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User's GuideFlatpack2 RectifiersFlatpack2 DC Power Supply Systems.350002.013
1 IntroductionInformation in this document is subject to change without notice and does not represent a commitmenton the part of Eltek Valere.No part of this document may be reproduced or transmitted in any form or by any means — electronicor mechanical, including photocopying and recording — for any purpose without the explicit writtenpermission of Eltek Valere.Copyright : Eltek Valere, 2010Safety PrecautionsNS-EN ISO 14001 CertifiedNS-EN ISO 9001 CertifiedCertificate No:11276-2007-AE-NOR-NACertificate No:4072-2007-AQ-NOR-NA The equipment described in this manual must only be operated byEltek Valere personnel or by persons who have attended a suitableEltek Valere training 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 power system. As the modulesincorporate large charged capacitors, it is dangerous to work inside thesystem 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 therecommendations herein Please read the manual carefully before using the equipment350002.013Issue 7.0, 2010 SepPublished 2010-09-07Mafe2User’s Guide Flatpack2 Rectifier Modules,350002.013, 7v0-2010-09
1 IntroductionTable of Contents1. Introduction4About this Guide . 4System Diagrams Flatpack2 DC Power Systems . 4Flatpack2 PS System Telecom .4Flatpack2 PS System Hybrid Solar .5Flatpack2 PS System Industrial.62.Flatpack2 Rectifier7Key Features . 7Typical Applications . 7Module Options . 8Heat Management Front-to-Back Air Flow .8Flatpack2 Rectifier 24V, 2000W .8Flatpack2 Rectifier 24V, 2000W WOR .8Flatpack2 Rectifier 24V, 1800W HE .9Flatpack2 Rectifier 48V, 1800W .9Flatpack2 Rectifier 48V, 2000W .9Flatpack2 Rectifier 48V, 3000W .9Flatpack2 Rectifier 48V, 2000W HE .9Flatpack2 Rectifier 48V, 3000W HE .10Flatpack2 Rectifier 48-60V, 2000W HE .10Flatpack2 Solar Charger 48V, 1500W HE – (Solar) .10Flatpack2 Rectifier 110VDC, 2000W HE WOR - (Industrial).11Flatpack2 Rectifier 220VDC, 2000W HE WOR - (Industrial).11Heat Management Back-to-Front Air Flow .12Flatpack2 Rectifier 48V, 2000W BF .12Flatpack2 Rectifier 48V, 2000W HE, BF .123.Installation of Flatpack2 Rectifiers13Safety Precautions . 13Mounting and Removing Rectifiers . 13Removing Blind Panels . 13Connections . 14CAN Bus Addressing (plug-and-play) . 14Correct Rectifier Position in Power Shelves .14Firmware Upgrade of the Rectifier Modules .144.Operation15Front Panel Interface . 15LED Indicators . 155.Technical Specifications16Specifications Flatpack2 Rectifier 24V, 2000W . 16Specifications Flatpack2 Rectifier 24V, 2000W WOR. 17Specifications Flatpack2 Rectifier 24V, 1800W HE . 18Specifications Flatpack2 Rectifier 48V, 1800W . 19Specifications Flatpack2 Rectifier 48V, 2000W . 20Specifications Flatpack2 Rectifier 48V, 3000W . 21Specifications Flatpack2 Rectifier 48V, 2000W HE . 22Specifications Flatpack2 Rectifier 48V, 3000W HE . 23Specifications Flatpack2 Rectifier 48-60V, 2000W HE . 24Specifications Flatpack2 Solar Charger 48V, 1500W HE – (Solar) . 25Specifications Flatpack2 Rectifier 110VDC, 2000W HE WOR - (Industrial) . 26Specifications Flatpack2 Rectifier 220VDC, 2000W HE WOR - (Industrial) . 27Specifications Flatpack2 Rectifier 48V, 2000W HE, BF . 28User’s Guide Flatpack2 Rectifier Modules,350002.013, 7v0-2010-093
1 Introduction1. IntroductionThe Flatpack2 rectifier module is a powerful and cost-effective power supply used inEltek Valere’s Flatpack2 DC power systems.About this GuideThis booklet provides users of Flatpack2 DC power systems with the required informationto install and operate the Flatpack2 rectifier modules. The booklet also presents therectifiers’ technical specifications, such as input voltage range, output power, operatingtemperature range, etc.Read also the generic and site specific documentation that was delivered with yourFlatpack2 DC power system.For detailed functionality description, browse and search through WebPower orPowerSuite Online Help.System Diagrams Flatpack2 DC Power SystemsThe Flatpack2 modules are the building blocks of Flatpack2 PS systems, used for DCpower supply of telecom and industrial equipment, in grid-fed sites or hybrid solar sites.Flatpack2 PS System TelecomThe example in Figure 1 represents a typical Flatpack2 PS system for DC power supply oftelecom equipment. The system is fed from an external AC mains supply, and consists ofrectifiers in power shelves, a controller and DC distribution unit. Battery banks, LVDcontactors, etc. are typically also a part of the system. The system controller monitorsthe whole system, and serves as the local user interface. You can configure the systemfrom a standard web browser, or installing the PowerSuite application in a computer.Alarm Outputs NC-C-NODigital Inputs ollerCAN BusPowerSuiteApplicationUSB cableFuse AlarmFlatpack2rectifiersLVLDTelecomequipmentAC Mains Grid(230VAC or 400VAC)AC mainssupplyselectorSymmetryAlarm &Temp. SensorAC Supply(Single- or threephase)Figure 14LVBDLoad Fuses& MCBsDCdistributionDC SupplyBattery string #1BatteryFuses(24V, 48V or 60V)Typical Flatpack2 PS system for DC power supply of telecom equipmentUser’s Guide Flatpack2 Rectifier Modules,350002.013, 7v0-2010-09
1 IntroductionFlatpack2 PS System Hybrid SolarThe example in Figure 2 represents a typical hybrid, solar Flatpack2 PS system for DCpower supply of telecom and industrial equipment.The system is fed from strings of solar panels (DC feed), and uses a diesel generator asAC 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 powershelves, 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 theSmartpack2 Basic controller monitors the system’s internal wiring. The I/O Monitor2 CANnode provides the system with input monitoring and output controlling signals.You can configure the system from a standard web browser, via WebPower, or installingthe PowerSuite application in a computer.WebPower(web-baseduser interface)InternetAlarm Outputs NC-C-NOEthernetcableConfig. InputsWind TurbineSmartpack2Master ControllerI/O Monitor2CAN nodeSmartpack2Basic ControllerFlatpack2Hybrid SolarSystemFuse AlarmCAN BusAC Mains Grid(230VAC or 400VAC)Flatpack2 HERectifiersLVLDTelecom andIndustrialequipmentAC GeneratorAC mainssupplyselectorLVBDFlatpack2 HESolar ChargersAC Supply(Single- or threephase)Temp.SensorsDCDistributionSolar PanelsDC SupplyBattery string #1(170-230VDC)Load Fuses& MCBsBatteryFusesDC Supply(48V)Figure 2 Typical hybrid, solar Flatpack2 PS system for DC power supply of telecom orindustrial equipmentUser’s Guide Flatpack2 Rectifier Modules,350002.013, 7v0-2010-095
1 IntroductionFlatpack2 PS System IndustrialThe example in Figure 3 represents a typical Flatpack2 PS system for DC power supply ofindustrial 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 powershelves, 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.RemoteMonitoringAlarm Outputs NC-C-NODigital InputsMMTApplicationUSB cableFlatpack2CabinetizedUPC4controllerFuse AlarmFlatpack2 HECAN Bus rectifiersLVLDAC Mains Grid(230VAC or 400VAC)DC LoadIndustrialEquipmentAC mainssupplyselectorSymmetryAlarm &Temp. SensorAC Supply(Single- or threephase)Figure 36Battery string #1LVBDLoad Fuses& MCBsDCdistributionBatteryFusesDC Supply(24V, 48V, 60V,110V, 125V, 220V)Typical Flatpack2 PS system for DC power supply of industrial equipmentUser’s Guide Flatpack2 Rectifier Modules,350002.013, 7v0-2010-09
2 Flatpack2 Rectifier2. Flatpack2 RectifierThe Flatpack2 rectifier module is a hot-pluggable, digitally controlled switch mode powersupply. The module is designed for battery charging and supplying of high quality DCpower to telecom, industrial, solar hybrid equipment and similar applications.The rectifier works in stand-alone mode or in parallel with other rectifiers, thencommunicating via CAN bus with the system’s main controller and other connectedrectifiers. Flatpack2 DC power systems are implemented by mounting the rectifiers in 23”or 19” power shelves (4 rectifiers across).A wide range of features are implemented in the Flatpack2 rectifier, as mentioned below.Key FeaturesFlatpack2 HE rectifier Highest efficiency in minimum spaceResonant topology makes the module efficiency industry leading, andcontributes to the rectifier’s ultra compact dimensions.Specially, the Flatpack2 HE rectifier stands out with 96.5% efficiency. Digital controllersPrimary and secondary controls are digitalized, enabling excellent monitoringand control characteristics. Also, the number of components has been reducedby 40% compared to previous rectifier generation - for highly reliable, longlife, trouble free DC power systems. Heat managementFront-to-back and back-to-front air flow modules, with chassis-integratedheat sinks, gives the module the most suitable working environment and nolimitations in the scalability of the desired system solution.Flatpack2 rectifier CAN bus networkedThe Flatpack2 rectifier is connected in a CAN bus network for communicationwith the controller and other rectifiers. Unique connectionA true plug-and-play connection system: reducing time-to-install related cost. Global approvalsFlatpack2 is CE marked, UL recognized and NEBS certified for worldwideinstallationTypical ApplicationsWireless, fiber and fixed line communicationToday’s communications demand state-of-the-art, cost efficient and compact DC powersystems. Flatpack2 rectifiers deliver industry leading power density and superb reliabilityat lowest lifetime cost.Broadband and network accessIncreasing network speed demands flexible and expandable DC power solutions. TheFlatpack2 rectifier is your key building block for future needs.Industrial and Solar Hybrid sitesAlso appropriate for power supply facilities with or without battery in all areas ofindustry, power generation and power distribution Th
Eltek Valere personnel or by persons who have attended a suitable Eltek Valere 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
