Operation Guide

Flatpack 2500, 48V

351410.013
Information in this document is subject to change without notice and does not represent
a commitment on the part of Eltek 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 purpose
without the explicit written permission of Eltek Energy AS.

Copyright ©: Eltek Energy AS, Norway 2005

Certificate no: 900005E Certificate no: 900005Q

351410.013 Issue 2, 2005 Nov

Published 2005-11-16

Mfm

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

Table of Contents

1 SCOPE 4

2 MAIN FEATURES 4
2.1 GENERAL 4
2.2 FEATURES 4

3 INSTALLATION PROCEDURES 5
3.1 SAFETY PRECAUTIONS 5
3.2 HANDLES AND LOCKING MECHANISM 5
3.3 INSTALLATION OF RECTIFIERS 6
3.4 REMOVAL OF RECTIFIERS 6

4 OPERATING INSTRUCTIONS 7
4.1 GENERAL 7
4.2 FRONT PANEL INTERFACE 7
4.3 RECTIFIER ALARM 7
4.4 OUTPUT VOLTAGE ADJUSTMENT 8
4.4.1 Internal adjustment (stand alone use) 8
4.4.2 Remote control of output voltage 8
4.5 CONNECTIONS 8

5 ERROR STATE TABLE AND FAULT-FINDING 9

6 SPECIFICATIONS 10
6.1 INPUT (AC) 10
6.1.1 Start / stop voltages and input voltage range 10
6.1.2 High voltage disconnect 10
6.2 OUTPUT (DC) 10
6.3 MECHANICAL DIMENSIONS 11
6.4 OTHER SPECIFICATIONS 11
6.4.1 Efficiency 11
6.4.2 Safety 11
6.4.3 Environment 11
6.4.4 Applicable standards 11

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

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

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

Symbol Meaning
A note following this symbol provides
important or critical information.

A note following this symbol clarifies or

emphasises a recommendation.

2 Main features

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

2.2 Features
• Front LED indicators, load current LED bargraph and output voltage adjustment
point 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

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

 3 Installation procedures

3.1 Safety precautions

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

Energy personnel or by persons who have attended a suitable Eltek Energy
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 rectifier system. As the rectifier
units 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

3.2 Handles and locking mechanism

The Flatpack 2500 rectifier incorporates handles that serve
two purposes: to lock the module into position and to serve
Release as pull-out handles.
hole

To unlock and release the handles, insert a small screw

driver into the holes in the upper corners of the rectifier
front panel to release the spring mechanism. Do not
use excessive force. The handle will release and pop
Handle in out
locked position

When both handles are released,

use them to pull the rectifier loose

Handle in
released
position

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

5 Use gentle force, when releasing the handles from their locked position
5 Open the handles before inserting the module fully into the power shelf

Operation Guide Flatpack 2500 Rectifier Module, 351410.013, v2-2005-11 5

3.3 Installation of rectifiers
Installation of Flatpack 2500 modules

Step Comments

SLIDE THE MODULE INTO THE Slide the module 2/3 into the power shelf and open the
POWER SHELF handles
Push the module fully into the power shelf and push
the handles into their slots to lock the rectifier into
FASTEN THE MODULE
position. Make sure the module is fully inserted before
locking the handles
VERIFY THAT THE RECTIFIER IS ON The green “ON” LED is lit and no alarm is activated

MOUNT BLIND PANELS ON EMPTY For safety reasons all vacant rectifier positions must be
RECTIFIER POSITIONS covered by blind panels

3.4 Removal of rectifiers

Removal of Flatpack 2500 modules

Step Comments

UNLOCK THE LEVERS Release the handles as described

Using both handles pull the rectifier forward to release
PULL THE RECTIFIER LOOSE
it from the connector
Take hold of the rectifier unit and pull it out from its
slot. Support the unit from below as it is being
SLIDE THE RECTIFIER OUT
removed. If the unit has been in use for some time it
may be hot.

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

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

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 front
accessible potentiometer. The front panel LEDs provide information regarding the rectifier
status and an LED bargraph shows how much current the unit is delivering, 0-100%. A
potential free alarm relay (“form-C” contacts) provides a signal if there is any internal
failure. The alarm relay operates in failsafe-mode, i.e. the relay coil is energized when
there is no alarm.

4.2 Front panel interface

“On” LED (green)
Alarm LED (red)
LED bar graph

Fan
Voltage adjustment potentiometer

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 OF The input voltage is either below minimum (85Vac) or
RANGE above maximum (310Vac)
The module has shut down due to high output voltage. The
rectifier will automatically shut itself down if it produces an
output voltage above the OVS limit. Unplug the rectifier
OVER VOLTAGE SHUTDOWN from the system, let it discharge for 1 minute and insert the
module in the system again. If the alarm is still activated,
the rectifier has probably an internal fault and needs
repairing
HIGH TEMPERATURE The module has shutdown due to high internal temperature
SHUTDOWN
FAN FAILURE One or all three fans has been stopped or failed
INTERNAL MALFUNCTION Internal failure
Table 1 Alarm events

Operation Guide Flatpack 2500 Rectifier Module, 351410.013, v2-2005-11 7

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 the
output voltage of the rectifier.

If more than one rectifier is to be installed in the system, it is advisable to install and
adjust one rectifier at a time. On completion, all the rectifiers may then be installed. The
rectifiers will only share the current equally if the output voltage is adjusted equally.

3 This adjustment is set at the factory during testing. It is advisable to avoid

making un-necessary re-adjustments, due account should be taken of the
effect this procedure may have on the customers equipment.

3 This adjustment shall not be done on rectifiers installed in a system with a

Flatpack MCU. Set the output voltage from the MCU`s front panel if
installed.

4.4.2 Remote control of output voltage

When used in a Flatpack power system containing a Flatpack MCU, the output voltage is
controlled 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 signal
interface connector for monitoring and control signals.

Signal
AC input (L) DC output (+) connector
AC input (N) DC output (-)
PE
Figure 2 Rear connections
The signal connector is for internal use only, and contains signals such as current share
bus, output voltage regulation bus, alarm relay outputs and others.

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

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

5 Error state table and fault-finding
A summary of operating and failure modes of the module is given in table 2 below, which
includes information for error recovery and verification. "Call service" means you should
contact your dealer or Eltek representative for assistance.

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

No AC or batteries Both input and output are disconnected from power sources
present
ALL LED'S OFF The rectifier system may have been switched OFF via the
External shutdown Monitoring & Control Unit (MCU). Refer to the Flatpack MCU
user manual for operation instructions.

Normal operation - To verify that the module is OK: Check the output voltage
Power or current which should be slightly below the float voltage. Measure
limit during the current, it should read more than the nominal current
POWER LED ON, charging
LED BARGRAPH
SHOWS MAX.
Derating due to To verify temperature de-rating: Determine the maximum
READING
high internal rectifier current of the system. Read the measured rectifier
temperature current in the display of the monitoring units. If the value
OR shown by the monitoring unit is less than the maximum
rectifier current, the rectifier(s) have most likely de-rated
LOW OUTPUT the output power due to high temperature.
VOLTAGE
De-rating due to Measure the input voltage. Be aware that the output power
low input voltage is derated for low input voltages. See specification for
details.

Loss of input Check all system input fuses or circuit breakers. Measure
voltage the input voltage. If only one module has failed check the
internal fuses in the rectifier.

Over voltage If modules act differently, the most likely error is internal
protection over voltage protection. Remove the rectifier from the
system and let it rest for 1 minute, and then reconnect it. If
the green LED lights up and the alarm LED is OFF, the
rectifier has assumed normal operation. If the module fails
again it should be removed for repair.
ALARM LED ON
ALL OTHER LEDS
OFF High temperature Observe the ambient temperature. At temperatures above
shutdown 70 degrees, the rectifier may shut down to avoid internal
damage.

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

Module failure None of the above solved the problem – probably module
fault. Call service.

POWER LED ON, Module error This mode may occur for a short time only during power-up
ALARM LED ON or power-down. Otherwise, call service.

Table 2 Error states

Operation Guide Flatpack 2500 Rectifier Module, 351410.013, v2-2005-11 9

6 Specifications

6.1 Input (AC)

Type Electrical Data
Input voltage: 85-275 VAC operating range
(higher than 250VAC only for a short time, not
continuously)
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 VAC
150 VAC De-rate Point 145 VAC – 150 VAC
174 VAC De-rate Point 170 VAC – 174 VAC
300 VAC Shut down 310 ±5 VAC - latching

6.1.2 High voltage disconnect

High voltage disconnect occur at 310 VAC ±5 VAC. The rectifier will disconnect itself from
the mains supply and then automatically restart. The module will run in hick-up mode
until 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 Data
Output 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 Voltage ±0.5% from 0 to full load
regulation
Dynamic response ± 4.0 %

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

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 Data
Efficiency: > 91% at 230 VAC and full load

6.4.2 Safety
Type Electrical Data
Mobility: 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 - service
access area. An external primary circuit breaker
must be used in the input line.
IEC protection class: IP20
Current from AC inputs to safety earth: < 3.5 mA at 50 Hz.
Discharge time: < 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 Data
Storage -40 to +85°C (-40 to +185°F)
Temperature: +10 to +30°C (+50 to +86°F) Recommended long-term storage temp.
Storage 0% to 99% RH non-condensing
Humidity: 10-30 % RH Recommended
Operating -25 to +55°C (-13 to +131°F)
Temperature: +55 to + 70°C (+131 to +158°F) Output power derated to avoid damage
(stand alone)
> 70°C (>158°F) Shut down to avoid possible damage
Operating 5% to 95% RH non-condensing
Humidity:
Acoustic Noice: < 55 dBA (sound pressure) For stand alone module at 1m distance

6.4.4 Applicable standards

Electrical safety: EN 60950
EMC: ETSI EN 300 386 V.1.3.1 (telecommunication network)
Harmonics: EN 61000-3-2
Environment: ETSI EN 300 019-2
ETSI EN 300 132-2

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

 ELTEK Energy
P-O- BOX 2340 StØmsØ
N-3003 DRAMMEN
NORWAY

Phone: +47 32203200

Telefax: +47 32203210
Internet: http://www.eltekenergy.com
e-mail: eltek@eltekenergy.com

Location Company Telephone Fax

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

www.eltekenergy.com