Eltek Valere Flatpack2 Manual de usuario

350002.013

User's Guide

Flatpack2 DC Power Supply Systems

Flatpack2 Rectifiers

1 Introduction

2User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09

Information in this document is subject to change without notice and does not represent a commitment

on the part of Eltek Valere.

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 Valere.

Safety Precautions



The equipment described in this manual must only be operated by

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 supply is disconnected

 Produc

ts 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 7.0, 2010 Sep

Published 2010-09-07

Mafe

NS-EN ISO 14001 Certified

Certificate No:

11276-2007-AE-NOR-NA

NS-EN ISO 9001 Certified

Certificate No:

4072-2007-AQ-NOR-NA

1 Introduction

User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09 3

Table of Contents

1. Introduction 4

About this Guide .............................................................................................................4

System Diagrams Flatpack2 DC Power Systems ......................................................4

Flatpack2 PS System ~ Telecom ..............................................................................4

Flatpack2 PS System ~ Hybrid Solar........................................................................5

Flatpack2 PS System ~ Industrial..............................................................................6

2. Flatpack2 Rectifier 7

Key Features...................................................................................................................7

Typical Applications ........................................................................................................7

Module Options...............................................................................................................8

Heat Management ~ Front-to-Back Air Flow ............................................................................8

Flatpack2 Rectifier 24V, 2000W................................................................................8

Flatpack2 Rectifier 24V, 2000W WOR......................................................................8

Flatpack2 Rectifier 24V, 1800W HE..........................................................................9

Flatpack2 Rectifier 48V, 1800W................................................................................9

Flatpack2 Rectifier 48V, 2000W................................................................................9

Flatpack2 Rectifier 48V, 3000W................................................................................9

Flatpack2 Rectifier 48V, 2000W HE..........................................................................9

Flatpack2 Rectifier 48V, 3000W HE........................................................................10

Flatpack2 Rectifier 48-60V, 2000W HE...................................................................10

Flatpack2 Solar Charger 48V, 1500W HE – (Solar)................................................10

Flatpack2 Rectifier 110VDC, 2000W HE WOR - (Industrial)...................................11

Flatpack2 Rectifier 220VDC, 2000W HE WOR - (Industrial)...................................11

Heat Management ~ Back-to-Front Air Flow ..........................................................................12

Flatpack2 Rectifier 48V, 2000W BF ........................................................................12

Flatpack2 Rectifier 48V, 2000W HE, BF .................................................................12

3. Installation of Flatpack2 Rectifiers 13

Safety Precautions........................................................................................................13

Mounting and Removing Rectifiers................................................................................. 13

Removing Blind Panels.................................................................................................13

Connections........................................................................................................................ 14

CAN Bus Addressing (plug-and-play)............................................................................. 14

Correct Rectifier Position in Power Shelves ...........................................................................14

Firmware Upgrade of the Rectifier Modules ...........................................................................14

4. Operation 15

Front Panel Interface........................................................................................................ 15

LED Indicators .................................................................................................................. 15

5. Technical Specifications 16

Specifications Flatpack2 Rectifier 24V, 2000W ............................................................16

Specifications Flatpack2 Rectifier 24V, 2000W WOR...................................................17

Specifications Flatpack2 Rectifier 24V, 1800W HE ......................................................18

Specifications Flatpack2 Rectifier 48V, 1800W ............................................................19

Specifications Flatpack2 Rectifier 48V, 2000W ............................................................20

Specifications Flatpack2 Rectifier 48V, 3000W ............................................................21

Specifications Flatpack2 Rectifier 48V, 2000W HE ......................................................22

Specifications Flatpack2 Rectifier 48V, 3000W HE ......................................................23

Specifications Flatpack2 Rectifier 48-60V, 2000W HE.................................................24

Specifications Flatpack2 Solar Charger 48V, 1500W HE – (Solar) ..............................25

Specifications Flatpack2 Rectifier 110VDC, 2000W HE WOR - (Industrial).................26

Specifications Flatpack2 Rectifier 220VDC, 2000W HE WOR - (Industrial).................27

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

1 Introduction

4User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09

1.Introduction

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

Eltek Valere’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

rectifiers’ 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 1Typical 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)

AC Supply

(Single- or three-

phase)

DC Supply

(24V, 48V or 60V)

1 Introduction

User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09 5

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 2Typical 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

6User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09

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 3Typical 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 Mains Grid

(230VAC or 400VAC)

AC Supply

(Single- or three-

phase)

DC Supply

(24V, 48V, 60V,

110V, 125V, 220V)

2 Flatpack2 Rectifier

User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09 7

2.Flatpack2 Rectifier

The Flatpack2 rectifier 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 rectifier works in stand-alone mode or in parallel with other rectifiers, then

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

rectifiers. 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 Features

Highest efficiency in minimum space

Resonant topology makes the module efficiency industry leading, and

contributes to the rectifier’s ultra compact dimensions.

Specially, the Flatpack2 HE rectifier 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 rectifier 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 rectifier is connected in a CAN bus network for communication

with the controller and other rectifiers.

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 rectifiers 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 rectifier 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 rectifier

2 Flatpack2 Rectifier

8User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09

Module Options

The Flatpack2 rectifier is available in various options, offering different performance and

characteristics.

Heat Management ~ Front-to-Back Air Flow

The following Flatpack2 rectifier options are always to be installed

in power systems designed for Front-to-Back Air Flow heat

management.

Flatpack2 Rectifier 24V, 2000W

Part number 241115.200. Refer to chapter “Specifications

Flatpack2 Rectifier 24V, 2000W” on page 16.

Flatpack2 Rectifier 24V, 2000W WOR

Part number 241115.250. This rectifier’s Wide Output voltage

Range is optimized for charging any type of batteries.

Refer to chapter “Specifications Flatpack2 Rectifier 24V,

2000W WOR” on page 17.

Air Flow

CAUTION:

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

designed for Front-to-Back heat management; otherwise the product guaranty

becomes invalidated.

Device

Hazard

Flatpack2 Module Options ~ Overview

241115.200 Flatpack2 Rectifier 24V, 2000W

241115.250 Flatpack2 Rectifier 24V, 2000W WOR

241115.205 Flatpack2 Rectifier 24V, 1800W HE

241115.001

Flatpack2 Rectifier 48V, 1800W

241115.100 Flatpack2 Rectifier 48V, 2000W

241119.100 Flatpack2 Rectifier 48V, 3000W

241115.105 Flatpack2 Rectifier 48V, 2000W HE

241119.105 Flatpack2 Rectifier 48V, 3000W HE

241115.705 Flatpack2 Rectifier 48-60V, 2000W HE

241115.650 Flatpack2 Solar Charger 48V, 1500W HE – (Solar)

241115.805

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

241115.815

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

241115.110 Flatpack2 Rectifier 48V, 2000W BF

241115.115 Flatpack2 Rectifier 48V, 2000W HE, BF

CAUTION:

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

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

Device

Hazard

2 Flatpack2 Rectifier

User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09 9

Flatpack2 Rectifier 24V, 1800W HE

Part number 241115.205. For a description, refer to chapter

“Flatpack2 Rectifier 48V, 2000W HE”, page 9. For technical

data, read chapter “Specifications Flatpack2 Rectifier 24V,

1800W HE”, page 18.

Flatpack2 Rectifier 48V, 1800W

Part number 241115.001. Refer to chapter “Specifications

Flatpack2 Rectifier 48V, 1800W” on page 19

Flatpack2 Rectifier 48V, 2000W

Part number 241115.100. Refer to chapter “Specifications

Flatpack2 Rectifier 48V, 2000W” on page 20

Flatpack2 Rectifier 48V, 3000W

Part number 241119.100. Flatpack2 DC power systems using

these modules are implemented by mounting the rectifiers in

dedicated High Current racks (4AC-HC-3kW Power Shelves,

Part 222058).

Refer to chapter “Specifications Flatpack2 Rectifier 48V,

3000W” on page 21.

Flatpack2 Rectifier 48V, 2000W HE

Part number 241115.105. The combination of innovative

design, efficiency and reliability makes the Flatpack2 HE

rectifier stands out. With an efficiency of up to 96.5%, the

losses have been reduced by 50% compared to the current

industry standard.

Also, the Flatpack2 HE rectifier has an extremely high

efficiency at low load, which historically has been a drawback

with most modern soft switching technologies.

Refer to chapter “Specifications Flatpack2 Rectifier 48V,

2000W HE” on page 22.

P (W)

Temp (°C)

+45

Flatpack2 Rectifier 48V, 2000W

Operating Temperature

Output voltage vs. Temperature

+75

2000

1350

CAUTION: Do not install 3kW rectifiers in power systems implemented with 2kW

power racks (4AC Power Shelves or 2AC Power Shelves); otherwise the product

guaranty becomes invalidated.

Device

Hazard

2 Flatpack2 Rectifier

10 User’s Guide Flatpack2 Rectifier Modules, 350002.013, 7v0-2010-09

Flatpack2 Rectifier 48V, 3000W HE

Part number 241119.105. Flatpack2 DC power systems using

these modules are implemented by mounting the rectifiers in

dedicated High Current racks (4AC-HC-3kW Power Shelves,

Part 222058) or in High Current & Voltage racks (4AC-HC-

HVDC Power Shelves, Part 268035).

Refer to chapters “Flatpack2 Rectifier 48V, 2000W HE”, page

9, for the High Efficiency feature, and to “Specifications

Flatpack2 Rectifier 48V, 3000W HE”, page 23.

Flatpack2 Rectifier 48-60V, 2000W HE

Part number 241115.705. In addition to the High Efficiency

feature — refer to chapter “Flatpack2 Rectifier 48V, 2000W

HE”, page 9 — the rectifier’s Wide DC Output Range (WOR)

enables support for battery banks of both NiCd and Pb. From

the controller, you can configure from 38 to 40 cells in NiCd

battery banks, and 24 or 30 cells in Pb battery banks.

The module will detect and auto-adjust its voltage mode at

start up.

For technical data, read chapter “Specifications Flatpack2

Rectifier 48-60V, 2000W HE” page 24.

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

Part number 241115.650. With the Maximum Peak Power

Tracking (MPPT) algorithm ensuring close to 100% panel

utilization and efficiency up to 96.5%, the galvanic isolated

solar charger sets new standards for renewable power in

totally green telecom sites.

The charger uses a digitalized advanced control algorithm

that finds the solar panel voltage that generates the

maximum power independent of sun availability. The

charging is continuous according to performance profile for

panels. In addition to finding the profiles peak power a full

scan is performed at a fixed interval to stay on peak even

with panel failures and major shadings. This gives close to

100% panel utilization.

The Flatpack2 HE SOLAR charger is suitable for any telecom

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

It can be used in parallel with any other Flatpack2 rectifiers

(front-to-back air flow systems only) fed by generator or

unreliable mains, on hybrid sites.

Solar chargers must be mounted in dedicated solar power

shelves with correct DC input feeding, see Figure 2, page 5.

Refer to chapter “Specifications Flatpack2 Solar Charger 48V,

1500W HE – (Solar)” on page 25.

CAUTION: Do not install 3kW rectifiers in power systems implemented with 2kW

power racks (4AC Power Shelves or 2AC Power Shelves); otherwise the product

guaranty becomes invalidated.

Device

Hazard

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