User Manual
Contents
1. Flatpack 1U Power Shelf with Rear Covers Consists of Flatpack 1U PR Nortel Critical Connections Guide B 1503418 1 Operation Guide 1 5mm FP PR w covers B IM505393 I IM505394 Issue 1 August 2004 Flatpack Installation Operation Critical Connections Guide 1U Power Rack Nortel This Guide is intended as supplemental documentation always refer to the full System Installation and Operation Guides for detailed startup information AC Input Termination Points Important AC Cover Removal Before installing rectifiers Part e 103006 CAUTION Release handles before installation AC Input Voltage Requirements The Flatpack rectifier will operate from 85 310 VAC Rear of Rectifier Mounting Shelf The output power of the rectifier is dependant on the ELL AC input range 120 VAC nominal will produce 600W eessen eae pea Maximum 208 220 240 VAC nominal inputs will en cm cp ek SHORTING JUMPERS produce 1200 W Maximum ti eebe SE GROUND AC Input Feed Sizing POSITION 5 POSITION 2 weg See LINE 1 RECTIFIER 2 Power Rack AC wiring arrangement POSITION 4 LINE 1 SE eral aaa 12 AWG 2400 W 14 AWG 2400 W Note that Rectifier 1 is on the left side as viewed from the front of the system 14 AWG 2400 W DC Distribution Terminations Termination Studs are 10 32 torque to 21 31 In Lb Service Spares 800 435 4872 International 815 479 6082 Eltek Energy LLC 115 Erick St2. due account should be taken of the effect this procedure may have on the customers equipment Service Spares 800 435 4872 International 815 479 6082 Eltek Energy LLC 115 Erick Street Crystal Lake IL 60014 Document Number 1503418 Eltek Phone 815 459 9100 Fax 815 459 9118 Rev 1 August 2004 Website http www eltekenerqy com Operation Guide me ak Flatpack 1U Power Shelf with Rear Covers IM505393 Issue 1 August 2004 Information in this document is subject to change without notice and does not represent a commitment on the part of ELTEK Energy 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 Copyright ELTEK Energy Norway 2004 Corporate Headquarters ELTEK Energy AS P O Box 2340 Str ms N 3003 DRAMMEN Norway Phone 47 32203200 Fax 47 32203210 Americas Region Headquarters ELTEK Energy LLC 115 Erick Street Crystal Lake Illinois 60014 USA Phone 1 800 447 3484 Phone 1 815 459 9100 Sales FAX 1 815 459 9118 24 hour domestic service helpline 1 800 435 4872 24 hour international service helpline 1 815 479 0682 Service FAX 1 815 459 0453 Visit our Web site on the Internet http www eltekenergy com IM505393 Issue 1 August 04 This document was produced using Mi
3. wire size YP European mm7 US AWG ne Im SOLID Table 1 Wire sizes for mains connections Operation Guide Flatpack IU Power Shelf 5 l 2 IM505393 August 2004 The mains terminals are placed in the back of the Power Shelf on the left hand side when seen from rear of the unit To access the terminals the AC cover must be removed as shown in Figure I Figure I AC Cover Removal Second Rectifier Module AC input LI NI First Rectifier Module AC input Figure 2 Mains Connections Flatpack Power Shelf Connection number Sie oi Table 2 Pin configuration for mains connections Operation Guide Flatpack IU Power Shelf 6 l 2 IM505393 August 2004 Mains Configuration SINGLE PHASE 120VAC Jumpers should be connected between pin 2 L1 and pin 3 L2 pin 4 N1 and 208V AC 230 VAC pin 5 N2 Mains Wires to be connected to protective earth PE L1 and N1 SINGLE PHASE DUAL No jumpers required Each rectifier is fed by separate mains feed Feed I to be INPUT connected to L1 N1 and PE feed 2 to be connected to L2 N2 and PE THREE PHASE 400 VAC Jumpers required between pin 4 N1 and pin 5 N2 WITH NEUTRAL AC feed to be connected to L1 L2 N1 and PE Note Phase 3 wire L3 will not be in use The wire should be trimmed and insulated THREE PHASE 230 VAC Jumpers required between pin 4 N1 and pin 5 N2 DELTA Mains wire L1 to be connected to pin 2 L1 mains wire L2 to be connected to pin
4. 4 N1 mains wire L3 to be connected to pin 3 L2 while PE is connected to pin PE Table 3 Mains configuration for Flatpack Power Shelf The AC mains input wiring must be protected by a readily accessible branch circuit protective device of the correct rating for the wire size as determined by maximum AC input current See Table 4 Note Wire sizing and fuse breaker ratings are based on NEC requirements at low AC mains line 10 below nominal Wire sizes are for confined copper conductors in a 55 C maximum ambient temperature per NEC Table 310 16 Branch protection is sized for gt 125 of input current Max Protective Protective Input Feed Nominal AC Mains Input SEET Element Element Arrangement Input Current Minimum Number of Rating Poles Positions gg Arms SINGLE PHASE 120VAC 12AWG 4 mm SINGLE PHASE 208VAC 12AWG 4 mm SINGLE PHASE 120VAC One Feed per SINGLE PHASE 208VAC Rectifier SINGLE PHASE 230 240VAC 16AWG 1 5 mm 16AWG 1 5 mm 16AWG 1 5 mm Operation Guide Flatpack IU Power Shelf 7 l 2 IM505393 August 2004 SINGLE PHASE 230 240VAC One Feed per Power Rack THREE PHASE 400 VAC WYE WITH NEUTRAL 14AWG 2 5 mm THREE PHASE 230 VAC DELTA Table 4 AC Input wire sizes and fuse breaker ratings 2 4 DC Connections Comments 1 DECIDE CABLE ENTRY The cables can enter from the top and or bottom Use a cable cutter and cable lug crimper fitted with the a
5. aking the total power from the Flatpack 1U Power Shelf 2800W The Flatpack 1U Power Shelf is designed for mounting into 19 cabinets It is supplied as a stand alone unit and can be mounted into equipment Extenders are supplied for installing the Flatpack 1U Power Shelf into ETSI racks or 23 racks This Operation Guide contains an overview of the power shelf and its connections together with a description of it s installation and commissioning 2 Installation Procedures 2 1 Safety Precautions Iv 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 lv The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty Iv 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 Iv Please read the manual carefully before using the equipment 2 2 Mechanical Installation 1 TAKE THE FLATPACK POWER Inspect the power shelf for any physical damages SHELF OUT OF THE Damaged equipment should be returned to your PACKAGING supplier 2 CHECK THAT THE MOUNTING Mounting angles are included for mounting into 19 ANGLES ON EACH SIDE ARE 21 amp 600mm ETSI and 23 cabinets The 19 DIMENSIONED FOR YOUR b
6. crosoft Word 9 0 dmh August 2004 Operation Guide Flatpack IU Power Shelf IM505393 July 2004 2 12 2 INSTALLATION PROCEDURES NEE 4 Zal SATTI EE RECH 4 22 IVE CA INTC Als TINS TATA RL EE 4 2 3 MAINS E e EE Ge NC 5 2 4 TC CONNECTIONS eet 8 25 ALARM CONNECT CG 9 BE E 9 2 6 CONNECTIONS FOR COMMUNICATION E 10 3 SYSTEM OPERATION aen rN poseueviaseconeavicecs 10 Jk GENERA sc a hss We ce erase cess E A A EET 10 A MECHANICAL DATA arna NEE EIE EEO AOE NAER 11 4 1 NVC ELAN TC Ale TINIE NS LOIN EE 11 4 2 MECHANICAL A ee 11 FIGURE EE EE 6 FIGURE 2 MAINS CONNECTIONS FLATPACK POWER SHEI 6 PIGURE 3 2 EE 8 FIGURE4 ALARM OUTPUT CONNEC KLS NEEN 9 FIGURE 5 COMMUNICATION INTERFACE FLATPACK POWER SHEIE cc eres essere eenneee 10 TABLE 1 WIRE SIZES FOR ee 5 TABLE 2 PIN CONFIGURATION FOR MAINS CONNECTION 6 TABLE 3 MAINS CONFIGURATION FOR FLATPACK POWER SHELF ccc ccceeeccecesecceeeaeeeeees 7 TABLE 4 AC INPUT WIRE SIZES AND FUSE BREAKER RATINGS 2 0 cece cccescccccccceceeeeesseecceeeesseeseneees 7 ABIES SARI OND ONS E 9 PROCEDURE 1 MECHANICAL INSTALLATION FLATPACK 1U DR 5 PROCEDURE 2 MECHANICAL INSTALLATION FLATPACK 2U MCU BANEL ceccccceeeeceeeeee 5 PROCEDURE 32 DG CONNEC EECH 8 Operation Guide Flatpack IU Power Shelf 3 l 2 IM505393 August 2004 1 Scope This User Manual describes the Flatpack 1U power shelf with two Flatpack 1500 rectifiers installed Each rectifier can supply 1400W of output power m
7. h 327mm 12 9 Height 43mm 1 7 WEIGHT 2 4 kg 5 3 Ibs 8 0 kg 17 6 Ibs with two Flatpack 1500 rectifiers installed 4 2 Mechanical Drawings Drawing I Flatpack IU Power Shelf seen from the front and back Operation Guide Flatpack IU Power Shelf l l l 2 IM505393 August 2004 TULL bt wes ia P se T ang cr d RE DDR a EN a LT CL III RBD IF III Wi Te ae a Lu EE EER Bel ELTEK Energy P O BOX 2340 St ms N 3003 DRAMMEN NORWAY Phone 4732203200 Telefax 47 32203210 Internet htto www eltekenergy com e mail eltek eltekenergy com Operation Guide Flatpack IU Power Shelf IM505393 August 2004
8. laced Fan failure failed Internal rectifier failure Component failure Rectifier must be removed and returned for repair Output voltage above 59 5Vdc Rectifier must be removed from the shelf and allowed to discharge for 1 minute Re install the rectifier If an alarm is still present the rectfier will have to be returned for repair Over voltage shutdown Table 5 Alarm conditions Operation Guide Flatpack IU Power Shelf 9 l 2 IM505393 August 2004 2 6 Connections for Communication The power shelf is fitted with a communication interface which can be used to connect additional shelves for future expansion As can be seen in Figure 5 there are two RJ45 connectors This allows daisy chaining of multiple shelves eem EE Er d E T Ri i Biia A Ve m s Figure 5 Communication Interface Flatpack Power Shelf 3 System Operation 3 1 General The Flatpack 1U Power Shelf is designed to incorporate two rectifiers Flatpack 1500 The Flatpack 1500 rectifier is a highly advanced rectifier designed for both stand alone use and system operation Several Flatpack 1U power shelves can easily be paralleled to obtain higher output power Refer to the Operation Guide for the Flatpack 1500 Rectifier Module for installation and operation instructions Operation Guide Flatpack IU Power Shelf l UC l 2 IM505393 August 2004 4 Mechanical Data 4 1 Mechanical Dimensions DIMENSIONS Width 439mm 17 3 Dept
9. ppropriate size die 2 DRESS THE CABLES INTO THE CABINET CUT TO LENGTH AND FIT CABLE LUGS The studs on the bus connections are dimensioned for 2 hole lugs with 10 32 hardware One or two hole lugs may be used 3 REMOVE THE DC COVERS See Figure 3 4 FASTEN THE CABLES TO THE DC TERMINALS 5 FASTEN ALL CABLES TO CABLE SUPPORT RAILS AND CUT CABLE TIES FLUSH Procedure 3 DC connections DC Ground Operation Guide Flatpack IU Power Shelf St l 2 IM505393 August 2004 2 5 Alarm Connection For standalone applications the power rack has an alarm relay output This will allow the user to monitor the rectifier alarms without the addition of an external controller A relay opening or closure can be used depending on the application The connection is made to a 3 position terminal block on the rear of the shelf see Figure 4 0090009009000080 Figure 4 Alarm output connection 2 5 1 Alarm conditions The following table lists the rectifier failure alarms which can be monitored from the shelf alarm output connection Input voltage drops below 85VAC Auto reset once input exceeds 859 VAC High mains voltage Input voltage exceeds 312VAC Auto reset once input decreases below 312VAC i Blown input fuse due to over current Rectifier must be removed and fuse replaced Input fuse protection space Alarm condition Explanation Reset instructions i One or both fans have stopped or Rectifier must be removed and fan s rep
10. rackets are factory installed If the application requires Operation Guide Flatpack 1U Power Shelf 4 l 2 IM505393 August 2004 SIZED CABINET mounting other than 19 add the appropriate extender a 3 INSTALL THE POWER SHELF The power shelf is fixed with four screws two on each INTO POSITION AND FASTEN side of the shelf TO THE RAIL Procedure I Mechanical Installation Flatpack IU PR 2 3 Mains Connections Note All AC wiring must be enclosed in metallic conduit to meet UL and NEC requirements One opening for e trade size conduit is present at the AC enclosure The conduit fitting must be attached fixed to the AC input enclosure wall through the opening provided Installation Step Comments okay LL VERIFY WHICH MAINS Compare the description in the user manual with CONFIGURATION IS APPLICABLE the jumper settings on the mains terminals See FOR YOUR SYSTEM Table 3 for details 2 IF NECESSARY RECONFIGURE See Table 3 for details THE MAINS TERMINALS ACCORDING TO THE SUPPLY AVAILABLE 4 CONNECT THE PROTECTIVE Connect AC safety ground earth conductor as EARTH BEFORE ANY OF THE LIVE identified by green or green yellow insulation TERMINATIONS coloration Procedure 2 Mechanical Installation Flatpack 2U MCU panel The table below indicates the maximum dimension of the mains wires Use only copper wiring rated for operation to 90 C or higher insulation temperature rating Wire Tvpe Maximum wire size Maximum
11. reet Crystal Lake IL 60014 Document Number 1503418 Eltek Phone 815 459 9100 Fax 815 459 9118 Rev 1 August 2004 Website http www eltekenerqy com Flatpack Installation Operation Critical Connections Guide 1U Power Rack Nortel This Guide is intended as supplemental documentation always refer to the full System Installation and Operation Guides for detailed startup information Alarm Output Terminations Con3 Con5 will accept wire 22 to 18 AWG Form C Contacts Standard For standalone applications the power rack has an alarm relay output This will allow the user to monitor the rectifier alarms without the addition of an MCU A relay opening or closure can be used depending on the application The connection is made to a 3 position terminal block on the rear of the shelf c Ne NO Basic Settings Setting The System Output Voltage The Flatpack 1500 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 each rectifier individually turn so that there is only one rectifier in the system at any one time on completion all the rectifiers may then be installed flatpack 1500 s SSVAC 27SVAC 43VDC Output voltage adjustment v This adjustment is normally set at the factory during testing It is advisable to avoid making un necessary re adjustments
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