.4 Other specifications

6.4.1 Efficiency

Type Electrical DataEfficiency: > 91% at 230 VAC and full load

6.4.2 Safety

Type Electrical DataMobility: 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 - serviceaccess area. An external primary circuit breakermust be used in the input line.

IEC protection class:

Current from AC inputs to safety earth:

Discharge time:

IP20

< 3.5 mA at 50 Hz.

< 1 second (connector pins to safe level)

Isolation Voltages: 3.0 KVAC input and output

1.5 KVAC input earth

1.0 KVDC input earth

6.4.3 Environment

Type DataStorage

Temperature:-40 to +85C (-40 to +185F)

+10 to +30C (+50 to +86F) Recommended long-term storage temp.

StorageHumidity:

0% to 99% RH non-condensing

10-30 % RH Recommended

OperatingTemperature:

(stand alone)

-25 to +55C (-13 to +131F)

+55 to + 70C (+131 to +158F) Output power derated to avoid damage

> 70C (>158F) Shut down to avoid possible damage

OperatingHumidity:

5% to 95% RH non-condensing

Acoustic Noice: < 55 dBA (sound pressure) For stand alone module at 1m distance

6.4.4 Applicable standards

Electrical safety: EN 60950EMC: ETSI EN 300 386 V.1.3.1 (telecommunication network)

Harmonics: EN 61000-3-2

Environment: ETSI EN 300 019-2ETSI EN 300 132-2


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ELTEK EnergyP-O- BOX 2340 StmsN-3003 DRAMMENNORWAY

Phone: +47 32203200

Telefax: +47 32203210

Internet: http://www.eltekenergy.come-mail: [email protected]

Location Company Telephone FaxNorway Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602China Eltek Energy Tech. Ltd. + 86 769 2651108 + 86 769 2296797Europe Eltek Energy UK Ltd. +44 1442 219355 +44 1442 245894Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175

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